FREE Certified Welder Weld Inspection and Defects Questions and Answers

Question 1

During a visual inspection of a multi-pass fillet weld made with FCAW, the inspector finds non-metallic particles trapped between the weld beads. What is this type of defect called?

Accepted Answer

Slag Inclusions

Answer

Porosity

Answer

Undercut

Answer

Lack of Fusion

Question 2

A welder performing a GMAW (MIG) weld on carbon steel notices numerous small, spherical cavities on the surface of the completed weld. Which of the following is the MOST likely cause of this porosity?

Accepted Answer

Inadequate shielding gas flow

Answer

Travel speed is too slow

Answer

Amperage is set too high

Answer

The work clamp has a poor connection

Question 3

In the terminology of weld inspection, what is the critical difference between a 'discontinuity' and a 'defect'?

Accepted Answer

A discontinuity is an interruption in the material, while a defect is a discontinuity that exceeds code limits and is cause for rejection. [4, 17]

Answer

A discontinuity is internal, while a defect is on the surface.

Answer

A discontinuity is only found with destructive testing, while a defect can be found with visual inspection.

Answer

A 'discontinuity' and a 'defect' are interchangeable terms for the same flaw.

Question 4

A welder's qualification test plate undergoes a guided side bend test. After being bent 180 degrees, the exposed weld surface shows several open flaws. What does this destructive test primarily evaluate?

Accepted Answer

The weld's soundness and ductility

Answer

The weld's chemical composition

Answer

The weld's electrical resistance

Answer

The weld's tensile strength

Question 5

A visual inspection reveals a sharp groove melted into the base metal along the toe of the weld, which has not been filled by the weld metal. What is this specific defect called?

Accepted Answer

Undercut

Answer

Overlap

Answer

Incomplete Penetration

Answer

Excessive Reinforcement

Question 6

An inspector is using a non-destructive testing method on a ferromagnetic steel weldment. The process involves inducing a magnetic field and applying fine iron particles to the surface. This method is most effective for detecting which type of defects?

Accepted Answer

Surface and near-surface discontinuities like cracks

Answer

Internal porosity deep within the weld

Answer

Incorrect alloy composition

Answer

Incorrect grain structure in the heat-affected zone

During a visual inspection of a multi-pass fillet weld made with FCAW, the inspector finds non-metallic particles trapped between the weld beads.What is this type of defect called?

During a visual inspection of a multi-pass fillet weld made with FCAW, the inspector finds non-metallic particles trapped between the weld beads.
What is this type of defect called?