Welding Quality Control and Inspection Methods Quiz
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Questions and Answers

What does the Rockwell hardness tester measure?

  • Size of the indentation
  • Resistance to permanent deformation
  • Depth of penetration under load (correct)
  • Tensile strength

    • What is the designation for Brinell hardness value?

  • HRC
  • HRB
  • HB (correct)
  • HV

    • Which hardness test allows testing of welds with small indentation size and easy location of specific regions?

  • Vickers hardness test (correct)
  • Rockwell hardness test
  • Brinell hardness test
  • None of the above

    • What is the limitation of Brinell and Vickers tests?

    <p>Requirement to measure the size of the indentation</p> Signup and view all the answers

    What is the distance requirement between each indentation in Vickers test?

    <p>No less than 25 times the indentation size</p> Signup and view all the answers

    What does hardness testing assess?

    <p>A material's resistance to permanent deformation</p> Signup and view all the answers

    What is the relationship between hardness and tensile strength of steel?

    <p>Hardness is related to mechanical properties and tensile strength of steel</p> Signup and view all the answers

    Which scale is commonly used for testing welds in Rockwell hardness test?

    <p>Rockwell C and Rockwell B</p> Signup and view all the answers

    What does the Vickers hardness number represent?

    <p>The Vickers Pyramid Number (HV)</p> Signup and view all the answers

    What is the purpose of the side-bend specimen test?

    <p>To reveal internal defects in double-V-groove welds</p> Signup and view all the answers

    What load range does the Vickers hardness test use?

    <p>5-100 kg load</p> Signup and view all the answers

    What is the primary use of the all-weld-metal tensile test specimen?

    <p>For welding consumables classification</p> Signup and view all the answers

    How is the ultimate strength of the transverse weld test specimen determined?

    <p>By dividing the maximum load reached during testing by the cross-sectional area</p> Signup and view all the answers

    What is the purpose of the guided bend test?

    <p>For welder and procedure qualification</p> Signup and view all the answers

    Why is a larger radius required for bending higher strength steels?

    <p>To reduce applied strain</p> Signup and view all the answers

    What precaution must be taken in the preparation of bend samples?

    <p>Edges being radiused and grinding marks being parallel to the length of the specimen</p> Signup and view all the answers

    What are the different types of guided bend tests?

    <p>Root-bend, face-bend, and side-bend</p> Signup and view all the answers

    Why are side-bends chosen for material over 10 mm?

    <p>Due to the difficulty of performing root- and face-bends on such thickness</p> Signup and view all the answers

    What does the face-bend test reveal?

    <p>Incomplete penetration or fusion</p> Signup and view all the answers

    What is the diameter of the all-weld-metal tensile test specimen?

    <p>12.5 mm</p> Signup and view all the answers

    What are the two commonly used tensile testing specimens?

    <p>The all-weld-metal tensile test specimen and the transverse weld test specimen</p> Signup and view all the answers

    What is the cross-sectional area of the all-weld-metal tensile specimen?

    <p>122.7 mm</p> Signup and view all the answers

    What is the purpose of the transverse weld test specimen?

    <p>For the qualification of welding procedures</p> Signup and view all the answers

    What is the definition of quality in welding?

    <p>The degree to which inherent characteristics fulfill requirements</p> Signup and view all the answers

    What is the difference between a discontinuity and a defect in welding?

    <p>A discontinuity is an interruption of the typical structure, while a defect renders a part unable to meet minimum standards</p> Signup and view all the answers

    What is the purpose of nondestructive testing (NDT) in welding?

    <p>To evaluate a component without damaging it</p> Signup and view all the answers

    What mechanical properties can be determined using tensile testing in welding?

    <p>Yield strength, ultimate strength, and ductility</p> Signup and view all the answers

    What is the definition of stress in a material?

    <p>The intensity of internal forces resisting an external force</p> Signup and view all the answers

    What happens during elastic behavior of a material?

    <p>The material returns to its original dimensions after stress is removed</p> Signup and view all the answers

    What is the yield stress in welding?

    <p>The stress at which a 0.2% permanent set is observed</p> Signup and view all the answers

    What do different stress-strain curves in metals indicate?

    <p>Different metals exhibit different stress-strain behaviors</p> Signup and view all the answers

    What is the purpose of tensile tests in welding?

    <p>To determine mechanical properties significant in welding</p> Signup and view all the answers

    What machines are used to carry out tensile tests in welding?

    <p>Special machines, mechanical, and hydraulic</p> Signup and view all the answers

    Why is understanding quality, discontinuity, and testing methods crucial in welding?

    <p>To maintain welding standards and ensure the reliability of welded structures</p> Signup and view all the answers

    What is the formula for calculating Vickers hardness number (HV)?

    <p>$HV = 1.854 \times \frac{P}{d^2}$</p> Signup and view all the answers

    Which type of hardness test can be applied to survey the hardness of relatively small areas such as sections of welds and heat-affected zones?

    <p>Vickers hardness test</p> Signup and view all the answers

    Which hardness testing method can only be used for obtaining hardness values over a relatively large area such as the face of a weld?

    <p>Brinell test</p> Signup and view all the answers

    What does the Charpy impact test measure?

    <p>Toughness by recording energy absorbed when a notched specimen is broken</p> Signup and view all the answers

    What units are used to measure the energy absorbed in a Charpy impact test?

    <p>Joules or foot-pounds</p> Signup and view all the answers

    What type of specimen is commonly used for Charpy impact testing?

    <p>Charpy U-notch specimen</p> Signup and view all the answers

    What does the transition temperature in impact testing indicate?

    <p>Temperature at which a certain energy is reached, used to compare the toughness of materials</p> Signup and view all the answers

    What can lead to misleading results in impact testing?

    <p>Machining specimens from the wrong location or orienting the notch incorrectly</p> Signup and view all the answers

    What is the purpose of impact tests in the classification of an electrode?

    <p>To identify the brittleness of the electrode at low temperatures</p> Signup and view all the answers

    What are the two types of hardness testing methods mentioned in the text?

    <p>Micro and macro</p> Signup and view all the answers

    What information do hardness traverses across a weld provide?

    <p>Information on as-welded and stress relieved conditions</p> Signup and view all the answers

    What is the purpose of micro or macro hardness testing in welds?

    <p>To identify specific regions in welds</p> Signup and view all the answers

    What is the significance of using a diamond or large steel ball in hardness testing?

    <p>To apply small or large loads</p> Signup and view all the answers

    What can different hardness testing methods require in terms of sample thickness?

    <p>Thick or thin samples depending on the method</p> Signup and view all the answers

    What is the primary use of hardness testing methods in welded structures?

    <p>To assess the brittleness of the weld</p> Signup and view all the answers

    What is the mode of transfer for the welding process mentioned in the text?

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

    What is the standard mentioned for the single electrode mechanized process?

    <p>CSA W47.1</p> Signup and view all the answers

    What is the purpose of checking the joint preparation and fit-up in welding?

    <p>To inspect the joint preparation surfaces</p> Signup and view all the answers

    Which item should be checked to ensure that all the required welds have been made?

    <p>Weld locations</p> Signup and view all the answers

    What is the primary use of visual inspection after welding?

    <p>To measure the weld sizes</p> Signup and view all the answers

    What is the purpose of reviewing welder qualifications?

    <p>To ensure that welders only weld joints for which they are qualified</p> Signup and view all the answers

    What should be monitored, if required, during welding?

    <p>Preheat and interpass temperatures</p> Signup and view all the answers

    What is the purpose of measuring fillet weld sizes?

    <p>To ensure they are correct</p> Signup and view all the answers

    What is the purpose of ensuring that electrodes are stored and handled correctly?

    <p>To maintain their quality and performance</p> Signup and view all the answers

    What is the purpose of checking for the presence of moisture, scale, slag, oil, grease, paint, etc. on the joint surface?

    <p>To ensure the quality of the joint surface</p> Signup and view all the answers

    What is the purpose of identifying the weld size requirements?

    <p>To ensure they are correct</p> Signup and view all the answers

    What is the primary use of visual inspection during welding?

    <p>To verify the welding process being used</p> Signup and view all the answers

    What is the purpose of the nick-break test in weld inspection?

    <p>To reveal internal weld discontinuities</p> Signup and view all the answers

    Where are the impact specimens located for a 20 mm thick test plate?

    <p>Mid-thickness</p> Signup and view all the answers

    What is the basis for all weld examination methods?

    <p>Visual inspection</p> Signup and view all the answers

    What is the purpose of the fillet weld break test?

    <p>To evaluate the general quality of the weld</p> Signup and view all the answers

    What does the nick-break test evaluate in a region of the welded joint?

    <p>Entire surface area</p> Signup and view all the answers

    What is examined when macroscopic examination is performed?

    <p>Cross-section of the finished weld</p> Signup and view all the answers

    When should visual inspection be performed in the welding process?

    <p>Before, during, and after welding</p> Signup and view all the answers

    What is the purpose of testing the heat-affected zone in weld inspection?

    <p>Can be troublesome due to its narrow width and slope</p> Signup and view all the answers

    What is the purpose of the macroscopic examination in weld inspection?

    <p>To examine the cross-section of the finished weld</p> Signup and view all the answers

    What is the purpose of the fillet weld break test in weld inspection?

    <p>To evaluate the general quality of the weld</p> Signup and view all the answers

    What is the purpose of the nick-break test in weld inspection?

    <p>To reveal internal weld discontinuities</p> Signup and view all the answers

    What is the basis for all weld examination methods?

    <p>Visual inspection</p> Signup and view all the answers

    What tools are used for traditional visual inspection of weld surface discontinuities?

    <p>Good lighting, magnifiers, rulers, micrometers and optical comparators</p> Signup and view all the answers

    What are examples of nondestructive examination methods mentioned in the text?

    <p>Witnessing the root pass and subsequent backgouging, radiographic inspection</p> Signup and view all the answers

    Why is visual inspection commonly used in production?

    <p>Perceived to require relatively little training and equipment</p> Signup and view all the answers

    What are the main tools used to facilitate visual inspection?

    <p>Commercial gauges, good lighting, magnifiers</p> Signup and view all the answers

    What type of discontinuities can the AC yoke be used to detect?

    <p>Linear discontinuities parallel to the direction of the weld</p> Signup and view all the answers

    Why is the use of prods prohibited by certain codes in magnetic particle inspection?

    <p>Chance of causing arc strikes</p> Signup and view all the answers

    Which materials cannot be examined using magnetic particle inspection?

    <p>Aluminum, brass, bronze, and austenitic stainless steels</p> Signup and view all the answers

    What is the primary purpose of radiographic inspection (RT) in welds?

    <p>Detect subsurface volumetric discontinuities</p> Signup and view all the answers

    What is the difference between X-radiography and gamma radiography?

    <p>The type of radiation used</p> Signup and view all the answers

    What is the danger associated with ionizing radiation used in radiography?

    <p>It is dangerous and cannot be felt, seen, smelled, or tasted</p> Signup and view all the answers

    What determines the appearance of light or dark shadows on the radiographic film?

    <p>Differences in the amount of radiation passing through the weld</p> Signup and view all the answers

    What is the primary use of the dry powder method in radiographic inspection?

    <p>More sensitive to subsurface discontinuities</p> Signup and view all the answers

    What is the primary use of the wet fluorescent method in radiographic inspection?

    <p>Locating smaller discontinuities</p> Signup and view all the answers

    What is the main limitation of radiography in the inspection of welds?

    <p>Material thickness and density must show up on the film image</p> Signup and view all the answers

    What is the primary purpose of establishing a safe zone and posting warning signs during radiography?

    <p>To prevent exposure to ionizing radiation</p> Signup and view all the answers

    What is the significance of evaluating the shape, density, and location of the images created by voids and inclusions on radiographic film?

    <p>Interpreting the radiographic film</p> Signup and view all the answers

    What does liquid penetrant inspection measure in welding?

    <p>Undercut and excess groove weld height</p> Signup and view all the answers

    What is the purpose of magnetic particle inspection in welding?

    <p>To detect fine cracking that comes to the surface</p> Signup and view all the answers

    What is the difference between visible dye and fluorescent dye penetrant?

    <p>Fluorescent dye penetrant requires ultraviolet light for viewing, while visible dye does not</p> Signup and view all the answers

    What is the main limitation of magnetic particle inspection?

    <p>Limited in detecting isolated indications such as porosity</p> Signup and view all the answers

    What is the primary use of fluorescent penetrant testing?

    <p>To detect leaks in welded joints in tanks and containers</p> Signup and view all the answers

    What is the purpose of applying a developer in liquid penetrant inspection?

    <p>To improve the visibility of indications</p> Signup and view all the answers

    What is the main advantage of liquid penetrant inspection in welding?

    <p>Simple, inexpensive, and does not require complex equipment</p> Signup and view all the answers

    How is the magnetic field induced in magnetic particle inspection?

    <p>By placing the part inside a coil to produce a longitudinal field</p> Signup and view all the answers

    When is direct current used in magnetic particle inspection?

    <p>To detect linear discontinuities near the surface</p> Signup and view all the answers

    What is the purpose of the ultraviolet or black light in fluorescent penetrant testing?

    <p>To improve the visibility of indications</p> Signup and view all the answers

    Which type of penetrant testing is effective for detecting leaks in welded joints in tanks and containers?

    <p>Fluorescent dye penetrant</p> Signup and view all the answers

    What is the main advantage of magnetic particle inspection over liquid penetrant inspection?

    <p>Ability to detect isolated indications such as porosity</p> Signup and view all the answers

    Study Notes

    Quality Control and Inspection Methods in Welding

    • Quality is defined as the degree to which inherent characteristics fulfill requirements, with the concept of meeting needs, requirements, and expectations being a common element.
    • A weld's quality is defined as its ability to perform reliably throughout its intended service life, and is influenced by workmanship, which depends on the skill of the welder and the experience of the supervisor.
    • Discontinuity refers to an interruption of the typical structure of a material, while a defect is a discontinuity that renders a part unable to meet minimum acceptance standards or specifications.
    • Inspection test methods include destructive testing, which involves destroying the completed weld to evaluate its characteristics, and nondestructive testing (NDT), where a component is evaluated without damaging it.
    • Tensile testing is used to determine mechanical properties such as yield strength, ultimate strength, and ductility of materials in welding.
    • Stress in a material is the intensity of internal forces resisting an external force, while strain measures the change in dimensions due to applied load.
    • Elastic behavior occurs when a material returns to its original dimensions after stress is removed, while plastic deformation results in permanent strain.
    • The yield stress is the stress at which a given permanent set is recorded, and it is usually defined as the stress at which a 0.2% permanent set is observed.
    • Different metals exhibit different stress-strain curves, with some showing a gradual change from elastic to plastic behavior, while others show an abrupt change.
    • Tensile tests involve loading a standard test specimen in tension until it fails, and can determine mechanical properties significant in welding, such as yield strength, ultimate strength, and ductility.
    • Special machines, mechanical, and hydraulic, are used to carry out tensile tests, exerting the necessary force in a controlled manner.
    • Understanding the concepts of quality, discontinuity, and testing methods is crucial in maintaining welding standards and ensuring the reliability of welded structures.

    Hardness Testing Methods and Impact Test in Welded Structures

    • Hardness testing methods include using a diamond or large steel ball and applying small or large loads
    • Different methods require measuring indent or not, and may require thick or thin samples
    • Micro or macro hardness testing is used, with preference for certain regions in welds and limitations on welds
    • Hardness traverses across a weld provide information on as-welded and stress relieved conditions
    • Impact tests are crucial in identifying materials' behavior under notches or cracks, especially in welded structures
    • Charpy impact test is commonly used to measure toughness by recording energy absorbed when a notched specimen is broken
    • The value of energy absorbed is measured in joules or foot-pounds
    • Charpy V-notch (CVN) specimen with specific dimensions is commonly used for testing
    • Steel's brittleness at low temperatures is revealed through impact tests at different temperatures
    • The transition temperature, at which a certain energy is reached, is used to compare the toughness of materials
    • Misleading results can occur if the impact test specimens are not machined from the right location or if the notch is oriented incorrectly
    • Impact tests are required as part of the classification of an electrode, and the specimens are machined from the same test weld as the tensile specimens

    Weld Inspection and Testing Methods

    • The test plate is 20 mm thick and the impact specimens are located mid-thickness
    • Notch is placed perpendicular to the plate surface on the centreline of the weld
    • Testing the heat-affected zone can be troublesome due to its narrow width and slope
    • Nick-break test is used for revealing internal weld discontinuities
    • Fractured surface is examined for discontinuities such as porosity, slag inclusions, incomplete penetration, and incomplete fusion
    • The nick-break test is required in codes to evaluate the entire surface area within a region of the welded joint
    • The fillet weld break test is used to evaluate the general quality of the weld
    • A force is applied to the back side of the welded T-joint until the fillet weld fractures
    • Macroscopic examination involves cutting through the finished weld to examine its cross-section
    • Visual inspection is the basis for all weld examination methods
    • Visual inspection is fast, inexpensive, and is performed before, during, and after welding
    • Before welding starts, weld preparations and fit-up dimensions must be verified to comply with requirements

    Non-Destructive Testing Methods in Welding

    • Liquid penetrant inspection measures undercut, excess groove weld height, fillet weld leg length, theoretical fillet weld throat, and permissible fillet weld tolerance for convexity and concavity.
    • Liquid penetrant inspection, also known as penetrant testing, is used to locate cracks, porosity, laps, and folds that are open to the surface.
    • The method involves preparing the surface, applying the penetrant, allowing it to dwell, removing excess penetrant, applying a developer, and visually examining the indication.
    • Liquid penetrant inspection is simple, inexpensive, and does not typically require complex equipment.
    • There are two basic types of penetrant: visible dye and fluorescent dye, with the latter requiring ultraviolet or black light for viewing.
    • Fluorescent penetrant testing is effective for detecting leaks in welded joints in tanks and containers.
    • Magnetic particle inspection is used to detect surface and near-surface discontinuities in ferromagnetic materials.
    • The method involves inducing a magnetic field into the part and dusting it with fine, colored, iron powder, which collects at the poles created by discontinuities.
    • Magnetic particle inspection is effective for detecting fine cracking that comes to the surface but limited in detecting isolated indications such as porosity.
    • The magnetic field can be induced using the AC/DC yoke method or by placing the part inside a coil to produce a longitudinal field between the poles.
    • Direct current is used to detect surface discontinuities and linear discontinuities near the surface, while alternating current is used for discontinuities breaking the surface of the weld.
    • Both liquid penetrant inspection and magnetic particle inspection are widely used non-destructive testing methods in the welding industry.

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    Description

    Test your knowledge of quality control and inspection methods in welding with this quiz. Explore concepts such as weld quality, discontinuity, inspection test methods, tensile testing, stress and strain, and mechanical properties. Enhance your understanding of maintaining welding standards and ensuring the reliability of welded structures.

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