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CWB1 > Weld Faults: Inspection and Causes > Flashcards

Weld Faults: Inspection and Causes Flashcards

1
Q

Weld spatter can cause inter-pass weld defects if not removed. (True/False)
Question 1 options:
True
False

A

True

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2
Q

What weld joint type can incomplete joint penetration occur in? (Multiple choice)
Question 2 options:

A) A groove weld joint.

B) A fillet weld joint.

C) Both groove and fillet weld joint types.

D) T-joint, corner joint and lap joint configurations.

A

A) A groove weld joint.

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3
Q

A defect is considered to be: (Multiple choice)
Question 3 options:

A) a rejected discontinuity prior to evaluation to a code standard or specification.

B) an evaluated discontinuity determined as rejectable based on a code, standard or specification.

C) an evaluation of a poor quality weldment based on an opinion of the inspector’s input.

D) any disruption in the normal physical or compositional features of a part.

A

B) an evaluated discontinuity determined as rejectable based on a code, standard or specification.

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4
Q

Surface contaminants such as oil, paint, rust, and mill scale can cause overlap. (True/False)
Question 4 options:
True
False

A

true

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5
Q

Which type of deficiency categorizes a reduction in tensile strength? (Multiple choice)
Question 5 options:

A) A structural deficiency.

B) A dimensional deficiency.

C) A property deficiency.

D) A deficiency with the WPS.

A

C) A property deficiency.

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6
Q

What type of crack grows from the fusion boundary to the centre of the weld metal? (Multiple choice)
Question 6 options:

A) A crater crack.

B) A hydrogen-induced cold crack.

C) An underbead crack.

D) A solidification crack.

A

D) A solidification crack.

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7
Q

CSA W59.2 allows for welding over top of a crater with defects when additional welding is required. (True/False).
Question 7 options:
True
False

A

False

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8
Q

An underbead crack is known to be a type of cold crack. (True/False)
Question 8 options:
True
False

A

True

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9
Q

What is the result of an excessive root face preparation? (Multiple choice)
Question 10 options:

A) Incomplete joint penetration.

B) Undercut on the material surface.

C) Excessive reinforcement.

D) Notch effect in the root weld.

A

A) Incomplete joint penetration.

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10
Q

What results from the preparation of a double V-groove weld that is misaligned? (Multiple choice)
Question 11 options:

A) Incomplete penetration.

B) Excessive weld reinforcement.

C) Weld concavity.

D) An incorrect bevel angle preparation.

A

A) Incomplete penetration.

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11
Q

What is a lamellar tear considered to be a result of? (Multiple choice)
Question 12 options:

A) Excessive welding speed.

B) Inter-pass contamination of the weld.

C) Through-thickness tensile stresses.

D) Hydrogen-induced stresses.

A

C) Through-thickness tensile stresses.

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12
Q

What is a lamellar tear? (Multiple choice)
Question 13 options:

A) A subsurface crack along the centreline of the weld metal.

B) A subsurface terrace and step-like crack parallel to the base material’s surface.

C) A lamination that can be found in a base material prior to being welded.

D) A planar-like indication found on the surface of a material transverse to the rolling direction.

A

B) A subsurface terrace and step-like crack parallel to the base material’s surface.

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13
Q

Convexity refers to: (Multiple choice)
Question 14 options:

A) The profile of a fillet weld.

B) The profile of a groove weld.

C) Suck back.

D) Excessive surface weld profile.

A

A) The profile of a fillet weld.

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14
Q

What is a possible consequence of arc strike? (Multiple choice)
Question 15 options:

A) Porosity.

B) Excess convexity.

C) Cracking.

D) Undercut.

A

C) Cracking.

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15
Q

Which nondestructive process is best suited to discover incomplete fusion? (Multiple choice)
Question 17 options:

A) A guided bend test.

B) A magnetic particle inspection.

C) A liquid penetrant inspection.

D) An ultrasonic inspection.

A

D) An ultrasonic inspection.

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15
Q

Overlap is defined as: (Multiple choice)
Question 16 options:

A) excessive weld reinforcement.

B) an unfused protrusion of weld metal beyond the weld toe.

C) welds that are fused beyond the edge of the preparation.

D) a parent metal discontinuity from the hot-rolling process.

A

B) an unfused protrusion of weld metal beyond the weld toe.

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16
Q

Incomplete joint penetration appears on a radiographic image as: (Multiple choice)
Question 18 options:

A) A dark straight line along the center of the weld.

B) A dark straight line on the toe of the weld.

C) A light contrast in the middle of the weld.

D) round elliptical dark spots.

A

A) A dark straight line along the center of the weld.

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16
Q

Which welding process may cause metallic inclusions to appear in white on a radiographic film? (Multiple choice)
Question 19 options:

A) SMAW and SAW

B) GMAW-P and GMAW-SP

C) GTAW and PAW

D) FCAW and MCAW

A

C) GTAW and PAW

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17
Q

According to CSA W47.1, how much undercut is allowed when visually inspecting a welded test assembly? (Multiple choice)
Question 21 options:

A) 1 mm

B) 1.6 mm

C) 2 mm

D) No amount of undercut is allowed.

A

A) 1 mm

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17
Q

When is it common to experience a hot crack? (Multiple choice)
Question 20 options:

A) When the weld area has cooled to just below 150 °C.

B) When the parent metal is low in sulphur content.

C) As the weld metal solidifies or at some elevated temperature.

D) When the material is susceptible to hydrogen embrittlement.

A

C) As the weld metal solidifies or at some elevated temperature.

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18
Q

According to ASME, which code addresses fabrication and construction for power piping? (Multiple choice)
Question 22 options:

A) ASME B31.1

A) ASME B31.3

C) ASME B31.5

D) ASME B31.9

A

A) ASME B31.1

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19
Q

According to CSA W59, what formula is used to calculate the allowable convexity of a fillet weld? (Multiple choice)
Question 23 options:

A) 0.007 times the actual face width of the weld.

B) 0.007 times the actual face width of the weld plus 1.6 mm.

C) 0.07 times the actual face width of the weld.

D) 0.07 times the actual face width of the weld plus 1.6 mm.

A

D) 0.07 times the actual face width of the weld plus 1.6 mm.

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20
Q

With the exception of cracks, ASME B31.1 allows for the acceptance of linear indications up to 5 mm long. (True/False)
Question 24 options:
True
False

A

True

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21
Q

When comparing the visual inspection criteria of CSA W59 to ASME B31.1, only ASME B31.1 allows for external surface cracks. (True/False)
Question 25 options:
True
False

A

False

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22
Q

ASME B31.3 Table 341.3.2 provides acceptance criteria for radiographic examination only. (True/False)
Question 26 options:
True
False

A

False

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23
Q

The terms code and standard can be used interchangeably. (True/False)
Question 27 options:
True
False

A

True

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24
Q

According to CSA W47.1, how much concavity is allowed when visually inspecting the root surface of a welded test assembly? (Multiple choice)
Question 28 options:

A) 1 mm

B) 1.6 mm

C) 2 mm

D) No amount of concavity is allowed.

A

C) 2 mm

25
Q

Visual inspection is a function that is to be performed: (Multiple choice)
Question 29 options:

A) after any destructive and non-destructive testing.

B) by qualified welding personnel.

C) before, during, and after welding completion.

D) before the welding procedure has been approved.

A

C) before, during, and after welding completion.

26
Q

Which task is to be a consideration for an inspector to complete prior to the start of welding? (Multiple choice)
Question 30 options:

A) A welding procedure review.

B) Verifying compliance to procedural variables.

C) Verifying overall dimensional accuracy.

D) Ensuring the quality of the tack welds.

A

A) A welding procedure review.

27
Q

A discontinuity can be defined as: (Multiple choice)
Question options:

A) an observed interruption in the weld or base material considered as defective.

B) an observable interruption in the weld or base material.

C) a disruption in the normal chemical or compositional features of a part.

D) an issue considered as noncompliant to codes and standards.

A

B) an observable interruption in the weld or base material.

28
Q

Cracks are often identified by their direction of travel. (True/False)
Question 1 options:
True
False

A

True

29
Q

Piping porosity can be defined as: (Multiple choice)
Question 2 options:

A) no longer rounded but having a length and approximately perpendicular to the weld face.

B) a localized array of porosity oriented in a relatively straight line.

C) porosity distributed internally and throughout the weld’s surface.

D) a localized array of porosity having a random geometric distribution.

A

A) no longer rounded but having a length and approximately perpendicular to the weld face.

30
Q

Which type of crack can be found in both fillet and groove welds, and is caused by thermal stresses in the HAZ? (Multiple choice)
Question 3 options:

A) A HICC.

B) A toe crack.

C) An underbead crack.

D) A solidification crack.

A

B) A toe crack.

31
Q

Which type of discontinuity is best described as a weld deposit not melting into a base or filler material? (Multiple choice)
Question 4 options:

A) Porosity.

B) Slag inclusion.

C) Incomplete fusion.

D) Undercut.

A

C) Incomplete fusion.

32
Q

Which type of crack can be either a hot or cold crack traveling in a longitudinal direction? (Multiple choice)
Question 5 options:

A) A solidification crack.

B) A root crack.

C) A toe crack.

D) An underbead crack.

A

B) A root crack.

33
Q

Cluster porosity is defined as: (Multiple choice)
Question 6 options:

A) porosity oriented in a relatively straight line.

B) porosity having a length greater than its width that lies approximately parallel to the weld axis.

C) a localized array of porosity having a random geometric distribution.

A

C) a localized array of porosity having a random geometric distribution.

34
Q

Which type of discontinuity is best described as a groove melted into the base metal adjacent to the weld toe or root and left unfilled? (Multiple choice)
Question 7 options:

A) Incomplete fusion.

B) Incomplete penetration.

C) Suck back.

D) Undercut.

A

D) Undercut.

35
Q

When is it common for a cold crack to occur? (Multiple choice)
Question 8 options:

A) Just as the weld metal reaches the lower transformation temperature.

B) At some point after the weld area has cooled to below 150 °C.

C) Immediately after the weld area has cooled to below 100 °C.

D) At some point after the weld area has cooled to below 250 °C.

A

B) At some point after the weld area has cooled to below 150 °C.

36
Q

Which welding process is most likely to create the presence of trapped gas resulting in pockmarks? (Multiple choice)
Question 9 options:

A) GMAW

B) GTAW

C) SAW

D) FCAW

A

C) SAW

37
Q

Undercut is defined as: (Multiple choice)
Question 10 options:

A) a notched groove in either the base metal or weld zone of a material created to relieve inherent stress.

B) an unfilled notch-like groove melted into the base metal adjacent to the weld toe or weld root.

C) a linear-like indication in the base metal transverse to the weld toe or weld root.

D) a weld bead showing a lack of penetration into the base metal’s surface.

A

B) an unfilled notch-like groove melted into the base metal adjacent to the weld toe or weld root.

38
Q

Underbead cracks are usually located: (Multiple choice)
Question 11 options:

A) Below the base metal’s surface.

B) Within the root of a weld.

C) Within the inter-passes of a groove weld.

D) In between layered passes of a fillet weld.

A

A) Below the base metal’s surface.

39
Q

Aligned porosity is defined as: (Multiple choice)
Question 12 options:

A) porosity aligned in cluster formations.

B) porosity which can behave like a crack.

C) porosity oriented in a relatively scattered pattern.

D) porosity lengths perpendicular to the weld face.

A

B) porosity which can behave like a crack.

40
Q

Which NDE method is commonly used to detect lamellar indications? (Multiple choice)
Question 13 options:

A) RT

B) LPI

C) UT

D) MPI

A

C) UT

41
Q

Wormhole porosity is defined as: (Multiple choice)
Question 14 options:

A) a form of elongated pore cause by large amounts of gas trapped during solidification.

B) porosity lying approximately perpendicular to the weld face and that may become a significant leak path possibility.

C) a localized array of porosity having a random geometric distribution.

D) an elliptical surface porosity distributed at the start of the weld.

A

A) a form of elongated pore cause by large amounts of gas trapped during solidification.

42
Q

Delamination is: (Multiple choice)
Question 15 options:

A) The separation of a plate material under stress, typically at plate edges.

B) Linear indications discovered while under shear stresses.

C) A discontinuity commonly found with radiography testing.

D) A tear in the surface of a material prior to welding.

A

A) The separation of a plate material under stress, typically at plate edges.

43
Q

Scattered porosity can be defined as: (Multiple choice)
Question 16 options:

A) a localized array of porosity having a geometric distribution.

B) no longer rounded but elliptical.

C) porosity distributed throughout the weld.

D) a form of subsurface elliptical inclusion throughout the weld.

A

C) porosity distributed throughout the weld.

43
Q

What would be the main concern in a sharp transition of joint misalignment with a single V-groove weld joint? (Multiple choice)
Question 17 options:

A) Slag inclusions.

B) Incomplete side wall fusion.

C) Irregular bead profile.

D) Stress concentrations.

A

D) Stress concentrations.

44
Q

What may be the result of an excessive bevel angle? (Multiple choice)
Question 18 options:

A) Increased distortion.

B) Incomplete joint penetration.

C) Slag entrapment.

D) Incomplete side wall fusion.

A

A) Increased distortion.

45
Q

What preventative measure can be taken to prevent oxidation inclusion? (Multiple choice)
Question 19 options:

A) A chemical treatment.

B) Passivation.

C) Cleaning.

D) Purging.

A

D) Purging.

46
Q

According to CSA W59, what is the maximum size of a single porosity pore allowed when completing a visual inspection? (Multiple choice)
Question 21 options:

A) 2.5 mm.

B) 3 mm.

C) 3.2 mm.

D) No porosity is allowed.

A

A) 2.5 mm.

46
Q

Tungsten inclusions may be caused by: (Multiple choice)
Question 20 options:

A) Filler wire feed speed too slow.

B) Filler wire feed speed too fast.

C) Incorrect shielding gas.

D) Dipping the electrode into the weld puddle.

A

D) Dipping the electrode into the weld puddle.

47
Q

AWS D1.1 covers statically loaded structures only. (True/False)
Question 22 options:
True
False

A

False

48
Q

According to CSA W59, what is the maximum diameter sum of porosity allowed within a 25 mm weld zone when completing a visual inspection? (Multiple choice)
Question 23 options:

A) 6 mm

B) 8 mm

C) 10 mm

D) 12 mm

A

C) 10 mm

49
Q

Which code is referred to for the qualification of welding procedures and welding personnel? (Multiple choice)
Question 24 options:

A) ASME B31.1

B) ASME Section IX

C) CSA W59

D) CSA W47.1

A

B) ASME Section IX

50
Q

According to ASME, which code addresses fabrication and construction for process piping? (Multiple choice)
Question 25 options:

A) ASME B31.1

B) ASME B31.3

C) ASME B31.5

D) ASME B31.9

A

B) ASME B31.3

51
Q

When should the welding inspector initiate reporting forms and weld mapping? (Multiple choice)
Question 26 options:

A) Not the responsibility of the inspector.

B) As a preliminary administrative step.

C) During welding commencement.

D) Once the welding is complete and accepted.

A

B) As a preliminary administrative step.

52
Q

According to AWS D1.1, what percentage of a fillet weld’s length may be undersized? (Multiple choice)
Question 27 options:

A) 10%

B) 12%

C) 15%

D) The entire length within the tolerance

A

A) 10%

53
Q

When should the final visual inspection of quenched and tempered or high stressed materials be completed? (Multiple choice)
Question 28 options:

A) As soon as the material has dropped below 150 °C.

B) Once ambient temperature is reached.

C) After a 48 hour time period has passed.

D) After a 24 hour period has passed.

A

C) After a 48 hour time period has passed.

54
Q

According to CSA W59, what is the maximum accumulated diameter sum of porosity allowed within a 300 mm weld zone when completing a visual inspection? (Multiple choice)
Question 29 options:

A) 10 mm

B) 15 mm

C) 20 mm

D) 25 mm

A

C) 20 mm

55
Q

Which type of acceptance criteria for welding inspection must be followed as a minimum? (Multiple choice)
Question 30 options:

A) Fabrication drawings.

B) Drawing specifications.

C) Codes and standards.

D) Weld procedures.

A

C) Codes and standards.

56
Q

How is piping porosity different than typical porosity? (Multiple choice)
Question 1 options:

A) It occurs only in pipes of substantial length.

B) It occurs only in structural shapes of substantial length.

C) It is long and perpendicular to the weld surface.

D) It is long and parallel to the weld surface.

A

C) It is long and perpendicular to the weld surface.

57
Q

What may be the result of an insufficient bevel angle? (Multiple choice)
Question 2 options:

A) An increase in initial costs in material preparation.

B) Increased distortion due to increased local heating.

C) Increased likelihood of slag entrapment.

D) Increased accessibility to the root of the joint.

A

C) Increased likelihood of slag entrapment.

58
Q

The weld reinforcement of a groove weld shall not exceed 3 mm. (True/False)
Question 3 options:
True
False

A

True

59
Q

What type of error results from a poor layout and fit-up? (Multiple choice)
Question 4 options:

A) A structural type error.

B) A dimensional error.

C) Property deficiencies errors.

D) A mechanical error.

A

B) A dimensional error.

60
Q

When is it common for a cold crack to occur? (Multiple choice)
Question 6 options:

A) Just as the weld metal reaches the lower transformation temperature.

B) At some point after the weld area has cooled to below 150 °C.

C) Immediately after the weld area has cooled to below 100 °C.

D) At some point after the weld area has cooled to below 250 °C.

A

B) At some point after the weld area has cooled to below 150 °C.

CWB1 (10 decks)

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