Weld Inspection and Defects Flashcards
7 cards from real Certified Welder practice questions. Tap to flip, then mark Knew It or Still Learning — missed cards come back until you master them.
Read the first 7 Weld Inspection and Defects flashcards as text
Which discontinuity is MOST likely to cause failure under fatigue loading compared to static loading?
Answer: Surface-breaking crack at the weld toe
Surface-breaking cracks, especially at the weld toe, act as stress risers that dramatically reduce fatigue life because cracks propagate rapidly under cyclic stress.
What is 'burn-through' in welding?
Answer: A hole melted completely through the base metal or weld
Burn-through occurs when excessive heat input completely penetrates and collapses the weld pool, creating a hole through the workpiece.
A welder qualifies using a 1G groove weld test position. Which positions are they qualified to weld in production?
Answer: 1G only (flat)
Qualification in the 1G (flat) position qualifies the welder only for flat position production welding per most codes including AWS D1.1.
When inspecting a completed weld, which condition requires removal and rewelding rather than blending or grinding as a repair?
Answer: Cracks of any size
Cracks are never blended or dressed to appear acceptable — they must be completely removed (verified by MT or PT) and rewelded.
Incomplete root penetration in a full-penetration groove weld is most directly caused by:
Answer: Insufficient heat input or too large a root face for the current settings
Incomplete root penetration results when the welding heat is insufficient to melt through the root land, or the root face is too thick for the heat input being used.
The primary advantage of phased array ultrasonic testing (PAUT) over conventional UT for weld inspection is:
Answer: The ability to electronically steer and focus the beam to inspect complex geometries faster
PAUT uses multiple elements with programmable time delays to electronically steer, focus, and sweep the beam, enabling faster and more thorough inspection of complex weld geometries.
Which preheating practice most effectively reduces the risk of hydrogen-induced cracking when welding high-strength low-alloy (HSLA) steel?
Answer: Preheating to at least the minimum required temperature and maintaining it as interpass temperature throughout welding
Maintaining minimum preheat and interpass temperature slows the cooling rate, allowing hydrogen to diffuse out before the HAZ hardens and becomes crack-susceptible.