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API 577 Flashcards

Welding Processes, Inspection, and Metallurgy

1
Q

What does a WPS provide?

A

Direction to the welder for production welds

API 577 6.1

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2
Q

What is the purpose of the PQR?

A

Establish the properties of the weldment

API 577 6.1

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3
Q

What must a WPS address?

A

Essential, Non-Essential and Supplementary essential variable when notch toughness is required

API 577 6.2

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4
Q

Essential variable effect [blank] of a weld?

A

The mechanical properties

API 577 6.2

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5
Q

Why does the code allow non-essential variable to be changed on the WPS, without requiring the WPS to be requalified?

A

Because non-essential variables don’t effect the mechanical properties of the weld

API 577 6.2

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6
Q

What is the required format for the WPS?

A

Format is not fixed, provided it addresses the essential, non-essential, and supplementary variable when required

API 577 6.2.3

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7
Q

What tests are required to qualify the WPS?

A
  • Tension
  • Bend
  • Notch Toughness (when required)
  • Hardness (when required)

API 577 6.3

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8
Q

What is the required format for the PQR?

A

Format is not fized, provided it addresses the essential, and supplementary variable when required

API 577 6.3

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9
Q

Why are base metals assigned P-Numbers

A

To reduce the number of welding procedure qualifications

API 577 7.2

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10
Q

What are base metal P-Number assignments based upon?

A

Base metal characterics (composition, weldability, and mechanical properties)

API 577 7.2

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11
Q

Why are filler metals assigned F-numbers?

A

To reduce the number of weldin procedure and performance qualifications

API 577 7.3

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12
Q

What are F-Numbers based upon?

A

Usability characteristics (i.e. welders ability to make satisfactory welds)

API 577 7.3

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13
Q

Why are AWS Classifications assigned to electrodes and welding rods?

A

Provides a means to identify filler metals for welding procedures

API 577 7.4

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14
Q

Why are filler metals assigned A-Numbers?

A

To reduce the number of welding procedure

API 577 7.5

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15
Q

What are A-Numbers based upon?

A

Chemical composition of the deposited weld metal

API 577 7.5

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16
Q

If radiography (RT) is used for qualification of a welder, what length of weld must be RT’d?

A

6” minimum

API 577

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17
Q

If a bend test will be used to qualify a welder, what other examination must also be performed?

A

Visual examination

API 577

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18
Q

What length of weld must be RT’d to qualify a welding operator?

A

3’

API 577 8.2

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19
Q

A welder’s performance qualification expires if the wedling process is not used during a [blank] period of time?

A

6 months

API 577 8.2

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20
Q

What is usd to verify a welder’s qualifications are current?

A

Continuity Report

API 577 8.2

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21
Q

NDE is defined as:

A

Examination of material without changing or destroying thier usefulness

API 577 9.1

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22
Q

What is the minimum required lighting level for visual inspection?

A

100’ candles or 1000 lux at the surface of the part

API 577 9.3.2.1

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23
Q

Magnetic particle is effective in detecting?

A

Surface and near surface discontinuities

API 577 9.4.1

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24
Q

When performing Magnetic particle examination with the yold placed perpendicular to the weld, defect that run [blank] to the weld can be detected?

A

Parrallel

API 577 9.4.1

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25
Q

When performaing Magnetic particle examination with e yolk placed parallel to the weld, defects that run [blank] to weld can be detected?

A

Perpendicular

API 577 9.4.1

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26
Q

What is the most popular indicator used to verify the direction magnetic flux lines?

A

Pie Gauge

API 577 9.4.2

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27
Q

What types of discontinuities is PT effective in detecting?

A

Surface-connecting discontinuities

API 577 9.6

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28
Q

What is the most common use for PT examination?

A

Austenitic stainless steel

API 577 9.6

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29
Q

What are the 3 basic steps required to perform a PT examination?

A
  1. Clean and apply pentrant
  2. Remove excess penetrant
  3. Apply developer

API 577 9.6

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30
Q

What are the two general penetrant techniques?

A

Color contrast and fluorescent techniques

API 577 9.6.1

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31
Q

What are the three penetrant systems that can be used for the color contrast or fluorescent technique?

A

Solvent removeable, water washable, and post emulsifiable

API 577 9.6.1

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32
Q

How can eddy current be used for PMI?

A

By detecting a change in the conductivity of materials

API 577 9.7

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33
Q

What is used to determine the sensitivity of a radiograph?

A

IQI

API 577 9.8.2

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34
Q

What are the two type of IQI’s that are used for radiography?

A

Hole type and wire type

API 577 9.8.2

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35
Q

What does 1T represent on a hole type penetrameter?

A

A hole with a diameter that is equal to the thickness of the penetrameter

API 577 9.8.2

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36
Q

The [blank] hole is required to be visible on an acceptable radiograph?

A

Essential

API 577 9.8.2

37
Q

What class radiographic fils are acceptable for radiography?

A

Class 1 or 2

API 577 9.8.3

38
Q

When multiple exposures are required to radiograph a circumferential weld, how much overlap is required on consectuive exposures?

A

1”

API 577 9.8.3

39
Q

How much coverage is required on each side a weld being radiographed?

A

3/4”

API 577 9.8.3

40
Q

What radioactive isotopes are typically used for radiography?

A

Iridium 192 and Cobalt 60

API 577 9.8.4

41
Q

What thickness range is Irudium 192 typically used for?

A

1/4” to 3”

API 577 9.8.4

42
Q

What thickness range is Colbat 60 typically used for?

A

1.5” to 7”

API 577 9.8.4

43
Q

How is the minimum or maximum thickness that can be radiographed for a given material deteremined?

A

By successfully demonstrating the required sensitivity is achieved

API 577 9.8.4

44
Q

When should the double-wall exposure technique be utilized?

A

When it is not practica to use a single wall technique

API 577 9.8.8.1

45
Q

What are the three types of discontinuities that are difficult to identify on a radiograph?

A
  • Crack
  • Lack of fusion
  • Overlap

API 577 9.8.9

46
Q

When radiographs are taken by x-ray, what should the denisty of film be in the area of interest?

A

1.8 to 4.0

API 577 9.8.9.4

47
Q

When radiographs are taken by gamma ray, what should the density of film be adjacent to a wire penetrameter?

A

2.0 to 4.0

API 577 9.8.9.4

48
Q

Where is the ase denisty of a radiograph measured?

A

Through the IQI (penetrameter)

API 577 9.8.9.4

49
Q

What is used to check for excessive backscatter?

A

Lead letter ‘B’ on back side of a film holder/cassette

API 577 9.8.9.5

50
Q

What size lead letter is used to determine if backscatter is exposing a radiographic film?

A

1/2” tall by 1/16” thick

API 577 9.8.9.5

51
Q

What does a light image of the letter ‘B’ on a dark background of a radiographic film indicate?

A

Insufficient protection from the backscatter radiation

API 577 9.8.9.5

52
Q

A dark image of the letter ‘B’ on a light background of a radiographic is?

A

Not a case for rejection of a radiograph

API 577 9.8.9.5

53
Q

What are the two main uses for straight beam UT technique?

A

Thickness measurements and check for laminations

API 577 9.9.1

54
Q

What temperature must the calibration block be when calibrating the UT instrument?

A

Within 25 deg F of the same temperature as the part that will be examined

API 577 9.9.3.1

55
Q

During UT examination of a weld, what is the maximum rate of movement for the transducer?

A

Less than 6” per second

API 577 9.9.5

56
Q

What gain setting should be used when scanning a weld with an UT shear-wave examination?

A

At least 2 times the reference level sensitivity established during calibration of the instrument

API 577 9.9.7.1

57
Q

Why is the hardness testing typically used after welding of PWHT?

A

Verify material is acceptably ‘soft’

API 577 9.10.1

58
Q

What is normally affested in a material during the welding process?

A

Mechanical and corrosion resistance properties

API 577 10.1

59
Q

In what way is a weld similar to a casting?

A

Shape of grains

API 577 10.2.1

60
Q

How is wrought material produced?

A

By mechanically working cast ignots into a shape (rolling, forging, or extrusion)

API 577 10.2.3

61
Q

What are the three zones that welds are comprised of?

A
  • Weld Metal
  • Heat Affected Zone (HAZ)
  • Base Metal

API 577 10.2.4

62
Q

What does weld metal consist of?

A

Melted base metal and deposited filler metal

API 577 10.2.4

63
Q

The HAZ makes up what part of the base metal in carbon steels?

A

Regions heated to temperatures above 1350 deg F

API 577 par 10.2.5

64
Q

Why does thick carbon steel components require a prehaet when welding?

A

Because carbon steel is a poor conductor of heat

API 577 10.3.3

65
Q

What is the coefficient of therma expansion?

A

Change in the length of materials when exposed to an increase or decrease in temperature

API 577 10.3.5

66
Q

What type of failure is common when metals with different coefficients of thermal expansions are joned together by welding?

A

Thermal fatigue

API 577 10.3.5

67
Q

What is the ultimate tensile strength of a material?

A

Amount of stress required to pull a tensile specimen to failure, divided by the cross-sectional area of the tensile specimen

API 577 10.4.2

68
Q

What is the yield strength of a material?

A

Maximum stress level that a material can withstand without permanently deformed (note: this is know as the elastic range of the material)

API 577 10.4.2

69
Q

A material’s ductilty is determined by what mechanical test?

A

Tensile Test

API 577 10.4.3

70
Q

Results from what mechanical test can the percent elongation of a material be determined?

A

Tensile Test

API 577 10.4.3

71
Q

A ben test if a proof test of what properties of a material?

A

Ductility and soundness of a weld

API 577 10.4.3

72
Q

What does high hardness indicate in alloy steels?

A

Untempered martensite in a weld

API 10.4.4

73
Q

What does low hardness indicate in allow steels?

A

Mater was over-tempered

API 577 10.4.4

74
Q

A material’s toughness is deteremined by what mechanical test?

A

Charpy Impact Test

API 577 10.4.5

75
Q

What is the definition of toughness?

A

Ability to absorb energy and deform plastically before failure

API 577 10.4.5

76
Q

What is the primary purpose of preheating carbon steel and low-alloy steels?

A

Reduce tendency for hydrogen induced delayed cracking

API 577 10.5

77
Q

How far should preheat be maintained on either side of a weld?

A

2”

API 577 10.5

78
Q

What is the primary purpose of PWHT?

A

Relieve residual stresses

API 577 10.6

79
Q

The ‘hardness’ of a material is dependent on the content of what chemical element?

A

Carbon

API 577 10.7

80
Q

What is the hardenability of material dependent upon?

A

By the presence of alloying elements (like chromium, molybdenum, and vanadium)

API 577 10.7

81
Q

The cooling-rate of the base metal HAZ controls the formation of what crystalline grain structure?

A

Martensite

*Note: Preheat is one way to slow the cooling-rate and minimize the form

API 577 10.7

82
Q

The susceptibility of material to [blank] increases as a material’s hardness increases?

A

Hydrogen induced cracking

API 577 10.7

83
Q

Chemical composition of metals and alloys is the primary factor that effects?

A

Weldability

API 577 10.9.2

84
Q

What chemical element makes welding more difficult?

A

Carbon

API 577 10.9.2

85
Q

The weldability of carbon and alloy steels can be deteremined by calculating what?

A

Carbon equivalent

API 577 10.9.2

86
Q

What are sulfur, phosphorus, tin, antimony, and arsenic are sometimes referred to as?

A

Tramp elements

API 577 10.9.2

87
Q

What is simplest mechanical test that can be performed to deteremine the weldability of a material?

A

Bend test

API 577 10.9.3

88
Q

Austenitic Stainless Steels are used for their?

A

Corrosion and resistance to high temperature degradation

API 577 10.10.2

89
Q

What is the most common measure of materials weldability and susceptibility to hot cracking?

A

Ferrite Number

API 577 10.10.2

API 653 (17 decks)

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