220 Inspection Flashcards
1
Q
Macroetch testing is a form of non-destructive inspection
T/f
A
False
2
Q
Macroetch testing requires an oxidizing acid to be used
T/f
A
T
3
Q
Macro etch testing requires an oxidizing acid to be Used to etch the metal
T/f
A
True
4
Q
Why is there an increasing need for welding quality?
- Gov. Regulations
- less conservative design
- economics
- safety
- all the above
A
ATB=all the above
5
Q
Weld quality control should begin after welding has been initiated.
T/F
A
False
6
Q
The welding inspector should have a basic understanding of:
- nondestructive test methods
- All the above
- welding processes
- codes and standards
A
ATB
7
Q
The welding inspector is exposed to which of the following safety hazards:
- falling objects
- eye hazards
- electrical shock
- all the above
- welding radiation
A
ATB
8
Q
The abbreviation “MSDS” means:
A
Material safety data sheet
9
Q
Eye hazards found in welding operations include:
- Radiation energy
- all the above
- smoke and fumes
- flying objects
A
ATB
10
Q
Which of the following is not considered a type of joint?
- t
- edge
- butt
- fillet
- corner
A
Fillet
11
Q
The term for the type of joint formed when the two pieces to be joined lie in parallel planes and their edges overlap is:
T Corner Edge Butt Lap
A
Lap
12
Q
The term for that portion of a single bevel joint where the two pieces to be joined come closest together is:
Radius None of the above Joint root Bevel angle Grove angle
A
Joint angle
13
Q
In a single V-groove weld, the term for the sloped surfaces against which the weld metal is applied is:
Root Groove faces Root face None of the above Groove angle
A
Groove faces
14
Q
The term for the type of weld produced by filling an elongated hole in an overlapping member attaching it to the member beneath is:
Spot weld Plug weld Slot weld Seam weld None
A
Slot
15
Q
The term for a type of weld having a generally triangular cross section and which is applied to either a T, corner, or lap joint is:
- Flare weld
- Slot weld
- Flange weld
- Spot weld
- Fillet weld
A
Fillet weld
16
Q
The term for the type of weld used to build up thinned surfaces, provide a layer of corrosion protection, or provide a layer of abrasion resistant material, is:
- Flare weld
- Flange weld
- Edge weld
- Slot weld
- Surfacing weld
A
- Surfacing weld
17
Q
The term for the type of weld applied to the opposite side of a joint before a single V-groove weld is completed on the near side of a joint is:
- back weld
- melt-through weld
- backing weld
- none
- root weld
A
Backing weld
18
Q
In a completed groove weld, the term for the surface of the weld on the side from which the welding was done is:
- weld reinforcement
- crown
- cap pass
- weld face
- root
A
Weld face
19
Q
In a completed weld, the term for the junction between the weld face and the base metal is:
- leg
- weld edge
- root
- weld reinforcement
- toe
A
Toe
20
Q
The term for the height of the weld face above the base metal in a groove weld is:
- crown
- all the above
- buildup
- face
- weld reinforcement
A
Weld reinforcement
21
Q
In a fillet weld, the leg and size are the same for what type of configuration?
- effective throat
- equal leg fillet weld
- concave weld
- convex weld
- oversize weld
A
Equal leg fillet weld
22
Q
The primary element of any welding symbol is referred to as the:
- weld symbol
- reference line
- tail
- arrow
- arrow side
A
Reference line
23
Q
The graphic description of the type of weld is called the:
- tail
- arrow
- welding symbol
- none
- weld symbol
A
Weld symbol
24
Q
A discontinuity is:
- none
- rejectible if it exceeds code limits.
- always a defect
- always acceptable
- always a reject
A
Rejectable if It exceed code limits
25
What discontinuity is generally considered to be most severe?
- arc strike
- porosity
- slag inclusions
- incomplete fusion
- crack
Crack
26
Which of the following discontinuities is less likely to be found visually?
- overlap
- undercut
- lamellar tear
- none
- toe crack
Lamellar tear
27
The weld discontinuity that results from improper termination of the welding arc is referred to as:
- overlap
- undercut
- incomplete fusion
- crater crack
- all the above
Crater crack
28
What weld discontinuity results when the welder travels too slowly, causing excess weld metal to flow out of the joint and lay on the base metal surface without fusing?
- Undercut
- none
- under fill
- overlap
- incomplete fusion
Overlap
29
LP produces a flaw indication that is much larger and easier for the eye to detect the flaw itself.
T/f
True
30
List the basic weld joints.
```
Lap
Tee
Butt
Corner
Edge
```
31
What is a destructive weld test used for
test for fusion and weld quality
32
Common types of destructive testing
```
Tensile testing
Nick-break test
Guided bend test
Fillet weld break test
Testing by etching
```
33
Types of Nondestructive testing
```
Visual inspection
Penetrant inspection
Magnetic particle testing
Radiographic inspection
Ultrasonic inspection
```
34
Common weld discontinuities and flaws in the typical weld.
```
porosity
Inclusions
Inadequate joint penetration
Incomplete fusion
Arc strikes
Overlap
Undercut
Crater cracks
underfill
```
35
A weld produced by filling a hole in an overlapping member, fusing to the member beneath.
Plug weld
36
Detailed written outlines explaining exactly how to weld is to be laid out, performed, and tested have made consistent quality welds possible:
Codes and standards
37
These are intended to be guidelines only and must be qualified for specific applications by testing:
Codes and standards
38
American Welding Society- used for bridges, buildings, and other structural steel.
AWS D1.1
39
AWS of Mechanical Engineers- Used for pressure vessels and nuclear components
ASME section IX
40
American Petroleum Institute-used for pipelines
API standard 1104
41
A set of written instructions by which a sound weld is made
Welding Procedure Qualification (WPS)
42
What do we call interruptions in the typical structure of the weld?
Discontinuities and flaws
43
A discontinuity that renders a part or product unable to meet minimum standards:
Defect
44
What percentage of welds have discontinuities and flaws, but are not necessarily defects?
All welds have some type of discontinuity or flaw in the weld or material being welded.
45
Gas that was dissolved in the molten weld pool forms bubbles that are trapped as the metal cools to become solid:
Porosity
46
What could cause porosity?
improper welding techniques, contamination, wrong filler
47
Welding over paint, dirt, oil, and rust can trap hydrogen gas in the weld pool. What does hydrogen entrapment cause?
Cracks
48
What causes porosity and how can it be prevented in arc welding?
1. Use properly dried welding consumables.
2. Use base metals that are free of contaminants.
3. Maintain welding machines in good condition.
4. Use proper welding technique
49
Inclusions are nonmetallic materials like:
Slag and oxides
50
What are some other causes of inclusions:
mill scale, rust and electrode coating falling and not fused into the weld
51
This weld defect is caused by less fusion than needed to produce a proper weld:
Inadequate joint penetration
52
The causes of inadequate joint penetration are:
a misdirected arc
not enough welding current
improper joint fit up
improper joint design
53
guided bend test will reveal arc strike, they open up when bent
...
54
This weld defect occurs when the weld is bigger than needed. The weld flows over the base metal without fusing to it:
Overlap
55
How can we prevent crater cracking:
By pulling the weld back slightly
56
This weld defect happens on groove welds, the weld reinforcement is below the surface of the base metal:
Underfill
57
This weld defect has tiny cracks that develop in the weld crater, the weld pool shrinks and solidifies:
Crater cracks
58
To fix underfill:
slow down travel rate or make more passes
59
The following are plate-generated problems:
laminations
delamninations
Lamellar tears
60
The area of base material, which is not melted and has had its microstructure and properties altered by welding or heat intensive cutting operations.
HAZ
61
This can occur during welding as a result of the non-uniform expansion and contraction of the weld
and base metal during the heating and cooling cycle.
Distortion
62
Pipe welding positions are:
```
1G
2G
5G
6G
6GR
```
63
Two parts meet at the abutting (touching) surfaces
Butt joint
64
Two parts join at a perpendicular angle.
T joint
65
Cross section forms a right triangle
Fillet welds
66
Used with butt joints
Butt joints
67
Used to fasten overlapping surfaces
Plug Welds
68
Used to fasten overlapping surfaces with an elongated hole
Slot welds
69
Fuses two edges together
| Often without filler metal
Edge welds
70
Like plug welds without the hole
| Often made with resistance welding
Spot welds
71
Convex
Curved outward
72
Concave
Curved inward
73
Porosity
Caused by trapped gas
74
Groove melted adjacent to toe
| Caused by long arc, incorrect angle or too much heat
Undercut
75
Improperly welded groove
| Often found at the root of an open groove
Under fill
76
Common with Stick Arc and Flux Core
Non-metallic -Slag Inclusions
77
Starting the arc outside of the groove or weld area
Arc strikes
78
Common when short arc welding
Poor fusion
79
Caused by uneven ( non-uniform ) heating and cooling
Distortion
80
Can show us discontinuities not easily seen with a visual inspection
NDE
81
Tests for weld soundness
Sound weld is all weld/no junk
Quality of fusion
Radiographic testing
82
tests for weld soundness
Ultrasonic Testing
83
Most common Destructive Test
Used for Welder Qualification
Determines quality of fusion
Guided bend test
84
Determines if the weld is as strong or stronger than the base metal
Tensile test
85
Tests a welders ability to make a weld that is similar to what he or she will be performing on the job
Welder qualification
86
the ability of a material to bend and stretch without cracking
Ductility
87
the ability of a material to stretch and then return to it's original size and shape
Elasticity
88
The amount of load applied
Stress
89
how far the material can stretch
Strain
90
The fillet weld that has the same leg and size dimensions
convex fillet weld
91
Porosity
Entrapment of gas
92
Inclusion
Entrapment of slag
93
Usually created by Amperage and Welder Movement
Undercut
94
The portion of the joint to be welded where members are closest to each other.
Joint root
95
Also known as hardsurfacing, this is a weld applied to a surface, as opposed to a joint. This type of weld is commonly used to strengthen selected surfaces of a component. It is used to build up thin surfaces and to provide a layer of corrosion protection and/or abrasion-resistance.
Surfacing weld
96
The height of the weld above the base metal in a groove weld.
Weld reinforcement
97
A weld performed by progressing along the joint with a side-to-side motion.
Weave bead
98
According to the AWS D1.1 code, if a welder continues to use a particular procedure, how long does his/her qualification remain in effect?
Indefinitely
99
These are tiny cracks that develop in weld craters as the weld pool shrinks and solidifies. An effective way of preventing this discontinuity is to slightly pull the weld back, allowing it to pool up on the weld bead before breaking the arc.
Crater crack
100
The weld discontinuity caused by starting the welding arc outside the weld joint is referred to as ________ _____________.
Arc strike
101
This is the first inspection method should ALWAYS be ________________.
Visual
102
The pipe welding position in which the pipe is parallel to the horizon and the weld is made vertically around the pipe.
5G
103
The pipe welding position in which the pipe is vertical to the horizon and the weld is made horizontally around the pipe.
2G
104
Discontinuity that is likely caused during the manufacturing of steel plate.
Lamination
105
During a guided bend test, the welding inspector is observing the weld, to make certain that the weld and the base metal are properly ___________
Fused
106
Slag inclusions form in welding processes that use flux; therefore, it is possible to have slag inclusions during which welding process?
SMAW
107
The CWI examination contains __________ parts, each _____ hours long.
3
2
108
__________________ the carbon content of steel increases the likelihood of cracking problems.
INCREASING
109
___________________ cracking can be caused by welding on wet or contaminated metal.
UNDERBEAD
110
True/False A linear discontinuity has a width that is close in size to its length.
FALSE
111
True/False Excessive convexity occurs when the weld metal rolls over the weld toe.
FALSE
112
True/False Insufficient shielding gas coverage is likely to cause undercut.
FALSE
