50 top most tricky questions for cwi practice test part a
During a welding operation using shielded metal arc welding (SMAW) on a thick carbon steel plate, the welder observes excessive spatter and inconsistent arc stability. The electrode is a low-hydrogen type, and the welding parameters are within the recommended range. The welder confirms that the electrodes were stored in a heated oven to prevent moisture pickup. What could be the most likely cause of these issues, considering the environmental conditions of the welding site? A) Incorrect electrode angle B) Contaminated base metal surface C) Excessive wind disrupting the arc D) Improper polarity setting
In radiographic testing (RT) of a butt weld, the inspector notices a series of small, rounded indications scattered throughout the weld. These indications appear lighter than the surrounding weld metal on the radiograph, suggesting a density difference. Could these indications be confused with slag inclusions, and what is the most likely weld imperfection they represent? A) Slag inclusions B) Porosity C) Tungsten inclusions D) Lack of fusion
When performing a visual inspection on a fillet weld joining two structural steel components, the inspector observes that the weld profile is excessively convex, and the leg lengths are slightly below the specified minimum. The weld surface is smooth with no visible porosity or cracks. What is the primary concern with this weld, and how might it affect the component’s performance in a fatigue-sensitive application? A) Reduced corrosion resistance B) Increased risk of fatigue cracking C) Improved impact strength D) Enhanced weld penetration
In gas tungsten arc welding (GTAW) of stainless steel, the welder uses pure argon as the shielding gas but notices a grayish discoloration on the weld bead and adjacent heat-affected zone (HAZ). The weld pool is stable, and the tungsten electrode is properly prepared. What is the most likely cause of this discoloration, and how can it be prevented in future welds? A) Excessive heat input; reduce current B) Insufficient shielding gas coverage; increase gas flow C) Contaminated filler wire; use cleaner wire D) Improper electrode type; switch to thoriated tungsten
A welding procedure for a high-strength low-alloy (HSLA) steel requires preheating to a specific temperature before welding. The welder applies preheat using a torch but notices that the base metal cools rapidly during welding, leading to incomplete fusion at the weld toes. Could this issue be related to the preheat application method, and what specific factor should be investigated to resolve this problem? A) Inadequate preheat temperature B) Uneven preheat distribution C) Excessive welding speed D) Incorrect electrode diameter
During magnetic particle testing (MT) of a welded joint, the inspector uses a yoke with alternating current (AC) and observes strong indications along the weld toe. When direct current (DC) is used, the indications disappear. What does this suggest about the nature of the discontinuities, and why might AC be more effective in this case? A) Subsurface cracks; DC is more sensitive to surface defects B) Surface cracks; AC is more sensitive to surface defects C) Slag inclusions; AC penetrates deeper D) Porosity; DC enhances visibility
In a multi-pass welding operation using flux-cored arc welding (FCAW), the inspector finds slag inclusions between weld passes despite the welder’s efforts to clean the weld thoroughly with a wire brush and chipping hammer. The slag appears entrapped near the weld root. What could be a contributing factor to this issue, and how might the welding technique be adjusted to minimize slag entrapment? A) Excessive heat input; reduce voltage B) Improper electrode angle; adjust to a drag angle C) Inadequate shielding gas; increase flow rate D) High travel speed; slow down
A welder is performing gas metal arc welding (GMAW) with a short-circuiting transfer mode on thin-gauge mild steel. The weld bead shows consistent lack of fusion along the weld toes, even though the voltage and wire feed speed are within the recommended range. Could the shielding gas composition be a factor, and what specific change might improve fusion? A) Using 100% CO2; switch to 75% argon, 25% CO2 B) Using 75% argon, 25% CO2; switch to 100% argon C) Using pure helium; switch to 100% CO2 D) Using 100% argon; switch to pure helium
In welding metallurgy, a high-carbon steel weld exhibits cracking in the heat-affected zone (HAZ) after cooling. The welding procedure included adequate preheat, and the cooling rate was controlled using insulated blankets. Could the cracking be related to the base metal’s chemical composition, and what specific element might be responsible for this issue? A) Low carbon content; increases brittleness B) High sulfur content; promotes hot cracking C) High carbon content; increases hardenability D) Low manganese content; reduces toughness
During a liquid penetrant testing (PT) inspection of a stainless steel weld, the inspector applies the penetrant and allows a dwell time of 10 minutes. After cleaning and applying the developer, no indications are visible. A subsequent inspection reveals fine surface cracks. What could have caused the initial test to miss these cracks, and what adjustment should be made? A) Insufficient dwell time; increase to 20 minutes B) Improper cleaning; use a solvent cleaner C) Wrong developer type; use a dry developer D) Excessive penetrant; apply a thinner layer
A welding inspector is evaluating a groove weld made with submerged arc welding (SAW) on a thick plate. The weld appears sound visually, but ultrasonic testing (UT) reveals planar discontinuities near the weld centerline. Could these discontinuities be confused with lack of fusion, and what is the most likely type of imperfection? A) Slag inclusions B) Centerline cracking C) Lack of fusion D) Porosity
When welding aluminum using GTAW, the welder notices that the weld pool is difficult to control, and the bead appears contaminated with black specks. The shielding gas is pure argon, and the filler wire is compatible with the base metal. Could the issue be related to surface preparation, and what specific step might have been overlooked? A) Inadequate preheat; apply preheat B) Presence of oxide layer; clean with a stainless steel brush C) Contaminated shielding gas; replace gas cylinder D) Incorrect filler wire; use a different alloy
In a welding operation, the welder uses SMAW with a cellulosic electrode on a pipeline joint. The weld passes visual inspection but fails a bend test due to excessive porosity. Could the electrode type be a contributing factor, and what alternative electrode might reduce porosity? A) Cellulosic electrode; switch to low-hydrogen electrode B) Low-hydrogen electrode; switch to rutile electrode C) Rutile electrode; switch to cellulosic electrode D) Basic electrode; switch to acidic electrode
During a safety audit of a welding shop, the inspector notices that welders are using inadequate ventilation while performing FCAW with a self-shielded wire. The shop has no local exhaust systems, and the welders report dizziness and nausea. What specific health hazard is associated with this situation, and what immediate action should be taken? A) Carbon monoxide exposure; install local exhaust ventilation B) Fume inhalation; provide respirators C) Arc flash exposure; use welding curtains D) Noise exposure; provide ear protection
A welding procedure for a low-alloy steel specifies post-weld heat treatment (PWHT) to reduce residual stresses. After PWHT, the inspector notices that the hardness of the weld metal has increased unexpectedly. Could this be due to an improper PWHT process, and what specific parameter should be checked? A) Holding time; ensure sufficient duration B) Cooling rate; ensure slow cooling C) Heating rate; ensure rapid heating D) Temperature; ensure it is below transformation range
In RT of a weld, the inspector observes a dark, elongated indication with irregular edges near the weld root. The indication is not aligned with the weld axis, distinguishing it from typical linear imperfections. Could this be mistaken for a crack, and what is the most likely imperfection? A) Crack B) Slag inclusion C) Lack of fusion D) Incomplete penetration
When inspecting a weld made with GMAW, the inspector finds that the weld bead is excessively wide with shallow penetration. The welder confirms that the voltage is set high, and the wire feed speed is moderate. Could the travel speed be a factor, and how might it be adjusted to improve the weld profile? A) High travel speed; reduce speed B) Low travel speed; increase speed C) High travel speed; increase voltage D) Low travel speed; reduce wire feed speed
In welding metallurgy, a stainless steel weld exhibits sensitization in the HAZ, leading to intergranular corrosion. The welding procedure used a low heat input, and the base metal was stabilized with titanium. Could the filler metal selection be a factor, and what specific characteristic of the filler metal should be considered? A) High carbon content; use low-carbon filler B) Low chromium content; use high-chromium filler C) Non-stabilized filler; use stabilized filler D) High nickel content; use low-nickel filler
During UT of a butt weld, the inspector detects a high-amplitude echo with a sharp rise near the weld root, but the indication does not move significantly with probe repositioning. Could this be confused with porosity, and what is the most likely discontinuity? A) Porosity B) Lack of fusion C) Slag inclusion D) Crack
A welder using SMAW on a high-strength steel notices that the weld bead has a rough appearance with excessive spatter. The electrode is a low-hydrogen type, and the welder is using DCEN polarity. Could the polarity be a factor, and what change might improve the weld quality? A) DCEN; switch to DCEP B) DCEP; switch to DCEN C) DCEN; switch to AC D) AC; switch to DCEP
In PT, the inspector observes bright red indications under blacklight after applying the developer, but the indications fade quickly. The weld is made on carbon steel, and the penetrant is fluorescent. What could cause this issue, and how should it be addressed? A) Excessive developer; reduce developer thickness B) Insufficient dwell time; increase penetrant dwell C) Improper cleaning; ensure thorough cleaning D) Wrong penetrant type; use visible dye penetrant
A welding procedure for aluminum using GMAW specifies a spray transfer mode. The welder notices burn-through on thin sections despite using the recommended parameters. Could the shielding gas be a factor, and what gas might reduce burn-through? A) 100% argon; switch to 100% helium B) 100% helium; switch to 100% argon C) 75% argon, 25% helium; switch to 100% helium D) 100% argon; switch to 75% argon, 25% helium
In welding metallurgy, a low-alloy steel weld exhibits excessive hardness in the HAZ after welding. The procedure included preheat, but no PWHT was performed. Could the absence of PWHT be a factor, and what would PWHT achieve in this case? A) No; PWHT increases hardness B) Yes; PWHT reduces hardness and residual stresses C) No; PWHT only improves corrosion resistance D) Yes; PWHT enhances weld penetration
During MT of a fillet weld, the inspector uses a prod technique with DC and observes no indications. A subsequent test with AC reveals fine linear indications along the weld toe. What does this suggest about the discontinuities, and why was AC more effective? A) Subsurface cracks; DC is more sensitive B) Surface cracks; AC is more sensitive C) Slag inclusions; AC penetrates deeper D) Porosity; DC enhances visibility
A welder using FCAW with a gas-shielded wire notices excessive smoke and fumes during welding. The shielding gas is 75% argon, 25% CO2, and the ventilation is adequate. Could the wire composition be a factor, and what change might reduce fume generation? A) High flux content; use a lower-flux wire B) Low flux content; use a higher-flux wire C) High carbon content; use a low-carbon wire D) Low manganese content; use a high-manganese wire
In RT, the inspector observes a light, branching indication in the weld metal that resembles a tree-like pattern. Could this be mistaken for porosity, and what is the most likely imperfection? A) Porosity B) Crack C) Slag inclusion D) Lack of fusion
A welding inspector is evaluating a weld made with SAW. The weld bead is smooth, but UT reveals a lack of sidewall fusion. The welder confirms that the flux was dry and the wire was clean. Could the welding parameters be a factor, and what specific parameter should be adjusted? A) Low voltage; increase voltage B) High current; reduce current C) Low travel speed; increase travel speed D) High wire feed speed; reduce wire feed speed
In welding metallurgy, a duplex stainless steel weld exhibits reduced corrosion resistance despite using a matching filler metal. The welding procedure used a moderate heat input. Could the cooling rate be a factor, and what adjustment might improve corrosion resistance? A) Slow cooling; increase cooling rate B) Fast cooling; decrease cooling rate C) Slow cooling; reduce heat input D) Fast cooling; increase preheat
During a safety inspection, the inspector notices that welders using GTAW are not wearing proper PPE, specifically lacking tinted face shields. What specific hazard are they exposed to, and what PPE should be mandated? A) Fume inhalation; respirators B) Arc radiation; tinted face shields C) Sparks; leather gloves D) Noise; earplugs
A welder using GMAW on stainless steel notices incomplete penetration in a groove weld. The parameters include a high voltage and a moderate wire feed speed. Could the joint preparation be a factor, and what change might improve penetration? A) Narrow joint gap; widen the gap B) Wide joint gap; narrow the gap C) Small bevel angle; increase the bevel angle D) Large bevel angle; decrease the bevel angle
In UT, the inspector observes a series of small, scattered echoes with low amplitude in the weld metal. These echoes move slightly with probe repositioning. Could these be confused with cracks, and what is the most likely discontinuity? A) Cracks B) Porosity C) Lack of fusion D) Slag inclusions
A welding procedure for carbon steel using SMAW specifies a low-hydrogen electrode. The welder notices that the arc is unstable, and the weld bead is irregular. Could the electrode storage be a factor, and what specific issue should be checked? A) Excessive moisture; ensure dry storage B) Incorrect diameter; use a larger electrode C) Damaged coating; use undamaged electrodes D) Wrong polarity; switch to AC
In welding metallurgy, a high-strength steel weld exhibits brittle fracture during service. The welding procedure included preheat and PWHT, but the filler metal was not low-hydrogen. Could the filler metal be a factor, and what characteristic should be considered? A) High carbon content; use low-carbon filler B) Non-low-hydrogen; use low-hydrogen filler C) Low manganese content; use high-manganese filler D) High chromium content; use low-chromium filler
During PT of a weld, the inspector applies the penetrant but notices that it beads up on the surface instead of spreading evenly. The weld is clean and free of grease. Could the surface condition be a factor, and what should be done? A) Smooth surface; roughen with sandpaper B) Rough surface; polish to smooth C) Wet surface; dry thoroughly D) Cold surface; warm to room temperature
A welder using GTAW on titanium notices a brittle weld with a dull appearance. The shielding gas is pure argon, and the weld is performed in a controlled environment. Could the shielding gas coverage be a factor, and what adjustment might improve weld quality? A) Insufficient gas flow; increase flow rate B) Excessive gas flow; reduce flow rate C) Wrong gas type; switch to helium D) Contaminated gas; replace cylinder
In RT, the inspector observes a dark, rounded indication with a smooth outline in the weld metal. Could this be mistaken for slag inclusion, and what is the most likely imperfection? A) Slag inclusion B) Porosity C) Tungsten inclusion D) Lack of fusion
A welding inspector is evaluating a fillet weld made with FCAW. The weld has a uniform appearance, but MT reveals linear indications parallel to the weld axis. Could these be confused with cracks, and what is the most likely discontinuity? A) Cracks B) Lack of fusion C) Slag inclusions D) Porosity
In welding metallurgy, a nickel alloy weld exhibits hot cracking in the weld metal. The welding procedure used a low heat input and a matching filler metal. Could the weld pool chemistry be a factor, and what element might contribute to hot cracking? A) High sulfur; use low-sulfur filler B) Low nickel; use high-nickel filler C) High chromium; use low-chromium filler D) Low carbon; use high-carbon filler
During a safety audit, the inspector notices that welders using SMAW are not using insulated electrode holders. What specific hazard are they exposed to, and what corrective action should be taken? A) Electric shock; use insulated holders B) Arc radiation; use tinted shields C) Fume inhalation; provide respirators D) Burns; use leather gloves
A welder using GMAW with a globular transfer mode notices excessive spatter and an irregular weld bead. The shielding gas is 100% CO2, and the parameters are within the recommended range. Could the transfer mode be a factor, and what change might improve weld quality? A) Globular transfer; switch to short-circuiting B) Short-circuiting; switch to globular C) Globular transfer; switch to spray transfer D) Spray transfer; switch to short-circuiting
In UT, the inspector observes a high-amplitude echo with a broad base near the weld toe. The indication shifts slightly with probe repositioning. Could this be confused with a crack, and what is the most likely discontinuity? A) Crack B) Slag inclusion C) Lack of fusion D) Porosity
A welding procedure for stainless steel using GTAW specifies a low heat input to prevent distortion. The welder notices that the weld bead is narrow with incomplete fusion. Could the heat input be a factor, and what adjustment might improve fusion? A) Low heat input; increase current B) High heat input; reduce current C) Low heat input; reduce travel speed D) High heat input; increase travel speed
In welding metallurgy, a carbon steel weld exhibits excessive grain growth in the HAZ, leading to reduced toughness. The welding procedure used a high heat input. Could the heat input be a factor, and what adjustment might reduce grain growth? A) High heat input; reduce heat input B) Low heat input; increase heat input C) High heat input; increase preheat D) Low heat input; reduce cooling rate
During MT of a weld, the inspector uses a coil with AC and observes no indications. A subsequent test with DC reveals subsurface indications. What does this suggest about the discontinuities, and why was DC more effective? A) Surface cracks; AC is more sensitive B) Subsurface cracks; DC is more sensitive C) Slag inclusions; AC penetrates deeper D) Porosity; DC enhances visibility
A welder using SAW on a thick plate notices that the weld bead is uneven with undercut along the edges. The flux is dry, and the wire is clean. Could the welding parameters be a factor, and what specific parameter should be adjusted? A) High voltage; reduce voltage B) Low current; increase current C) High travel speed; reduce travel speed D) Low wire feed speed; increase wire feed speed
In PT, the inspector observes no indications after applying the developer, but a subsequent RT reveals fine surface cracks. The penetrant was applied correctly, and the dwell time was adequate. Could the developer application be a factor, and what should be checked? A) Insufficient developer; increase thickness B) Excessive developer; reduce thickness C) Wrong developer type; use a non-aqueous developer D) Contaminated developer; use fresh developer
A welding procedure for titanium using GTAW specifies a trailing shield to protect the weld. The welder notices a brittle weld despite using the shield. Could the trailing shield be a factor, and what specific issue should be checked? A) Insufficient gas flow; increase flow rate B) Contaminated gas; replace cylinder C) Excessive shield size; reduce shield size D) Improper shield positioning; adjust positioning
In welding metallurgy, a low-alloy steel weld Exhibits lack of toughness due to martensite formation in the HAZ. The welding procedure included preheat but no PWHT. Could PWHT improve toughness, and what would it achieve? A) No; PWHT increases martensite formation B) Yes; PWHT tempers martensite and improves toughness C) No; PWHT only reduces corrosion D) Yes; PWHT enhances weld penetration
During a safety inspection, the inspector notices that welders using FCAW are not wearing flame-resistant clothing. What specific hazard are they exposed to, and what PPE should be mandated? A) Arc radiation; tinted face shields B) Sparks and slag; flame-resistant clothing C) Fume inhalation; respirators D) Electric shock; insulated gloves
A welder using GMAW on a thick plate notices incomplete penetration despite using a high current and a wide joint gap. Could the electrode extension be a factor, and what adjustment might improve penetration? A) Long electrode extension; reduce extension B) Short electrode extension; increase extension C) Long electrode extension; increase voltage D) Short electrode extension; reduce wire feed speed
Answers
C) Excessive wind disrupting the arc
B) Porosity
B) Increased risk of fatigue cracking
B) Insufficient shielding gas coverage; increase gas flow
B) Uneven preheat distribution
B) Surface cracks; AC is more sensitive to surface defects
B) Improper electrode angle; adjust to a drag angle
A) Using 100% CO2; switch to 75% argon, 25% CO2
C) High carbon content; increases hardenability
A) Insufficient dwell time; increase to 20 minutes
B) Centerline cracking
B) Presence of oxide layer; clean with a stainless steel brush
A) Cellulosic electrode; switch to low-hydrogen electrode
B) Fume inhalation; provide respirators
D) Temperature; ensure it is below transformation range
B) Slag inclusion
A) High travel speed; reduce speed
C) Non-stabilized filler; use stabilized filler
D) Crack
A) DCEN; switch to DCEP
A) Excessive developer; reduce developer thickness
B) 100% helium; switch to 100% argon
B) Yes; PWHT reduces hardness and residual stresses
B) Surface cracks; AC is more sensitive
A) High flux content; use a lower-flux wire
B) Crack
A) Low voltage; increase voltage
B) Fast cooling; decrease cooling rate
B) Arc radiation; tinted face shields
C) Small bevel angle; increase the bevel angle
B) Porosity
A) Excessive moisture; ensure dry storage
B) Non-low-hydrogen; use low-hydrogen filler
A) Smooth surface; roughen with sandpaper
A) Insufficient gas flow; increase flow rate
B) Porosity
B) Lack of fusion
A) High sulfur; use low-sulfur filler
A) Electric shock; use insulated holders
C) Globular transfer; switch to spray transfer
B) Slag inclusion
A) Low heat input; increase current
A) High heat input; reduce heat input
B) Subsurface cracks; DC is more sensitive
A) High voltage; reduce voltage
C) Wrong developer type; use a non-aqueous developer
