CWI Practical Visual Inspection 4 — Questions and Answers
Question 1: A visual inspector notices that a T-joint fillet weld has weld metal covering the base metal surface beyond the weld toe with no fusion. This is best described as:
- Underfill
- Overlap (Correct answer)
- Excessive convexity
- Incomplete penetration
Correct answer: Overlap
Overlap is the protrusion of unfused weld metal beyond the weld toe onto the base metal surface, acting as a mechanical notch.
Question 2: When using a fillet weld gauge (such as a bridge cam gauge), how do you measure the actual throat of a convex fillet weld?
- Measure the longest leg and divide by 1.414
- Use the gauge to measure from the weld root to the weld face along the theoretical throat line (Correct answer)
- Measure the total width of the fillet and divide by 2
- Measure both legs separately and add them together
Correct answer: Use the gauge to measure from the weld root to the weld face along the theoretical throat line
The actual throat is measured from the weld root perpendicular to the weld face; for a convex fillet, a bridge cam gauge measures this directly.
Question 3: During visual inspection of a structural steel weld, a CWI must verify that the joint preparation (groove angle and root opening) conforms to:
- The welder's preferred technique
- The WPS and applicable code requirements (Correct answer)
- AWS D1.1 Table 3.1 only, regardless of the project code
- The fabricator's internal standards only
Correct answer: The WPS and applicable code requirements
Joint preparation must conform to the project's Welding Procedure Specification (WPS) and the applicable code, ensuring consistent weld quality.
Question 4: What characteristic of a weld profile indicates burn-through?
- Excessive weld reinforcement above the base metal
- A hole or complete melt-through of the base metal in the weld zone (Correct answer)
- Undercut along the weld toes
- A rough, irregular weld face surface
Correct answer: A hole or complete melt-through of the base metal in the weld zone
Burn-through is characterized by a hole or complete penetration of the base metal in the weld area, caused by excessive heat input.
Question 5: A CWI is inspecting a groove weld and finds that the weld shows visible porosity at a rate exceeding code limits. What is the appropriate action?
- Apply a coating to seal the pores and re-inspect
- Reject the weld and require removal and repair per applicable code (Correct answer)
- Grind the surface smooth and accept the weld
- Document and submit a waiver to the owner
Correct answer: Reject the weld and require removal and repair per applicable code
When porosity exceeds code acceptance limits, the weld must be rejected, and the defective portion must be removed and repaired per the applicable repair procedure.
Question 6: Which type of weld crack runs parallel to the weld axis and is most commonly found in the weld metal or heat-affected zone?
- Transverse crack
- Longitudinal crack (Correct answer)
- Crater crack
- Toe crack
Correct answer: Longitudinal crack
Longitudinal cracks run parallel to the weld axis and can occur in the weld metal or HAZ, often due to high residual stress or hydrogen embrittlement.
Question 7: Proper lighting conditions for visual weld inspection require a minimum illuminance of:
- 100 foot-candles (1000 lux)
- 50 foot-candles (500 lux) at the examination surface (Correct answer)
- 25 foot-candles (250 lux)
- 200 foot-candles (2000 lux)
Correct answer: 50 foot-candles (500 lux) at the examination surface
AWS and most codes require a minimum of 50 foot-candles (approximately 500 lux) of illumination at the examination surface for reliable visual inspection.
CWI Practical Visual Inspection 4
A visual inspector notices that a T-joint fillet weld has weld metal covering the base metal surface beyond the weld toe with no fusion.
This is best described as: