EXERCISE QUESTIONS – INTRODUCTION AND MODULE # 1

1.1 Where are the definitions associated with welding as per AWS D1.1 to be found?
a. AWS A2.4
b. AWS A3.0
c. Annex B
d. b and c above
e. All of the above

1.2 Safety precautions to be observed during welding to AWS D1.1 are found in

a. Annex J
b. ANSI Z49.1
c. Annex K
d. a and b above
e. All of the above

1.3 What does the nonstandard term “ down hand” mean?

a. Welding vertically downward

b. Welding in the flat position
c. The pause during electrode changes
d. The pause of welding during deslagging

1.4 In what year was the first bridge welding specification published by the AWS?

a. 1928
b. 1934
c. 1936
d. 1972
e. 1988

1.5 Which of the following steels are intended to be used in work covered by D1.1

a. All alloy steels with a yield strength of 97 000 psi or less

b. Low carbon steels, 5/32 in. thick
c. Low alloy steels with a yield
d. Low carbon stainless steels
e. None of the above

1.6 When contract documents stipulate the use of AWS D1.1

a. All provisions of AWS D1.1 are mandatory

b. All welding procedures must be qualified according to section 4
c. Any AWS code may be used
d. The engineer may modify the requirements of AWS D1.1
e. a and d are both correct
EXERCISE QUESTIONS – MODULE # 2

2.1 Part A. What is the minimum length of a fillet weld?

a. 3 inches
b. Twice the base metal thickness
c. 4 times the nominal size of the fillet weld
d. 6 inches
e. Size shall be specified on the drawing

2.2 Part A. What is the minimum diameter of a plug weld?

a. 1. In
b. The thickness of the thinner plate
c. The thickness of the thicker plate
d. The thickness of the plate it is in plus 5/16 in.
e. Up to the Engineer’s discretion

2.3 Part B In a complete joint penetration weld, where the stress is tension normal to the effective
area the allowable stress is

a. Same as base metal

b. Same as filler metal
c. Not a weld joint design consideration
d. 0.30 times the tensile strength of the filler metal
e. Not specified

2.4 Part D. What is the Z loss dimension for a prequalified PJP T-, Y-, K- connector with a groove
angle of 50° using short circuiting transfer GMAW in the horizontal position?

a. 0
b. 1/8 in.
c. 1/4 in.
d. 6 mm
e. c & d above

2.5 The effective throat of a skewed T joint with an acute angle of 45 degrees is determined by;

a. The requirements of the shop drawings

b. 1/16 in. less than the thickness of the base metal
c. The distance from the root to the diagrammatic face
d. The distance from the root to the face less the Z loss dimension
e. Recommendations of the engineer

2.6 What is the maximum size of the fillet weld in a lap joint of member 3/8 in. thick?

a. 3/16 inch.
b. 1/4 inch.
c. 5/16 inch.
d. 3/8 inch.
e. Any size at designer’s option except if cyclically loaded
2.7 What is the maximum allowable stress for CJP groove weld metal splicing two ASTM A36
steel members, subject to loading of 2 X 106 life time stress reversals, assuming the welds are
ground flush and inspected by Ultrasonic Testing (Class R)

a. 7500 psi
b. 10 000 psi
c. 13 500 psi
d. 15 000 psi
e. 19 000 psi
EXERCISE QUESTIONS – MODULE # 3

3.1 What is the minimum tensile strength of steel conforming to ASTM A572, Grade 65?

a. 60 000 psi
b. 65 000 psi
c. 70 000 psi
d. 75 000 psi
e. 80 000 psi

3.2 What is the required minimum preheat and interpass temperature for 1 inch. Thick API 5L
grade B steel welded with flux cored are welding?

a. 150° F
b. 100° F
c. 50° F
d. None
e. None except if ambient temperature is < 50° F

3.3 May a groove preparation detailed for SMAW be used unchanged for FCAW prequalified
WPSs?

a. Yes
b. No
c. Only if FCAW is used in DCEP mode
d. Only when welding group I or group II steels are being welded
e. Only at designers options except if joints are statically loaded

3.4 What is the range of groove angels for joint designation BC-P8, as fit up?

a. 45° to 55°
b. 40° to 55°
c. 35° to 50°
d. 30° to 45°
e. 25° to 40°

3.5 What is the maximum depth of bevel S2 for join designation B-U3 when welding 3-1/2 in
plate?

a. 1-1/4 in.
b. 1-1/8 in.
c. 1
d. 7/8 in.
e. 3/4 in

3.6 When utilizing a prequalified joint design to weld A588 steel, what is the maximum size for a
single pass fillet weld made with the SMAW process?

a. 5/16 in.
b. 1/4 in.
c. 3/8 in.
d. 1/2 in.
e. 1/8 in
EXERCISE QUESTIONS – MODULE # 4

4.1 Plug and slot tests welded in the horizontal position qualify a WPS in what position (s)?

a. All
b. Flat and horizontal
c. All except overhead
d. Horizontal
e. None of the above

4.2 A groove weld qualification on 1/2 in. plate qualifies a procedure for what range of thickness?

a. 0 to 1 in.
b. 0 to 3/4 in.
c. 1/8 in. to 1 in.
d. 1/8 in. to 3/4 in.
e. None of the above

4.3 What diameters of electrodes are qualified by procedure test using a 5/64 in. FCAW
electrode?

a. All diameters
b. 5/64 in. only
c. 5/64 in. and smaller
d. 5/64 in. and larger
e. None of the above

4.4 May qualified WPS for a CJP groove weld be used to weld PJP grooves?

a. Yes
b. No
c. Only when used for T- groove joints with a superimposed fillet weld
d. Only if designated weld size is demonstrated by three macroetch cross-section specimens
e. Only if designated weld size is checked by on-job macro sections

4.5 The minimum length of a T-joint fillet weld test coupon for welder performance qualification is

a. 6 in.
b. 7 in.
c. 9 in.
d. 15 in.
e. 8 in. minimum

4.6 If a welder is successfully qualified on 5/8 in. thick A36 steel with an E6010 electrode, which of
the following situations is the welder also qualified for?

a. Using an E7018 electrode on A588 steel

b. Using an E6013 electrode on A36 steel less than or equal to 3/4 in.
c. Using the GMAW process on A36 steel
d. The welder is qualified to use any SMAW electrode on any steel in table 3.1
e. The welder in qualified only with E6013 on Group I steels
EXERCISE QUESTIONS – MODULE # 5

5.1 How many times may low hydrogen electrodes be rebaked?

a. Once
b. Twice
c. Not limited
d. Not limited, except if coating is damaged
e. Not specified

5.2 What grade or grades of steel should be used for spacers?

a. Any approved (Table 3.1 or Annex M) base metal

b. Only steels of the 60 ksi class
c. Any approved steel matching the weld metal
d. The same as the base metal
e. Any grade of steel, as the spacer will be gouged out during welding

5.3 What is the allowable deviation from straightness for a 40-foot long primary truss member?

a. 1/2 in.
b. 7/16 in.
c. 3/8 in.
d 5/16in.
e. 1/4 in.

5.4 What is the allowable variation between the center lines of the web and flange of a 30 foot long
built-up I-beam?

a. 1/2 in.
b. 7/16 in.
c. 3/8 in.
d. 5/16 in.
e. 1/4 in.

5.5 What is allowable misalignment between members of a butt joint, under any circumstances?

a. No misalignment permitted
b. 1/8 in.
c. 10% of the thickness of the thinner member
d. 10% of the thickness of the thicker member
e. Both b and c above

5.6 Which of the following in NOT true regarding the acceptability of a tack weld?

a. Undercut and porosity must always be removed from a tack weld

b. Tack welds not incorporated into final welds of statically loaded structures need not always be
removed.
c. Incorporated tack welds must be made with an electrode meeting the requirements of that used
for the final weld.
d. Multiple-pass tack welds shall have cascaded ends.
e. Undercut and porosity need not be removed from tack welds in SAW.
EXERCISE QUESTIONS- MODULE # 6

6.1 Who is responsible to ensure that welding equipment conforms to the provisions of 5.11?

a. The contractor
b. The Engineer
c. The welder
c. The welding inspector
e. Not specified

6.2 What maximum depth of undercut is permitted in transverse splices of primary members?

a. 0.01 in.
b. 1/32 in.
c. 1/16 in.
d. None permitted
e. Not specified

6.3 Except for stiffener-to-web joints, the maximum diameter of piping porosity in fillet welds is

a. 1/32 in.
b. 1/16 in.
c. 3/32 in.
d. 1/8 in.
e. None of the above

6.4 For a groove welded tension member in 3/4 in. plate, what is the maximum size of fusion
discontinuity permitted in a statically loaded member?

a. 1/2 in.
b. 7/16 in.
c. 3/8 in.
d. 5/16 in.
e. 1/4 in.

6.5 For the joint in Question 6.4, what designation hole type IQI should be used?

a. 10
b. 12
c. 15
d. 17
e. 20

6.6 What is the essential wire diameter (of wiretype IQI) for the joint in Question 6.4?

a. 0.010 in.
b. 0.013 in.
c. 0.016 in.
d. 0.020 in.
e. 0.025 in.
6.7 NDT procedures are provided in AWS D1.1 for which of the following processes?

a. RT
b. UT
c. a and b above
e. b and c above

6.8 In what circumstances, if any, can a CWI whose certification has expired, accept D1.1 work?

a. Not permitted due to expiry of certification

b. Requires Engineer approval
c. Permitted with a current visual acuity test
d. Permitted with a current visual acuity test and Engineer approval
e. May only work as a CAWI
EXERCISE QUESTIONS- MODULE # 7

7.1 What action is required if a crack 1/4 in. long is observed in a standard 5/8 in. stud head?

a. No action, use as is
b. Repair crack and use
c. Do not use, replace stud
d. Suitable only

7.2 Through what angle are the daily start up test studs to e bent, assuming 360° flash?

a. Bend test not required with 360° flash

b. 30°
c. 15°
d 10°
e. +- 10°

7.3 Prequalified welding procedures may be used to weld studs with the following processes?

a. SMAW only
b. GTAW, SMAW, GMAW
c. SAW. GMAW, FCAW
d. FCAW, GMAW, SMAW
e. Prequalified welding processes are not acceptable for welding studs
EXERCISE QUESTIONS- MODULE # 8

8.1 Which of the following is not a recommended method of cyclic loading improvement?

a. Toe grinding with a carbide burr or pencil grinder

b. Toe grinding plus hammer peening
c. Toe grinding plus shot peening of the weld toes
d. Reshaping of weld toes by TIG welding
e. Hammer peening of weld toes

8.2 When using heat to straighten or curve tempered steel, the maximum temperature of heated
areas shall not exceed:

a. 600 degrees
b. 1200 degrees
c. 250 degrees
d. 1100 degrees
e. The maximum temperature is unlimited

8.3 Base metal surfaces of existing base metal in contact with new base metal which will be
welded shall be thoroughly cleaned of all foreign matter including paint for at least:

a. 1 inch
b. 1 inch from the root of the weld
c. 2 inches from the toe of the weld
d. 2 inches from the weld reinforcement
e. 2 inches from the root of the weld