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AWS API 1104 Endorsement study materials
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AWS API 1104 Endorsement practice questions

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Question 1Pipeline (API 1104)

Under API 1104, what is the primary purpose of the radiographic examination of a girth weld?

  1. To confirm the chemical composition of the base metal
  2. To measure the yield strength of the deposited weld metal
  3. To reveal internal discontinuities such as porosity, slag, and lack of fusion Correct answer.
  4. To verify the surface finish of the weld cap

Explanation

Radiography transmits radiation through the completed weld and records density differences on film or a digital detector, so internal volumetric discontinuities appear as image variations. It is an inspection method for internal soundness, not a mechanical or chemical test. Surface conditions and cap profile are evaluated visually or by other means.

Question 2Pipeline (API 1104)

When API 1104 acceptance criteria are applied, which of the following is classified as a crack-type discontinuity that is generally unacceptable regardless of length?

  1. Transverse crack in the weld metal Correct answer.
  2. Incomplete fusion at the sidewall
  3. Isolated rounded porosity
  4. Elongated slag inclusion aligned with the weld axis

Explanation

Cracks are planar, sharp-tipped discontinuities that concentrate stress and are treated as unacceptable in girth welds under API 1104 criteria. They are rejected on detection rather than being sized against a length allowance. Slag, incomplete fusion, and porosity are evaluated against separate size and distribution limits.

Question 3Pipeline (API 1104)

A welder qualification test weld is made on pipe, and the specimen is bent so that the weld cap is on the tension side of the bend. Which property is this specimen primarily intended to evaluate?

  1. Ductility and soundness of the weld and heat-affected zone under tension Correct answer.
  2. Hardness of the weld metal in the as-welded condition
  3. Impact toughness at low service temperature
  4. Corrosion resistance of the deposited weld

Explanation

A root-bend or face-bend specimen places the weld region on the tension surface so that bending strains the weld and heat-affected zone. The test reveals ductility and the presence of defects that open under strain. It does not measure hardness, impact energy, or corrosion behavior.

Question 4Pipeline (API 1104)

In API 1104 terminology, what does the term 'girth weld' refer to?

  1. A longitudinal seam weld made in the pipe mill
  2. A weld overlay applied to resist corrosion
  3. A circumferential weld joining two pipe ends or a pipe to a fitting Correct answer.
  4. A repair weld made on the pipe body

Explanation

A girth weld is the circumferential butt weld that joins pipe sections end to end, or joins pipe to fittings, in a pipeline. It is distinguished from the longitudinal seam produced during pipe manufacture. Repair welds and overlays are separate categories of welding activity.

Question 5Pipeline (API 1104)

Which nondestructive method is best suited to detecting lack of fusion oriented parallel to the weld face on a completed girth weld?

  1. Dye penetrant examination
  2. Radiographic examination
  3. Visual inspection of the cap
  4. Ultrasonic examination Correct answer.

Explanation

Ultrasonic testing directs a beam through the weld and detects planar reflectors, including lack of fusion, that are oriented unfavorably for radiography. Radiography is less reliable for tight planar defects aligned with the beam path. Visual and penetrant methods detect only surface-connected indications.

Question 6Pipeline (API 1104)

A welder qualifies on 12-inch pipe with a wall thickness of 0.500 inch. Under API 1104 welder qualification rules, the thickness qualification generally covers which range of production thickness?

  1. Any thickness, since thickness is not a qualification variable
  2. From the tested thickness up to twice the tested thickness Correct answer.
  3. From half the tested thickness up to the tested thickness
  4. Only the exact thickness tested

Explanation

API 1104 welder qualification ties thickness coverage to the test coupon: a successful test on a given wall thickness qualifies the welder for production thicknesses from that value up to twice that value. Thinner production welds are not automatically covered by a thicker test. Diameter and position are separate essential variables.

Question 7Pipeline (API 1104)

During visual inspection, a weld exhibits undercut along the toe of the cap. What is the nature of this discontinuity?

  1. A crack propagating from the root
  2. A void formed by gas entrapment during solidification
  3. A groove melted into the base metal at the weld toe that remains unfilled Correct answer.
  4. An inclusion of slag trapped between passes

Explanation

Undercut is a groove melted into the base metal along the weld toe or root that is left unfilled by weld metal. It reduces the effective throat and creates a stress concentration. It is distinct from slag, porosity, and cracking.

Question 8Pipeline (API 1104)

Why does API 1104 require that the root pass of a girth weld be cleaned before the hot pass is applied?

  1. To increase the travel speed of the subsequent pass
  2. To remove slag and oxides that could be trapped as inclusions Correct answer.
  3. To reduce the preheat temperature of the pipe
  4. To lower the hydrogen content of the shielding gas

Explanation

Cleaning between passes removes slag, oxides, and spatter that could otherwise be entrapped and form inclusions or cause lack of fusion. Interpass cleaning is a basic quality control measure for multipass welds. It does not control preheat, travel speed, or gas composition.

Question 9Pipeline (API 1104)

A radiographic image of a girth weld shows a dark, irregular, elongated indication aligned along the weld axis near the fusion line. Which discontinuity is most consistent with this appearance?

  1. Slag inclusion Correct answer.
  2. Tungsten inclusion
  3. Root concavity
  4. Rounded porosity

Explanation

Slag inclusions appear as irregular, often elongated dark indications, frequently aligned parallel to the weld axis along the fusion line. Their irregular shape and alignment distinguish them from rounded porosity. Tungsten is denser than steel and appears as a light indication, while root concavity is not an internal inclusion.

Question 10Pipeline (API 1104)

What is the purpose of preheating pipe before welding a girth weld in cold weather?

  1. To change the chemistry of the base metal
  2. To increase the deposition rate of the electrode
  3. To eliminate the need for post-weld inspection
  4. To drive off moisture and reduce the risk of hydrogen-assisted cracking Correct answer.

Explanation

Preheat raises the pipe temperature so that moisture is driven off and the cooling rate is moderated, which lowers the risk of hydrogen-assisted cracking. It also assists fusion and reduces shrinkage stresses. Preheat does not alter base metal chemistry or remove inspection requirements.

Question 11Pipeline (API 1104)

A tensile test specimen from a girth weld fails in the base metal away from the weld, and the measured strength exceeds the specified minimum. How should this result be interpreted?

  1. The result shows the weld metal is weaker than the base metal
  2. The weld is acceptable because the joint achieved the required strength Correct answer.
  3. The test must be repeated because base metal failure indicates a defect
  4. The test is invalid because failure did not occur in the weld

Explanation

When a tensile specimen reaches the required tensile strength and fails in the base metal outside the weld, the weld is considered acceptable because the joint carried the required load. Failure in the base metal is not a defect in the weld. It indicates the weld metal is at least as strong as the base metal.

Question 12Pipeline (API 1104)

Which document typically specifies the welding procedure, essential variables, and ranges qualified for a given pipeline girth weld?

  1. The mill certificate for the pipe
  2. The radiographer's certification card
  3. The pipeline alignment sheet
  4. The welding procedure specification supported by a procedure qualification record Correct answer.

Explanation

The welding procedure specification states the variables and ranges to be used in production, and it is supported by a procedure qualification record that documents the test used to qualify it. Mill certificates address material properties, and alignment sheets address route geometry. Certification cards and alignment sheets do not define welding variables.

Question 13Pipeline (API 1104)

A welder qualified in the 5G position on 8-inch pipe wishes to weld in the 6G position on the same diameter. What is the usual qualification consequence?

  1. A separate qualification test in the 6G position is required Correct answer.
  2. The 5G qualification automatically covers 6G
  3. Only a visual check of the welder's previous work is needed
  4. The welder may weld 6G if a supervisor observes the work

Explanation

Welding position is an essential variable in welder qualification, and the fixed 6G position is more demanding than the rolled 5G position. A welder qualified only in 5G is therefore not qualified for 6G and must pass a test in that position. Observation alone does not extend qualification.

Question 14Pipeline (API 1104)

What does the term 'essential variable' mean in the context of procedure qualification?

  1. A variable that affects cost but not weld quality
  2. A variable that, if changed beyond qualified limits, requires requalification of the procedure Correct answer.
  3. A variable that applies only to manual welding
  4. A variable recorded only for traceability

Explanation

An essential variable is a welding parameter or condition that materially affects the mechanical properties or soundness of the joint. Changing it outside the qualified range invalidates the procedure and requires requalification. Nonessential variables may be changed within limits without requalification.

Question 15Pipeline (API 1104)

A nick or gouge is found on the pipe surface adjacent to the girth weld after welding. What is the standard concern that drives a repair decision?

  1. It reduces the local wall thickness and can act as a stress concentrator Correct answer.
  2. It changes the color of the coating
  3. It increases the pipe's internal pressure rating
  4. It alters the pipe's chemical composition

Explanation

Surface damage such as a gouge removes wall thickness and creates a notch that concentrates stress, which can lead to cracking or reduced pressure capacity. Repair or removal is therefore evaluated against wall thickness and stress criteria. It does not change chemistry or increase pressure rating.

Question 16Pipeline (API 1104)

In a nick-break test, what is being evaluated?

  1. The hardness profile across the heat-affected zone
  2. The tensile strength of the weld metal
  3. The corrosion resistance of the joint
  4. The soundness and fusion of the weld cross section Correct answer.

Explanation

A nick-break specimen is notched and broken to expose the weld cross section so that fusion, penetration, and internal discontinuities can be examined. It is a soundness test rather than a strength measurement. It does not measure hardness or corrosion resistance.

Question 17Pipeline (API 1104)

Which condition most directly promotes hydrogen-assisted cracking in a girth weld?

  1. Welding with a short arc length
  2. High heat input with slow cooling
  3. Moisture on the pipe surface or in the electrode coating combined with restrained joint geometry Correct answer.
  4. Use of a cellulosic electrode stored in a dry oven

Explanation

Hydrogen-assisted cracking requires a source of hydrogen, a susceptible microstructure, and tensile restraint. Moisture introduced from the pipe surface or consumable coating supplies hydrogen, and a highly restrained joint raises stress. High heat input and dry consumables reduce, rather than promote, the risk.

Question 18Pipeline (API 1104)

A welder uses a larger-diameter electrode than the one listed in the qualified procedure, keeping all other parameters the same. What is the correct action before production welding?

  1. Requalify the procedure or obtain an approved revision covering the change Correct answer.
  2. Proceed, because electrode diameter is not a welding variable
  3. Reduce the current and proceed without documentation
  4. Proceed, because larger electrodes improve fusion

Explanation

Electrode diameter is typically an essential variable because it changes heat input, bead shape, and deposition characteristics. Using a different diameter than qualified requires an approved procedure revision or requalification. Changing current informally does not correct the documentation gap.

Question 19Pipeline (API 1104)

How is the depth of a surface discontinuity typically measured during field inspection of a girth weld?

  1. By measuring the weld cap height
  2. By using a pit gauge or depth micrometer after surface preparation Correct answer.
  3. By counting the number of passes
  4. By estimating from the radiographic density

Explanation

Surface discontinuity depth is measured mechanically with a pit gauge or depth micrometer referenced to the adjacent sound surface. Radiographic density is not a reliable depth measure for surface features. Cap height and pass count do not give defect depth.

Question 20Pipeline (API 1104)

A girth weld shows incomplete penetration at the root. Which factor is a common cause of this condition?

  1. Insufficient heat input or a root face that is too thick for the current Correct answer.
  2. Excessive root gap with high current
  3. Excessive travel speed with a wide root gap
  4. Use of a backing ring

Explanation

Incomplete penetration occurs when the arc does not melt through to the root, often because heat input is too low or the root face is too thick for the applied current. Excessive gap or excessive current tends to promote burn-through rather than lack of penetration. A backing ring generally aids root fusion.

Question 21Pipeline (API 1104)

What is the role of a procedure qualification record in the API 1104 framework?

  1. It certifies the radiographer's eyesight
  2. It lists the welders currently employed on the project
  3. It documents the daily welding progress on the spread
  4. It records the results of the test weld used to support a welding procedure specification Correct answer.

Explanation

The procedure qualification record documents the test weld, the variables used, and the destructive test results that demonstrate the procedure can produce sound welds. The welding procedure specification is then written within those qualified ranges. Personnel lists, progress reports, and vision certification are separate records.

Question 22Pipeline (API 1104)

A length of pipe shows laminations in the base metal revealed during ultrasonic inspection. Why is this important for girth welding?

  1. Laminations improve weld penetration
  2. Laminations eliminate the need for preheat
  3. Laminations can cause lack of fusion or cracking when intersected by the weld Correct answer.
  4. Laminations change the pipe's outside diameter

Explanation

Laminations are planar separations parallel to the pipe surface that interrupt through-thickness continuity. When a weld intersects them, they can cause lack of fusion, tearing, or cracking under restraint. They do not improve penetration, change diameter, or remove preheat requirements.

Question 23Pipeline (API 1104)

Which welding position requires the welder to progress around a stationary pipe with the axis horizontal, welding from bottom to top on one side and top to bottom on the other?

  1. 1G
  2. 6G
  3. 2G
  4. 5G Correct answer.

Explanation

In the 5G position the pipe is fixed with its axis horizontal and the weld progresses around the circumference, covering flat, vertical, and overhead portions. The 1G position is flat with the pipe rotated, and 2G is a vertical pipe with a horizontal weld. The 6G position places the pipe at an inclined angle.

Question 24Pipeline (API 1104)

A weld is to be made on high-strength pipe with a specified minimum yield strength of 70 ksi. Compared with lower-strength pipe, what additional consideration most affects procedure qualification?

  1. Lower restraint because the pipe is stronger
  2. Higher preheat and interpass control to manage cracking susceptibility Correct answer.
  3. Reduced need for destructive testing
  4. Elimination of the root pass

Explanation

Higher-strength steels are generally more sensitive to hydrogen-assisted cracking and to heat input effects, so preheat and interpass temperatures are controlled more carefully. Qualification testing is still required, and restraint is not reduced by higher strength. The root pass remains necessary.

Question 25Pipeline (API 1104)

What does a hardness survey across a girth weld cross section help to identify?

  1. The tensile strength of the weld metal
  2. Regions with elevated hardness that may be prone to cracking Correct answer.
  3. The presence of internal porosity
  4. The chemical composition of the pipe

Explanation

A hardness survey maps hardness across the weld metal, heat-affected zone, and base metal. Localized high-hardness regions, especially in the heat-affected zone, indicate a microstructure that may be susceptible to cracking. It does not directly measure strength, porosity, or chemistry.

Question 26Pipeline (API 1104)

Which type of test is used in API 1104 procedure qualification to evaluate the soundness of the weld metal and fusion at the root of a girth weld?

  1. Charpy impact test
  2. Nick-break test Correct answer.
  3. Bend test
  4. Hardness survey

Explanation

The nick-break test exposes the full cross section of the weld by sawing a nick into each side and breaking the specimen, revealing lack of fusion, slag, porosity, and root defects. It is a standard soundness test in API 1104 procedure qualification. Bend tests evaluate ductility and fusion, while impact and hardness tests measure other properties.

Question 27Pipeline (API 1104)

In API 1104, which welding position describes welding on a pipe that is fixed with its axis horizontal while the welder progresses around the pipe from the bottom to the top?

  1. 6G
  2. 1G
  3. 5G Correct answer.
  4. 2G

Explanation

The 5G position involves a pipe fixed with its axis horizontal, and the welder welds around the circumference from the bottom upward, typically progressing through vertical and overhead portions. The 1G position is flat rolled pipe, 2G welds vertically downward on a horizontal axis, and 6G uses a pipe inclined at about 45 degrees.

Question 28Pipeline (API 1104)

What is the primary purpose of the root pass in a girth weld?

  1. To establish fusion and penetration at the pipe bore Correct answer.
  2. To add reinforcement for strength
  3. To temper the heat-affected zone
  4. To provide the final cap contour

Explanation

The root pass is the first pass deposited and its job is to fuse the pipe ends together at the root, achieving adequate penetration and fusion at the bore. A sound root prevents defects such as incomplete penetration and burn-through that later passes cannot correct. Cap contour and reinforcement are established by later passes.

Question 29Pipeline (API 1104)

Which discontinuity appears on a radiograph as a dark, straight, sharply defined line aligned with the weld axis and is typically caused by slag trapped between passes?

  1. Undercut
  2. Arc strike
  3. Porosity
  4. Slag inclusion Correct answer.

Explanation

Slag inclusion appears radiographically as dark elongated indications, often straight and aligned with the weld axis, because slag has lower density than steel and traps between passes. Porosity appears as rounded dark spots, undercut appears at the weld toe, and arc strikes are surface features.

Question 30Pipeline (API 1104)

What does the abbreviation WPS stand for in pipeline welding documentation?

  1. Weld Procedure Survey
  2. Welder Performance Sheet
  3. Weld Performance Specification
  4. Welding Procedure Specification Correct answer.

Explanation

A Welding Procedure Specification (WPS) is the written document that provides the welding parameters and ranges required to make a production weld. It is supported by procedure qualification records that demonstrate the procedure produces sound welds. Welders qualify separately to the WPS.

Question 31Pipeline (API 1104)

Which of the following is classified as a planar discontinuity in a girth weld?

  1. Lack of fusion Correct answer.
  2. Porosity
  3. Slag
  4. Undercut

Explanation

Lack of fusion is a planar discontinuity because it has essentially no volume and lies in a plane, making it sharp and crack-like. Porosity and slag are volumetric discontinuities with measurable three-dimensional extent. Planar defects are generally more detrimental because they concentrate stress.

Question 32Pipeline (API 1104)

Which document records the actual welding parameters used and the test results obtained when qualifying a welding procedure?

  1. Welding Procedure Specification
  2. Procedure Qualification Record Correct answer.
  3. Welder Qualification Record
  4. Inspection and Test Plan

Explanation

The Procedure Qualification Record (PQR) documents the actual variables used during qualification welding and the results of mechanical tests performed on the test weld. It supports the WPS by proving the procedure produces sound welds. The WPS is the production instruction derived from the PQR.

Question 33Pipeline (API 1104)

Which non-destructive method is most commonly used to detect internal planar defects such as lack of fusion in a completed girth weld?

  1. Radiographic testing Correct answer.
  2. Visual inspection
  3. Dye penetrant testing
  4. Magnetic particle testing

Explanation

Radiographic testing transmits radiation through the weld and reveals internal discontinuities by density differences on film or digital detectors. It can detect internal lack of fusion, porosity, and slag, although planar defects oriented parallel to the beam may be missed. Magnetic particle and dye penetrant methods detect only surface or near-surface defects.

Question 34Pipeline (API 1104)

A welder qualifies on 6-inch pipe with a wall thickness of 0.375 inch. Under API 1104, what is the maximum pipe diameter on which the welder may subsequently weld without requalification?

  1. 12 inches
  2. 6 inches
  3. 8 inches
  4. Unlimited Correct answer.

Explanation

API 1104 welder qualification rules allow a welder qualified on a given pipe size to weld on any larger diameter, so qualification on 6-inch pipe covers all diameters above 6 inches with no upper limit. Wall thickness qualification is also governed by the qualified thickness, but diameter is not restricted upward. This reflects that welding around a smaller pipe is generally more demanding.

Question 35Pipeline (API 1104)

A girth weld exhibits a crater at the end of a pass where the arc was terminated abruptly. Which practice best prevents this condition?

  1. Reducing the root gap
  2. Filling the crater before breaking the arc Correct answer.
  3. Decreasing the electrode diameter
  4. Increasing travel speed at the end of the pass

Explanation

Craters form when the arc is broken abruptly and the weld pool solidifies without sufficient filler added. Filling the crater by pausing or using a back-step technique before extinguishing the arc prevents crater cracks and shrinkage voids. Increasing travel speed or reducing root gap does not address the termination.

Question 36Pipeline (API 1104)

A welding procedure qualified with cellulosic electrodes is being considered for a higher-strength pipe. Which additional concern most directly affects the risk of hydrogen cracking?

  1. Increased diffusible hydrogen from the electrode coating Correct answer.
  2. Larger root gap
  3. Higher current density
  4. Faster travel speed

Explanation

Cellulosic electrodes generate significant hydrogen in the arc atmosphere, and higher-strength steels are more susceptible to hydrogen-assisted cracking in the heat-affected zone. Controlling hydrogen through electrode selection, preheat, and moisture control is critical. Current density, root gap, and travel speed affect other aspects of weld quality.

Question 37Pipeline (API 1104)

During a bend test on a procedure qualification weld, a specimen shows a discontinuity exceeding the acceptance limit on the tension surface. What is the consequence for the procedure?

  1. Only the affected welder is disqualified
  2. The test is repeated on a new specimen from the same weld
  3. The procedure is qualified with a note limiting its use
  4. The procedure fails qualification and must be revised and requalified Correct answer.

Explanation

If a qualification test specimen fails to meet acceptance criteria, the procedure is not qualified and the essential variables must be revised and the procedure requalified. A single failing specimen cannot be ignored or waived. Welder disqualification is a separate matter from procedure qualification.

Question 38Pipeline (API 1104)

A welder is qualified using the downhill progression technique. Which change would require requalification under API 1104?

  1. Welding on a larger diameter pipe
  2. Welding in a different ambient temperature
  3. Changing the pipe grade within the qualified range
  4. Changing from downhill to uphill progression Correct answer.

Explanation

Welding progression direction is an essential variable for welder qualification, so switching from downhill to uphill requires requalification. Larger diameter pipe is covered by the qualified range, ambient temperature is not a welder essential variable, and pipe grade changes within qualified limits do not by themselves require requalification of the welder.

Question 39Pipeline (API 1104)

A girth weld shows a longitudinal crack in the weld metal shortly after welding. Which combination of factors is most consistent with this failure?

  1. High heat input and slow cooling
  2. Low current and fast travel
  3. High restraint, high hardness, and elevated hydrogen Correct answer.
  4. Excessive root gap and misalignment

Explanation

Hydrogen-assisted cracking typically requires a susceptible hard microstructure, elevated diffusible hydrogen, and tensile restraint. The combination of high restraint, high hardness, and elevated hydrogen is the classic triad leading to delayed weld-metal or heat-affected-zone cracking. High heat input and slow cooling generally reduce hardness and cracking risk.

Question 40Pipeline (API 1104)

Which test evaluates the strength of a girth weld by pulling a specimen until it fails, with acceptance based on the location and load at failure?

  1. Guided bend test
  2. Macroetch test
  3. Charpy V-notch test
  4. Tensile test Correct answer.

Explanation

The tensile test pulls a transverse weld specimen until failure and evaluates whether the weld achieves the required strength, with acceptance often based on failure occurring in the base metal or the weld meeting a specified load. Bend tests assess ductility, Charpy tests assess toughness, and macroetch reveals weld structure.

Question 41Pipeline (API 1104)

A welder qualified on 0.250-inch wall thickness wishes to weld on 0.500-inch wall pipe. Under typical API 1104 welder qualification rules, what is required?

  1. The welder must requalify for the greater thickness Correct answer.
  2. The welder may weld up to twice the qualified thickness
  3. The welder may weld only after a production test
  4. No additional qualification is needed

Explanation

Welder qualification is limited by the wall thickness tested, and welding on substantially greater thickness generally requires requalification because heat sink and penetration behavior change. A production test does not substitute for qualification. The qualified thickness range is defined by the standard and the tested thickness.

Question 42Pipeline (API 1104)

What is the primary reason API 1104 requires qualification of a welding procedure before production welding begins?

  1. To satisfy customer documentation preferences
  2. To reduce the cost of welding consumables
  3. To standardize welding equipment settings across contractors
  4. To demonstrate that the procedure produces welds meeting specified mechanical and soundness requirements Correct answer.

Explanation

Procedure qualification demonstrates through mechanical testing and soundness examination that the proposed welding procedure produces welds meeting the required properties. This provides a documented basis for production welding and verifies that essential variables are controlled. Cost, preference, and equipment standardization are not the governing reasons.

Question 43Pipeline (API 1104)

A weld exhibits incomplete fusion between the fill passes on one side of the joint. Which condition is the most likely cause?

  1. Excessive preheat
  2. Use of a backing ring
  3. Excessive travel speed with insufficient overlap of passes Correct answer.
  4. Too small a root gap

Explanation

Incomplete fusion between passes commonly results from travel speed too high or pass placement that fails to overlap and remelt the previous bead, leaving unmelted surfaces. Excessive preheat and small root gap do not cause sidewall lack of fusion in the same way. Proper bead placement and travel speed ensure fusion into the preceding pass.

Question 44Pipeline (API 1104)

When interpreting a radiograph, a rounded dark indication of low density located near the weld root is most likely which discontinuity?

  1. Lack of penetration
  2. Slag inclusion
  3. Porosity Correct answer.
  4. Crack

Explanation

Porosity appears as rounded dark indications because gas cavities have lower density than the surrounding steel. Slag inclusions are typically elongated and irregular, lack of penetration appears as a straight dark line at the root, and cracks appear as fine jagged dark lines. Shape and density help distinguish these indications.

Question 45Pipeline (API 1104)

What is the purpose of a macroetch examination of a girth weld cross section?

  1. To assess notch toughness
  2. To reveal the weld profile, fusion, and penetration Correct answer.
  3. To measure tensile strength
  4. To determine the carbon equivalent

Explanation

Macroetching a polished cross section with a suitable acid reveals the weld profile, fusion boundaries, penetration, and internal structure. It is a visual examination of the weld cross section rather than a mechanical test. Tensile strength, carbon equivalent, and toughness are determined by other methods.

Question 46Pipeline (API 1104)

A pipeline is being welded in a cold environment and the procedure specifies preheat. Which factor most directly justifies the preheat requirement?

  1. Reducing the need for root cleaning
  2. Increasing deposition rate
  3. Reducing the cooling rate to prevent hard, crack-susceptible microstructures Correct answer.
  4. Improving the appearance of the cap

Explanation

Preheat slows the cooling rate after welding, which reduces the formation of hard martensitic microstructures and allows hydrogen to escape, lowering cracking risk. It also helps remove moisture from the joint surfaces. Deposition rate, cap appearance, and root cleaning are not the primary reasons for preheat.

Question 47Pipeline (API 1104)

A welder produces a weld with a cap that is excessively convex and high. Which effect does this most likely have on the weld?

  1. Reduced risk of undercut
  2. Lower residual stress
  3. Improved fatigue resistance
  4. Increased stress concentration at the weld toe Correct answer.

Explanation

An excessively convex, high cap creates a sharp transition angle at the weld toe, which concentrates stress and can reduce fatigue life. A smooth, favorable cap profile blends into the base metal and reduces stress concentration. Convexity does not improve fatigue resistance or reduce residual stress.

Question 48Pipeline (API 1104)

Which of the following best describes the essential variable concept as applied to a welding procedure under API 1104?

  1. A variable that applies only to welder qualification
  2. A variable that affects weld appearance only
  3. A variable that, if changed beyond permitted limits, requires requalification Correct answer.
  4. A variable that is recorded for information only

Explanation

An essential variable is a welding parameter or condition that, if changed beyond the qualified range, can affect the mechanical properties or soundness of the weld and therefore requires requalification of the procedure. Nonessential variables may be changed within limits without requalification. Essential variables apply to procedure qualification, not only to welders.

Question 49Pipeline (API 1104)

A girth weld on high-strength pipe shows a hardness of 350 HV in the coarse-grained heat-affected zone. What does this most likely indicate?

  1. A region of excessive grain growth with low strength
  2. A soft, ductile region unlikely to crack
  3. A hard, crack-susceptible region requiring control of cooling and hydrogen Correct answer.
  4. An area of incomplete fusion

Explanation

High hardness in the coarse-grained heat-affected zone indicates formation of hard microstructures such as martensite, which are susceptible to hydrogen-assisted cracking. Controlling heat input, preheat, and hydrogen levels reduces hardness. Incomplete fusion is a separate discontinuity, and high hardness does not indicate low strength.

Question 50Pipeline (API 1104)

A procedure qualification uses a specific electrode classification and shows acceptable results. The contractor wishes to substitute a different electrode classification with similar strength. What is the correct action under API 1104?

  1. Perform a production test weld instead of requalification
  2. Requalify the procedure because electrode classification is an essential variable Correct answer.
  3. Notify the inspector only
  4. Proceed without requalification because strength is similar

Explanation

Electrode classification is an essential variable in procedure qualification, and a change to a different classification generally requires requalification because it can alter hydrogen content, toughness, and weldability. Similar strength does not justify skipping requalification. A production test weld does not substitute for procedure qualification.