CWI WPS, PQR, and Welder Qualification 4 — Questions and Answers
Question 1: Under ASME Section IX, what is an F-number used to classify?
- Base metal P-groups for procedure qualification
- Filler metals grouped by usability characteristics (Correct answer)
- The position in which a welder is qualified
- The type of flux used in SAW welding
Correct answer: Filler metals grouped by usability characteristics
F-numbers in ASME Section IX classify filler metals by their usability characteristics to reduce the number of qualification tests required.
Question 2: A welder qualified using GTAW process wants to also work using SMAW on the same project. What must occur?
- No additional qualification is needed if the base metal is the same
- The welder must qualify separately using the SMAW process (Correct answer)
- The contractor may use one WPS to cover both processes
- The welder only needs to pass a visual inspection for SMAW
Correct answer: The welder must qualify separately using the SMAW process
Each welding process requires separate welder qualification because the skills required to operate GTAW and SMAW are distinct.
Question 3: During a procedure qualification test, a transverse tensile specimen fails at 68,000 psi. The base metal minimum specified tensile strength is 70,000 psi. What is the result?
- The test passes because 68,000 psi is within acceptable tolerance
- The test fails because the specimen did not meet the base metal tensile requirement
- The test is inconclusive and must be repeated with different specimens
- The test passes if the fracture occurred in the base metal away from the weld (Correct answer)
Correct answer: The test passes if the fracture occurred in the base metal away from the weld
Under AWS D1.1, a tensile test that fails below the required minimum but fractures in the base metal may still be acceptable per code provisions.
Question 4: What does the 'A-number' classify in ASME Section IX?
- Base metal alloy groupings for procedure qualification
- The deposited weld metal analysis (chemical composition) (Correct answer)
- The mechanical properties of the finished weld
- The flux classification used in submerged arc welding
Correct answer: The deposited weld metal analysis (chemical composition)
A-numbers in ASME Section IX classify deposited weld metal according to its chemical composition for procedure qualification purposes.
Question 5: A WPS qualified with GTAW root and SMAW fill/cap passes for a carbon steel groove weld. If the contractor wants to use GTAW for all passes, what is required?
- A new PQR supporting a full GTAW WPS must be qualified (Correct answer)
- No additional qualification is needed since GTAW is already part of the WPS
- A simple amendment to the existing WPS is sufficient
- Only welder requalification is needed, not procedure requalification
Correct answer: A new PQR supporting a full GTAW WPS must be qualified
Using GTAW for all passes constitutes a change in the combination of processes, requiring a new or additional PQR to support the revised WPS.
Question 6: Under AWS D1.1, which test is used to evaluate a welder's qualification for fillet welds specifically?
- Side bend test on fillet weld specimens
- Macro test (cross-section) and fillet weld break test (Correct answer)
- Full-penetration groove weld tensile test
- Radiographic examination of the fillet weld
Correct answer: Macro test (cross-section) and fillet weld break test
AWS D1.1 uses a fillet weld break test and macro examination (cross-section) to evaluate welder qualification for fillet welds.
Question 7: Which of the following correctly describes an 'essential variable' in the context of welding procedure qualification?
- A variable that can be changed without affecting weld quality
- A variable whose change requires requalification of the welding procedure (Correct answer)
- A variable that applies only to welder qualification, not procedure qualification
- A variable that must be recorded on the WPS but not on the PQR
Correct answer: A variable whose change requires requalification of the welding procedure
An essential variable is one that, when changed beyond allowable limits, requires a new PQR and requalification of the welding procedure.
CWI WPS, PQR, and Welder Qualification 4
Under ASME Section IX, what is an F-number used to classify?