Q: For Cyclically Loaded structures under AWS D1.1, the acceptance criteria for porosity are:

Cyclic loading (fatigue) requires stricter acceptance criteria because defects act as stress risers that initiate fatigue cracks.

Q: Under AWS D1.1, are cracks acceptable?

AWS D1.1 Table 6.1 states clearly: 'The weld shall have no cracks.'

Q: According to AWS D1.1, weld reinforcement for a CJP groove weld in a butt joint shall not exceed:

Weld reinforcement shall not exceed 1/8 inch (3 mm) in height.

Q: For visual inspection under AWS D1.1, 'complete fusion' is required:

Thorough fusion must exist between all layers of weld metal and between the weld metal and base metal.

Q: Under AWS D1.1, the maximum allowable overlap is:

Overlap is prohibited. The criteria typically state 'Prohibited' or implied by fusion requirements.

Q: For a fillet weld to be acceptable under AWS D1.1, the location of the weld relative to the joint must be:

Visual inspection criteria require the weld location and size to be 'As specified on the detail drawing'.

Q: According to AWS D1.1, arc strikes found on the base metal:

Arc strikes must be ground smooth and checked for cracks (visually or MT/PT) to ensure no damage remains.

Q: In AWS D1.1 Static loading, porosity with a diameter of 1/32 inch is acceptable if:

For static loading, piping porosity 1/32 inch or larger is restricted by frequency: sum of diameters < 3/8 inch in any linear inch.

Q: A CJP groove weld in a butt joint is inspected visually. The weld face is flush with the base metal (zero reinforcement). This is:

Reinforcement is *permitted* up to 1/8 inch, but a flush surface is perfectly acceptable (and often preferred for fatigue) provided there is no underfill.

Question 1

According to AWS D1.1 Table 6.1 (Statically Loaded), what is the maximum allowable undercut for material thickness less than 1 inch?

Accepted Answer

For statically loaded structures, undercut shall not exceed 1/32 inch (1 mm). (Exception: 1/16 inch is allowed for accumulation of length < 2 inches in any 12 inches).

Question 2

For Cyclically Loaded structures under AWS D1.1, the acceptance criteria for porosity are:

Accepted Answer

Cyclic loading (fatigue) requires stricter acceptance criteria because defects act as stress risers that initiate fatigue cracks.

Question 3

Under AWS D1.1, are cracks acceptable?

Accepted Answer

AWS D1.1 Table 6.1 states clearly: 'The weld shall have no cracks.'

Question 4

According to AWS D1.1, weld reinforcement for a CJP groove weld in a butt joint shall not exceed:

Accepted Answer

Weld reinforcement shall not exceed 1/8 inch (3 mm) in height.

Question 5

For visual inspection under AWS D1.1, 'complete fusion' is required:

Accepted Answer

Thorough fusion must exist between all layers of weld metal and between the weld metal and base metal.

Question 6

Under AWS D1.1, the maximum allowable overlap is:

Accepted Answer

Overlap is prohibited. The criteria typically state 'Prohibited' or implied by fusion requirements.

Question 7

For a fillet weld to be acceptable under AWS D1.1, the location of the weld relative to the joint must be:

Accepted Answer

Visual inspection criteria require the weld location and size to be 'As specified on the detail drawing'.

Question 8

According to AWS D1.1, arc strikes found on the base metal:

Accepted Answer

Arc strikes must be ground smooth and checked for cracks (visually or MT/PT) to ensure no damage remains.

Question 9

In AWS D1.1 Static loading, porosity with a diameter of 1/32 inch is acceptable if:

Accepted Answer

For static loading, piping porosity 1/32 inch or larger is restricted by frequency: sum of diameters < 3/8 inch in any linear inch.

Question 10

A CJP groove weld in a butt joint is inspected visually. The weld face is flush with the base metal (zero reinforcement). This is:

Accepted Answer

Reinforcement is *permitted* up to 1/8 inch, but a flush surface is perfectly acceptable (and often preferred for fatigue) provided there is no underfill.

Question 11

Under API 1104 (Pipeline), are 'burn-throughs' acceptable?

Accepted Answer

API 1104 allows burn-through (BT) if the maximum dimension does not exceed 1/4 inch (and other density limits). This differs from D1.1 structural.

Question 12

Which code would typically be used for pressure vessel inspection?

Accepted Answer

ASME Boiler and Pressure Vessel Code (BPVC) Section VIII covers pressure vessels. D1.1 is structural steel; API 1104 is pipelines.

Question 13

When inspecting under AWS D1.1, undersized fillet welds are:

Accepted Answer

D1.1 Table 6.1 Note: Fillet welds may be undersized by 1/16 inch for 10% of the length, provided the undersize does not occur at the ends.

Question 14

Under ASME Section IX, what is the acceptance criterion for a guided bend test?

Accepted Answer

ASME Section IX (and AWS D1.1) generally allow open discontinuities on the convex surface up to 1/8 inch.

Question 15

For AWS D1.1 Cyclic Loading, what is the maximum allowable undercut?

Accepted Answer

Cyclic criteria are very strict. For stress transverse to the weld in thin material, undercut is limited to 0.01 inch.

Question 16

According to AWS D1.1, if a backing bar is removed, the root surface must be:

Accepted Answer

When backing is removed, the root surface must be ground smooth/flush to remove the lack of fusion plane that existed between the backing and the root.

Question 17

A 'rounded indication' in RT (AWS D1.1) is defined as one where:

Accepted Answer

Rounded indications have a length less than 3 times their width. Elongated indications have length > 3x width.

Question 18

Under AWS D1.1, measuring fillet weld size for acceptance:

Accepted Answer

The effective size must be verified. For convex, leg size determines throat. For concave, actual throat must be measured to ensure it meets the design throat.

Question 19

Under API 1104, 'Inadequate Penetration' (IP) is considered a defect if:

Accepted Answer

API 1104 allows IP (without high-low) if the aggregate length doesn't exceed 1 inch in 12 inches (varies by section, but 1 inch individual is a common threshold).

Question 20

In AWS D1.1 Visual Inspection, craters are acceptable if:

Accepted Answer

Craters must be filled to the full cross-section (no underfill) AND be free of cracks.

Question 21

For AWS D1.5 (Bridge Code), are craters allowed?

Accepted Answer

Bridge codes (D1.5) are strict. Craters must be filled to the full cross section.

Question 22

When inspecting groove welds in butt joints (AWS D1.1), misalignment of parts shall not exceed:

Accepted Answer

Offset (misalignment) is limited to 10% of thickness, but not more than 1/8 inch.

Question 23

Which code allows the use of 'slugs' (adding loose metal) in a weld?

Accepted Answer

The use of slugs (adding rods or metal chunks to fill a gap) is prohibited by all major welding codes as it results in lack of fusion.

Question 24

According to AWS D1.1, excessive convexity is rejectable because:

Accepted Answer

While it wastes metal, the code rejection basis is the stress concentration created by the sharp re-entrant angle at the toe.

Question 25

For a procedure qualification (PQR) tensile test under AWS D1.1, the tensile strength must be:

Accepted Answer

The specimen must withstand a load at least equal to the minimum specified tensile strength of the base metal being tested.

Question 26

In AWS D1.1, cleaning of the completed weld involves removal of:

Accepted Answer

D1.1 requires the removal of slag. Spatter removal is also generally required for inspection and coating, though 'loose' spatter is the specific requirement.

Question 27

Is 'whiskers' (wire feed through) acceptable in a finished weld under AWS D1.1?

Accepted Answer

Whiskers are considered a discontinuity and generally must be removed/cut off to prevent potential lack of fusion paths or injury.

Question 28

Under AWS D1.1, which NDT method is generally required for detecting cracks in CJP groove welds subject to cyclic loading?

Accepted Answer

Cyclically loaded CJP welds typically require internal volumetric inspection (RT or UT) to ensure no internal fatigue initiation sites exist.

Question 29

Acceptance criteria for Visual Inspection (VT) are found in which section of AWS D1.1?

Accepted Answer

Section 6 (Inspection) contains Table 6.1, which lists the Visual Inspection Acceptance Criteria.

Question 30

If a weld fails visual inspection:

Accepted Answer

Visual inspection is the first line of defense. Defects found visually must be corrected before expensive NDT methods are applied.

Acceptance Criteria Practice Questions

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