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.

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