FREE CWI Welding Processes and Terminology Questions and Answers

Question 1

Which of the following welding processes utilizes a continuously fed consumable electrode and a shielding gas, but does NOT typically use an external flux?

Accepted Answer

Gas Metal Arc Welding (GMAW)

Answer

Shielded Metal Arc Welding (SMAW)

Answer

Flux-Cored Arc Welding (FCAW)

Answer

Submerged Arc Welding (SAW)

Question 2

A welder is experiencing excessive spatter and an unstable arc while performing a short-circuit GMAW weld. Upon inspection, the gas flow rate is correct, and the electrode stick-out is within tolerance. Which parameter is MOST likely misadjusted to cause these issues?

Accepted Answer

Voltage is too high

Answer

Travel speed is too slow

Answer

Wire feed speed is too low

Answer

Amperage is too low

Question 3

What is the primary purpose of the flux coating on a Shielded Metal Arc Welding (SMAW) electrode?

Accepted Answer

To provide shielding gas and deoxidizers for the weld pool

Answer

To increase the melting rate of the electrode

Answer

To improve the electrical conductivity of the base metal

Answer

To cool the weld joint rapidly after welding

Question 4

Which welding terminology refers to the removal of metal from the base metal, usually along the toe of the weld, leaving a groove?

Accepted Answer

Undercut

Answer

Incomplete fusion

Answer

Overlap

Answer

Porosity

Question 5

During a visual inspection, a CWI observes a discontinuity where the weld metal extends beyond the toe or root of the weld. This condition is known as:

Accepted Answer

Overlap

Answer

Crater crack

Answer

Lack of penetration

Answer

Weld reinforcement

Question 6

Which of the following welding processes is typically used for welding thick sections in a single pass due to its deep penetration capabilities and high deposition rates, often in automated setups?

Accepted Answer

Submerged Arc Welding (SAW)

Answer

Gas Tungsten Arc Welding (GTAW)

Answer

Shielded Metal Arc Welding (SMAW)

Answer

Resistance Spot Welding (RSW)