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AWS D1.5 Endorsement study materials
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AWS D1.5 Endorsement practice questions

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Question 1Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

Under AASHTO/AWS D1.5M/D1.5, which document establishes the qualification requirements for welding procedures used in bridge fabrication?

  1. AWS D1.2/D1.2M Structural Welding Code-Aluminum
  2. AWS D1.3/D1.3M Structural Welding Code-Sheet Steel
  3. AWS D1.1/D1.1M Structural Welding Code-Steel
  4. AWS D1.5M/D1.5 Section 5 Correct answer.

Explanation

Bridge Welding Code D1.5 contains its own qualification requirements in Section 5, which governs procedure qualification for bridge fabrication. D1.1 is the general structural steel code and does not govern D1.5 bridge work unless specifically referenced. D1.3 covers sheet steel and D1.2 covers aluminum, so neither applies to bridge structural steel welding qualification.

Question 2Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

A welding procedure specification for bridge fabrication is being prepared. Which variable is classified as essential and therefore requires requalification when changed?

  1. Shop humidity
  2. Production schedule
  3. Welder's name
  4. Filler metal classification Correct answer.

Explanation

Essential variables are those changes that can affect the mechanical properties of the weld and therefore require requalification of the procedure. Filler metal classification is an essential variable because it directly changes deposit chemistry and strength. Welder identity, scheduling, and ambient humidity are not essential variables under the code.

Question 3Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

What is the minimum length of a welder performance qualification test coupon that must be welded to qualify a welder for bridge work?

  1. 600 mm
  2. 450 mm
  3. 150 mm
  4. 300 mm Correct answer.

Explanation

D1.5 requires a performance qualification test coupon of at least 300 mm in length for the welder to demonstrate the ability to produce a sound weld over a representative length. Shorter coupons do not provide enough weld length for adequate visual and nondestructive evaluation. Longer coupons are permitted but are not the minimum.

Question 4Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

For complete joint penetration groove welds in tension members, what nondestructive examination method does D1.5 require?

  1. Visual inspection only
  2. Liquid penetrant testing only
  3. Magnetic particle testing only
  4. Radiographic or ultrasonic testing Correct answer.

Explanation

D1.5 requires volumetric examination by radiographic or ultrasonic testing for complete joint penetration groove welds in tension members because surface methods cannot detect internal discontinuities. Visual inspection alone is insufficient for these critical welds. Liquid penetrant and magnetic particle testing are surface methods and do not satisfy the volumetric requirement.

Question 5Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

Which welding process is prequalified by D1.5 for bridge fabrication without procedure qualification testing?

  1. Shielded metal arc welding Correct answer.
  2. Friction stir welding
  3. Electrogas welding
  4. Electroslag welding

Explanation

D1.5 prequalifies shielded metal arc welding when used with the prequalified joint details and essential variable ranges listed in the code. Electroslag and electrogas welding are not prequalified and require procedure qualification. Friction stir welding is not a prequalified process for steel bridge fabrication.

Question 6Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

What is the minimum preheat temperature required for welding ASTM A709 Grade 50 steel when the base metal thickness is 25 mm and the ambient temperature is above 0 °C?

  1. 50 °C
  2. 21 °C
  3. 32 °C
  4. 10 °C Correct answer.

Explanation

D1.5 Table 5.8 specifies a minimum preheat of 10 °C for ASTM A709 Grade 50 steel at thicknesses up to 50 mm when the ambient temperature is at or above 0 °C. Higher preheat values apply to thicker sections or lower ambient temperatures. The 10 °C value is the baseline requirement for this grade and thickness.

Question 7Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

Which type of joint detail is prohibited by D1.5 in bridge fabrication because it creates an abrupt change in section?

  1. Full penetration groove weld with backing
  2. Fillet weld with a convex face
  3. Partial penetration groove weld with a sharp notch Correct answer.
  4. Square groove weld with a permanent backing

Explanation

D1.5 prohibits partial penetration groove welds that leave a sharp notch at the root because such notches concentrate stress and promote fatigue cracking. Full penetration groove welds with backing, convex fillet welds, and square groove welds with permanent backing are permitted when detailed per the code. The prohibition targets notch-like root conditions that cannot be inspected or repaired easily.

Question 8Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

A welder qualified on a 10 mm thick test plate using the shielded metal arc welding process may weld production material in which thickness range without requalification?

  1. Up to 20 mm
  2. Unlimited thickness Correct answer.
  3. Up to 25 mm
  4. Up to 10 mm only

Explanation

Under D1.5, a welder who qualifies on a test plate at least 10 mm thick is qualified to weld production material of unlimited thickness for that process and position. Qualification on thinner plate restricts the welder to a corresponding thickness range. The 10 mm threshold is the key value that unlocks unlimited thickness qualification.

Question 9Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

During visual inspection of a completed fillet weld, the inspector observes undercut along the toe of the weld. What is the maximum allowable undercut for a fillet weld in bridge fabrication?

  1. 0.8 mm Correct answer.
  2. 1.5 mm
  3. 1.0 mm
  4. 2.0 mm

Explanation

D1.5 limits undercut in fillet welds to 0.8 mm because deeper undercut reduces the effective throat and creates a stress concentration at the weld toe. The limit applies regardless of weld size for primary bridge members. Undercut exceeding this value must be repaired before acceptance.

Question 10Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

A procedure qualification test is performed on 20 mm thick base metal. For what range of production thickness is the qualified procedure valid?

  1. 20 mm only
  2. 5 mm to 40 mm Correct answer.
  3. 10 mm to 40 mm
  4. Unlimited thickness

Explanation

D1.5 permits a procedure qualified on 20 mm plate to be used for production thicknesses from 5 mm up to 40 mm, which is twice the test thickness. The lower bound of 5 mm reflects the minimum thickness for which the procedure is considered applicable. Thicknesses outside this range require separate qualification.

Question 11Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

Which position qualifies a welder to weld in all positions for a given process under D1.5?

  1. Test in the 6GR position Correct answer.
  2. Vertical position only
  3. Flat position only
  4. Horizontal position only

Explanation

Qualification in the 6GR position, which combines fixed pipe at 45 degrees with a restriction ring, qualifies the welder for all positions including flat, horizontal, vertical, and overhead. Testing in a single position such as flat, horizontal, or vertical limits the welder to that position and those less demanding. The 6GR test is the most comprehensive position qualification.

Question 12Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

A fracture-critical member is being fabricated. What additional requirement does D1.5 impose on the welding procedure for this member?

  1. The procedure must be re-qualified every six months
  2. The procedure must use only manual processes
  3. The procedure must be qualified by a third-party agency
  4. The procedure must be qualified with impact testing Correct answer.

Explanation

Fracture-critical members require welding procedures qualified with impact testing to demonstrate adequate toughness and resistance to brittle fracture. Third-party qualification, process restrictions, and periodic requalification are not the specific additional requirement imposed by D1.5 for these members. The impact testing ensures the weld metal and heat-affected zone meet toughness criteria.

Question 13Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

During welding of a thick bridge girder, the inspector measures interpass temperature. What is the maximum interpass temperature for ASTM A709 Grade 50 steel unless otherwise qualified?

  1. 150 °C
  2. 230 °C Correct answer.
  3. 315 °C
  4. 260 °C

Explanation

D1.5 limits the interpass temperature for ASTM A709 Grade 50 steel to 230 °C to avoid degradation of toughness in the heat-affected zone. Higher interpass temperatures can coarsen the microstructure and reduce impact resistance. A procedure qualification may justify a different limit, but 230 °C is the default maximum.

Question 14Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

A complete joint penetration groove weld in a tension member is inspected by ultrasonic testing. What acceptance criterion applies to planar discontinuities?

  1. Discontinuities are evaluated against the acceptance criteria of D1.5 Clause 6 Correct answer.
  2. Any discontinuity is acceptable if it is shorter than 25 mm
  3. Ultrasonic testing is not required for tension members
  4. Only surface-breaking discontinuities are evaluated

Explanation

D1.5 Clause 6 provides the acceptance criteria for ultrasonic testing of complete joint penetration groove welds, including limits on discontinuity length and amplitude. A fixed 25 mm length allowance does not exist; acceptance depends on the specific evaluation criteria. Surface-breaking discontinuities are evaluated separately, and ultrasonic testing is required for tension members.

Question 15Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

Which condition requires requalification of a welding procedure that was originally qualified using shielded metal arc welding?

  1. Changing the welder performing the production welding
  2. Changing the electrode brand while keeping the same classification
  3. Changing from E7018 to E7028 electrode classification Correct answer.
  4. Changing the preheat temperature within the qualified range

Explanation

A change in filler metal classification from E7018 to E7028 alters the deposit chemistry and mechanical properties, making it an essential variable that requires requalification. Changing the electrode brand within the same classification, changing the welder, or adjusting preheat within the qualified range does not require requalification. Essential variable changes must be evaluated against the procedure qualification record.

Question 16Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

A welded bridge connection is classified as a demand-critical weld. What does D1.5 require for this weld beyond the standard requirements?

  1. Welding must be performed only in the flat position
  2. The weld must be made with a single pass
  3. The weld must be post-weld heat treated
  4. Enhanced inspection and quality control beyond standard requirements Correct answer.

Explanation

Demand-critical welds are those whose failure would have severe consequences, so D1.5 requires enhanced inspection and quality control measures beyond those for standard welds. Position restrictions, mandatory post-weld heat treatment, and single-pass requirements are not the additional measures specified. The enhanced measures typically include increased NDT frequency and more stringent acceptance criteria.

Question 17Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

A welder qualified on a 6 mm thick test plate using the flux cored arc welding process is assigned to weld a 25 mm thick production joint. What is the maximum thickness the welder is qualified to weld?

  1. 25 mm
  2. 6 mm
  3. Unlimited thickness
  4. 12 mm Correct answer.

Explanation

When the test plate is less than 10 mm thick, D1.5 limits the qualified production thickness to twice the test plate thickness. A 6 mm test plate therefore qualifies the welder up to 12 mm, and the 25 mm production joint exceeds that limit. The welder must be requalified on a thicker test plate to weld the 25 mm joint.

Question 18Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

What is the minimum required preheat for welding ASTM A709 Grade 50 steel when the base metal thickness is 75 mm and the ambient temperature is 0 °C?

  1. 50 °C Correct answer.
  2. 100 °C
  3. 21 °C
  4. 10 °C

Explanation

D1.5 Table 5.8 requires a minimum preheat of 50 °C for ASTM A709 Grade 50 steel when the thickness exceeds 50 mm and the ambient temperature is at or below 0 °C. Thicker sections conduct heat away rapidly and need higher preheat to prevent cracking. The 50 °C value applies to this thickness and ambient condition combination.

Question 19Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

A welding procedure qualified with a 20 kJ/mm heat input is used in production. What is the maximum heat input permitted without requalification?

  1. 30 kJ/mm
  2. 40 kJ/mm
  3. 25 kJ/mm Correct answer.
  4. 20 kJ/mm

Explanation

D1.5 permits heat input increases up to 25 percent above the qualified value without requalification, so 20 kJ/mm qualifies up to 25 kJ/mm. Exceeding this allowance changes the cooling rate and can degrade toughness, requiring requalification. The 25 percent rule balances production flexibility with metallurgical control.

Question 20Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

Which document must be submitted to the Engineer for approval before welding begins on a bridge fabrication project?

  1. The shop's equipment maintenance log
  2. The project safety plan
  3. The welder's resume
  4. The welding procedure specification and procedure qualification record Correct answer.

Explanation

D1.5 requires the fabricator to submit the welding procedure specification and supporting procedure qualification record to the Engineer for approval before production welding. A welder's resume, equipment maintenance log, and safety plan are not the submittals required for welding approval. The approved WPS and PQR demonstrate that the procedure has been properly qualified.

Question 21Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

A complete joint penetration groove weld is made in a fracture-critical tension member. What is the required frequency of ultrasonic testing?

  1. 50 percent of the weld length
  2. 100 percent of the weld length Correct answer.
  3. 25 percent of the weld length
  4. 10 percent of the weld length

Explanation

D1.5 requires 100 percent ultrasonic testing of complete joint penetration groove welds in fracture-critical tension members because any undetected defect could lead to catastrophic failure. Partial testing frequencies such as 10, 25, or 50 percent are insufficient for these critical welds. The full volumetric examination ensures the entire weld length is evaluated.

Question 22Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

A welding procedure qualified using the shielded metal arc welding process is being considered for use with the submerged arc welding process. What action is required?

  1. No action is required because both are arc welding processes
  2. The procedure must be requalified for the new process Correct answer.
  3. The welder must be requalified but the procedure remains valid
  4. Only a change in welding position requires requalification

Explanation

A change in welding process is an essential variable under D1.5, so a procedure qualified with shielded metal arc welding cannot be used for submerged arc welding without requalification. The two processes differ in flux handling, heat input, and deposit characteristics. Welder requalification alone does not address the procedure change.

Question 23Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

A welder qualified on a test plate in the vertical position with the gas metal arc welding process is assigned to weld in the overhead position. What is the welder's qualification status?

  1. The welder is qualified for overhead because vertical is more difficult
  2. The welder is not qualified for overhead and must be requalified Correct answer.
  3. The welder is qualified for overhead only with a different electrode
  4. The welder is qualified for overhead if the thickness is less than 10 mm

Explanation

Position qualification is specific: a welder qualified in the vertical position is not qualified for overhead welding unless tested in that position or in a position that qualifies all positions. Vertical is not considered to encompass overhead under D1.5. The welder must complete an overhead or all-position qualification test.

Question 24Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

A procedure qualification record shows that the qualified heat input was 15 kJ/mm. Production welding is performed at 19 kJ/mm. What is the status of the production welding?

  1. It is acceptable because heat input is not an essential variable
  2. It is acceptable if the welder is qualified for the process
  3. It is acceptable because 19 kJ/mm is within 25 percent of 15 kJ/mm
  4. It is not acceptable because it exceeds the 25 percent allowance Correct answer.

Explanation

A 25 percent increase above 15 kJ/mm is 18.75 kJ/mm, so 19 kJ/mm exceeds the permitted allowance and the production welding is not covered by the qualified procedure. Exceeding the heat input allowance can alter cooling rates and toughness, requiring requalification. Welder qualification does not compensate for an out-of-range procedure variable.

Question 25Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

A bridge girder contains a complete joint penetration groove weld that intersects a transverse butt weld. What detailing requirement applies to this intersection under D1.5?

  1. The intersection must be reinforced with a cover plate
  2. The welds must be separated by at least 100 mm
  3. The transverse weld must be made first and then ground flush
  4. The intersecting welds must be detailed to avoid a notch or abrupt change in section Correct answer.

Explanation

D1.5 requires that intersecting welds be detailed to avoid notches and abrupt changes in section that concentrate stress and promote fatigue cracking. A fixed 100 mm separation is not the governing rule, and weld sequencing or cover plates are not the specified detailing solution. Proper detailing ensures smooth force flow through the connection.

Question 26Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

Before welding begins on a bridge fabrication project, what must the fabricator submit to the Engineer for approval?

  1. A mill certificate for the welding consumables only
  2. A welder's personal employment history
  3. A welding procedure specification and its supporting procedure qualification record Correct answer.
  4. A bill of lading for the base metal heat numbers

Explanation

D1.5 requires that each welding procedure specification be supported by a procedure qualification record demonstrating that the procedure produces welds meeting the required mechanical properties. Both documents must be submitted to and approved by the Engineer before production welding starts. Mill certificates and heat number records are separate quality documentation, not the welding procedure approval submittal.

Question 27Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

A welder is qualified using the shielded metal arc welding process on a test plate. Which additional process may that welder weld without separate qualification?

  1. Flux cored arc welding with a rutile consumable
  2. Gas metal arc welding in the spray transfer mode
  3. No other process; each process requires separate qualification Correct answer.
  4. Submerged arc welding in the flat position

Explanation

D1.5 qualification is process-specific: a welder qualified for shielded metal arc welding is qualified only for that process unless requalified. Cross-process exemptions are not permitted because each process has distinct arc characteristics, consumables, and defect tendencies. Separate qualification testing is therefore required for each additional process.

Question 28Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

A welder qualifies on a 10 mm thick test plate using the gas metal arc welding process. For what range of production base metal thickness is the welder qualified?

  1. 10 mm to 20 mm only
  2. 10 mm to 25 mm only
  3. 6 mm to 10 mm only
  4. Unlimited thickness Correct answer.

Explanation

Under D1.5, a welder who qualifies on a test plate at least 10 mm thick is qualified for production base metal of unlimited thickness. The test thickness establishes the upper limit only when it is less than 10 mm. Qualification on thinner plates restricts production thickness accordingly.

Question 29Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

A welder is qualified on a 6 mm thick test plate using the flux cored arc welding process. What is the maximum production base metal thickness the welder may weld?

  1. Unlimited
  2. 6 mm
  3. 12 mm Correct answer.
  4. 18 mm

Explanation

When the qualification test plate is less than 10 mm thick, D1.5 limits the qualified production thickness to twice the test plate thickness. A 6 mm test plate therefore qualifies the welder up to 12 mm. Qualification on a plate 10 mm or thicker removes the thickness limit.

Question 30Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

A welder is qualified in the vertical position with the gas metal arc welding process. Which production welding position is that welder permitted to perform?

  1. Flat and horizontal only
  2. Overhead only
  3. All positions
  4. Vertical only Correct answer.

Explanation

Position qualification under D1.5 is specific to the position tested unless the test is made in the 6G position, which qualifies all positions. A welder qualified in the vertical position is therefore limited to vertical welding for that process. Separate qualification is required for flat, horizontal, or overhead production welding.

Question 31Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

Which welding position, when used for a welder qualification test, qualifies the welder for all positions?

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

Explanation

The 6G test position requires welding a pipe in the inclined fixed position, which exposes the welder to flat, horizontal, vertical, and overhead welding within a single test. D1.5 recognizes 6G qualification as qualifying the welder for all positions. The 1G, 2G, and 3G tests qualify only their respective positions.

Question 32Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

A welding procedure qualified with a heat input of 20 kJ/mm is used in production. What is the maximum heat input permitted for production welding under that procedure?

  1. 40 kJ/mm
  2. 20 kJ/mm Correct answer.
  3. 24 kJ/mm
  4. 30 kJ/mm

Explanation

D1.5 requires production heat input to remain within the range qualified by the procedure qualification record. The qualified heat input is an essential variable, so production welding may not exceed the qualified value unless the procedure is requalified. A 20 kJ/mm qualification therefore caps production at 20 kJ/mm.

Question 33Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

A procedure qualification record lists a qualified heat input of 15 kJ/mm. Production welding is performed at 19 kJ/mm. What is the status of the production welding?

  1. Not acceptable because heat input exceeds the qualified value Correct answer.
  2. Acceptable because the increase is less than 10 percent
  3. Acceptable if the interpass temperature is reduced
  4. Acceptable if the welder is qualified for the higher heat input

Explanation

Heat input is an essential variable in D1.5 procedure qualification, and production welding must not exceed the qualified heat input. Welding at 19 kJ/mm exceeds the 15 kJ/mm qualified value and is therefore outside the qualified procedure. The remedy is requalification of the procedure at the higher heat input, not adjustment of other variables.

Question 34Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

During welding of a thick bridge girder, the inspector measures interpass temperature. What is the maximum interpass temperature permitted for ASTM A709 Grade 50 steel unless the qualified procedure specifies otherwise?

  1. 230 degrees C Correct answer.
  2. 150 degrees C
  3. 400 degrees C
  4. 315 degrees C

Explanation

D1.5 limits interpass temperature for ASTM A709 Grade 50 steel to 230 degrees C unless a qualified procedure establishes a different limit. Excessive interpass temperature can degrade toughness and increase distortion. The lower value of 150 degrees C applies to other, more restrained conditions rather than as the general maximum for this grade.

Question 35Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

What is the minimum preheat temperature required for welding ASTM A709 Grade 50 steel when the base metal thickness is 65 mm?

  1. 107 degrees C Correct answer.
  2. 52 degrees C
  3. 21 degrees C
  4. 10 degrees C

Explanation

D1.5 preheat requirements increase with base metal thickness for ASTM A709 Grade 50 steel. For thicknesses of 65 mm and greater, a minimum preheat of 107 degrees C is required. Lower preheat values apply only to thinner sections of the same grade.

Question 36Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

A complete joint penetration groove weld in a tension member is inspected by ultrasonic testing. Which acceptance criterion applies to the weld?

  1. The weld is accepted if the welder is qualified for the position
  2. The weld is accepted if the radiographic film shows no porosity
  3. The weld is accepted if visual inspection shows no surface discontinuities
  4. The weld must meet the ultrasonic acceptance criteria of D1.5 for cyclically loaded tension members Correct answer.

Explanation

D1.5 defines ultrasonic testing acceptance criteria for complete joint penetration groove welds in tension members, and the weld must satisfy those criteria. Visual inspection alone cannot detect internal discontinuities in a complete joint penetration weld. Radiographic testing is a separate method with its own criteria and does not substitute for the specified ultrasonic evaluation.

Question 37Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

A complete joint penetration groove weld is made in a fracture-critical tension member. What is the required inspection frequency for ultrasonic testing?

  1. 10 percent of the weld length
  2. 50 percent of the weld length
  3. 100 percent of the weld length Correct answer.
  4. Ultrasonic testing is not required for fracture-critical members

Explanation

D1.5 requires that complete joint penetration groove welds in fracture-critical tension members be inspected by ultrasonic testing over the full weld length. Fracture-critical members demand the highest inspection confidence because a crack could lead to catastrophic failure. Partial sampling is not permitted for these members.

Question 38Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

A fracture-critical member is being fabricated. What additional requirement does D1.5 impose on the welding procedure for that member?

  1. The procedure must be qualified with toughness testing of the weld and heat-affected zone Correct answer.
  2. The procedure must include a postweld heat treatment step
  3. The procedure must be qualified by an independent testing agency
  4. The procedure must be qualified with a higher minimum preheat

Explanation

For fracture-critical members, D1.5 requires that the welding procedure qualification include Charpy V-notch toughness testing of the weld metal and heat-affected zone. This ensures the joint has adequate resistance to brittle fracture. Standard procedure qualification without toughness testing is not sufficient for these members.

Question 39Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

A welding procedure is qualified using shielded metal arc welding. Which change would require requalification of the procedure under D1.5?

  1. Changing the welding process to submerged arc welding Correct answer.
  2. Changing the production welding position within the qualified range
  3. Changing the welder performing the production welding
  4. Changing the manufacturer of the base metal within the same specification

Explanation

A change in welding process is an essential variable in D1.5 procedure qualification and requires requalification. Welder identity, position within the qualified range, and base metal manufacturer within the same specification are not essential variables. Requalification ensures the new process produces acceptable mechanical properties.

Question 40Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

A welding procedure qualified with shielded metal arc welding is being considered for submerged arc welding. What is required before submerged arc welding may be used in production?

  1. Only approval from the welding supervisor
  2. Nothing, because both are arc welding processes
  3. A new procedure qualification for the submerged arc welding process Correct answer.
  4. Only a change in the welder qualification record

Explanation

Because the welding process is an essential variable, changing from shielded metal arc welding to submerged arc welding requires a new procedure qualification. The two processes differ in flux handling, heat input, and mechanical properties. Welder qualification and supervisory approval cannot substitute for procedure qualification.

Question 41Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

Which joint detail is prohibited by D1.5 in bridge fabrication because it creates an abrupt change in section?

  1. A full penetration groove weld with a backing bar
  2. A double-sided fillet weld
  3. A partial penetration groove weld with an abrupt transition Correct answer.
  4. A complete joint penetration groove weld with a smooth transition

Explanation

D1.5 prohibits partial penetration groove welds that produce an abrupt change in section because the resulting stress concentration promotes fatigue cracking. Details must provide a gradual transition where section changes occur. Backing bars, double-sided fillets, and smooth complete joint penetration welds are not prohibited on this basis.

Question 42Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

A bridge girder contains a complete joint penetration groove weld that intersects a transverse butt weld. What detailing requirement applies to this intersection?

  1. The intersection must be avoided by relocating the transverse weld
  2. The transverse weld must be made first and the longitudinal weld must cross it without interruption
  3. The welds must be separated by at least 300 mm
  4. The intersecting welds must be detailed so that the weld intersections are minimized or avoided Correct answer.

Explanation

D1.5 requires that intersecting welds be detailed to minimize or avoid weld intersections, because intersecting welds create complex residual stress and potential defect concentrations. Where intersections cannot be avoided, specific sequencing and inspection requirements apply. Arbitrary separation distances and unqualified relocation are not the governing rule.

Question 43Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

During visual inspection of a completed fillet weld, the inspector observes undercut along the toe of the weld. Which acceptance criterion applies to undercut in a primary member?

  1. Undercut is acceptable regardless of depth
  2. Undercut must not exceed the limits specified in D1.5 for the member type and direction of stress Correct answer.
  3. Undercut is acceptable if the weld is later painted
  4. Undercut is acceptable if it is less than 1 mm deep

Explanation

D1.5 establishes maximum allowable undercut depths that depend on member type and whether the stress is parallel or transverse to the weld. Undercut beyond those limits reduces section and acts as a stress concentration, so it must be repaired. Painting or arbitrary depth allowances do not satisfy the acceptance criteria.

Question 44Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

A welding procedure specification lists a preheat of 50 degrees C. What does D1.5 require regarding preheat during production welding?

  1. Preheat may be discontinued after the first pass
  2. Preheat may be reduced if the ambient temperature is above freezing
  3. The preheat must be maintained until welding is completed Correct answer.
  4. Preheat is required only for the root pass

Explanation

D1.5 requires that the specified preheat be maintained throughout welding until the weld is completed. Interrupting preheat can cause rapid cooling, harden the heat-affected zone, and promote cracking. Preheat is not limited to the root pass or to the first portion of the weld.

Question 45Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

A fabricator proposes to use a welding procedure qualified on 20 mm thick base metal for production material 50 mm thick. What does D1.5 require?

  1. The procedure must be requalified for the 50 mm production thickness Correct answer.
  2. The procedure is qualified only up to 20 mm
  3. The procedure is qualified for unlimited thickness because it exceeds 10 mm
  4. The procedure is qualified only up to 40 mm because the limit is twice the test thickness

Explanation

D1.5 procedure qualification limits the qualified base metal thickness range based on the test thickness. A procedure qualified on 20 mm base metal does not extend to 50 mm production material, so requalification at a qualifying thickness is required. The twice-thickness rule applies to welder qualification on plates under 10 mm, not to procedure qualification.

Question 46Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

Which document establishes the welding variables that must be followed during production welding on a bridge project?

  1. The welder's qualification test report
  2. The welding procedure specification Correct answer.
  3. The shop drawing title block
  4. The mill certificate for the base metal

Explanation

The welding procedure specification defines the qualified welding variables, including process, consumable, preheat, heat input, and position, that production welding must follow. Mill certificates document base metal properties, and welder qualification reports document individual welder capability. Shop drawing title blocks do not establish welding variables.

Question 47Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

A welder qualified on a 25 mm thick test plate using the shielded metal arc welding process is assigned to weld production material 40 mm thick. What is the welder's qualification status?

  1. The welder is qualified only up to 25 mm
  2. The welder is qualified up to 50 mm
  3. The welder must requalify on a thicker test plate
  4. The welder is qualified for unlimited thickness Correct answer.

Explanation

Because the test plate is at least 10 mm thick, D1.5 qualifies the welder for production base metal of unlimited thickness. The 25 mm test thickness does not cap production at 25 mm or at twice that value. Requalification is not required for the 40 mm production material.

Question 48Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

A welding procedure qualification test is performed with a heat input of 12 kJ/mm. Which production heat input would remain within the qualified procedure without requalification?

  1. 16 kJ/mm
  2. 14 kJ/mm
  3. 18 kJ/mm
  4. 10 kJ/mm Correct answer.

Explanation

Production heat input must not exceed the value qualified by the procedure qualification record. A production heat input of 10 kJ/mm is below the 12 kJ/mm qualified value and is therefore acceptable. Values above 12 kJ/mm exceed the qualified heat input and would require requalification.

Question 49Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

A bridge fabrication shop plans to weld ASTM A709 Grade 50 steel with a thickness of 25 mm. What minimum preheat does D1.5 require?

  1. 52 degrees C
  2. 21 degrees C Correct answer.
  3. 107 degrees C
  4. 10 degrees C

Explanation

D1.5 preheat requirements for ASTM A709 Grade 50 steel vary with base metal thickness. For thicknesses from 20 mm to less than 38 mm, a minimum preheat of 21 degrees C applies. The higher values of 52 degrees C and 107 degrees C apply to thicker sections.

Question 50Bridge Welding (D1.5) Endorsement - AASHTO/AWS D1.5M/D1.5

An inspector is reviewing a completed weld on a fracture-critical member. Which inspection method does D1.5 require for complete joint penetration groove welds in tension members of this type?

  1. Ultrasonic testing in addition to visual inspection Correct answer.
  2. Visual inspection only
  3. Magnetic particle testing only
  4. Dye penetrant testing only

Explanation

D1.5 requires ultrasonic testing of complete joint penetration groove welds in tension members, including those in fracture-critical members, in addition to visual inspection. Surface methods such as dye penetrant and magnetic particle testing cannot detect internal planar discontinuities. Visual inspection alone is insufficient for these welds.