Project Quality Plan for Welding and Control.ppt

Quality plan of Welding

1. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
QUESTION TIME!!
MULTI CHOICE QUESTIONS

2. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Electrodes classified as E 43 2 C (BS EN 499)
and E 6010 ( AWS A5.1) would:
a) be baked for 1 hour
b) not require baking
c) be dried for 1 hour at 100
0
C and stored at 70
0
C
d) be dried for 1 hour at 180
0
C
QUESTION 1

3. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
In order to calculate arc energy, it is necessary
to know:
a) Current and Voltage
b) Current, Voltage , and Travel speed
c) Current , Voltage, and weave width
d) Wire feed, Voltage, and burn-off time
QUESTION 2

4. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
What unit is used for tensile strength values?
a) Joules
b) J/mm
2
c) N/ mm
2
d) P/ mm
2
QUESTION 3

5. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
The quality of a radiographic technique is
assessed:
a) By using a densitometer
b) From the kVA used, and the film-to-focus
distance
c) From the IQI
d) From the object-to-film distance
QUESTION 4

6. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Which of the following heating methods would
not be allowed for PWHT?
a) Electrical resistance mats
b) Hand-held gas torch
c) Gas fired heating
d) Induction furnace
QUESTION 5

7. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Which of the following statements about
Lamellar tearing is correct?
a) They are caused by the removal of strong-
backs
b) They are located in the centre of the weld
metal
c) They are formed during steel manufacture
d) They are formed during, or immediately after
welding
QUESTION 6

8. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Before carrying out Ultrasonic testing, it is
important:
a) To remove all excess weld metal
b) To carry out penetrant testing first
c) To calibrate the densitometer
d) To carry out some surface preparation
QUESTION 7

9. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
When a weld imperfection is located:
a) It must always be repaired
b) It must be rejected
c) The welder’s qualification documents should be
reviewed
d) It should be assessed against the relevant code
QUESTION 8

10. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Increasing the arc voltage of a SAW welded joint,
will result in:
a) Deeper penetration
b) More spatter
c) A narrow weld width
d) A wider weld width
QUESTION 9

11. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Which of the following is NOT an essential
variable:
a) Welding process
b) Bevel angle
c) Material type
d) PWHT
QUESTION 10

12. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
What does a large Z through the dual reference
line to BS EN 22553 indicate?
a) Throat thickness
b) Intermittent welds which must be staggered
c) Leg length
d) Toes must be blended
QUESTION 11

13. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Which defect is NOT normally associated with the
TIG welding process?
a) Tungsten inclusions
b) Crater pipe
c) Spatter
d) Porosity
QUESTION 12

14. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
According to AWS A5.1, what type of covering
would an E6013 electrode have?
a) Fused
b) Basic
c) Rutile
d) Cellulosic
QUESTION 13

15. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Welding procedures must be qualified, because:
a) The welder needs to practice before production
begins
b) To prove that the NDT method can locate defects
c) To prove that the fabricator can control welding
d) To ensure that the joint properties satisfy the
specification
QUESTION 14

16. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Cyclic stress loading can lead to:
a) Fatigue failure
b) Brittle fracture
c) Ductile tearing
d) Stress corrosion cracking
QUESTION 15

17. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Hydrogen cracking is most likely in:
a) Aluminium
b) High strength low alloy steel
c) Low carbon steel
d) Austenitic stainless steel
QUESTION 16

18. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Fillet weld fracture tests are carried out to:
a) Assess the root for penetration and fusion
b) Estimate the fracture toughness
c) Estimate resistance to fatigue failure
d) All of the above
QUESTION 17

19. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
In the TIG welding process, slope -in/ slope -out
capability would be useful in order to:
a) Avoid start porosity and crater pipes
b) Reduce the risk of tungsten inclusions
c) Stabilise the arc
d) Allow more time for the filler metal to melt
QUESTION 18

20. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Which of the following MMA covered electrodes will
give deeper penetration compared to the others?
a) High iron powder
b) Rutile
c) Cellulosic
d) Basic
QUESTION 19

21. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Ultra-Violet and Infra-Red radiation created during
welding:
a) Help arc initiation
b) Can cause skin burns
c) Increase the welding speed
d) Be used for NDT
QUESTION 20

22. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
With which NDT method would you use a “probe”?
a) X-Ray radiography
b) Magnetic Particle Inspection
c) Ultrasonic testing
d) Gamma radiography
QUESTION 21

23. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
TIG welding of Aluminium would normally require
which polarity?
a) AC
b) DC electrode negative
c) DC electrode positive
d) All of the above
QUESTION 22

24. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
What would be the required leg length of a fillet weld
with a design throat of 9 mm?
a) 9.5 mm
b) 12.6 mm
c) 6.3 mm
d) 7.8 mm
QUESTION 23

25. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
A BS EN 22553 weld symbol reference line has the
number 131 at the end of it. What does this represent?
a) MMA process to be used
b) The welding position
c) The weld shall be made using the MIG process
d) The total weld length
QUESTION 24

26. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Which test is carried out to determine a materials
susceptibility to lamellar tearing?
a) Charpy test
b) Transverse tensile test
c) STRA test
d) Vickers test
QUESTION 25

27. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Which standard is concerned with Welder Approval?
a) BS EN 499
b) BS EN 288
c) BS EN 970
d) BS EN 287
QUESTION 26

28. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
The included angle of a typical 15mm carbon steel
Single-Vee butt joint would be?
a) 30
0
b) 70
0
c) 120
0
d) 90
0
QUESTION 27

29. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Which element may result in a carbon steel weld
having “hot shortness”?
a) Silicon
b) Martensite
c) Sulphur
d) Manganese
QUESTION 28

30. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
What does the term back-steprefer to?
a) The use of step wedges for radiography
b) The use of step wedges to open up the joint root
faces
c) The weld run sequence
d) The welder returning to the completed joint
QUESTION 29

31. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Which welding position would normally give the
highest heat input during MMA welding?
a) PA (1G)
b) PC (2G)
c) PF (3G)
d) All positions would be the same
QUESTION 30

32. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
PREPARE FOR THE ANSWERS!!
WRITE YOUR NAME ON YOUR PAPER
SWAP YOUR PAPER WITH
SOMEONE ELSE

33. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Electrodes classified as E 43 2 C (BS 499)
and E 6010 ( AWS A5.1) would usually:
a) Be baked for 1 hour
b) Not require baking
c) Be dried for 1 hour at 100
0
C and stored at 70
0
C
d) Be dried for 1 hour at 180
0
C
QUESTION 1
ANSWER: B

34. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
In order to calculate arc energy, it is necessary
to know:
a) Current and Voltage
b) Current, Voltage , and Travel speed
c) Current , Voltage, and weave width
d) Wire feed, Voltage, and burn-off time
QUESTION 2
ANSWER: B

35. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
What unit is used for tensile strength values?
a) Joules
b) J/mm
2
c) N/ mm
2
d) P/ mm
2
QUESTION 3
ANSWER: C

36. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
The quality of a radiographic technique is
assessed:
a) By using a densitometer
b) From the kVA used, and the film-to-focus
distance
c) From the IQI
d) From the object-to-film distance
QUESTION 4
ANSWER: C

37. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Which of the following heating methods would
not be allowed for PWHT?
a) Electrical resistance mats
b) Hand-held gas torch
c) Gas fired heating
d) Induction furnace
QUESTION 5
ANSWER: B

38. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Which of the following statements about
Lamellar tearing is correct?
a) They are caused by the removal of strong-
backs
b) They are located in the centre of the weld
metal
c) They are formed during steel manufacture
d) They are formed during, or immediately after
welding
QUESTION 6
ANSWER: D

39. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Before carrying out Ultrasonic testing, it is
important:
a) To remove all excess weld metal
b) To carry out penetrant testing first
c) To calibrate the densitometer
d) To carry out some surface preparation
QUESTION 7
ANSWER: D

40. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
When a weld imperfection is located:
a) It must always be repaired
b) It must be rejected
c) The welder’s qualification documents should be
reviewed
d) It should be assessed against the relevant code
QUESTION 8
ANSWER: D

41. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Increasing the arc voltage of a SAW welded joint,
will result in:
a) Deeper penetration
b) More spatter
c) A narrow weld width
d) A wider weld width
QUESTION 9
ANSWER: D

42. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Which of the following is NOT an essential
variable:
a) Welding process
b) Bevel angle
c) Material type
d) PWHT
QUESTION 10
ANSWER: B

43. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
What does a large Z through the dual reference
line to BS EN 22553 represent?
a) Throat thickness
b) Intermittent welds which must be staggered
c) Leg length
d) Toes must be blended
QUESTION 11
ANSWER: B

44. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Which defect is NOT normally associated with
TIG?
a) Tungsten inclusions
b) Crater pipe
c) Spatter
d) Lack of fusion
QUESTION 12
ANSWER: C

45. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
According to AWS A5.1, what type of covering
would an E6013 electrode have?
a) Fused
b) Basic
c) Rutile
d) Cellulosic
QUESTION 13
ANSWER: C

46. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Welding procedures must be qualified, because:
a) The welder needs to practice before production
begins
b) To prove that the NDT method can locate defects
c) To prove that the fabricator can control welding
d) To ensure that the joint properties satisfy the
specification
QUESTION 14
ANSWER: D

47. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Cyclic stress loading can lead to:
a) Fatigue failure
b) Brittle fracture
c) Ductile tearing
d) Stress corrosion cracking
QUESTION 15
ANSWER: A

48. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Hydrogen cracking is most likely in:
a) Aluminium
b) High strength low alloy steel
c) Low carbon steel
d) Austenitic stainless steel
QUESTION 16
ANSWER: B

49. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Fillet weld fracture tests are carried out to:
a) Assess the root for penetration and fusion
b) Estimate the fracture toughness
c) Estimate resistance to fatigue failure
d) All of the above
QUESTION 17
ANSWER: A

50. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
In the TIG welding process, slope-in/ slope -out
capability is useful in order to:
a) Avoid start porosity and crater pipes
b) Reduce the risk of tungsten inclusions
c) Stabilise the arc
d) Allow more time for the filler metal to melt
QUESTION 18
ANSWER: A

51. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Which of the following covered MMA electrodes will
give deeper penetration compared with the others?
a) High iron powder
b) Rutile
c) Cellulosic
d) Basic
QUESTION 19
ANSWER: C

52. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Ultra-Violet and Infra-Red radiation created during
welding:
a) Help arc initiation
b) Can cause skin burns
c) Increase the welding speed
d) Be used for NDT
QUESTION 20
ANSWER: B

53. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
With which NDT method would you use a “probe”?
a) X-Ray radiography
b) Magnetic Particle Inspection
c) Ultrasonic testing
d) Gamma radiography
QUESTION 21
ANSWER: C

54. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
TIG welding of Aluminium normally requires which
polarity?
a) AC
b) DC electrode negative
c) DC electrode positive
d) All of the above
QUESTION 22
ANSWER: A

55. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
What would be the required leg length of a fillet weld
with a design throat of 9 mm?
a) 9.5 mm
b) 12.6 mm
c) 6.3 mm
d) 7.8 mm
QUESTION 23
ANSWER: B

56. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
A BS EN 22553 weld symbol reference line has the
number 131 at the end of it. This symbolises what?
a) MMA process to be used
b) The welding position
c) The weld shall be made using the MIG process
d) The total weld length
QUESTION 24
ANSWER: C

57. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Which test is carried out to determine a materials
susceptibility to lamellar tearing?
a) Charpy test
b) Transverse tensile test
c) STRA test
d) Vickers test
QUESTION 25
ANSWER: C

58. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Which standard is concerned with Welder Approval?
a) BS EN 499
b) BS EN 288
c) BS EN 970
d) BS EN 287
QUESTION 26
ANSWER: D

59. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
The included angle of a typical 15mm carbon steel
Single-Vee MMA butt joint would be?
a) 30
0
b) 70
0
c) 120
0
d) 90
0
QUESTION 27
ANSWER: B

60. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Which element may result in a carbon steel weld
having “hot shortness”?
a) Silicon
b) Martensite
c) Sulphur
d) Manganese
QUESTION 28
ANSWER: C

61. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
What does the term back-steprefer to?
a) The use of step wedges for radiography
b) The use of step wedges to open up the joint root
faces
c) The weld run sequence
d) The welder returning to the completed joint
QUESTION 29
ANSWER: C

62. Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
Which welding position would normally give the
highest heat input during MMA welding?
a) PA (1G)
b) PC (2G)
c) PF (3G)
d) All positions would be the same
QUESTION 30
ANSWER: c