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 blend smooth 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) = (8x10)/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
- Learn 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<=0.3x10 = 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+0.1x35 = 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) = (350x32)/(310x1000), don't k-factor.
- 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 (AC) and sub-surface defects (DC - prod)
- 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 --> ductile fracture.
- Answer b/d -->brittle fracture.
Q 32: A
- E6013 --> 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.
