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Appendix 1
Multiple Choice Questions – Paper 1

1 Which mechanical test can be used to measure the toughness of weld metal,
HAZ and parent material?

a Macro.
b Nick break.
c Hardness.
d Charpy impact.

2 Which is the best destructive test for showing lack of sidewall fusion in a 25mm
thickness butt weld?

a Nick break.
b Side bend.
c Charpy impact.
d Face bend test.

3 The principal purpose of a welder qualification test is to:

a Test the skill of the welder.

b Assess the weldability of the materials.
c Decide which NDT methods to use.
d Give the welder practice before doing production welding.

4 A fabrication procedure calls for the toes of all welds to be blended in by grinding.
The reason for doing this is to:

a Make the welds suitable for liquid (dye) penetrant inspection.

b Improve the fatigue life.
c Reduce residual stresses.
d Improve the general appearance of the welds.

5 For full penetration single-sided butt joints, root bead penetration and profile are
mainly influenced by:

a Root face.
b Bevel angle.
c Root gap.
d Included angle.

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6 Which of the following would be cause for rejection by most fabrication standards
when inspecting fillet welds with undercut, a small amount of?

a Depth.
b Length.
c Width.
d Sharpness.

7 When visually inspecting the root bead of a single V-butt weld it should be
checked for:

a Lack of root penetration.

b HAZ hardness.
c Tungsten inclusions.
d Slag.

8 The strength of a fillet weld is determined by:

a Leg length.
b Weld profile.
c Weld width.
d Throat thickness.

9 The European Standard for NDE of fusion welds by visual examination is:

a EN 15614.
b EN 2560.
c EN 287.
d EN 17637.

10 Visual inspection of a fabricated item for a high integrity application should cover
inspection activities:

a Before, during and after welding.

b Before welding only.
c After welding only.
d During and after welding only.

11 Incomplete root penetration in a single V butt joint may be caused by:

a Excessive root face.

b Excessive root gap.
c The current setting being too low.
d Both a and c.

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12 Incomplete root fusion in a single V butt weld may be caused by:

a Linear misalignment.
b Root gap being too large.
c Root faces being too small.
d Welding current too high.

13 When visually inspecting the face of a finished weld which of the following flaws
would be considered the most serious:

a Excess weld metal height.

b Start porosity.
c Spatter.
d Arc strikes.

14 A burn-through may occur if the:

a Current is too low.

b Root face is too large.
c Root gap is too large.
d Arc voltage is too high.

15 A Code of Practice is a:

a Standard of workmanship quality only.

b Set of rules for manufacturing a specific product.
c Specification for the finished product.
d Code for the qualification of welding procedures and welders qualifications.

16 A solid inclusion in a weld may be:

a Entrapped slag.
b Entrapped gas.
c Lack of inter-run fusion.
d None of the above.

17 Which of the following is a planar imperfection?

a Lack of sidewall fusion.

b Slag inclusion.
c Linear porosity.
d Root concavity.

18 For fillet welds it is normal practice in the UK and USA to measure:

a Throat thickness.
b Leg lengths.
c Penetration depths.
d Both a and c.

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19 In a bend test, when the face of the specimen is in tension and root is in
compression, the test is called a
:
a Root bend.
b Side bend.
c Face bend.
d Longitudinal bend.

20 Heavy porosity on the surface of some MMA welds made on a construction site is
most likely to be caused by:

a Use of the wrong class of electrodes.

b Use of excessive current.
c Moisture pick-up in the electrode covering.
d A bad batch of electrodes.

21 Slag inclusions may be present in:

a Manual metal arc welds.

b Metal inert gas welds.
c Metal active gas welds.
d All welds.

22 The main cause of undercut is:

a Excessive amps.
b Excessive OCV.
c Excessive travel speed.
d Current too low.

23 Which group of welders is most likely to require continuous monitoring by a

welding inspector?

a Concrete shuttering welders.

b Overland pipeline welders.
c Tack welders.
d Maintenance welders.

24 Which of the following fillet welds is the strongest assuming they are all made
using the same material and welded using the same WPS?

a 8mm throat of a mitre fillet.

b 7mm leg + 2mm excess weld metal.
c Mitre fillet with 10mm leg.
d Concave fillet with 11mm leg.

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25 A typical included angle for MMA welding a full penetration pipe butt joint is:

a 35°
b 70°
c 90°
d Dependent on the pipe diameter.

26 A fillet weld has an actual throat thickness of 8mm and a leg length of 7mm, what
is the excess weld metal?

a 2.1mm
b 1.8mm
c 3.1mm
d 1.4mm

27 The fusion boundary of a fillet weld is the:

a Boundary between the weld metal and HAZ.

b Boundary between individual weld runs.
c Depth of root penetration.
d Boundary between the HAZ and parent material.

28 If a Welding Inspector detects a type of imperfection not allowed by the

application Standard he must:

a Request further NDE.

b Reject the weld.
c Prepare a concession request.
d Reject the weld if he considers it to be harmful.

29 BS EN 17637 allows the use of a magnifying glass for visual inspection, but
recommends that the magnification is:

a x2.
b x2 to x5.
c x5 to x10.
d Not greater than x20.

30 The majority of welder qualification tests are carried out using unbacked joints,
because:

a It is quicker and cheaper if back gouging is not required.

b If the welding process is not TIG back purging is not required.
c All welder qualification tests are done on small diameter pipe.
d It requires more skill and increases the welders’ qualification range.

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Multiple Choice Questions – Paper 2

1 Deflection of the arc by magnetic forces that can make welding difficult to control
is commonly known as:

a Arc initiation.
b Arc misalignment.
c Arc blow.
d Arc constriction.

2 Which of the following electrode types is classified to EN ISO 2560?

a E 38 3 R.
b E 6013.
c E 7018 - G.
d E 51 33 B.

3 Which type of electrode is used for stovepipe welding for overland pipeline
construction?

a Rutile.
b Cellulosic.
c High recovery rutile.
d Acid-rutile.

4 The three main types of MMA electrodes used for welding C and C-Mn steels
are:

a Basic, cellulosic and rutile.

b Neutral, cellulosic and rutile.
c Basic, cellulosic and neutral.
d Rutile, low hydrogen and basic.

5 A WPS may specify a maximum width for individual weld beads (weave width)
when welding C-Mn steels. If the width is exceeded it may cause:

a Lack of inter-run fusion.

b A reduction in HAZ toughness.
c Lack of sidewall fusion.
d Too low a deposition rate.

6 You notice that MMA electrodes with the flux covering removed are being used
as filler rods for TIG welding. This should not be allowed because:

a It is wasteful.
b The rod diameter may be too large.
c The weld metal composition may be wrong.
d The rod is too short.

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7 In TIG welding a current slope-out device reduces:

a Tungsten spatter.
b Risk of crater cracking.
c Risk of arc strikes.
d Interpass temperature.

8 Which type of power source characteristic is normally used for manual welding?

a Constant voltage.
b Flat characteristic.
c Constant current.
d A motor generator.

9 In MMA welding penetration is principally controlled by:

a Arc voltage.
b Welding speed.
c Ferro-silicon in the electrode coating.
d Current.

10 Pipe bores of some materials must be purged with argon before and during TIG
welding to:

a Prevent linear porosity.

b Prevent burn-through.
c Prevent oxidation of the root bead.
d Eliminate moisture pick-up in the root bead.

11 The chemical composition of the weld metal deposited by a C-Mn steel MMA
electrode is usually controlled by:

a Core wire composition.

b Additions in the flux coating.
c Iron powder in the flux coating.
d Dilution from the base material.

12 Silicon is added to steel and the covering of MMA electrodes to:

a Provide deoxidation.
b Improve strength.
c Improve toughness.
d Provide more resistance to hydrogen cracking.

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13 A fusible insert for TIG welding helps:

a Reduce porosity.
b Give controlled root penetration.
c Avoid the need for a back purge.
d By acting as a backing for the root run.
e
14 According to AWS 2.4 a weld symbol for the other side is placed:

a Above the dashed line.

b Below the dashed line.
c Above the solid line.
d Below the solid line.

15 The term low hydrogen electrode is often used for certain electrodes. What type
of covering will they have?

a Cellulosic.
b Rutile.
c Acid.
d Basic.

16 A hydrogen controlled MMA electrode can always be recognised by the:

a EN code letter (or AWS code number).

b Electrode length.
c Trade name.
d Colour of the covering.

17 According to BS EN 22553 which of the following symbols requires weld toes to

be smoothly blended on the other side?

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18 Which of the following units is used to express heat input?

a Joules.
b N/mm2.
c J/mm2.
d kJ/mm.

19 Which of the following elements is added to steel to give resistance to creep at

elevated service temperatures?

a Nickel.
b Manganese.
c Molybdenum.
d Aluminium.

20 Nick break and fillet fracture tests are used for assessing:

a Weld quality.
b Weld metal ductility.
c Weld metal toughness.
d Resistance to fracture.

21 Which of the following steels is considered non-magnetic?

a 18%Cr, 8%Ni.
b 2.25Cr 1Mo.
c 9%Cr,1Mo.
d 9%Ni.

22 Weld spatter during MMA welding is most likely to be caused by:

a Excessive current.
b Incorrect baking and storage of electrodes.
c Bad batch of electrodes.
d Too low an OCV.

23 A qualified Welding Procedure Specification is used to:

a Give instruction to the welder.

b Give information to the welding inspector.
c Give confidence that welds will have the specified properties.
d All of the above.

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24 An arc strike (stray flash) on a steel component is regarded by some codes as

unacceptable because:

a It will cause copper contamination.

b It may cause hard spots.
c It may give cracking.
d Both B and C.

25 In a transverse tensile test brittleness would be indicated if:

a There is a reduction in cross-section at the position of fracture.

b The fracture surface is flat and featureless but has a rough surface.
c Fracture occurred in the weld metal.
d The fracture face shows beach marks.

26 The surface of a fatigue crack will:

a Be rough and torn.

b Have sharp chevron markings.
c Be smooth.
d Have shear lips.

27 What does the number 141 refer to on this drawing?

a WPS number.
b Welding process. 141
c Filler material.
d Acceptance standard.

28 The current/polarity used for TIG welding all materials except aluminium and
magnesium is:

a DC negative.
b DC positive.
c AC.
d Square wave AC.

29 A typical temperature range for baking basic coated electrodes is:

a 150-200°C.
b 200-250°C.
c 300-350°C.
d 400-450°C.

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30 If welding travel speed is doubled but the current and voltage remain the same
the heat input will be:

a Reduced by 50%.
b Increased by a factor of two.
c About the same.
d Reduced by approximately 25%.

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Multiple Choice Questions – Paper 3

1 Which type of submerged arc welding flux is susceptible to moisture pick-up?

a Neutral.
b Agglomerated.
c Fused.
d All about the same.

2 A large grain size in the HAZ of a C-Mn steel weld joint may have:

a Low ductility.
b Low toughness.
c High toughness.
d High tensile strength.

3 A STRA test is used to measure the:

a Tensile strength of the welded joint.

b Level of residual stress in butt joints.
c Fracture toughness of the HAZ.
d Through-thickness ductility of a steel plate (the Z direction).

4 The risk of hydrogen cracking is greater when MMA welding:

a C-Mn steels.
b Austenitic stainless steel.
c Low alloy steels for elevated temperature service.
d Low carbon steels for cryogenical service.

5 The property of a material which has the greatest influence on welding distortion
is its:

a Yield strength.
b Coefficient of thermal expansion.
c Elastic modulus.
d Coefficient of thermal conductivity.

6 Which of the following is a suitable shielding gas for FCAW of stainless steels?

a 100% argon.
b 70% argon + 30%He.
c Argon + 5% hydrogen.
d Argon + 20% CO2.

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7 The presence of iron sulphides in a weld bead may cause:

a Solidification cracking.
b Hydrogen cracking.
c Lamellar tearing.
d Weld decay.

8 A macrosection is particularly good for showing:

a The weld metal HAZ microstructure.

b Overlap.
c Joint hardness.
d Spatter.

9 Which of the following procedures would be expected to produce the least

distortion in a 15mm straight butt weld?

a TIG weld, single-sided, multi-pass.

b MMA weld, single-sided, multi-pass.
c MMA weld, double-sided, multi-pass.
d SAW weld, 1 pass per side.

10 A suitable gas/gas mixture for GMAW of aluminium is:

a 100%CO2.
b 100% Argon.
c 80% argon + 20% CO2.
d 98% argon + 2% O2.

11 Which of the following is associated with SAW more often than it is with MMA
welds?

a Hydrogen cracking in the HAZ.

b Solidification cracking in the weld metal.
c Reheat cracking during PWHT.
d Lamellar tearing.

12 EN ISO 5817 (Level C) specifies that the limit for the diameter (D) of a single
pore in a weld is:

D ≤ 0.3s, but max.4mm where s = material thickness.

For which of the following situations is the pore acceptable?

a s = 20mm, measured pore diameter = 5mm.

b s = 15mm, measured pore diameter = 4.5mm.
c s = 10mm, measured pore diameter = 3mm.
d s = 10mm, measured pore diameter = 3.5mm.

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13 To measure arc voltage accurately it is recommended that the voltmeter should

be connected:

a Across the arc and as near as practical to the arc.

b Across the power source terminals prior to arc initiation.
c Across the power source terminals during the welding operation.
d Anywhere in the circuit.

14 Lamellar tearing has occurred in a steel fabrication. What technique could have
been used to find it before the weld was made?

a X-ray examination.
b Liquid penetrant examination.
c Ultrasonic examination.
d It could not have been found by any inspection method.

15 Preheating a low alloy steel prior to welding will minimise the risk of:

a Porosity.
b Excessive distortion.
c HAZ cracking.
d Lack of fusion.

16 Typical temperatures used for normalising a C-Mn steel plate are:

a 600-650°C.
b 1000-1100°C.
c 700-800°C.
d 880-920°C.

17 For GMAW the burn-off rate of the wire is directly related to:

a Stick out length.

b Wire feed speed.
c Arc voltage.
d Travel speed.

18 When MMA welding a 60mm wall nozzle to a 100mm wall vessel shell, preheat
temperature should be checked:

a Before welding starts/re-starts.

b On the shell and nozzle.
c At points at least 75mm from the joint edge.
d All of the above.

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19 A crack running along the centreline of a weld bead could be caused by:

a Use of damp flux.

b Lack of preheat.
c Arc voltage too high.
d Weld bead too deep and very narrow.

20 To improve resistance to service failure caused by cyclic loading, it is good

practice to:

a Use low heat input welding.

b Use steel with a low CEV.
c Ensure there are no features that give high stress concentration.
d PWHT the fabrication.

21 The use of low carbon austenitic stainless steels and stabiliser stainless steels
will minimise the risk of:

a HAZ cracking.
b Weld decay.
c Weld metal cracking.
d Distortion.

22 Which type of SAW flux is susceptible to breaking down into fine particles during
circulation?

a Fused.
b Neutral.
c Alloyed.
d Agglomerated.

23 The maximum hardness in the HAZ of a steel will increase if:

a Heat input is increased.

b CEV is increased.
c Joint thickness is decreased.
d Basic electrodes are used.

24 BS EN ISO 5817 (Level B) specifies the limit for excess weld metal (h) on a butt
weld as:

h ≤ 1mm + 0.1b, but max. 5mm, b = weld width.

In which of the following situations is the measured excess weld metal acceptable.

a b = 10 measured excess weld metal = 2.5mm.

b b = 20 measured excess weld metal = 3.5mm.
c b = 35 measured excess weld metal = 4.5mm.
d b = 45 measured excess weld metal = 5.5mm.

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25 A C-Mn steel is being welded by MMA and the electrode run-out lengths that
have been used are much shorter than specified by the WPS. This deviation may
give:

a Increased risk of hydrogen cracking.

b Increased risk of solidification cracking.
c Lower values of HAZ toughness.
d Higher values of HAZ hardness.

26 The first procedure prepared for a Weld Procedure Qualification test weld is a:

a pWPS.
b WPS.
c WPQR.
d WPAR.

27 Transfer of material identification by hard stamping is sometimes not allowed for

high integrity applications because it:

a Is too slow.
b Can be a safety hazard.
c May damage the material.
d Causes problems with coating operations.

28 When welding thin plate distortion can be minimised by:

a Welding from both sides.

b Using U preparations rather than V types.
c Using strongbacks.
d Using back-step welding.

29 Which of the following would be considered to be high heat input welding?

a 550J/mm.
b 55J/mm.
c 5.5J/mm.
d 5kJ/mm.

30 Initiation of a TIG arc using a high frequency spark may not be allowed because
it:

a Often causes tungsten inclusions.

b Can damage electronic equipment.
c Is an electrical safety hazard.
d Often causes stop/start porosity.

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Multiple Choice Questions – Paper 4

1 Which of these drawing symbols shows weld penetration depth in accordance

with BS EN 22553?

10s
a
10
s

s10
b

10
c

s10
d

2 BS EN 288 and BS EN ISO 15614 are specifications for:

a Welder approval testing.

b Welding equipment calibration.
c Welding procedure approval.
d Consumables for submerged arc welding.

3 What determines the penetrating power of gamma rays?

a Time.
b Type of isotope.
c Source-to-film distance.
d Source strength.

4 Which element has the greatest effect on the HAZ hardness of C-Mn steel?

a Molybdenum.
b Chromium.
c Titanium.
d Carbon.

5 Preheating a steel plate with a carbon equivalent value (CEV) of 0.48 may be
required to:

a Drive moisture from the plate.

b Prevent excessive hardening in the HAZ.
c Prevent the formation of carbides.
d Improve the mechanical properties of the weld metal.

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6 A welder approval certificate should be withdrawn if:

a He has not done any welding for four months.

b He has been absent from work for seven months.
c The repair rate for his welds exceeds 1%.
d His work has been examined by UT only.

7 In friction welding, the metal at the interface when the joining occurs is described
as being in the:

a Liquid state.
b Intercritical state.
c Plastic state.
d Elastic state.

8 A penetrameter (IQI) is used to measure the:

a Size of discontinuity in a weld joint.

b Density of a radiographic film.
c Degree of film contrast.
d Quality of the radiographic technique.

9 Which of the following cutting methods is suitable for cutting stainless steel?

a Plasma.
b Oxy-acetylene.
c Oxy-propane.
d It depends upon the thickness.

10 Which of the following would be classed as the most serious type of defect?

a A buried linear slag inclusion.

b Buried lack of inter-run fusion.
c Surface-breaking lack of sidewall fusion.
d Surface porosity.

11 Ultrasonic testing has an advantage over other NDT methods for the detection of:

a Lack of sidewall fusion.

b Root undercut.
c Incompletely filled groove.
d Root concavity.

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12 Exceeding the maximum interpass temperature specified for a C-Mn steel weld
joint may give:

a Excessive porosity.
b Burn through.
c Lower toughness.
d Higher strength.

13 MIG/MAG welding has a tendency to give lack of sidewall fusion when using:

a Spray transfer conditions.

b 100% CO2 shielding gas.
c Pulsed current.
d Dip transfer.

14 The temperature range over which a steel goes from having high to low
toughness is called the:

a Critical transformation temperature.

b Ductility dip temperature.
c Bi-modal temperature.
d Transition temperature.

15 For SAW what is the effect of raising arc voltage but keeping all other parameters
the same?

a Weld bead width will increase.

b Depth of penetration will increase.
c Weld bead width will decrease.
d Depth of penetration will decrease.

16 Changing an essential variable beyond the allowed limits for a qualified wielding
procedure:

a May change the mechanical properties of the joint.

b May adversely affect the quality of the weld.
c Will require a new welding procedure to be approved.
d All of the above.

17 With reference to the various grades of stainless steels which of the following
statements is true?

a They are all non-magnetic.

b They all require 100% Ar for GMAW.
c They all have very high thermal conductivity.
d Only certain grades can be used for service at very low temperatures.

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18 Which of the following AWS A5.1 electrodes has a rutile covering:

a E 6010.
b E 7016.
c E 7018.
d E 6013.

19 Welds made with very high heat input will show a reduction in:

a Tensile ductility.
b Notch toughness.
c Fatigue strength.
d Creep resistance.

20 During PWHT of a complex fabrication it is heated to the soak temperature at a

much faster rate than specified by the procedure. This may:

a Cause excessive oxidation.

b Not allow sufficient time to relieve stresses.
c Introduce excessive compressive stresses.
d Cause distortion.

21 When MAG welding in dip transfer (a short-circuiting mode) spatter can be

reduced by:

a Using inductance.
b Using 100%CO2.
c Using Ar + 30%He.
d Increasing the stick-out length.

22 Repair welding of in-service plant and equipment may be more difficult than
making repairs during initial fabrication because:

a The material may be contaminated.

b Access to repair area may be difficult.
c Positional welding may be needed.
d All of the above.

23 For gamma radiography of a steel weld at 35mm thickness, the recommended

isotope is:

a Thulium 170.
b Ytterbium 169.
c Iridium 192.
d Cobalt 60.

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24 The sensitivity of a radiograph is assessed:

a Using a densitometer.
b Using an image quality indicator (IQI).
c From the kVA used.
d From the source/tube to work standoff distance used.

25 A transverse tensile test from a Weld Procedure Approval Record (WPAR) test
plate is used to measure the:

a Tensile strength of the weld

b Tensile strength of the joint
c Stress/strain characteristics of the weld
d Stress/strain characteristics of the joint

26 The highest and lowest heat input positions are considered to be:

a PB highest; PA lowest.
b PE highest; PC lowest.
c PD highest; PB lowest.
d PF highest; PG lowest.

27 What type of covering will an electrode have that is suitable for welding 60mm C-
Mn steel and can give good weld metal toughness at -50°C?

a Rutile.
b Basic.
c Cellulosic.
d Choice will depend on the welding position.

28 The dip transfer or short-circuiting mode of metal transfer used for MIG/MAG
welding is characterised by:

a Giving deep penetration.

b Being suitable for positional welding.
c Giving low spatter.
d Giving high deposition.

29 Carbon equivalent values (CEV) are used to determine how to avoid the risk of:

a Hydrogen cracking.
b Lamellar tearing.
c Solidification cracking.
d Weld decay.

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30 When two different material types are welded together the joint is referred to as:

a A composite joint.
b A transition joint.
c An autogenous weld.
d Heterogeneous joint.

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