QUESTIONS and ANSWERS regarding welding

Que.1. What are the welding procedure qualification tests for groove weld?
Ans.1. Tests required for the WPS of groove weld are
A) Tension Test
B) Guided Bend Test
1. Transverse side bend (04 Nos.)
2. Transverse face bend (02 Nos.)
3. Transverse root bend (02 Nos.)
4. Longitudinal Face Bend (02 Nos.)
5. Longitudinal Root Bend (02 Nos.)
C) Notch Toughness Test (if required in code)

Que.2. What are the welder performance qualification tests for groove weld?
Ans.2. Tests required for the WPQ of groove weld are
1. Face bend (01 no.)
2. Root bend (01 No.)
3. Side bends (02 Nos.)

Que.3. What are the welding procedure qualification tests for fillet weld?
Ans.3. Tests required for the WPS of fillet weld are
Macro Test (5 Nos.) for Plate
Macro Test (4 Nos.) for Pipe

Que.4. What are the welding performance qualification tests for fillet weld?
Ans.4. Tests required for the WPQ of fillet weld are
Fracture Test (01 No.)
Macro Test (01 No.)

Que.5. What are the conditions for preheating before welding?

Ans.5. The conditions for preheating before welding are
Preheat required if job temperature is less than 10°C.
Carbon content is greater than 0.30% and part thickness is greater than 25 mm thickness.

Que.6. How to reduce the improper penetration?

Ans.6. Preventive measures to reduce the improper penetration
a) Make proper joint design
b) Proper Travel speed selection (travel speed not to be high)
c) Selection of suitable electrode diameter
d) Proper Current (current not to be low)
e) Proper angle of electrode to the job

Que.7. How to reduce the lack of fusion?

Ans.7. Preventive measures to reduce the lack of fusion
a) Proper welding Current (current not to be too low)
b) Proper travel speed (travel speed not to be high)
c) Proper joint design
d) Proper cleaning after sub sequent passes of welding.

Que.8. What is the polarity used for SMAW & GTAW?

Ans.8. SMAW: DCEP, GTAW: DCEN
Que.9. What are the preventive measures to reduce welding distortion?
Ans.9. Preventive measures to reduce welding distortion.
a) Proper welding current (current not to be too high).
b) Make proper joint design.
c) Tack the weld part properly with fixtures.
d) Follow proper welding sequence.

Que.10. Why flux coating is required in E7018 electrode?

Ans.10. Flux coating is required in E7018 electrode because
a) It is low hydrogen electrode
b) To prevent the moisture absorption in the electrode from environment
c) To avoid the contact of outside air with weld pool.
d) Shielding of weld bead during welding.

Que.11. What is the requirement for E7018 heating?

Ans.11. The requirement for E7018 heating
Do as per manufacturer instruction, if not specified follow the following
a) Re-dry at 250°C for 2 hour and then maintain it at 150°C and issue for use in portable oven
which is maintain between 80°C to 100°C. OR
b) Re-dry at 350°C for 1 hour and then maintain it at 150°C and issue for use in portable oven
which is maintain between 80°C to 100°C.

Que.12. What are the precautions taken to reduce oxidation in SS pipe welding?
Ans.12. The precautions taken to reduce oxidation in SS welding
a) Material contamination should be removed
b) Purging gas should be used as per requirement at inside.
c) Shielding gas should be used during welding along with Tungsten electrode in GTAW.
d) Flux coated electrode should be used in SMAW.

Que.13. What are the precautions taken during the welding of SS material?
Ans.13. The precautions taken during the welding of SS material
a) Material contamination should be removed.
b) Use tools and tackles which are compatible with SS material.
c) Shielding gas should be used during welding.
d) Avoid the contact of CS material to SS material.

Que.14. Can CS qualified welder perform welding in SS material? Give reason.

Ans.14. No, because the P no. is different, this is essential parameter for welder performance.

Que.15. Can welder qualified with ER70-S-2 perform welding with ER309L? Give reason.
Ans.15. No, because the F no. and P No. is different, this is essential variable for welder performance and
WPS is different.

Que.16. What are the essential variables for welding procedure qualification?
Ans.16. Essential variables for welding procedure qualification
a) P- no. qualified
b) Thickness qualified
c) F-no. qualified
d) Post weld heat treatment
e) Preheat temperature
f) Type of fuel gas.
g) Use of thermal process.
h) Welding Process
Que.17. What are the essential variables for welder performance qualification?
Ans.17. Essential variables for welder performance qualification
a) Joint (backing or without backing)
b) P- no. qualified
c) Base metal thickness qualified
d) Thickness of weld deposited
e) F-no. qualified
f) Position (uphill or vertical down welding).
g) Pipe diameter.
h) Welding Process

Que.18. What are the supplementary essential variables for welding procedure qualification?
Ans.18. Supplementary essential variables for welding procedure qualification
Notch toughness requirement (change in group no.).
Post weld heat treatment,

Que.19. What are the non essential variables for welding performance qualification?
Ans.19. The non essential variables for welder performance qualification
a) Joint design
b) String / weave bead.
c) Method of back gauging or cleaning.

Que.20. What are the upper & lower limits for welder qualified in 1 inch NB pipe?
Ans.20.. Upper limit: Unlimited, Lower limit: 1 inch NB pipe.

Que.21. What is the upper & lower limit for welder test coupon sample of 6 inch diameter?
Ans.21. Upper limit: Unlimited, Lower limit: 73 mm OD diameter.

Que.22. What is the upper & lower limit for welder welds 18 mm thick plate?
Ans.22. For base metal lower limit: 5 mm, Upper limit: Max to be weld.

Que.23.Plate of 3 inch welded by GTAW up to 1 inch & 2 inch welded by SMAW by a welder then what
are the limits for welds?
Ans.23. For GTAW base metal 5 mm to max to be weld, & for SMAW 5 mm to max to be weld with backing.
For GTAW weld metal max to be weld, & for SMAW max to be weld with backing.

Que.24. Sample of 3 inch plate is welded 1 inch by one welder and 2 inch weld by another welder, what
are the limits of welds?
Ans.24. For 1st welder weld metal 5mm to max to be weld & for 2nd welder 5 mm to max to be weld with
backing.

Que.25. What are P- Number, Group No., F- Number and A- Number?

Ans.25. P- Number: are assigned to base metal for the purpose of reducing the no. of WPS or BPS. These
assignments are based essentially on comparable base metal characteristics such as, composition,
weldability or brazeability and mechanical properties.
Group No. : Ferrous base metal assigned, creating subset of P no. that are used when WPS are
required to be qualified by impact testing.
F- Number: is based essentially on their usability characteristics which fundamentally determine the
ability of welders to make satisfactory welds with a given filler metal.
A- Number: identification of weld metal chemical composition designate on PQR & WPS.

Que.26. What is P- No. of CS, SS, Al & its alloys?

Ans.26. P-No. of CS - 1, SS – 8, Al – 21
Que.27. Define code & procedure?
Ans.27. Code: a set of mandatory requirements to get output as per intended use.
Procedure: an orderly sequence of activities describing how a specific technique shall be applied.

Que.28. What is the reverse polarity and straight polarity?

Ans.28. Reverse polarity: DCEP Direct current electrode positive.
Straight polarity: DCEN Direct current electrode negative

Que.29. Why preheat is required?

Ans.29. Preheat is required
a) To drive away moisture from the weld area.
b) To slower the thermal gradient.
c) To slows the cooling rate.
d) Avoid crack during welding.

Que.30. Why PWHT is required?

Ans.30. PWHT is required for
a) Stress relief of material near weld zone.
b) Thermal tempering treatment.
c) Refine the coarse grain structure, reduce stresses after welding & remove any hard zones in
HAZ.
d) Regain their original properties.

Que.31. What are WPS, WPQ, and PQR?

Ans.31. Welding Procedure Specification: to determine the mechanical properties and soundness of weld
metal.
Welder Performance Qualification: to determine the ability of welder or welding operator to deposit
sound weld metal.
Procedure Qualification Record: It is the record of variable during welding including the mechanical
and soundness test of weld metal.

Que.32. What is meant by essential, non essential and supplementary essential variable in welding
Procedure Qualification?

Ans.32. Essential Variable (Procedure): A change in a welding condition which will affect the mechanical
properties (other than notch toughness) on the weld metal (e.g. P-No., welding process, Filler metal,
electrode, preheat, PWHT).
Essential Variable (Performance): A change in a welding condition which will affect the ability of a
welder to deposit sound weld metal (such as a change in welding process, deletion of backing,
electrode, F-No., technique, etc)
Supplementary Essential Variable: A change in a welding condition which will affect the notch
toughness properties of a weldment (for example, change in welding process, uphill or down vertical
welding, heat input, preheat or PWHT, etc).
Nonessential Variable (Procedure): A change in a welding condition which will not affect the
mechanical properties of a weldment (such as joint design, method of back gouging or cleaning, etc).

Que.33. How you identify CS & SS after machining?

Ans.33. This can be identified by the following methods
a) By magnet
b) By PMI (positive metal Indicator)
Que.34. What are the welding defects and its causes and remedies?
Ans.34. The common welding defects and its causes and remedies are listed below.

Welding Defects Causes Remedies

1) Excessively long or short arc length 1) Maintain proper arc length.
2) Welding current too high 2) Use proper welding current.
3) In-sufficient or damp shielding gas 3) Increase gas flow rate & check gas
Porosity 4) Too fast travel speed purity.
5) Base metal surface covered with oil, 4) Reduce (Maintain) travel speed as
grease, moisture, rust, mill scale etc. required.
6) Wet, unclean or damaged electrode 5) Properly maintain and store electrode
1) Insufficient weld size 1) Adjust weld size to part thickness.
2) Excessive joint restraint 2) Reduce joint restraint through proper
3) Poor joint design and / or penetration design.
4) Filler metal does not match with base 3) Select the proper joint design.
metal 4) Use more ductile filler.
Cracks
5) Rapid cooling rate 5) Reduce cooling rate through preheat.
6) Base metal surface covered with oil, 6) Properly clean base metal prior to
grease, moisture, rust, dirt or mill scale welding.
7) Re dry Low Hydrogen Electrode at
required temperature for required time.
1) Faulty electrode manipulation 1) Pause at each side of the weld bead
2) Welding current too high when using a weaving technique
3) Too long an arc length 2) Use proper electrode angle
4) Too fast travel speed 3) Use proper welding current for electrode
Undercut
5) Arc blow size and welding position
4) Reduce arc length
5) Reduce travel speed
6) Reduce effects of arc blow
1) Improper tack welding and / or faulty 1) Tack weld parts with allowance for
joint preparation distortion
2) Improper bead sequence. 2) Use proper bead sequence
3) Improper setup and fixing. 3) Tack or clamp parts securely.
Distortion
4) Excessive weld size. 4) Make welds to specified size.
5) Prepare welding sequence.
6) Maintain inter pass temperature during
welding.
1) Arc blow 1) Attempt to reduce the effect of arc blow
2) Welding current too high 2) Reduce welding current
Spatters
3) Too long an arc length 3) Reduce arc length
4) Wet, unclean or damaged electrode 4) Properly maintain and store electrode
1) Improper travel speed 1) Reduce travel speed
2) Welding current too low 2) Increase welding current
3) Faulty joint penetration 3) Weld design should allow electrode
4) Too large electrode diameter accessibility to all surfaces within the
Lack of Fusion
5) Magnetic arc blow joint
6) Wrong electrode angle 4) Reduce electrode diameter
5) Reduce effects of magnetic arc blow
6) Use proper electrode angle
 1) Travel speed too fast 1) Decrease travel speed
2) Welding current too low 2) Increase welding current
3) Poor joint design and / or preparation 3) Increase root opening or decrease root
4) Electrode diameter too large face
Poor penetration
5) Wrong type of electrode 4) Use smaller electrode
6) Excessively long arc length 5) Use electrode of deeper penetration
characteristics
6) Reduce arc length
1) Unbalanced magnetic field during 1) Use alternating current.
Magnetic arc welding 2) Reduce welding current and arc length.
blow 2) Excessive magnetism in pads or fixture 3) Change the location of the connection on
the work piece.
1) Incomplete slag removal between 1) Completely remove slag between passes
passes 2) Use a uniform travel speed
2) Erratic travel speed 3) Reduce width of weaving technique
3) Too wide a weaving motion 4) Use a smaller electrode size for better
Inclusion 4) Too large an electrode access of joint
5) Letting slag run ahead of arc 5) Increase travel speed or change
6) Tungsten spitting or sticking electrode angle or reduce arc length
6) Properly prepare tungsten and use
proper current

Que.35. Write procedure format

Ans.35. The procedure has the following chapters
1. Objective
2. Scope of work
3. Applicability
4. Reference Document
5. Responsibility
6. Pre-requisite
7. Equipment, tools and tackles
8. Procedure
9. Precaution
10. Acceptance criteria
11. Records & attachments
12. Distribution

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