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AWS CWI 9-Yr Recert practice questions

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Question 1Structural Steel (D1.1) Endorsement

Under AWS D1.1, what is the minimum required preheat for welding ASTM A36 steel that is 1 inch thick using a non-low-hydrogen process at an ambient temperature of 40°F?

  1. 225°F
  2. 150°F Correct answer.
  3. 50°F
  4. 70°F

Explanation

D1.1 Table 3.2 sets minimum preheat based on the steel's group and thickness. For Group I steel such as A36 at 1 inch thickness welded with a process other than low-hydrogen, the minimum preheat is 150°F. The 40°F ambient reading does not lower that requirement; when ambient is below 32°F the preheat minimum is raised further, but here the controlling value is the table minimum.

Question 2Structural Steel (D1.1) Endorsement

AWS D1.1 classifies a discontinuity found by visual inspection as a defect when it does what?

  1. Is detected by more than one inspector
  2. Appears on the root pass only
  3. Exceeds the acceptance criteria of the applicable code clause Correct answer.
  4. Is located within the heat-affected zone

Explanation

A discontinuity is simply an interruption in the metal's uniformity, while a defect is a discontinuity that fails the applicable acceptance criteria. The same indication can be acceptable in one weld classification and rejectable in another. Location, pass, or the number of inspectors observing it does not determine defect status.

Question 3Structural Steel (D1.1) Endorsement

Which condition is a required qualification test for a welder under AWS D1.1 when the welder will make complete-joint-penetration groove welds in the flat position?

  1. A reduced-section tension test in the flat position
  2. A guided-bend test Correct answer.
  3. A fracture test of a fillet weld only
  4. A macroetch test of the heat-affected zone

Explanation

D1.1 Clause 4 qualification for groove welders relies on visual inspection plus bend testing of the completed test coupon. The guided-bend specimens reveal fusion defects and internal soundness that visual examination alone cannot show. Fillet tests, tension tests, and macroetch are not the prescribed acceptance method for groove-weld performance qualification.

Question 4Structural Steel (D1.1) Endorsement

A welder qualified in the vertical position with the uphill progression makes a groove weld in the flat position. Under D1.1, how is that welder's qualification affected?

  1. The welder must requalify for the flat position
  2. The qualification covers the flat position automatically Correct answer.
  3. The welder may weld flat only with a qualified procedure
  4. The qualification lapses after 30 days

Explanation

D1.1 position qualification rules allow a welder qualified in a more difficult position to weld in positions that are less demanding. Vertical uphill is considered the most restrictive groove position, so it qualifies the welder for flat, horizontal, and overhead groove welding as well. No separate flat test is needed.

Question 5Structural Steel (D1.1) Endorsement

What does AWS D1.1 require before production welding begins on a project using a new welding procedure specification?

  1. A procedure qualification record supported by mechanical test results Correct answer.
  2. A chemical analysis of the base metal
  3. A verbal approval from the engineer of record
  4. A visual inspection of the first ten production welds

Explanation

Clause 4 requires each WPS to be supported by a procedure qualification record demonstrating that test coupons met the required mechanical properties. The PQR documents the actual welding parameters and test outcomes. Verbal approvals or first-production inspections do not substitute for documented qualification.

Question 6Structural Steel (D1.1) Endorsement

In D1.1, what is the maximum allowable undersized fillet weld leg for a weld specified as 5/16 inch?

  1. 1/32 inch smaller than specified Correct answer.
  2. 1/16 inch smaller than specified
  3. No undersize is permitted
  4. 1/8 inch smaller than specified

Explanation

D1.1 Table 6.1 permits a fillet weld to be slightly undersized, with the allowance tied to the specified size. For a 5/16 inch fillet the permitted reduction is 1/32 inch. Larger reductions would compromise the design strength assumed for the joint.

Question 7Structural Steel (D1.1) Endorsement

Which welding process listed below is prequalified for use under AWS D1.1 without procedure qualification testing when the code's conditions are met?

  1. SMAW Correct answer.
  2. Electroslag welding
  3. Friction stir welding
  4. Electron beam welding

Explanation

D1.1 prequalifies several common arc processes, including shielded metal arc welding, when used with prequalified joint details, base metals, and filler metals within the code's limits. Electroslag, electron beam, and friction stir welding are outside the prequalified list and require qualification. Prequalification avoids testing only while all listed conditions are satisfied.

Question 8Structural Steel (D1.1) Endorsement

A continuous fillet weld along the edge of a plate is specified as 1/4 inch. What minimum inspection is required to verify size along its length?

  1. Measure at the ends and at intervals not exceeding 12 inches Correct answer.
  2. Measure once per weldment regardless of length
  3. Measure only at the start of the weld
  4. Measure only the largest cross section

Explanation

D1.1 visual inspection practice requires checking fillet weld size at the ends and at regular intervals so that the entire length is represented. A 12 inch maximum interval is a common criterion used to confirm consistent size. Measuring only one point can miss localized undersize that would be rejectable.

Question 9Structural Steel (D1.1) Endorsement

Under D1.1, what is the acceptance limit for undercut in the base metal adjacent to a statically loaded groove weld, when the undercut is more than 2 inches from a primary member?

  1. 1/32 inch maximum Correct answer.
  2. 1/16 inch maximum
  3. Any depth is acceptable
  4. 1/8 inch maximum

Explanation

D1.1 Table 6.1 limits undercut adjacent to groove welds based on member type and loading. For statically loaded members away from primary members, the permitted undercut depth is 1/32 inch. Deeper undercut concentrates stress and reduces section, so it must be repaired.

Question 10Structural Steel (D1.1) Endorsement

What is the purpose of a root gap in a single-V-groove joint welded under D1.1 prequalified details?

  1. To allow complete fusion at the root Correct answer.
  2. To reduce the amount of filler metal required
  3. To speed up the cooling rate
  4. To eliminate the need for a backing strip

Explanation

The root gap provides access so the welder can achieve fusion through the full thickness at the joint root. It is part of the prequalified joint detail and is tied to the root opening range in the code. The gap is not primarily about saving filler or controlling cooling.

Question 11Structural Steel (D1.1) Endorsement

A groove weld is to be made on quenched-and-tempered steel. Which action does D1.1 require regarding heat input?

  1. Heat input is controlled only for fillet welds
  2. Heat input must be maximized to slow cooling
  3. Heat input is unrestricted if preheat is applied
  4. Heat input must be controlled within limits established by procedure qualification Correct answer.

Explanation

Quenched-and-tempered steels can lose strength in the heat-affected zone if heat input is excessive or if cooling is too slow. D1.1 therefore requires heat input control, with limits verified through procedure qualification. Preheat alone does not remove the need to control energy input.

Question 12Structural Steel (D1.1) Endorsement

What does AWS D1.1 require for the surface of a weld that will receive a fatigue-critical application?

  1. Weld reinforcement must be as high as possible
  2. Profile must be checked to avoid sharp transitions and undercut Correct answer.
  3. Weld must be left in the as-welded condition with no inspection
  4. Weld must be painted before inspection

Explanation

For cyclically loaded structures, D1.1 requires weld profile control because sharp transitions and undercut act as stress concentrations that initiate fatigue cracks. The weld-toe geometry and reinforcement are inspected against acceptance criteria. Higher reinforcement or painting before inspection would not satisfy these requirements.

Question 13Structural Steel (D1.1) Endorsement

Under D1.1, what is the required disposition of a weld that fails visual acceptance criteria?

  1. It must be repaired or removed and reinspected Correct answer.
  2. It may be accepted if the flaw is less than 1/8 inch deep
  3. It may be accepted if the part is statically loaded
  4. It may be accepted if the engineer is notified verbally

Explanation

D1.1 requires nonconforming welds to be corrected, either by repair or removal, and then reexamined to confirm the correction meets acceptance criteria. Verbal notification does not waive code requirements. Static loading does not create a general exemption from visual acceptance limits.

Question 14Structural Steel (D1.1) Endorsement

A welder qualified under D1.1 has not welded with the qualified process for eight months. What is the status of the qualification?

  1. It expires because the welder has not used the process within six months Correct answer.
  2. It expires only after twelve months
  3. It remains valid indefinitely
  4. It remains valid if the welder pays a renewal fee

Explanation

D1.1 welder qualification lapses when the welder has not used the qualified process for a defined period, commonly six months. Continued use of the process maintains validity without retesting. After a lapse, requalification testing is required before the welder resumes that work.

Question 15Structural Steel (D1.1) Endorsement

Which statement best describes the D1.1 requirement for verifying the fit-up of a prequalified single-V-groove joint before welding?

  1. Root opening, groove angle, and land must be within the prequalified ranges Correct answer.
  2. Fit-up is verified after welding is complete
  3. Fit-up is the welder's choice if the engineer is absent
  4. Only the groove angle is checked

Explanation

Prequalified joint details depend on specific ranges for root opening, groove angle, root face, and alignment. If any of these falls outside the tabulated ranges, the joint is no longer prequalified and requires procedure qualification. Checking only after welding is too late to correct fit-up problems.

Question 16Structural Steel (D1.1) Endorsement

What does the D1.1 definition of a procedure qualification record include?

  1. The welding variables used and the results of mechanical tests Correct answer.
  2. Only the base-metal mill certificate
  3. Only the visual inspection results
  4. Only the welder's name and certification date

Explanation

The PQR documents the essential welding variables actually used during qualification testing and the mechanical test results that demonstrate the procedure's adequacy. It supports the WPS and is retained as quality records. Visual results or mill certificates alone do not constitute a PQR.

Question 17Structural Aluminum (D1.2) Endorsement

Under AWS D1.2, which filler metal classification is specified for gas metal arc welding of 6061-T6 aluminum using argon shielding gas?

  1. ER5356 Correct answer.
  2. ER4043
  3. ER5183
  4. ER1100

Explanation

D1.2 pairs 5XXX base metals and the 6061 alloy with 5XXX-series filler metals for GMAW, and ER5356 is the standard 5 percent magnesium filler used with argon. ER4043 is a silicon filler typically used with helium-rich mixtures or for 6XXX castings where crack sensitivity is managed differently.

Question 18Structural Aluminum (D1.2) Endorsement

What is the primary reason AWS D1.2 requires that aluminum surfaces be cleaned immediately before welding?

  1. To increase the electrical conductivity of the joint
  2. To prevent distortion from thermal expansion
  3. To reduce the amount of shielding gas required
  4. To remove the oxide film that melts well above the base metal Correct answer.

Explanation

Aluminum immediately forms a tenacious aluminum oxide film whose melting point is far above the metal itself, so it must be removed mechanically or chemically before welding. If left in place, the oxide interferes with fusion and promotes porosity and incomplete penetration.

Question 19Structural Aluminum (D1.2) Endorsement

Which shielding gas is most commonly specified for gas tungsten arc welding of aluminum under D1.2?

  1. 75 percent argon plus 25 percent carbon dioxide
  2. 90 percent argon plus 10 percent oxygen
  3. 100 percent carbon dioxide
  4. 100 percent argon Correct answer.

Explanation

Argon is the standard shielding gas for GTAW of aluminum because it provides stable arc starting and good cleaning action at the low currents often used. Carbon dioxide and oxygen-bearing mixtures are steel gases and are unacceptable for aluminum.

Question 20Structural Aluminum (D1.2) Endorsement

In aluminum welding, what does the term 'heat-affected zone softening' refer to?

  1. Formation of a brittle intermetallic layer at the fusion line
  2. Absorption of hydrogen into the weld pool
  3. Growth of the oxide film during cooling
  4. Loss of strength in strain-hardened or heat-treated base metal near the weld Correct answer.

Explanation

Welding heat overages or anneals the temper of strain-hardened and heat-treatable aluminum in the region beside the weld, lowering its strength. D1.2 accounts for this by requiring strength reduction or postweld heat treatment in design and qualification.

Question 21Structural Aluminum (D1.2) Endorsement

Which aluminum alloy series is generally considered non-heat-treatable and strengthened only by strain hardening?

  1. 6XXX
  2. 5XXX Correct answer.
  3. 7XXX
  4. 2XXX

Explanation

The 5XXX series relies on solid-solution magnesium and strain hardening rather than precipitation hardening. The 2XXX, 6XXX, and 7XXX series are heat-treatable and gain strength through solution treatment and aging.

Question 22Structural Aluminum (D1.2) Endorsement

A welder is qualifying a groove weld procedure on 6061-T6 plate under D1.2. Which test specimen set is required for procedure qualification of a complete joint penetration groove weld?

  1. Only a nick-break specimen
  2. Only a radiographic examination
  3. Tensile and guided-bend specimens Correct answer.
  4. Only a bend specimen

Explanation

D1.2 procedure qualification for full-penetration groove welds calls for reduced-section tensile specimens plus guided-bend specimens to demonstrate both strength and ductility. Radiography alone does not qualify a procedure because it does not measure mechanical properties.

Question 23Structural Aluminum (D1.2) Endorsement

When preparing aluminum for welding, why does D1.2 prohibit the use of a carbon-steel wire brush?

  1. Steel brushes leave an oxide layer behind
  2. Steel bristles embed iron that can cause contamination and corrosion Correct answer.
  3. Steel brushes remove too much base metal
  4. Steel brushes overheat the aluminum surface

Explanation

Iron particles rubbed into the aluminum surface act as contaminants and can initiate corrosion or embrittlement in the weld area. D1.2 requires stainless steel or other non-contaminating brushes dedicated to aluminum.

Question 24Structural Aluminum (D1.2) Endorsement

A visual inspection of an aluminum fillet weld reveals a uniform, smooth undercut along the toe. What does D1.2 generally require for undercut in cyclically loaded structures?

  1. No limit, provided the weld is painted
  2. Limits on depth and length that are more restrictive than for statically loaded work Correct answer.
  3. Acceptance only if the undercut is intermittent
  4. Acceptance whenever the undercut is less than half the plate thickness

Explanation

D1.2 imposes tighter undercut limits for cyclically loaded members because undercut acts as a stress concentrator that accelerates fatigue cracking. Static structures permit somewhat greater undercut depth and length.

Question 25Structural Aluminum (D1.2) Endorsement

Which preweld or interpass condition must be verified when welding thick aluminum sections under D1.2?

  1. That the shielding gas is preheated
  2. That the joint is coated with anti-spatter compound
  3. That the base metal is free of moisture and the interpass temperature does not exceed limits Correct answer.
  4. That the base metal is below the specified minimum preheat temperature

Explanation

Moisture on aluminum promotes hydrogen porosity, and excessive interpass temperature degrades properties in heat-treated alloys. D1.2 therefore addresses cleanliness and interpass temperature control rather than preheating thick sections.

Question 26Structural Aluminum (D1.2) Endorsement

During GMAW of aluminum, a welder observes a dark, sooty smudge along the weld edges. What is the most likely cause?

  1. Filler metal with too much magnesium
  2. Base metal that is too cold
  3. Insufficient shielding gas coverage or contaminated gas Correct answer.
  4. Excessive travel speed with adequate gas coverage

Explanation

A black sooty deposit on aluminum weld edges signals inadequate shielding, often from low gas flow, drafts, or a clogged torch. Restoring proper gas coverage and cleaning the joint eliminates the smudge.

Question 27Structural Aluminum (D1.2) Endorsement

Which nondestructive method is especially effective for detecting laminations and lack of fusion in thick aluminum groove welds because of aluminum's low density?

  1. Magnetic particle testing
  2. Eddy current testing
  3. Dye penetrant testing
  4. Radiographic testing Correct answer.

Explanation

Radiography works well on aluminum because its low density allows good contrast and penetration in thick sections, revealing internal discontinuities such as lack of fusion and porosity. Magnetic particle testing cannot be used because aluminum is nonmagnetic.

Question 28Structural Aluminum (D1.2) Endorsement

A fabricator must qualify a welding procedure for 5083-H116 base metal using GMAW. Which filler metal does D1.2 typically require for this combination?

  1. ER1100
  2. ER2319
  3. ER4043
  4. ER5356 Correct answer.

Explanation

For 5XXX base metals such as 5083, D1.2 uses 5XXX-series filler metals, and ER5356 is the common choice for strength and crack resistance. ER4043 and ER2319 are associated with different alloy families.

Question 29Structural Aluminum (D1.2) Endorsement

Why does D1.2 require that aluminum be welded with a push (forehand) technique in many GMAW applications?

  1. It prevents heat-affected zone softening
  2. It increases deposition rate beyond the machine rating
  3. It provides better oxide cleaning and visibility of the arc Correct answer.
  4. It eliminates the need for shielding gas

Explanation

Pushing the torch keeps the arc ahead of the puddle, giving better cleaning action and visibility of the joint in aluminum GMAW. It does not change deposition limits or eliminate shielding needs.

Question 30Structural Aluminum (D1.2) Endorsement

A design uses 6061-T6 aluminum and the engineer proposes designing the welded connection to the full as-welded strength of the base metal. Why does D1.2 caution against this approach?

  1. The heat-affected zone loses temper and strength, so allowable stresses must reflect the reduced properties Correct answer.
  2. The weld metal always has higher strength than the base metal
  3. 6061-T6 cannot be welded by any arc process
  4. The filler metal is prohibited from matching the base metal

Explanation

Welding overages the 6061-T6 temper in the heat-affected zone, reducing strength below the original base metal values. D1.2 therefore requires design allowables that recognize this softened zone unless postweld heat treatment restores properties.

Question 31Structural Aluminum (D1.2) Endorsement

A welded 5083 aluminum structure will be exposed to sustained elevated temperature in service. What concern does D1.2 raise for such 5XXX weldments?

  1. Loss of magnetic permeability
  2. Sensitization to intergranular corrosion from magnesium precipitation at grain boundaries Correct answer.
  3. Hydrogen embrittlement of the weld metal
  4. Formation of martensite in the heat-affected zone

Explanation

Sustained elevated temperature can cause magnesium-rich phases to precipitate along grain boundaries in 5XXX alloys, making the material sensitive to intergranular corrosion, especially in the heat-affected zone. Service temperature limits are therefore imposed for these alloys.

Question 32Structural Aluminum (D1.2) Endorsement

Two procedure qualification tensile specimens from a 6061-T6 groove weld fail in the base metal at a load above the specified minimum. How should this result be interpreted under D1.2?

  1. The test is invalid because failure must occur in the weld
  2. The test is acceptable because the joint achieved the required strength Correct answer.
  3. The test is acceptable only if bend specimens also fail
  4. The test must be repeated because base-metal failure indicates a defect

Explanation

When a tensile specimen fails in the base metal outside the weld at a load meeting or exceeding the required strength, the joint has demonstrated adequate strength and the test passes. Base-metal failure at adequate load is not a rejection criterion.

Question 33Bridge Welding (D1.5) Endorsement

Under AASHTO/AWS D1.5, what is the minimum required Charpy V-notch impact toughness for weld metal in fracture-critical tension members when tested at the specified test temperature?

  1. 20 ft-lb (27 J)
  2. 15 ft-lb (20 J)
  3. 10 ft-lb (14 J)
  4. 25 ft-lb (34 J) Correct answer.

Explanation

D1.5 requires Charpy V-notch toughness of at least 25 ft-lb (34 J) average for weld metal in fracture-critical members, measured at the specified test temperature. This threshold ensures the weld can tolerate small flaws and resist brittle fracture under cyclic bridge loading. Lower values apply only to non-fracture-critical applications.

Question 34Bridge Welding (D1.5) Endorsement

Which welding process does D1.5 list as prequalified for groove welds in the vertical position on bridge members?

  1. Flux cored arc welding
  2. Submerged arc welding
  3. Electroslag welding
  4. Shielded metal arc welding Correct answer.

Explanation

D1.5 prequalifies shielded metal arc welding for groove welds in all positions, which makes it the workhorse process for field and shop bridge work. Other processes carry position restrictions or require qualification. Recognizing which processes are prequalified in the vertical position is essential for selecting a compliant procedure.

Question 35Bridge Welding (D1.5) Endorsement

A bridge fabricator plans to use a prequalified joint detail. What does D1.5 require regarding procedure qualification testing for that joint?

  1. Only a tension test of the base metal is required
  2. A full procedure qualification test is always required
  3. Only visual inspection of the first production weld is required
  4. No procedure qualification test is required if all prequalified conditions are met Correct answer.

Explanation

Prequalified joints are exempt from procedure qualification testing only when every condition of the prequalified status is satisfied, including process, position, thickness, and joint geometry. If any condition falls outside those limits, the joint becomes unqualified and testing is required. This distinction drives most fabrication planning decisions.

Question 36Bridge Welding (D1.5) Endorsement

For complete joint penetration groove welds, what nondestructive examination does D1.5 require on fracture-critical members?

  1. Magnetic particle testing of the root pass only
  2. Radiographic testing of 10 percent of the weld length
  3. Ultrasonic testing of 100 percent of the weld length Correct answer.
  4. Visual inspection only

Explanation

D1.5 requires 100 percent ultrasonic testing of complete joint penetration groove welds in fracture-critical tension members. Ultrasonic testing detects planar flaws such as lack of fusion and cracks that are critical to fracture performance. Visual inspection alone cannot reveal internal discontinuities of this type.

Question 37Bridge Welding (D1.5) Endorsement

Which base metal specification is commonly approved for use with D1.5 bridge fabrication?

  1. ASTM A240
  2. ASTM A500
  3. ASTM A36 Correct answer.
  4. ASTM A53

Explanation

ASTM A36 is a widely used structural carbon steel listed as an approved base metal in D1.5 for bridge fabrication. The specification assigns strength and toughness values that the welding procedure must match. Other listed materials include higher-strength grades such as A572 and A709.

Question 38Bridge Welding (D1.5) Endorsement

A welder is qualifying under D1.5 for a groove weld in the 3G position using a backing strip. Which essential variable change would require requalification?

  1. Changing the electrode brand while keeping the same classification
  2. Changing the preheat temperature within the qualified range
  3. Changing from a backing strip to a backing weld Correct answer.
  4. Changing the welding current within the qualified range

Explanation

Backing type is an essential variable, so switching from a backing strip to a backing weld changes the qualification. Essential variables affect the mechanical properties of the weld and must be requalified. Current, preheat within range, and electrode brand within the same classification are nonessential.

Question 39Bridge Welding (D1.5) Endorsement

A welder qualified in the 3G position with a groove weld wants to weld in the 4G position. What does D1.5 permit?

  1. The welder may weld in 4G only on non-fracture-critical members
  2. The welder may weld in 4G only with overhead approval
  3. The welder must requalify specifically in the 4G position Correct answer.
  4. The welder may weld in 4G without further testing

Explanation

Position qualification is specific, and a 3G qualification does not extend to the 4G overhead position under D1.5. The welder must pass a separate test in the 4G position to be qualified for overhead groove welding. Position ranges are defined in the qualification tables and must be followed exactly.

Question 40Bridge Welding (D1.5) Endorsement

During fabrication, a welder qualified under D1.5 stops production welding for eight months. What is required before resuming work on fracture-critical members?

  1. Requalification because the welder has not welded for more than six months Correct answer.
  2. Only a visual check of a test coupon
  3. Nothing, because the qualification does not expire
  4. Only a review of the procedure specification

Explanation

D1.5 requires requalification when a welder has not used a qualified process for a defined period, commonly six months. An eight-month gap exceeds that limit, so the welder must be requalified before returning to fracture-critical work. Maintaining continuity records is therefore a critical administrative control.

Question 41Bridge Welding (D1.5) Endorsement

A fabricator must preheat a thick A709 Grade 50 member before welding. Which factor most directly determines the minimum preheat temperature under D1.5?

  1. The welder's preference
  2. The ambient humidity in the shop
  3. The color of the weld as it cools
  4. The base metal thickness and chemistry combined with the process Correct answer.

Explanation

Minimum preheat in D1.5 is set by base metal thickness and chemistry together with the welding process, because these control cooling rate and hydrogen cracking risk. Thicker sections and higher carbon equivalent demand higher preheat. Preheat tables in the code translate these inputs into a required temperature.

Question 42Bridge Welding (D1.5) Endorsement

A weld is inspected and found to have undercut along the toe of a groove weld in a tension member. Which acceptance consideration applies under D1.5?

  1. Undercut is acceptable at any depth in tension members
  2. Undercut depth is limited and must be evaluated against the applicable acceptance criteria Correct answer.
  3. Undercut is only a concern in compression members
  4. Undercut is acceptable if it is painted over

Explanation

Undercut reduces section and creates a stress concentration, so D1.5 limits its depth and requires evaluation against acceptance criteria that vary with member type. In tension members the limits are stricter because the flaw can initiate fatigue cracking. Any undercut exceeding the limit must be repaired.

Question 43Bridge Welding (D1.5) Endorsement

A fabricator proposes to repair a crack discovered in a completed CJP groove weld on a fracture-critical member. What does D1.5 require before the repair weld is made?

  1. The repair may be made by any welder on site
  2. The repair procedure must be qualified and the area prepared to sound metal Correct answer.
  3. The repair may proceed immediately with no documentation
  4. The crack may be left if it is shorter than one inch

Explanation

Crack repairs on fracture-critical members require an approved repair procedure and excavation of the crack back to sound metal before welding. The repair must also be performed by a qualified welder and reexamined afterward. Documentation of the repair is part of the required quality record.

Question 44Bridge Welding (D1.5) Endorsement

Which statement best describes the D1.5 requirement for stud welding in composite bridge construction?

  1. Stud welding requires qualification and inspection of bend tests on production studs Correct answer.
  2. Studs need no inspection because they carry only shear
  3. Stud welding is prohibited on bridge girders
  4. Studs may be welded to primed surfaces without restriction

Explanation

D1.5 requires stud welding to be qualified and includes bend testing of production studs to verify soundness of the weld collar and fusion. Bent studs are examined for cracks or separation that indicate inadequate welding. This inspection is essential because stud failure compromises composite action.

Question 45Bridge Welding (D1.5) Endorsement

A design calls for a complete joint penetration groove weld in a tension member, but the joint detail is not listed as prequalified. What is the most appropriate course of action under D1.5?

  1. Qualify the procedure by testing before production welding Correct answer.
  2. Weld it as prequalified because the design specified CJP
  3. Reduce the weld size to avoid qualification
  4. Skip ultrasonic testing to save cost

Explanation

When a joint detail falls outside the prequalified list, the fabricator must qualify the welding procedure by test before production. Qualification demonstrates that the procedure produces welds meeting required mechanical properties. Proceeding without qualification would violate D1.5 regardless of the design intent.

Question 46Bridge Welding (D1.5) Endorsement

An inspector finds that a welder used a qualified procedure but deviated from the qualified preheat by 100 degrees Fahrenheit below the specified minimum on a thick section. What is the correct conclusion?

  1. The deviation is an essential variable change and the weld must be evaluated and likely rejected Correct answer.
  2. The deviation is acceptable because preheat is only a recommendation
  3. The deviation is acceptable if the weld passes visual inspection
  4. The weld is acceptable because the procedure itself was qualified

Explanation

Preheat below the qualified minimum is a departure from an essential variable that increases cracking risk and can degrade toughness. The weld must be evaluated under the code's repair and rejection provisions rather than accepted on procedure qualification alone. Visual inspection cannot confirm the absence of hydrogen-induced cracking.

Question 47Bridge Welding (D1.5) Endorsement

Two welding procedures both meet the minimum Charpy energy, but one produces significantly lower toughness at the specified test temperature. How should this be interpreted for a fracture-critical bridge member?

  1. The lower-toughness procedure may increase fracture risk and should be scrutinized or rejected Correct answer.
  2. Charpy energy is irrelevant to bridge performance
  3. Toughness above the minimum has no engineering significance
  4. Either procedure is equally acceptable because both meet the minimum

Explanation

Meeting the minimum does not make procedures equivalent; lower toughness reduces the margin against brittle fracture in fracture-critical members. The engineer should scrutinize the lower-toughness procedure and consider whether it provides adequate reserve. Higher toughness is a meaningful safety benefit under cyclic and cold-temperature service.

Question 48Bridge Welding (D1.5) Endorsement

What is the primary purpose of requiring qualified welding procedures and welder qualification in D1.5 bridge fabrication?

  1. To speed up the fabrication schedule
  2. To eliminate the need for inspection
  3. To reduce the cost of welding consumables
  4. To ensure welds achieve required strength and toughness for the intended service Correct answer.

Explanation

Qualification verifies that both the procedure and the welder can consistently produce welds meeting the strength and toughness demands of bridge service. Bridges experience fatigue and potential brittle fracture, so demonstrated performance is essential. Cost and schedule are secondary considerations.

Question 49Railroad (D15.1) Endorsement

Under AWS D15.1, which document governs the qualification of welding procedures for railroad equipment fabrication?

  1. AWS D15.2, Recommended Practices for the Welding of Rails and Related Rail Components
  2. AWS D1.1, Structural Welding Code-Steel
  3. AWS D15.1, Railroad Welding Specification for Cars and Locomotives Correct answer.
  4. AWS D1.5, Bridge Welding Code

Explanation

AWS D15.1 is the specification that governs welding of railroad cars and locomotives, and it contains its own procedure qualification requirements that apply to that equipment. D1.1 and D1.5 address structural steel and bridges, and D15.2 addresses rail welding rather than car and locomotive fabrication.

Question 50Railroad (D15.1) Endorsement

In AWS D15.1 practice, what is the primary purpose of a welding procedure qualification record?

  1. To list the purchase orders on which a filler metal was consumed
  2. To document that a procedure, when followed, produces joints meeting required properties Correct answer.
  3. To record the monthly deposition hours of each welding machine
  4. To certify the individual welder's manual skill

Explanation

Procedure qualification demonstrates that the combination of base metal, filler metal, joint design, and essential variables produces a weld meeting the required mechanical properties. Welder skill is addressed separately through performance qualification, and the record is not a machine log or purchasing document.