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Question 1Welding Fundamentals and Processes (Part A)

In the SMAW electrode classification E7018, what does the number 70 represent?

  1. Typical deposition rate of 70 percent
  2. Minimum yield strength of 70,000 psi
  3. Minimum tensile strength of 70,000 psi Correct answer.
  4. Maximum carbon content of 0.70 percent

Explanation

The first two digits of an E70xx electrode give the minimum as-welded tensile strength in ksi, so E70 means 70,000 psi minimum tensile strength. Yield strength and composition are not encoded in those digits. The suffix digits describe position and coating/current.

Question 2Welding Fundamentals and Processes (Part A)

Which joint configuration places two members at approximately 90 degrees in the form of a T?

  1. Lap joint
  2. Corner joint
  3. T-joint Correct answer.
  4. Butt joint

Explanation

A T-joint has one member perpendicular to the face of the other, forming the stem and flange of a T. Butt joints align members end to end, lap joints overlap parallel surfaces, and corner joints meet at an edge.

Question 3Welding Fundamentals and Processes (Part A)

In the AWS position designation, a groove weld made in the horizontal position is identified as:

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

Explanation

AWS groove weld positions use 1G flat, 2G horizontal, 3G vertical, and 4G overhead. The horizontal position is therefore 2G.

Question 4Welding Fundamentals and Processes (Part A)

On a welding symbol, a weld placed on the same side as the reference line arrow is:

  1. Welded in the field
  2. Welded on the other side
  3. Welded all around
  4. Welded on the arrow side Correct answer.

Explanation

The side of the joint to which the arrow points is the arrow side; a symbol below the reference line denotes an arrow-side weld, while a symbol above denotes the other side.

Question 5Welding Fundamentals and Processes (Part A)

An E6013 electrode is designed to deposit weld metal with a minimum tensile strength of:

  1. 60,000 psi Correct answer.
  2. 13,000 psi
  3. 6,000 psi
  4. 70,000 psi

Explanation

The first two digits of the E60xx classification specify minimum tensile strength in ksi, so E6013 deposits at least 60,000 psi tensile strength. The 13 refers to position and coating/current, not strength.

Question 6Welding Fundamentals and Processes (Part A)

What is the primary purpose of preheating a thick carbon steel joint before welding?

  1. To slow cooling and reduce cracking risk Correct answer.
  2. To increase the welding current capacity
  3. To increase the travel speed of the welder
  4. To remove the need for post-weld inspection

Explanation

Preheating raises base metal temperature so the weld cools more slowly, which lowers hardness and helps hydrogen escape, reducing cracking. It does not change equipment capacity or eliminate inspection.

Question 7Welding Fundamentals and Processes (Part A)

Slag inclusion in a multipass SMAW weld is most often caused by:

  1. Too small a root gap
  2. Failure to remove slag between passes Correct answer.
  3. Excessive travel speed on the root pass
  4. Using DC current rather than AC current

Explanation

Slag trapped between passes occurs when the slag from the previous bead is not fully chipped and brushed away. Current type and root gap do not directly cause slag entrapment.

Question 8Welding Fundamentals and Processes (Part A)

In brazing, the filler metal melts at a temperature:

  1. Exactly at the melting temperature of the base metal
  2. At any temperature below 450 degrees F
  3. Above the melting temperature of the base metal
  4. Below the base metal melting point but above 840 F Correct answer.

Explanation

Brazing uses a filler that melts above 840 F (450 C) but below the melting point of the base metal. Soldering occurs below 840 F, and welding melts the base metal.

Question 9Welding Fundamentals and Processes (Part A)

Which GMAW metal transfer mode is characterized by low heat input and is commonly used on thin sheet with small-diameter wire?

  1. Short-circuit transfer Correct answer.
  2. Pulsed spray transfer mode
  3. Globular transfer mode
  4. Spray transfer mode

Explanation

Short-circuiting transfer alternates short circuits and arc re-establishment at low current, giving low heat input suitable for thin material. Spray and pulsed spray require higher currents and are used on thicker sections.

Question 10Welding Fundamentals and Processes (Part A)

Why must SAW flux be kept dry and stored according to the manufacturer's recommendations?

  1. Wet flux increases deposition efficiency
  2. Dry flux conducts current better
  3. Moisture in flux can cause hydrogen cracking Correct answer.
  4. Wet flux changes the electrode classification

Explanation

Moisture in flux breaks down in the arc to hydrogen, which can produce porosity and hydrogen-assisted cracking in the weld. Flux condition does not change electrode classification.

Question 11Welding Fundamentals and Processes (Part A)

In the GTAW tungsten electrode designation EWTh-2, the 'Th' and '2' indicate:

  1. 2 percent thoria added to the tungsten Correct answer.
  2. Thoriated coating and 2 percent nickel
  3. Tungsten hardness grade 2
  4. 2 percent thorium and a 2-inch length

Explanation

EWTh-2 is a tungsten electrode containing approximately 2 percent thorium oxide (thoria), which improves electron emission and arc starting. The digits denote alloy content, not length or hardness.

Question 12Welding Fundamentals and Processes (Part A)

Self-shielded flux-cored arc welding differs from gas-shielded FCAW mainly because it:

  1. Relies on flux core protection, not external gas Correct answer.
  2. Uses a solid electrode wire instead of a tubular wire
  3. Requires a larger shielding gas flow rate
  4. Cannot be used in outdoor windy conditions

Explanation

Self-shielded FCAW generates its own protective atmosphere from the flux core, so no external shielding gas is supplied. Gas-shielded FCAW uses a separate shielding gas and is more sensitive to wind.

Question 13Welding Fundamentals and Processes (Part A)

Given 25 volts, 200 amps, and a travel speed of 10 in/min, what is the heat input in joules per inch?

  1. 3,000 J/in
  2. 50,000 J/in
  3. 30,000 J/in Correct answer.
  4. 500 J/in

Explanation

Heat input equals voltage times amperage times 60 divided by travel speed in inches per minute: (25 x 200 x 60) / 10 = 30,000 J/in. Omitting the 60 gives 500, and other values arise from arithmetic errors.

Question 14Welding Fundamentals and Processes (Part A)

Which condition is most likely to produce porosity in a GMAW weld?

  1. Using a slightly larger contact tip
  2. High travel speed with proper gas flow
  3. Welding with a clean, dry base metal
  4. Loss of shielding gas coverage at the pool Correct answer.

Explanation

Porosity results when gas is trapped in the solidifying weld, commonly from lost or disturbed shielding, drafts, or contaminated surfaces. Contact tip size and clean base metal do not introduce porosity.

Question 15Welding Fundamentals and Processes (Part A)

Which technique helps control angular distortion in a long butt weld?

  1. Increasing the root gap progressively
  2. Increasing the welding current to maximum
  3. Welding continuously from one end
  4. Using a balanced backstep sequence Correct answer.

Explanation

Backstep and balanced sequences distribute heat and shrinkage so distortion is offset or reduced. Continuous welding from one end concentrates shrinkage and worsens distortion.

Question 16Welding Fundamentals and Processes (Part A)

Using CE = C + Mn/6 + (Cr+Mo+V)/5 + (Ni+Cu)/15, a steel with C 0.20, Mn 1.20, and no other alloys has a carbon equivalent of about:

  1. 1.20
  2. 0.40 Correct answer.
  3. 0.20
  4. 0.24

Explanation

Only carbon and manganese contribute here: 0.20 + 1.20/6 = 0.20 + 0.20 = 0.40. Higher values would raise hardenability and cracking risk.

Question 17Welding Fundamentals and Processes (Part A)

As carbon content of plain carbon steel increases, weldability generally:

  1. Increases because the steel becomes softer
  2. Improves because preheat requirements drop
  3. Decreases as hardenability and cracking risk rise Correct answer.
  4. Remains unchanged up to 0.60 percent carbon content

Explanation

Higher carbon raises hardenability, so welds and heat-affected zones can form hard martensite and crack without preheat or controlled cooling. Weldability therefore decreases as carbon increases.

Question 18Welding Fundamentals and Processes (Part A)

For GTAW on carbon steel, direct current electrode negative (DCEN) is preferred because it:

  1. Allows the use of a smaller gas nozzle
  2. Prevents tungsten contamination
  3. Concentrates heat in the workpiece for penetration Correct answer.
  4. Cleans the oxide layer from the surface

Explanation

With DCEN, electrons flow from the tungsten to the work, depositing more heat in the workpiece and giving deeper penetration while limiting tungsten erosion. Oxide cleaning is characteristic of DCEP or AC.

Question 19Welding Fundamentals and Processes (Part A)

How should covered low-hydrogen electrodes such as E7018 be stored before use?

  1. In a freezer to prevent oxidation
  2. In a heated holding oven at elevated temperature Correct answer.
  3. In water to keep the coating pliable
  4. In an open rack at room temperature

Explanation

Low-hydrogen electrodes absorb moisture unless held in heated holding ovens, typically around 250 to 300 F, to keep the coating dry. Room storage allows moisture pickup and hydrogen cracking risk.

Question 20Welding Fundamentals and Processes (Part A)

What is the likely result of setting shielding gas flow too high in GMAW?

  1. Deeper penetration and improved sidewall fusion quality
  2. Reduced spatter and a smoother bead
  3. Lower gas consumption and cost
  4. Turbulence that draws in air and causes porosity Correct answer.

Explanation

Excessive flow creates turbulence that draws ambient air into the shielding envelope, leading to porosity and an unstable arc. Adequate but not excessive flow gives laminar coverage.

Question 21Welding Fundamentals and Processes (Part A)

Sensitization of austenitic stainless steel occurs when:

  1. Molybdenum is added to improve pitting resistance
  2. The steel is quenched rapidly from the annealing temperature
  3. Chromium carbides precipitate at grain boundaries Correct answer.
  4. Ferrite content exceeds 50 percent in the weld

Explanation

In the 800 to 1500 F range, carbon combines with chromium to form grain-boundary carbides, depleting adjacent metal of chromium and reducing corrosion resistance. Rapid cooling through that range or using low-carbon grades prevents it.

Question 22Welding Fundamentals and Processes (Part A)

Which combination is most appropriate for GTAW of aluminum?

  1. DCEN with helium shielding
  2. DCEP with carbon dioxide shielding
  3. DCEN with a thoriated tungsten electrode only
  4. AC with argon shielding and high-frequency start Correct answer.

Explanation

Alternating current alternates cleaning (DCEP) and penetration (DCEN) half-cycles, which suits aluminum's tenacious oxide, and argon is the standard shielding gas. CO2 is not used for GTAW and DCEN alone provides little oxide cleaning.

Question 23Welding Fundamentals and Processes (Part A)

The oxyfuel cutting process removes metal primarily by:

  1. Oxidizing the iron, then blowing away the oxide Correct answer.
  2. Mechanical blowing of molten metal by the oxygen jet
  3. Melting the metal with the preheat flame alone
  4. Vaporizing the metal at the kerf

Explanation

The preheat flame brings steel to ignition temperature, and the cutting oxygen stream oxidizes the iron; the high-velocity jet then removes the molten oxide and metal. Pure melting or vaporization is not the cutting mechanism.

Question 24Welding Fundamentals and Processes (Part A)

A welding procedure specification (WPS) is supported by a procedure qualification record (PQR) that documents:

  1. The visual inspection acceptance criteria
  2. Only the welder's certification test results
  3. The cost of consumables used on the project
  4. The variables used and test coupon results Correct answer.

Explanation

The PQR records the essential variables actually used to weld the qualification test coupon and the results of mechanical testing, and it supports the WPS. Welder performance is qualified separately.

Question 25Welding Fundamentals and Processes (Part A)

Residual stress in a weldment is primarily caused by:

  1. Excessive shielding gas flow during welding
  2. The presence of a backing strip
  3. Use of direct current instead of alternating current
  4. Restraint of contraction as the weld cools Correct answer.

Explanation

As weld metal and the heat-affected zone cool, thermal contraction is resisted by surrounding cooler, rigid material, generating internal stress. Gas flow and current type do not create the primary residual stress pattern.

Question 26Welding Fundamentals and Processes (Part A)

In shielded metal arc welding, the cellulosic coating on an E6010 electrode decomposes to produce a shielding atmosphere composed mainly of:

  1. carbon dioxide and hydrogen Correct answer.
  2. argon and helium
  3. nitrogen and chlorine
  4. pure oxygen

Explanation

Cellulose in the coating decomposes in the arc to form carbon monoxide and hydrogen, which create the shielding atmosphere. These gases also help stabilize the arc.

Question 27Welding Fundamentals and Processes (Part A)

Which shielding gas mixture is most commonly used for short-circuiting transfer GMAW on carbon steel?

  1. 100% argon
  2. 100% helium
  3. 75% argon and 25% carbon dioxide Correct answer.
  4. 50% argon and 50% oxygen

Explanation

A 75% argon/25% CO2 mixture is the common short-circuiting gas for carbon steel because it balances arc stability, spatter control, and penetration.

Question 28Welding Fundamentals and Processes (Part A)

A neutral oxyacetylene flame is used when welding steel because it:

  1. adds carbon to the weld
  2. produces an oxidizing slag
  3. removes carbon from the weld
  4. neither adds nor removes carbon Correct answer.

Explanation

A neutral flame has an approximately one-to-one oxygen-to-acetylene ratio, so it is neither carburizing nor oxidizing. This makes it suitable for welding steel without altering carbon content.

Question 29Welding Fundamentals and Processes (Part A)

In submerged arc welding, the welding arc is:

  1. struck in a vacuum chamber
  2. buried beneath a layer of granular flux Correct answer.
  3. visible above a shielding gas cloud
  4. used only with a nonconsumable electrode

Explanation

The SAW arc is covered by a layer of granular flux that melts to shield the arc and weld pool. The arc is not visible during normal operation.

Question 30Welding Fundamentals and Processes (Part A)

The main function of the flux in a flux-cored arc welding wire is to:

  1. cool the weld puddle rapidly
  2. form shielding gas and slag Correct answer.
  3. conduct current to the workpiece
  4. increase carbon in the weld

Explanation

The flux core decomposes in the arc to generate shielding gas and form a slag layer over the weld. The slag protects the solidifying metal from contamination.

Question 31Welding Fundamentals and Processes (Part A)

For GTAW of carbon steel with direct current electrode negative, the tungsten electrode is normally prepared with a:

  1. spherical balled tip
  2. wide chisel edge
  3. flat square end
  4. sharp pointed tip Correct answer.

Explanation

DCEN concentrates heat at the workpiece and allows a pointed tungsten tip to stabilize the arc. A pointed tip is standard for carbon steel GTAW with DCEN.

Question 32Welding Fundamentals and Processes (Part A)

Under AWS position designations, a groove weld made in the flat position is identified as:

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

Explanation

The AWS position number 1 designates flat, 2 designates horizontal, 3 designates vertical, and 4 designates overhead. Therefore, a flat groove weld is 1G.

Question 33Welding Fundamentals and Processes (Part A)

Which welding process is a solid-state process that joins materials without melting the base metal?

  1. submerged arc welding
  2. shielded metal arc welding
  3. gas metal arc welding
  4. friction stir welding Correct answer.

Explanation

Friction stir welding joins materials by stirring and forging them in a plasticized state below the melting point. The other listed processes are fusion welding processes.

Question 34Welding Fundamentals and Processes (Part A)

In the SMAW electrode classification E7018, the digit 1 indicates that the electrode:

  1. requires direct current electrode positive
  2. has a minimum tensile strength of 70,000 psi
  3. is designed only for flat position
  4. can be used in all welding positions Correct answer.

Explanation

In E7018, E means electrode, 70 is the minimum tensile strength in ksi, 1 means all positions, and 8 indicates a low-hydrogen coating with specific current requirements.

Question 35Welding Fundamentals and Processes (Part A)

In short-circuiting GMAW transfer, metal is transferred to the weld pool when the:

  1. the electrode touches the puddle Correct answer.
  2. arc sprays fine droplets across the gap
  3. shielding gas ionizes into a plasma jet
  4. wire retracts without touching the puddle

Explanation

In short-circuiting transfer, the electrode contacts the weld pool and the arc extinguishes briefly. The wire then pinches off a droplet and the arc restarts.

Question 36Welding Fundamentals and Processes (Part A)

If all other variables are held constant, increasing the travel speed in a welding operation will:

  1. increase heat input per inch
  2. double the deposition efficiency
  3. decrease heat input per inch Correct answer.
  4. have no effect on heat input

Explanation

Heat input per unit length is proportional to voltage times current divided by travel speed. Increasing travel speed spreads the same energy over more distance and lowers heat input per inch.

Question 37Welding Fundamentals and Processes (Part A)

When welding the root pass of austenitic stainless steel pipe, a backing or purge gas is used mainly to:

  1. reduce the need for interpass cleaning
  2. increase the travel speed
  3. add carbon to the weld metal
  4. prevent oxidation of the root Correct answer.

Explanation

Austenitic stainless steel root passes oxidize readily when oxygen is present. An inert purge excludes oxygen and prevents oxidation, often called sugaring, on the inside surface.

Question 38Welding Fundamentals and Processes (Part A)

Porosity in aluminum GMAW or GTAW welds is most commonly caused by:

  1. too little travel speed
  2. copper inclusions from the filler wire
  3. hydrogen dissolved in the weld pool Correct answer.
  4. excess argon in the shielding gas

Explanation

Aluminum readily absorbs hydrogen in the molten weld pool, and the hydrogen forms porosity as the metal solidifies. Cleanliness and proper shielding are critical to reducing hydrogen pickup.

Question 39Welding Fundamentals and Processes (Part A)

Backstep welding is used primarily to:

  1. reduce distortion Correct answer.
  2. eliminate the need for preheat
  3. produce a wider heat-affected zone
  4. increase penetration on thick plate

Explanation

Backstep welding makes short beads in a direction opposite the general progression so that shrinkage is distributed and balanced. This helps reduce distortion in long joints.

Question 40Welding Fundamentals and Processes (Part A)

Undercut in a completed weld is most often associated with:

  1. travel speed that is too slow
  2. excessive current or a long arc Correct answer.
  3. electrode angle of 90 degrees
  4. insufficient shielding gas flow

Explanation

Excessive current or an excessively long arc can gouge the base metal at the weld toes before the molten metal fills the groove. The result is a concave undercut along the weld edge.

Question 41Welding Fundamentals and Processes (Part A)

Hydrogen-induced cracking in high-strength steel welds is promoted by:

  1. low restraint and dry electrodes
  2. excess argon in the shielding gas
  3. high preheat and slow cooling
  4. moisture in the arc environment Correct answer.

Explanation

Hydrogen from moisture, dirt, or other sources can diffuse into the weld metal and cause cracking when the microstructure is hard and restraint is high. Dry electrodes and proper preheat help reduce this risk.

Question 42Welding Fundamentals and Processes (Part A)

The main advantage of pulsed GMAW compared with continuous GMAW is that it:

  1. can weld only in the flat position
  2. eliminates the need for any shielding gas
  3. requires no wire feed system
  4. gives better heat and spatter control Correct answer.

Explanation

Pulsed GMAW alternates between peak and background current to control droplet transfer. This provides better control of heat input and reduces spatter compared with continuous GMAW.

Question 43Welding Fundamentals and Processes (Part A)

In FCAW with constant voltage, increasing the wire feed speed while holding voltage constant generally:

  1. has no effect on current
  2. shortens the arc and raises current Correct answer.
  3. lengthens the arc and lowers current
  4. changes the shielding gas composition

Explanation

Higher wire feed speed increases burnoff and welding current, so the arc self-regulates to a shorter length. The voltage setting remains the primary control of arc length.

Question 44Welding Fundamentals and Processes (Part A)

A welding arc that is too long in SMAW most often produces:

  1. automatic arc blow correction
  2. a smoother bead with less spatter
  3. more spatter and less penetration Correct answer.
  4. deeper penetration and narrower bead

Explanation

A long arc spreads heat over a wider area and reduces penetration while increasing spatter and arc instability. Maintaining a short arc improves penetration and control.

Question 45Welding Fundamentals and Processes (Part A)

An oxyacetylene flame with a distinct feathery inner cone and excess acetylene is called a:

  1. cutting flame
  2. oxidizing flame
  3. carburizing flame Correct answer.
  4. neutral flame

Explanation

A carburizing flame has excess acetylene and shows a feathery secondary cone around the inner cone. It can add carbon to steel and is used for specific applications such as certain hardfacing alloys.

Question 46Welding Fundamentals and Processes (Part A)

In austenitic stainless steel, sigma phase is most likely to form after prolonged exposure to what temperature range?

  1. 1000°C to 1200°C (1830°F to 2190°F)
  2. Below 0°C (32°F)
  3. 150°C to 300°C (300°F to 570°F)
  4. 600°C to 900°C (1100°F to 1650°F) Correct answer.

Explanation

Sigma phase is a brittle intermetallic that forms in austenitic stainless steels during prolonged exposure to roughly 600°C to 900°C. It reduces toughness and corrosion resistance.

Question 47Welding Fundamentals and Processes (Part A)

Arc blow during DC welding is most commonly caused by:

  1. excessive travel speed
  2. insufficient shielding gas
  3. wrong electrode coating color
  4. magnetic forces around the arc Correct answer.

Explanation

Arc blow results from magnetic forces that deflect the arc, especially in DC welding of ferromagnetic materials or when the ground connection is poorly placed. Adjusting ground location and using short arcs can reduce it.

Question 48Welding Fundamentals and Processes (Part A)

In FCAW, increasing the electrode extension while keeping other variables constant will generally:

  1. have no effect on the weld
  2. increase current and penetration
  3. lower current and penetration Correct answer.
  4. change the flux composition

Explanation

A longer electrode extension increases resistance heating in the wire, which raises burnoff and lowers welding current. Lower current generally reduces penetration.

Question 49Welding Fundamentals and Processes (Part A)

In submerged arc welding, which polarity generally produces the deepest penetration?

  1. Alternating current
  2. Direct current electrode negative
  3. Direct current electrode positive Correct answer.
  4. Direct current with a pulsed arc

Explanation

DCEP concentrates more heat at the workpiece, which generally produces deeper penetration in SAW. DCEN concentrates heat at the electrode and gives higher deposition with less penetration.

Question 50Welding Fundamentals and Processes (Part A)

Lamellar tearing is most likely to occur in:

  1. thin sheet welded with low heat input
  2. rolled plate with through-thickness strain Correct answer.
  3. austenitic stainless steel with low restraint
  4. wrought aluminum with a clean surface

Explanation

Lamellar tearing occurs when nonmetallic inclusions in rolled plate align in planes parallel to the surface and the weld applies through-thickness strain. The inclusions separate and tear under that stress.