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CWS Welding practice questions

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Question 1Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

What is the minimum head and eye protection required when performing shielded metal arc welding?

  1. Safety glasses with side shields alone
  2. Safety glasses with side shields worn under a clear face shield
  3. A hard hat with a mounted clear visor
  4. A welding helmet with the correct filter shade Correct answer.

Explanation

SMAW produces intense visible light, ultraviolet radiation, and sparks, so a welding helmet with an appropriately rated filter shade is required. Safety glasses alone or a clear face shield do not protect against arc radiation.

Question 2Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

Which class of portable fire extinguisher is designed for use on energized electrical equipment?

  1. Class D
  2. Class B
  3. Class A
  4. Class C Correct answer.

Explanation

Class C extinguishers use nonconductive agents and are intended for fires involving energized electrical equipment. Once power is removed, the fire is usually treated as a Class A or B fire.

Question 3Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

What is the primary purpose of a hot work permit?

  1. To document that the welder has reviewed the shop's written respiratory protection plan
  2. To document the welder's certification level
  3. To authorize overtime pay for welding work
  4. To confirm fire hazards are assessed and controlled before work Correct answer.

Explanation

A hot work permit is a formal check that combustible materials, fire suppression, and fire watch arrangements have been addressed before any spark- or flame-producing work starts. It is a fire-prevention control, not a record of welder qualifications or payroll.

Question 4Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

In a confined space, welding fume and oxygen levels must be controlled by...

  1. Mechanical ventilation and atmospheric monitoring Correct answer.
  2. Relying on the natural draft through the confined space entry opening
  3. Wearing a dust mask
  4. Welding in short bursts

Explanation

Confined spaces can accumulate toxic fumes and displace oxygen, so mechanical ventilation and continuous atmospheric testing are required before and during welding. Natural draft is not reliable and dust masks do not supply oxygen.

Question 5Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

Porosity in a weld is most commonly caused by...

  1. An excessively sharp tungsten electrode that has been contaminated
  2. Too little welding current alone
  3. Gas trapped as the weld pool solidifies Correct answer.
  4. Excessive travel speed alone

Explanation

Porosity forms when gas dissolved in or entrained by the molten weld pool cannot escape before solidification. Common sources include moisture, oil, paint, and inadequate shielding.

Question 6Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

Which practice best prevents slag inclusion between weld passes?

  1. Thorough cleaning of each pass before the next is deposited Correct answer.
  2. Increasing travel speed so the slag is pushed to the weld toes
  3. Using a larger electrode
  4. Welding over the slag to trap it

Explanation

Slag inclusion occurs when slag from a previous pass is not removed before the next pass is deposited. Chipping, brushing, and inspecting each pass are the standard preventive measures.

Question 7Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

Which inspection method should be performed on every weld before any other testing?

  1. Radiographic testing
  2. Ultrasonic testing
  3. Destructive bend testing
  4. Visual inspection Correct answer.

Explanation

Visual inspection is the first and most basic examination; it checks bead profile, size, cleanliness, and obvious surface defects. Other methods are applied after visual acceptance or when the specification requires them.

Question 8Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

Where should the welding ground clamp be attached?

  1. To the welding machine casing
  2. To a nearby pipe of any material
  3. To the building's structural steel, wherever convenient
  4. To the workpiece or a metallic table directly supporting it Correct answer.

Explanation

The work lead should be connected as close as possible to the weld area on the workpiece or its supporting table so the welding current has a direct, low-resistance path. Attaching to building steel or piping can cause stray current, arcing, and damage.

Question 9Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

As welding current increases, the filter lens shade number should generally...

  1. Decrease, because the arc becomes more stable at higher currents
  2. Be replaced by clear safety glasses
  3. Remain the same regardless of current
  4. Increase, because arc brightness and ultraviolet output rise Correct answer.

Explanation

Higher current produces a brighter arc with more intense visible and ultraviolet radiation, so a darker filter shade is needed to protect the eyes. The specific shade is selected from the applicable safety table based on process and current.

Question 10Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

Atmospheric testing before entry into a confined space should confirm that oxygen is within which range?

  1. 19.5% to 23.5% Correct answer.
  2. 10% to 15%
  3. 24% to 28%
  4. 16% to 19%

Explanation

Confined-space entry requires oxygen between 19.5 and 23.5 percent by volume; below that is oxygen deficient and above that is oxygen enriched. Both conditions increase the risk of injury or fire.

Question 11Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

Which control is the preferred first line of defense against welding fume exposure?

  1. Posting warning signs at the shop entrance
  2. Respirators worn by every welder throughout the entire shift
  3. Rotating welders every two hours
  4. Local exhaust ventilation at the arc Correct answer.

Explanation

Engineering controls such as local exhaust ventilation capture fume at the source before it reaches the welder's breathing zone. Respirators are a secondary safeguard used when engineering controls cannot reduce exposure sufficiently.

Question 12Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

A fire watch assigned to hot work must be able to...

  1. Approve the welding procedure specification
  2. Recognize fire hazards and use extinguishing equipment Correct answer.
  3. Operate the welding machine controls
  4. Perform the welder's qualification test and certify the results

Explanation

The fire watch's job is to monitor for ignition during and after hot work and to sound an alarm or extinguish a fire. The fire watch must know how to use the available extinguishing equipment.

Question 13Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

Liquid penetrant testing is used to detect...

  1. Variations in weld metal hardness
  2. Surface-breaking defects in nonporous materials Correct answer.
  3. Internal voids located deep within a thick-section groove weld
  4. Residual stress patterns in a finished weld

Explanation

Penetrant testing relies on capillary action to draw a visible dye or fluorescent liquid out of surface-breaking discontinuities. It cannot detect defects that are entirely below the surface.

Question 14Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

Ultrasonic testing is most useful for detecting...

  1. Weld spatter on the base metal
  2. Paint thickness on the finished part
  3. Planar defects such as lack of fusion inside the weld Correct answer.
  4. Surface porosity and nothing below the surface of the weld

Explanation

Ultrasonic testing sends high-frequency sound waves through the material and detects echoes from internal reflectors such as lack of fusion, cracks, and laminations. It is particularly effective for planar defects.

Question 15Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

A guided bend test is performed primarily to evaluate a weld's...

  1. Ductility and soundness Correct answer.
  2. Corrosion resistance in aggressive service environments
  3. Yield strength
  4. Magnetic permeability

Explanation

A bend test strains the weld and heat-affected zone to reveal cracking, lack of fusion, and other defects while indicating ductility. It is a qualitative soundness test rather than a strength measurement.

Question 16Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

A fillet weld gauge is used to measure...

  1. Leg size and throat of a completed fillet weld Correct answer.
  2. Travel speed during welding
  3. Root opening, land width, and fit-up gap before welding
  4. Shielding gas flow rate

Explanation

Fillet weld gauges are shaped to compare the actual leg length or throat dimension against the specified size. They are used after welding to verify that the fillet meets the drawing or WPS requirement.

Question 17Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

Which combination of conditions most often produces undercut?

  1. Too little current combined with an unusually slow travel speed
  2. A short arc and a slight work angle
  3. Excessive current and too fast a travel speed Correct answer.
  4. Clean base metal and dry electrodes

Explanation

Undercut is a groove melted into the base metal along the weld toe that is left unfilled. Excessive current and high travel speed melt the edges faster than the weld metal can fill them.

Question 18Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

Lack of fusion is most often caused by...

  1. A weaving technique that pauses briefly at both sidewalls of the joint
  2. Insufficient heat input or improper joint preparation Correct answer.
  3. Preheating the base metal before welding
  4. Using a short arc length with a stable current

Explanation

Lack of fusion occurs when the weld metal does not bond to the base metal or to a previous pass. Low heat input, fast travel, or poor joint preparation can leave unmelted surfaces.

Question 19Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

Preheating a thick carbon steel joint before welding primarily helps to...

  1. Slow the cooling rate and reduce cracking risk Correct answer.
  2. Eliminate the need for joint preparation
  3. Increase the travel speed well beyond the range qualified in the WPS
  4. Increase the weld's carbon content

Explanation

Preheat raises the base metal temperature so the weld cools more slowly, which lowers hardness and reduces the risk of hydrogen-assisted cracking. It does not replace joint preparation or permit welding outside qualified parameters.

Question 20Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

Low-hydrogen electrodes such as E7018 must be stored...

  1. Wet before use to improve electrical conductivity
  2. In a heated or sealed container per the manufacturer's instructions Correct answer.
  3. In an open bin next to the welding station so they are easy to reach
  4. In contact with the workpiece so they stay grounded

Explanation

E7018 coatings are sensitive to moisture, which can introduce hydrogen into the weld and cause cracking. Manufacturer recommendations for holding ovens or sealed containers must be followed.

Question 21Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

A carbon steel has a carbon equivalent of 0.48%. What does this indicate for welding?

  1. The weld will automatically meet radiographic acceptance criteria
  2. The steel cannot be welded by any arc process
  3. Preheat and controlled heat input are likely required to avoid hydrogen cracking Correct answer.
  4. No preheat is needed because a high carbon equivalent lowers hardenability

Explanation

A carbon equivalent above roughly 0.40 percent indicates increased hardenability and a greater risk of hydrogen-assisted cracking in the heat-affected zone. Preheat, controlled heat input, and low-hydrogen consumables are typical precautions.

Question 22Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

When welding austenitic stainless steel, interpass temperature is usually limited to...

  1. Increase the magnetic permeability of the weld
  2. Prevent ferrite formation in the weld metal
  3. Avoid sensitization and hot cracking Correct answer.
  4. Reduce slag production between passes

Explanation

Excessive interpass temperature in austenitic stainless steel can promote sensitization, distortion, and solidification cracking. Procedures therefore cap interpass temperature, commonly around 150°C (300°F).

Question 23Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

Magnetic particle testing is preferred over dye penetrant testing when...

  1. The part is nonmagnetic and only surface defects matter
  2. The part is ferromagnetic and near-surface defects must be found Correct answer.
  3. The weld will be painted immediately after inspection
  4. The defect is a deep internal void in an austenitic stainless steel weld

Explanation

Magnetic particle testing requires a ferromagnetic material and can reveal surface and slightly subsurface discontinuities. It is chosen over penetrant when the material is magnetic and near-surface defects are of concern.

Question 24Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

A qualified WPS calls for E7018 electrodes. If production switches to E6010 without qualification, the...

  1. Change only requires a new visual inspection
  2. WPS remains valid because both electrodes are classified in the same AWS filler metal group
  3. Welder's certification automatically covers the change
  4. WPS must be requalified because the electrode classification is an essential variable Correct answer.

Explanation

Electrode classification is an essential variable in most welding procedure specifications, so changing from E7018 to E6010 requires requalification. Welder qualification does not substitute for procedure qualification.

Question 25Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

Which condition would most reduce the ability of radiography to detect a small crack in a thick weld?

  1. Using a finer-grained film
  2. Increasing the exposure time appropriately for the section thickness
  3. Removing excess weld reinforcement
  4. Poor alignment of the radiation beam with the crack plane Correct answer.

Explanation

Radiography detects a crack best when the radiation beam is aligned with the crack's plane so the beam sees a change in thickness. Misalignment can make a tight planar crack nearly invisible.

Question 26Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

What minimum eye protection is required for a worker chipping slag from a completed weld?

  1. No eye protection if the weld has cooled
  2. Safety glasses with side shields Correct answer.
  3. Tinted sunglasses
  4. A welding helmet with a shade 10 lens

Explanation

Chipping produces flying slag and scale that can injure the eyes. Safety glasses with side shields provide the required impact protection for this task.

Question 27Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

Who should authorize hot work in an area where flammable liquids or vapors may be present?

  1. An authorized person after inspecting the area Correct answer.
  2. The welder after a quick visual check
  3. The fire watch, who signs the permit after checking
  4. The fire watch before the arc is struck

Explanation

A hot work permit must be issued by a designated responsible person who inspects the area and confirms that fire precautions are in place. The welder or fire watch cannot self-authorize the work.

Question 28Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

Which class of fire extinguisher is intended for fires involving energized electrical equipment?

  1. Class D
  2. Class C Correct answer.
  3. Class B
  4. Class A

Explanation

Class C extinguishers are rated for fires in energized electrical equipment because their extinguishing agents are nonconductive. Class A is for ordinary combustibles, Class B for flammable liquids, and Class D for combustible metals.

Question 29Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

How should oxygen cylinders be stored in relation to fuel-gas cylinders?

  1. 20 ft apart or separated by a 5 ft noncombustible barrier Correct answer.
  2. Chained together in the same rack without caps
  3. At least 10 ft apart with no barrier between them
  4. Lying horizontally side by side on the floor

Explanation

Oxygen and fuel-gas cylinders must be separated to prevent a fire from involving both types of gas. The accepted separation is at least 20 ft or a noncombustible barrier at least 5 ft high.

Question 30Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

A welding cable has exposed conductor strands near the electrode holder. What is the correct action?

  1. Wrap it with electrical tape and continue
  2. Cut off the holder and reuse the cable
  3. Keep welding if it is not hot to the touch
  4. Take it out of service and repair it Correct answer.

Explanation

Exposed conductors create shock and arc-flash hazards and can cause burns or fires. Damaged welding cable must be removed from service and properly repaired or replaced.

Question 31Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

What is the primary purpose of placing welding screens around an arc welding station?

  1. To reduce welding fume in the work area
  2. To block arc radiation and sparks from others Correct answer.
  3. To keep the weldment from cooling too quickly
  4. To prevent the electrode from absorbing moisture

Explanation

Welding screens protect nearby workers from ultraviolet and visible arc radiation and from flying sparks. Fume control is a separate ventilation issue.

Question 32Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

In the electrode classification E7018, what does the '70' represent?

  1. The electrode diameter in thousandths of an inch
  2. The maximum welding current in amperes
  3. The minimum tensile strength in 1,000 psi Correct answer.
  4. The minimum elongation in percent

Explanation

In the E70xx classification, 70 indicates a minimum tensile strength of 70,000 psi for the deposited weld metal. The '18' refers to the coating and current type.

Question 33Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

When local exhaust ventilation cannot keep welding fume below allowable exposure limits, what should be provided?

  1. A fan blowing across the welder's face
  2. Respiratory protection matched to the fume Correct answer.
  3. A larger welding helmet with a bigger lens
  4. Longer breaks between weld passes

Explanation

Engineering controls are preferred, but when they cannot reduce fume exposure below the allowable limit, appropriate respiratory protection must be used. A fan can spread fume rather than remove it.

Question 34Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

Which document records the test results that support a welding procedure specification?

  1. Material test report (MTR)
  2. Welder performance qualification (WPQ)
  3. Hot work permit
  4. Procedure qualification record (PQR) Correct answer.

Explanation

The PQR documents the variables and test results from qualifying a welding procedure. The WPS is then written from the qualified PQR.

Question 35Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

Under common welding codes, a welder's performance qualification lapses if the welder does not use the qualified process for how long?

  1. 30 days
  2. 5 years
  3. 6 months Correct answer.
  4. 2 years

Explanation

Many common welding codes invalidate a welder's qualification after six months without welding with the qualified process. Continued use of the process maintains the qualification.

Question 36Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

How should preheat temperature be verified before welding a code joint?

  1. A calibrated contact thermometer at the joint Correct answer.
  2. By checking ambient shop temperature with a wall gauge
  3. By estimating from the welding current used
  4. By touching the joint with a gloved hand

Explanation

Preheat must be measured at the joint with a calibrated contact thermometer or temperature-indicating device. Hand feel and shop temperature do not confirm the metal temperature.

Question 37Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

What is the primary purpose of postweld heat treatment for a thick carbon steel pressure vessel?

  1. Remove slag from the weld surface
  2. Relieve residual welding stresses Correct answer.
  3. Increase the weld metal tensile strength
  4. Prevent porosity in subsequent passes

Explanation

Postweld heat treatment raises the weldment to a controlled temperature to relax residual stresses and reduce cracking risk. It is not a surface-cleaning or porosity-prevention operation.

Question 38Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

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

  1. Using a larger electrode at higher current
  2. Backstep or balanced welding Correct answer.
  3. Welding continuously from one end to the other
  4. Increasing the arc length

Explanation

Backstep and balanced welding distribute heat input and shrinkage more evenly along the joint. This reduces the cumulative distortion that occurs when a long weld is run continuously from one end.

Question 39Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

An E7018 electrode is left overnight in an open shop and then used. Which defect is most likely?

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

Explanation

E7018 is a low-hydrogen electrode that absorbs moisture if exposed to humid air. The moisture introduces hydrogen and gas into the arc, producing porosity.

Question 40Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

What is the purpose of a couplant in ultrasonic testing?

  1. To clean the weld surface and remove all mill scale
  2. To carry sound between the transducer and the part Correct answer.
  3. To magnetize the test piece for inspection
  4. To increase the frequency of the transducer

Explanation

A couplant removes the air gap between the transducer and the test surface so ultrasonic energy can pass into the part. Air would otherwise reflect most of the sound.

Question 41Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

Magnetic particle testing is applicable only to which type of material?

  1. Copper-nickel alloys
  2. Austenitic stainless steel
  3. Ferromagnetic materials Correct answer.
  4. Aluminum alloys

Explanation

Magnetic particle testing relies on magnetizing the part and observing flux leakage at discontinuities. This requires a ferromagnetic material such as carbon steel.

Question 42Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

Why is a dwell time specified after applying liquid penetrant to a weld?

  1. To cool the weld to room temperature
  2. To let penetrant enter surface discontinuities Correct answer.
  3. To let the penetrant dry into a uniform surface film
  4. To magnetize the surface for inspection

Explanation

Dwell time allows capillary action to draw penetrant into surface-breaking flaws. Excess penetrant is then removed and developer is applied to reveal the indications.

Question 43Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

What is the main purpose of hydrostatic testing a completed pressure vessel?

  1. To determine the carbon equivalent of the steel
  2. To measure the weld metal hardness
  3. To qualify the welding procedure
  4. To verify pressure tightness and strength Correct answer.

Explanation

A hydrostatic test pressurizes the vessel with water to demonstrate pressure tightness and structural integrity. Procedure qualification and material testing are separate activities.

Question 44Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

Why must welding inspection gauges and meters be calibrated periodically?

  1. To increase their measuring range for large welds
  2. To keep measurements accurate and traceable Correct answer.
  3. To make them easier to read in the shop
  4. To satisfy the welder's personal preference

Explanation

Calibration confirms that an instrument's readings agree with a known standard so inspection decisions are based on accurate measurements. Uncalibrated tools can lead to accepting or rejecting incorrect work.

Question 45Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

What does a macro etch examination of a weld cross section primarily reveal?

  1. The diffusible hydrogen content
  2. The exact chemical composition of the weld
  3. The tensile strength of the joint
  4. Weld profile, fusion, and penetration Correct answer.

Explanation

Macro etching exposes the cross-sectional geometry of the weld, including penetration, fusion boundaries, and profile. Chemical composition, tensile strength, and hydrogen content require separate tests.

Question 46Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

A weld is made at 200 A and 25 V with a travel speed of 5 in/min. What is the heat input?

  1. 25 kJ/in.
  2. 120 kJ/in.
  3. 60 kJ/in. Correct answer.
  4. 10 kJ/in.

Explanation

Heat input is calculated as voltage times current times 60, divided by travel speed in inches per minute and by 1000. For these values, (25 × 200 × 60) ÷ (5 × 1000) equals 60 kJ/in.

Question 47Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

A WPS is qualified on 1/4 in. carbon steel plate, but production requires 1-1/2 in. plate. What is the correct action?

  1. Increase the current by 50% and proceed
  2. Requalify the procedure for the thicker plate Correct answer.
  3. Have the welder take a new eye examination
  4. Use the WPS as written because thickness is not essential

Explanation

Base metal thickness is an essential variable, and a procedure qualified on thin plate has a limited qualified thickness range. Welding 1-1/2 in. plate requires requalification or a WPS already qualified for that thickness.

Question 48Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

Which combination most promotes hydrogen-assisted cracking in a steel weld?

  1. Low carbon equivalent, low sulfur, high travel speed
  2. High restraint, hard microstructure, hydrogen Correct answer.
  3. High preheat, slow cooling, clean joint
  4. Low restraint, low hardness, dry electrodes

Explanation

Hydrogen-assisted cracking requires hydrogen in the weld, a susceptible hard microstructure, and tensile stress such as restraint. Removing any one of these factors reduces the risk.

Question 49Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

Which condition most reduces the sharpness of a radiographic image of a thick weld?

  1. A small source with a long source-to-film distance
  2. A large source or short source-to-film distance Correct answer.
  3. A short exposure time with low kilovoltage
  4. A fine-grain film with lead intensifying screens

Explanation

Geometric unsharpness increases when the radiation source is large or when the source is close to the film. A smaller source and a longer source-to-film distance improve image sharpness.

Question 50Welding Safety & Quality (OSHA compliance and workplace safety; defect prevention and quality control; inspection and testing procedures)

What is the primary metallurgical concern when an austenitic stainless steel weld is held in the 800°F to 1500°F range?

  1. Sensitization from chromium carbide precipitation Correct answer.
  2. Graphitization of the weld metal
  3. Formation of untempered martensite
  4. Temper embrittlement of the heat-affected zone

Explanation

Holding austenitic stainless steel in this temperature range can precipitate chromium carbides at grain boundaries, depleting chromium and reducing corrosion resistance. This condition is called sensitization.