NDT Weld Inspection & Evaluation 2 — Questions and Answers
Question 1: What is the correct sequence for measuring a fillet weld using a fillet weld gauge?
- Measure convexity first, then leg length
- Place the gauge against the toe and read the leg size directly (Correct answer)
- Measure throat first, then calculate leg size
- Measure preheat temperature before gauge placement
Correct answer: Place the gauge against the toe and read the leg size directly
A fillet weld gauge is placed with its flat edge against the base metal and the perpendicular edge against the weld face, allowing direct reading of the leg size at the point of contact.
Question 2: Which weld joint condition is described as incomplete joint penetration (IJP)?
- Weld metal deposited beyond the groove face
- Failure of the weld to extend through the full thickness of the joint (Correct answer)
- Excess reinforcement above the plate surface
- Weld metal overlapping the base metal surface
Correct answer: Failure of the weld to extend through the full thickness of the joint
Incomplete joint penetration occurs when the weld metal does not extend through the full depth of the groove joint, leaving unfused base metal at the weld root.
Question 3: ASME Section IX requires that a welder's qualification test record include which minimum information?
- Welder's home address and union number
- Essential variables, test results, and date of qualification (Correct answer)
- Brand name of electrodes used during the test
- Inspector's personal certification number only
Correct answer: Essential variables, test results, and date of qualification
ASME Section IX mandates that welder performance qualification records document essential variables (process, position, base metal, filler metal), test results, and the date the qualification was achieved.
Question 4: What is the minimum illumination level recommended by most codes for visual weld inspection?
- 50 foot-candles
- 100 foot-candles (Correct answer)
- 200 foot-candles
- 500 foot-candles
Correct answer: 100 foot-candles
AWS D1.1 and most applicable codes require a minimum of 100 foot-candles (1076 lux) of illumination at the inspection surface to ensure adequate visibility of weld discontinuities.
Question 5: An overlap condition in a weld is best described as:
- Weld metal that extends beyond the fusion zone onto the base metal without bonding (Correct answer)
- Two adjacent weld passes that are too close together
- Excessive convexity in the weld crown
- Base metal melted beyond the intended heat-affected zone
Correct answer: Weld metal that extends beyond the fusion zone onto the base metal without bonding
Overlap is a surface discontinuity where weld metal flows over the base metal surface but fails to fuse with it, creating a notch-like condition that can trap moisture and initiate cracking.
Question 6: When inspecting pipe welds in the 6G position, what does the '6G' designation indicate?
- The pipe is horizontal and rotates during welding
- The pipe is fixed at a 45° incline and does not rotate (Correct answer)
- The pipe is vertical with overhead welding only
- The pipe is horizontal with flat position welding only
Correct answer: The pipe is fixed at a 45° incline and does not rotate
The 6G position places the pipe at a 45° fixed incline, requiring the welder to weld in all positions (flat, horizontal, vertical, and overhead) without rotating the pipe, making it the most challenging and comprehensive qualification.
Question 7: Which of the following is a volumetric weld discontinuity detectable by radiographic testing but typically NOT by visual inspection alone?
- Surface crack at the weld toe
- Undercut along the weld edge
- Internal slag inclusion (Correct answer)
- Weld spatter on the base metal
Correct answer: Internal slag inclusion
Internal slag inclusions are subsurface discontinuities fully enclosed within the weld metal that cannot be seen by visual inspection; radiography detects them as irregular dark indications on the film.
NDT Weld Inspection & Evaluation 2
What is the correct sequence for measuring a fillet weld using a fillet weld gauge?