Welding Inspection Standards Quiz
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Questions and Answers

What is the recommended minimum illumination level for visual inspection according to ISO 17637?

  • 500 lux (correct)
  • 400 lux
  • 600 lux
  • 350 lux

    • What is the maximum distance an inspector should be from the surface during visual inspection?

  • 300mm
  • 600mm (correct)
  • 900mm
  • 1200mm

    • When is visual inspection of the finished weld deemed to be a minimum requirement?

  • In the as-welded condition (correct)
  • After surface treatment
  • Before welding begins
  • During fabrication only

    • Which tool is NOT typically used to facilitate visual examination of welds?

    <p>Micrometer</p> Signup and view all the answers

    What viewing angle should the inspector aim to achieve during visual inspection?

    <p>30°</p> Signup and view all the answers

    Which of the following statements about visual inspection aids is true?

    <p>They can include advanced tools like mirrored boroscopes.</p> Signup and view all the answers

    What is one of the primary conditions for access during visual inspection?

    <p>The area must be adequately illuminated.</p> Signup and view all the answers

    Which item is specifically used to check parameters like bevel angles and weld profile?

    <p>Dedicated weld gap gauges</p> Signup and view all the answers

    What is one of the duties of a welding inspector regarding inspection aids?

    <p>Ensure they are in good condition.</p> Signup and view all the answers

    Which factor must a welding inspector consider concerning welding equipment?

    <p>They need to be in suitable condition and calibrated as appropriate.</p> Signup and view all the answers

    What must a welding inspector verify regarding welders' qualifications?

    <p>Identification of welders qualified for each Welding Procedure Specification (WPS).</p> Signup and view all the answers

    What is the minimum requirement for preheat temperature when specified in a WPS?

    <p>It must meet the conditions stated in the WPS.</p> Signup and view all the answers

    During welding, what aspect must a welding inspector confirm about the weather conditions?

    <p>They must be suitable and comply with the Code.</p> Signup and view all the answers

    Which should a welding inspector ensure regarding welding consumables?

    <p>They are as specified by the WPSs and controlled as per QC procedures.</p> Signup and view all the answers

    What is a critical action that a welding inspector must take regarding weld preparations?

    <p>They must follow the WPS and/or drawings.</p> Signup and view all the answers

    What condition must weld faces meet according to inspection standards?

    <p>They should be free from defects, contamination, and damage.</p> Signup and view all the answers

    What causes surface porosity in welding?

    <p>Low fluxing activity</p> Signup and view all the answers

    Which method is effective in preventing loss of shielding gas during MIG/MAG welding?

    <p>Reduce arc length</p> Signup and view all the answers

    What is the role of high manganese electrodes in welding free-cutting steels?

    <p>To produce manganese sulfides</p> Signup and view all the answers

    Which condition can lead to a crater pipe in a welded joint?

    <p>Inadequate crater filling techniques</p> Signup and view all the answers

    What can be done to prevent excessive turbulence from shielding gas flow?

    <p>Optimise gas flow rate</p> Signup and view all the answers

    What is a common cause of solid inclusions in welded joints?

    <p>Presence of foreign substances</p> Signup and view all the answers

    Which of the following is a method to prevent crater pipes in TIG welding?

    <p>Correct crater filling techniques</p> Signup and view all the answers

    How can a welder mitigate the effects of excessive sulfur in free-cutting steels?

    <p>By using high manganese electrodes</p> Signup and view all the answers

    What is the main purpose of destructive tests in welded joints?

    <p>To measure the hardness and tensile strength.</p> Signup and view all the answers

    Which of the following describes quantitative tests in destructive testing?

    <p>They measure properties like tensile strength.</p> Signup and view all the answers

    What type of tests are used to check for defects in welded joints?

    <p>Bend tests and macroscopic examination.</p> Signup and view all the answers

    Transverse tensile tests are primarily used for what purpose?

    <p>To qualify welding procedures for strength verification.</p> Signup and view all the answers

    Which description correctly defines the similarity between welded joints and base metals?

    <p>The properties of welded joints should not be worse than the base metals.</p> Signup and view all the answers

    What is the role of standards like EN 895 in transverse tensile testing?

    <p>They specify dimensions and preparation for test specimens.</p> Signup and view all the answers

    Which of the following is NOT a mechanical property measured in quantitative tests?

    <p>Sound quality of the joint.</p> Signup and view all the answers

    What differentiates qualitative tests from quantitative tests?

    <p>Qualitative tests verify absence of defects.</p> Signup and view all the answers

    What is one way to prevent porosity caused by grease or water contamination on a prepared surface?

    <p>Clean the prepared surface</p> Signup and view all the answers

    What can cause the formation of worm holes in a weld?

    <p>Trapped gas during solidification</p> Signup and view all the answers

    To reduce the risk of air entrapment in gas shield processes, what should be checked?

    <p>Hose connections</p> Signup and view all the answers

    What is a recommended prevention method for surface porosity?

    <p>Use an unlaminated parent material</p> Signup and view all the answers

    What is the effect of using dry electrodes in good condition?

    <p>Decreases the chance of porosity</p> Signup and view all the answers

    What should be used to ensure adequate deoxidation in welding processes?

    <p>Electrode with sufficient deoxidant activity</p> Signup and view all the answers

    What risk should be identified before surface treatment to avoid gas evolution from priming paints?

    <p>Reactivity of materials</p> Signup and view all the answers

    What is one method to prevent turbulence that can lead to weld imperfections?

    <p>Optimise gas flow rate</p> Signup and view all the answers

    Where are crater cracks specifically found?

    <p>Only in the weld metal</p> Signup and view all the answers

    What is the primary cause of solidification cracks?

    <p>High impurity content in the weld metal</p> Signup and view all the answers

    What type of crack is associated with liquation during welding?

    <p>Hot cracks</p> Signup and view all the answers

    What condition can increase the likelihood of solidification cracking?

    <p>Stop/start condition during welding</p> Signup and view all the answers

    Which type of cracks are known to occur in creep resisting steels due to precipitation?

    <p>Cold cracks</p> Signup and view all the answers

    What type of hot crack occurs near the fusion line and is related to heating the material?

    <p>Liquation crack</p> Signup and view all the answers

    What can cause intergranular liquid films to form during the solidification process?

    <p>Segregation of elements like sulphur</p> Signup and view all the answers

    What is a characteristic feature of a solidification crack?

    <p>It can open to the surface and resemble shrinkage voids</p> Signup and view all the answers

    What is the minimum illumination level, in lux, required for visual inspection according to ISO 17637?

    <p>350 lux</p> Signup and view all the answers

    What are the three essential aspects a welding inspector should consider during a materials inspection?

    <p>Material type and weldability, material traceability, material condition and dimensions</p> Signup and view all the answers

    A homogeneous joint is a welded joint where the weld metal and the parent material have significant differences in mechanical properties and/or chemical composition.

    <p>False</p> Signup and view all the answers

    What is the definition of a "weld"?

    <p>A union of pieces of metal made by welding.</p> Signup and view all the answers

    What is the purpose of "back purging" when TIG welding?

    <p>To protect the back of the weld from excessive oxidation.</p> Signup and view all the answers

    Crater cracks are only found in the weld metal.

    <p>True</p> Signup and view all the answers

    What is the definition of a "solidification crack"?

    <p>A crack that occurs in the weld metal as a result of the solidification process.</p> Signup and view all the answers

    Hydrogen-induced cracking occurs primarily in the weld metal.

    <p>False</p> Signup and view all the answers

    What is the term for a "non-metallic inclusion" that is a very thin platelet with its principal planes parallel to the plate surface?

    <p>Lamellar tearing</p> Signup and view all the answers

    What is the definition of a "slag inclusion"?

    <p>Slag trapped during welding, which has an irregular shape.</p> Signup and view all the answers

    What is the definition of an "undercut"?

    <p>An irregular groove at the toe of a weld run in the parent metal.</p> Signup and view all the answers

    What are the three generic types of flux covering used for MMA welding?

    <p>Rutile, Basic, Cellulosic</p> Signup and view all the answers

    What is the "operating factor" (O/F) in welding refer to?

    <p>The percentage of arc on time in a given time.</p> Signup and view all the answers

    What does the term "spray transfer" refer to in MIG/MAG welding?

    <p>Free-flight metal transfer.</p> Signup and view all the answers

    What does the term "synergic" welding refer to?

    <p>A one-knob control system that automatically sets optimal welding parameters.</p> Signup and view all the answers

    What is the purpose of the "shielding gas" in TIG welding?

    <p>To protect the tungsten electrode and the weld zone from atmospheric contamination.</p> Signup and view all the answers

    What is the definition of "electrode extension"?

    <p>The distance between the contact tube and the tungsten tip.</p> Signup and view all the answers

    What is the most common type of inert gas used for MIG welding of aluminium?

    <p>Argon.</p> Signup and view all the answers

    What is the most common shielding gas mixture used for spray transfer in MIG welding of stainless steels?

    <p>Argon + 2-2.5% CO2.</p> Signup and view all the answers

    What is the primary function of the "contact tip to workpiece distance" (CTWD) in MIG/MAG welding?

    <p>It controls arc length, which influences the welding current and heat input, and affects weld bead width and penetration.</p> Signup and view all the answers

    What are the two primary categories of metal transfer used in MIG/MAG welding?

    <p>Dip transfer and spray transfer.</p> Signup and view all the answers

    What is a "fusible insert"?

    <p>A consumable item that is fused into the root of a weld during TIG welding of pipes.</p> Signup and view all the answers

    Flux-cored arc welding (FCAW) is generally used for lighter-gauge metals.

    <p>False</p> Signup and view all the answers

    What are the two main types of flux used in SAW welding?

    <p>Fused flux and agglomerated flux.</p> Signup and view all the answers

    Welding in the "flat" position produces the highest heat input.

    <p>False</p> Signup and view all the answers

    The main purpose of PWHT in welding is to improve the resistance of the joint to brittle fracture.

    <p>True</p> Signup and view all the answers

    What is the primary source of hydrogen that can cause hydrogen-induced cracking in steel welds?

    <p>Moisture in the welding flux.</p> Signup and view all the answers

    What is the name for the process of "heating a joint immediately prior to welding"?

    <p>Preheat.</p> Signup and view all the answers

    What is the primary purpose of "preheat"?

    <p>To reduce the risk of hydrogen cracking and to improve overall weld quality.</p> Signup and view all the answers

    What is the definition of "interpass temperature"?

    <p>The temperature of the weld metal and HAZ between passes during a multi-run weld.</p> Signup and view all the answers

    What is the name of the type of welding that involves a continuous electrode submerged in a powdered flux?

    <p>Submerged arc welding (SAW).</p> Signup and view all the answers

    Oxy-fuel cutting is suitable for all grades of steel.

    <p>False</p> Signup and view all the answers

    What are the two main methods of thermal cutting?

    <p>Oxy-fuel cutting and plasma arc cutting.</p> Signup and view all the answers

    Arc air gouging is typically used for deep gouging operations.

    <p>False</p> Signup and view all the answers

    What is the main difference between 'transferred arc' and 'non-transferred arc' plasma arc cutting?

    <p>The transferred arc method uses the workpiece as the negative electrode, while the non-transferred arc method maintains the electrodes inside the torch.</p> Signup and view all the answers

    What is the definition of a "weld repair"?

    <p>A process of restoring a weld or a welded joint to a sound and serviceable condition.</p> Signup and view all the answers

    The reason for a particular repair should always be recorded.

    <p>True</p> Signup and view all the answers

    PWHT (post-weld heat treatment) is always necessary for welded joints.

    <p>False</p> Signup and view all the answers

    What are the five main categories of factors affecting residual stresses?

    <p>Material properties, amount of restraint, joint design, fit-up, welding sequence.</p> Signup and view all the answers

    What is "lamellar tearing"?

    <p>A type of cracking that occurs only in steel plate and other rolled products.</p> Signup and view all the answers

    Weld decay is commonly observed in low carbon grades of stainless steel.

    <p>False</p> Signup and view all the answers

    What is the primary cause of 'weld distortion'?

    <p>Thermal expansion and contraction of the weld metal and the surrounding cold metal during welding.</p> Signup and view all the answers

    Which of the following welding methods generally produces the highest deposition rate?

    <p>SAW</p> Signup and view all the answers

    Which of the following welding variables directly affects the depth of fusion/penetration in a weld?

    <p>Welding current</p> Signup and view all the answers

    What is the main purpose of "welding jigs and fixtures"?

    <p>To maintain dimensional accuracy and prevent distortion during welding.</p> Signup and view all the answers

    Pre-bending is a more efficient method for controlling distortion than using strongbacks.

    <p>False</p> Signup and view all the answers

    What are the three primary techniques used to prevent distortion during assembly?

    <p>Tack welding, back-to-back welding, and stiffening.</p> Signup and view all the answers

    Correcting distortion using thermal techniques is a simple and straightforward process.

    <p>False</p> Signup and view all the answers

    Study Notes

    CSWIP 3.1 - Welding Inspector

    • This document is a training and examination service of TWI Ltd.
    • It provides structured content for the CSWIP 3.1 Welding Inspector certification.
    • The document covers various aspects of welding inspection, including duties, definitions, imperfections, testing, WPS/welder qualification, materials, codes, and standards.
    • It is aligned with BS EN ISO 15607.

    Section 1 - Typical Duties of Welding Inspectors

    • Welding inspectors ensure welded items meet the specified requirements.
    • They have responsibilities for quality control (QC) activities.
    • Knowledge of QC procedures and welding technology is crucial.
    • Visual inspection is often the first NDE step, followed by other NDT methods for certain applications.
    • Welding inspectors are required to be familiar with relevant standards, rules, and specifications (e.g., WPSs, Application Standards, drawings, QC procedures), at the start of a new project.
    • Inspectors should ensure all necessary inspection aids are in good working order and calibrated.

    Section 2 - Terms and Definitions

    • Brazing is a joining process where molten filler metal is drawn into the joint by capillary attraction.
    • Braze welding is a joining process similar to fusion welding, using filler metal with a lower melting point, but neither using capillary action as in brazing nor intentionally melting the parent metal.
    • A joint is a connection where the individual components, suitably prepared and assembled, are joined by welding or brazing.
    • A weld is a union of pieces of metal made by welding.
    • Welding is the joining of two or more parts by heat, pressure, or a combination using methods that ensure continuity in the nature of the metal between these parts.
    • There are different types of joints (e.g., butt, corner, edge, cruciform, lap).
    • There are different types of welds (e.g., butt, fillet, autogenous, slot, plug).

    Section 3 - Welding Imperfections and Materials Inspection

    • Imperfections are deviations from the ideal weld.
    • Defects are unacceptable imperfections.
    • Cracks, cavities, and solid inclusions are common types of imperfections.
    • Lack of fusion, penetration, shape/dimension issues, and miscellaneous imperfections are other types of imperfections.
    • The identification of imperfections is important for understanding their causes and preventing recurrence.

    Section 4 - Destructive Testing

    • Destructive tests are used to measure a mechanical property or assess the quality of the joint.
    • These tests involve destroying the weld by taking various test pieces from it.
    • Common destructive test types include: Transverse tensile tests, impact toughness tests, and hardness testing.
    • Test specimens are standardised in terms of dimensions and are regularly tested to meet design specifications in various codes (e.g., EN 895).

    Section 5 - Non-destructive Testing

    • Non-destructive testing (NDT) methods are used to evaluate the weld integrity without destroying the weld.
    • Key NDT methods include radiographic testing (X-rays and gamma rays), ultrasonic testing, magnetic particle testing, and dye penetrant testing.

    Section 6 - WPS/Welder Qualifications

    • A WPS (Welding Procedure Specification) provides detailed instructions for welding procedures and variables for each welding job.
    • Welders must be qualified to the standards specified in the WPS to ensure the highest quality in their work.
    • A WPQR (Welder Procedure Qualification Record) is a record that specifies the conditions observed during testing; this allows welders to confidently follow the correct procedure under appropriate conditions.

    Section 7 - Materials Inspection

    • Materials type and weldability should be considered during inspection according to the relevant standards (e.g., BS EN 10025).
    • Inspectors must check compliance with relevant standards, documents, and other relevant instructions.

    Section 8 - Codes and Standards

    • Codes and standards provide specific guidance and the methods for conducting the welding procedure qualification.
    • Different types of codes and standards (normative documents, standards, harmonized standards, and regulations) are used for the welding process.

    Section 9 - Welding Symbols

    • Welding details can be conveyed using sketches or symbolic representations.
    • Symbolic representations are preferred for detailed drawings to avoid overcomplication.
    • The standards for creating the required symbols are covered.

    Section 10 - Introduction to Welding Processes

    • Welding involves an electrical discharge between an electrode and a workpiece.
    • Welding parameters (travel speed, arc voltage, and arcing current) affect productivity and quality.
    • The heat generated during welding affects metal penetration and droplet transfer.
    • Various types of arc welding (MMA, TIG, MIG/MAG, and SAW) are detailed.

    ... (Sections 11-24 remain the same)

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    CSWIP 3.1 Welding Inspector Course Notes PDF

    Description

    Test your knowledge on welding inspection standards, particularly focusing on visual inspection criteria as per ISO 17637. This quiz covers topics such as illumination levels, inspector access, and the use of inspection aids. Perfect for aspiring or current welding inspectors.

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