CSWIP – WIS5-90516b Questions and Answers

CSWIP – WIS5-90516b Part 1

Q 1: D

Section 4.1.3, impact toughness test.

Q 2: B

Section 4.1.6 and figure 4.16, side bend test.

Q 3: A

Section 6.3, welder qualification to make a sound weld, defect free.

Q 4: B

Section 2.3, “toe” definitions, and figure 6.31 – concave fillet weld.

Q 5: C

Root bead penetration mainly influenced by root gap.

Q 6: D

Section 3.6.1, undercut sharpness due to high travel speed, high welding current, lowest heat input gives to high hardness.

Section 10.3 heat input determine.

Q 7: A

Hardness test is another NDT method.

Root beads made with low amperage and voltage to control penetration; it may not occur tungsten inclusion.

Q 8: D

Section 2.6.2 shape of fillet welds, throat thickness.

Q 9: D

Section 1.1, basic requirements for visual inspection.

Q 10: A

Section 1.1.5, duties of welding inspector.

Q 11: D

Incomplete root penetration means fusion face of root are not melted, see Figure 3.18.

“Excessive root gap given more root penetration or excess penetration”.

Q 12: A

Incomplete root fusion or lack of root fusion, one fusion face of root is not melted, see Figure 3.16.

– Answer B, root gap to large give more penetration.

– Answer C, root face being too small easy to melt the root edge.

– Answer D, Amperage too high given more penetration.  

Q 13: D

“flaws” is other name of defects, most using in API specification.

Keyword “the most serious” mean the most of project specification are not accepted the defect like surface planer defect, crack, …

– Answer A, B, C may be accepted if these imperfections are allowed by Acceptance Criteria, see An Acceptance Levels at page 595 or Appendix A2-36.

– Arc strikes are not permitted for plate/pipe and macro.

– An arc strike is a type of crack, can produce a hard HAZ, lead to serious cracking in-service.

– Better to grind out and then MPI for surface detection.

Q 14: C

See Section 3.6.10 or Figure 3.28.

Root gap too large or high welding current may occur burn-through defect.

Q 15: B

Answer A, not correct at “quality only”.

Answer C, not correct, specification not only for “finished product”.

Answer D, not correct, code of practices may be standard, recommend practices (RP), or procedures, …

Q 16: A

Solid inclusion such flux, oxide, tungsten, slag trapped in the weld metal.

See Section 3.4.

Q 17: A

Planar imperfection such lamination, crack, lack of fusion (sidewall, root, inter-run, cap).

Slag / porosity is a non-planar defect.

Q 18: B

Throat thickness (actual) is extremely hard to measure, it will calculate by 1.141 times leg length. It may check in the macro sample.

Q 19: C

Face tension –> face bend

Root tension –> root bend

Side tension –> face bend

Q 20: C

Key works “heavy porosity, MMA, site, is most likely” are considered moisture contents.

Q 21: A

MIG and MAG welding process use a solid wire welding consumable, defect not included slag.

MMA, slag produce from covered electrode, for weld pool protection from atmosphere, it may trap in the weld metal.

Q 22: A

Key word “main cause, undercut is”, best answer is excessive amps or high welding current.

Other cause may be high travel speed.

Q 23: B

Key words “is most likely, continuous monitoring”, best answer is B for pipe welder.

Q 24: A

Key words “strongest, fillet welds”, which one given thicker of throat thickness.

See Section 2.6.1.

Q 25: B

Keywords “included angle, full penetration, pipe butt joint, MMA”, best practice is 70 degree.

See Section 2.4.1 and Figure 2.11.

Q 26: C

Answer: 8 – 7*0.7 = 3.1 mm in throat thickness.

See Figure 2.28.

Q 27: A

Fusion boundary or fusion line see Figure 2.8 or Figure 2.9.

Q 28: B

Keyword “not allowed by the application standard” means defects, defect is not allowed.

See Section 3.1, or acceptance level sheet in appendix A2-36.

Q 29: B

Keyword “a magnifying glass” and see Section 1.1.4, appendix 5.

Q 30: D

See Section 6.3 and Section 6.3.2.

Q 31: C

Common occur SAW process because high current, DC EP polarity.

Reduce arc blow by change DC to AC power source.

Q 32: A

E6013/E7016 classified in AWS A5.1.

E 51 33 B, number “51” is min. yield strength and “33” is min. absorbed energy is not classified in ISO 2560.

See Figure 16.3.

Q 33: B

Keyword “stovepipe” or “country pipeline”, root bead made by Cellulosic electrode, downhill position (PF).

See Section 11.3.5.

Q 34: A

See Section 11.3.5 and Table 16.1.

Q 35: B

Max. weld bead > low travel speed > high heat input > low toughness.

See Figure 2.38 – weave bead, Section 10.3 – heat input influence.

Note: Heat input / arc energy major influence on the travel speed.

Q 36: C

Filler rods/cored wire/sticks of MMA electrode is a general of low-quality rimming steel.

See Section 16.1.

Q 37: B

Keyword “slope-out”, also learning slope-up.

See Section 12.4 and 12.5.

Q 38: C

Keyword “manual welding, power source or drooping characteristic”.

See Section 10.5.1 and Figure 10.1.

Q 39: D

Keyword “penetration, controlled”.

See Section 10.3.1.

Q 40: C

Keyword “purged with Ag, backing gas” for purpose avoid excessive oxidation or control root bead.

See Section 12.2.6.

Q 41: B

Filler rods/cored wire/sticks of MMA electrode is a general of low-quality rimming steel, refer Question 36 of this part.

The coating contains many elements and compounds.

See Section 16.1.

Q 42: A

See Section 16.1.

Q 43: B

See Section 16.4

Q 44: C

Keyword “AWS A2.4, other side”, see Section 9.12.

Q 45: D

Keyword “low hydrogen or hydrogen scale”.

See Section 11.3.5 and Section 17.3.3, or EN 1011-2.

Q 46: A

Keyword “hydrogen control”, see Figure 16.3 (letter H5) is a max. scale of hydrogen. See Annex C2 of EN 1011-2.

Q 47: C

Keyword “weld toes to be smoothly blended on the other side”,

Other side shall be placed on the dash-line.

See Section 9.4 and 9.8.

Q 48: D

Heat input and arc energy, see Section 10.3.

Q 49: C

Keyword “creep resistance”, See Section 7.3.

Q 50: A

Accessing quality of weld, or quality of joint.

See Section 4 and Section 4.1.7.

CSWIP – WIS5-90516b Part 2

Q 1: A

Keyword “is the most susceptible”.

Weld configuration of U preparation too small angle bevel with another V preparation, see Section 2.4.1 and Figure 2.14.

Q 2: C

See Section 2.6.1 or BS 499-1.

 

Q 3: B

See Figure 2.28.

 

Q 4: C

See Figure 2.34.

Q 5: C

Keyword “not, welding inspector”.

See Section 1.1.6.

Q 6: D

See Section 3.3.4.

 

Q 7: B

Keyword “controlled”, by design throat thickness.

Note: measured by actual leg length.

 

Q 8: C

Non-planar defects such porosity, slag, …

Planar defects such crack, lamination, lack of fusion, …

Q 9: A

Measurement of arc voltage, voltage as close as the welding arc.

 

Q 10: C

See Section 1.1.6 – duties of welding inspector.

 

Q 11: C

See Section 3.6.10.

Q 12: B

Keyword “weld metal deposited per minute”, see BS 499-1.

 

Q 13: D

See BS 499-1, different between cold lap and overlap.

See Figure 7.1 and Figure 3.22.

Q 14: C

Throat thickness = 19*0.7 = 13.3 mm.

See Section 2.6.2.

Q 15: B

Pre-heat purpose to reduce cooling rate and increase welding speed.

See Section 17.3.3 – Avoid HAZ hydrogen cracking.

Q 16: D

Refer to WPS or see Section 2.4.2 – types of preparation.

Q 17: D

See Section 1.1

Q 18: A

Linear misalignment (1) = (8×10)/100 = 0.8 mm (answer)

Linear misalignment (2) < = 2 mm (max.).

Whichever value is less.

Q 19: B

Keyword “excessive chevron shaped cap ripple”.

Increased travel speed > narrow weld bead > decreased penetration.

See Section 14.3.3 – SAW Process.

Q 20: A

See Section 2.6.2 – concave fillet weld.

See Section 19.1.2 – residual stress.

Refer ISO 5817/6520-1 – code 505.

 

Q 21: D

Arc strike > quick cooling > hardening surface, initial point, crack, reduce base metal thickness.

See Section 3.7.1.

Q 22: C

Opening planar defect are more serious than internal defects due to initial point to propagation failure service.

Q 23: A

The minimum light illumination is 350 lux.

The minimum RECOMMENDS light illumination 500 lux.

See Section 1.1.3.

Q 24: D

See Section 13.5.

Function of the filling powder:

·        Stabilize the arc.

·        Add alloy elements.

·        Produce gaseous shield.

·        Produce slag.

·        Add iron powder.

 

Q 25: C

Keyword “magnetic forces”.

See Section 11.3.4.

Q 26: B

SAW process high A and V > increase penetration, greater depth to width ratio, susceptible to hot cracking.

See Section 17.4.

Q 27: C

See Section 10.5.1.

Q 28: A

Keyword “nickel and its alloys, TIG, DC-ve”.

See Section 12.2.2.

Q 29: B

Learning from Heat Input formula, see Section 10.3.

Fast travel speed > low heat input > fast cooling rate > high hardness.

See Section 11.3.3.

Q 30: B

DC to AC: reduce arc blow, deflect arc due to the following AC in two directions.

See Section 11.3.4.

Q 31: C

The same answer WIS5-90516b_1a_37.

Q 32: C

See Section 15.1 – disadvantages.

 

Q 33: C

MMA is manual welding process, constant current power source.

See Figure 11.3.

Q 34: C

Keyword “plate over 25 mm”.

See Figure 13.16.

Q 35: C

Keyword “aluminum”, cleanliness problem with DC polarity.

Q 36: A

Keyword “deepest penetration”, DC+ given deepest penetration compare with AC polarity.

Q 37: C

Bare filler has lowest hydrogen.

 

Q 38: C

See Section 7.3.

Q 39: C

See Section 10.4.

Q 40: B

See Section 13.1

Travel speed control by welder, wire feed speed and arc length are controlled automatically.

Q 41: C

Keyword “MAG welding plant”, MAG shielding gas should be check “gas flow rate, stick-out length (contact tip to workpiece distance, electrode extension)”.

Note: MAG > constant voltage > arc length constant >

–         If increase stick-out length (increase voltage), decreased current, less penetration, or

–         If decrease stick-out length > increase current > depth penetration.

Best answer C, see Section 22.5.

Q 42: C

Keyword “T joint, highest resistance”,

See Section 2.6.2 – Concave fillet weld.

Q 43: A

Lear more in the WPS, and heat input calculation, see Section 10.3.

Heat input = 6.5 or 12 kJ/mm > too high.

Heat input = 1.2 Jouls/mm > too low.

Q 44: C

Throat thickness = 15*0.7 = 10.5 mm, actual is 8.5 mm less than design throat thickness > concave fillet weld.

See Section 2.6.2.

Q 45: D

Keyword “MMA, most difficult control”.

MMA is manual welding process, constant current power source, control arc length by welder.

See Figure 10.1.

Q 46: B

Keyword “sub-zero condition or temperature”.

 

 

Q 47: C

Preheat temperature and avoid cold cracking see Figure  C2 of EN 1011-2.

 

 

Q 48: D

Keyword “Charpy V notch test”.

See Section 4.1.3.

Q 49: B

Keyword “high heat input” > decrease travel speed > weave bead > low toughness.

Q 50: D

Keyword “creep strength or creep resistance”. See Section 7.3.

CSWIP – WIS5-90516b Part 3

Q 1: A

Keywords “non-magnetic”, austenitic stainless steel, minimum of 10.5% chromium.

Q 2: A

See Section 3.7.2.

Q 3: D

See Section 6.1.

Q 4: D

Keywords “arc strike”, arc strike > quickly cooling > high hardness, local surface damages (crack).

See Section 3.7.1.  

Q 5: B

Keyword “brittleness” > flat, rough surface.

Q 6: B

Keyword “fatigue” > beach marks, chevron markings.

 

Q 7: B

See Section 9.11.

Q 8: A

DC EN, see Section 12.2.2.

Q 9: C

Keyword “basic coated electrodes”.

See Section 16.3.

Q 10: A

Keyword “travel speed is doubled” > 2xtravel speed > reduced heat input = 50%.

See Section 10.3.

Q 11: B

Keyword “moisture pick-up”.

See Section 16.6.

Q 12: B

Keyword “large grain size in the HAZ, or growth grain size”.

 

Q 13: D

See Section 17.5.3

Q 14: A

Keyword “hydrogen cracking” > moisture contents.

See Section 17.3.3.

Q 15: B

Keyword “greatest”, see Section 19.4.1.

Q 16: D

Keyword “FCAW of stainless steel”, see Section 13.2.3.

 

Q 17: A

See Section 17.4.3.

Q 18: B

See Appendix 5.

 

Q 19: D

See Section 19.6.3.

Q 20: B

100% argon.

Q 21: B

SAW with high A/V and DCEP > depth penetration > D:W ratio > solidification cracking.

See Section 17.4.

Q 22: C

D<=0.3×10 = 3 mm, max. 4mm.

Q 23: A

See Section 22.5.

Q 24: D

Lamellar tearing occurs only after welding.

Lamination on rolling plate/shape will best detect by UT.

Q 25: C

See Section 17.3.3.

Q 26: D

See Figure 20.1

Q 27: B

Keyword “burn-off rate” > current > wire feed speed.

See Section 13.2.1.

Q 28: C

See Section 23.4 “for t>50 mm”.

Q 29: D

See Figure 17.6 and Section 17.4.

Q 30: C

Keyword “cyclic loading”.

Join design > less residual stress or reduce initial point > reduce service failure.

Q 31: B

Keyword “low carbon, stabilizer”.

See Section 17.6.1.

Q 32: D

Keyword “breaking down into fine particles”.

See Section 16.6.

Q 33: B

See Section 17.3.3 – “susceptible HAZ microstructure”.

Q 34: C

h <= 1+0.1×35 = 4.5 mm, max. .5 mm.

Q 35: C

Keyword “run-out length (ROL)”, see EN 1011-2.

Shorter ROL > decreased travel speed > increased heat input > low toughness.

See Section 10.3.

Q 36: A

See Table 6.1.

Q 37: C

Some project not allowed shape V notch die stamped due to create an initial point or reduce material thickness.

Best practice to use low-stress stamping, refer to Annex A.2.1.9 of NACE MR 0175 2015.

Q 38: D

Keyword “thin plate, distortion”, see Section 19.7.

Q 39: D

Keyword “high heat input”.

Q 40: A

Keyword “high frequency (HF)”, HF consists of high voltage sparks of several thousand volts which last for a few microseconds. Refer to TWI-Job Knowledge.

 

Q 41: B

See Section 9.9.1. Letter “s” first, after size “10”.

Q 42: C

See Section 8.

Q 43: D

See Section 5.2.3.

Q 44: D

See Section 7.3.

Q 45: B

See Section 17.3.3.

Q 46: B

See ISO 9606 and Section 6.3.4.

Q 47: C

Keywords “plasticized layer”.

Q 48: D

Contrast – relates to the degree of difference.
Definition – relates to the degree of sharpness.
Sensitivity – relates to the overall quality of the radiograph.

Read more in slide contents of Section 5.

Q 49: A

Keyword “stainless steel”. Oxygen stream max. 850 deg. C. Cutting stainless steel need high temperature at least 1050 deg. C and more.

See Section 15.2.

Q 50: C

Keywords “the most serious type of defect”. 

CSWIP – WIS5-90516b Part 4

Q 1: C

See Section 17.3.1.

Q 2: B

See Figure 4.6.

Q 3: D

See Figure 20.1.

Q 4: D

Keywords “highest preheat temperature”, See Figure C.1 of EN 1011-2.

Q 5: A

See Section 19.4.1.

Q 6: A

Preheat > slow cooling rate> increased travel speed.

Q 7: A

Keyword “fast travel speed” > fast cooling rate > narrow HAZ > increase hardness.

Q 8: C

Keyword “high heat input” > lowest toughness  at HAZ.

Q 9: A

Arc energy = (AxVx60)/(TSx1000) = (350×32)/(310×1000).

See Section 10.3.

Q 10: A

Small diameter electrode > reduce A/V > low heat input.

Multi-passes > high degree of grain refinement.

Q 11: A

See Section 4.1.1.

Don’t confuse with “all weld tensile test”.

Q 12: A

See Section 4.1.1 and 4.1.3 – Objective.

Tensile/VPN test have unit à quantitative tests.

Q 13: A

See Section 4.1.6.

Q 14: A

See Section 8.

Q 15: B

See Section 8.

Q 16: D

See Section 6.2.

Q 17: D

See Duties of Welding Inspector.

Q 18: B

See Section 17.6.1.

Q 19: D

See Section 6.2.3.

Q 20: B

MT will detect surface and sub-surface defects.

See Section 5.4 and 5.5.

Q 21: B

See Section 3.4.4 – tungsten inclusion.

See Section 5.2.4.

Q 22: D

See Section 17.5.3.

Q 23: B

Keywords “no internal access” > access from outside > DWSI method.

Q 24: D

See Section 19.6.5.

Q 25: A

Keywords “dark straight line” in the RT film, check density.

Q 26: D

Follow the approved WPS.

Q 27: B

Symmetric weld > omit dash line.

Intermittent 50 mm in length > See Figure 9.9.

Q 28: B

Excessive voltage > increase flux consumption.

See Figure 14.4.

Q 29: C

Keyword “never baked” because damage the coating.

Q 30: C

See Figure 16.3.

Q 31: B

Fatigue crack occurs during operation.

Answer a à ductile fracture.

Answer b/d à brittle fracture.

 

 

Q 32: A

E6013 à Rutile coating, general purpose.

Q 33: D

See Section 17.4 and Section 7.3.

Q 34: A

Commonly used inert gas.

Q 35: A

Good finding the planar defects by UT, see Section 5.3.2.

See advantage of RT in the Section 5.2.5.

Q 36: A

See Section 5.2.3.

Q 37: C

Increased %C > increased hardness and strength, decreased ductility, decreased toughness.

 

Q 38: C

Means “how to avoid solidification crack”, see Section 17.4.3.

Q 39: A

Gauge length = (72-50)/50 %.

See Figure 4.5.

Q 40: C

See formula in the Section 2.6.2.

Q 41: B

Q 42: B

See Section 9.5 and 9.12.

Q 43: A

See Section 16.2, 70 means 70ksi of the minimum tensile strength.

Q 44: A

Keyword “randomly torn”. See answer Q 31 of this part.

Q 45: B

DCEP, see Section 11.3.4.

Q 46: B

See Section 7.3.

Q 47: C

See Section 5.2.5.

Q 48: D

C-Mn: HAZ cracking, see Section17.3.3.

HSLA: weld metal, see Section17.3.3.

Weld zone = HAZ + Weld metal, see Figure 2.8.

Q 49: B

Lamellar tearing occurs after welding, only on base metal. See Section 17.5.1.

Q 50: D

Keyword “control travel speed and arc gap, 80%Ag+20%CO2” > See Section 13.1.

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