Question 1

According to AWS D1.1, a prequalified WPS may be used for which of the following materials?

Accepted Answer

Prequalified status is limited to specific base metals listed in AWS D1.1 Table 3.1. Materials not listed must be qualified by testing.

Question 2

For a prequalified SMAW joint, the maximum thickness of a root pass in a groove weld is:

Accepted Answer

AWS D1.1 Table 3.7 limits the thickness of the root pass for SMAW to 1/4 inch (6 mm) for prequalified procedures.

Question 3

When welding Quenched and Tempered (Q&T) steels like ASTM A514, the maximum heat input is limited to maintain:

Accepted Answer

Excessive heat input acts as an annealing cycle, softening the HAZ and reducing the tensile strength below the minimum specified for Q&T steels.

Question 4

According to AWS D1.1, the maximum convexity allowed for a 5/16 inch fillet weld is:

Accepted Answer

For fillet welds with a width of face > 5/16 inch, convexity cannot exceed 1/8 inch. (For <= 5/16, it is 1/16 inch). Wait, check table 5.8 or 6.1. For width <= 5/16, convexity max is 1/16. For width > 5/16, max is 1/8. A 5/16 leg weld usually has a face width > 5/16? No, 5/16 leg face is 0.44. So > 5/16. Max convexity is 1/8 inch.

Question 5

Peening is permitted on intermediate weld layers to control distortion, but it is prohibited on:

Accepted Answer

AWS D1.1 prohibits peening on the root pass (risk of cracking/concealing defects) and the final layer (work hardening hampers inspection/performance).

Question 6

For manual shielded metal arc welding (SMAW), the maximum size of a single-pass fillet weld allowed in the flat position is:

Accepted Answer

AWS D1.1 Table 3.7 limits single-pass fillet welds in the flat position to 3/8 inch. (1/2 inch allowed for SAW).

Question 7

When wind speeds exceed ___ mph, shielding gas processes (GMAW/FCAW-G) shall not be done unless shelter is provided.

Accepted Answer

AWS D1.1 Section 5.12.1 requires protection from wind velocities greater than 5 mph (8 kph) to prevent loss of shielding gas coverage.

Question 8

If a low-hydrogen electrode (E7018) is exposed to the atmosphere for less than the maximum allowed time, it may be returned to the holding oven. If exposed for longer, it must be:

Accepted Answer

Electrodes exposed beyond the limit must be baked at high temperature (e.g., 500°F-800°F) to drive off absorbed moisture. Drying at holding temp (250°F) is insufficient.

Question 9

The minimum preheat temperature for welding 1-inch thick ASTM A36 steel with low hydrogen electrodes is typically:

Accepted Answer

According to AWS D1.1 Table 3.3 (Prequalified Minimum Preheat), Category B steels (like A36) up to 3/4" thickness require 32°F; over 3/4" thru 1-1/2" require 50°F.

Question 10

Weld tabs (run-off plates) used in D1.1 construction must be:

Accepted Answer

For statically loaded structures, tabs *may* remain. However, for cyclically loaded structures (and often general practice), D1.1 requires tabs to be removed and the ends finished smooth.

Question 11

Under AWS D1.1, the tolerance for the root opening of a groove weld 'as fit-up' (before welding) allows an increase of:

Accepted Answer

AWS D1.1 Section 5.22 allows a fit-up tolerance of +1/4 inch for root opening (for certain joints). If greater, correction is needed.

Question 12

A welder certified on plate is also qualified to weld pipe:

Accepted Answer

Under AWS D1.1, a plate qualification generally qualifies for pipe with an outside diameter greater than 24 inches (considered flat enough to approximate plate).

Question 13

Backing for groove welds in AWS D1.1 shall be continuous for the full length of the weld and:

Accepted Answer

Backing must be fused to ensure a sound root. Lack of fusion at the backing interface is a defect.

Question 14

Repairs to the base metal (e.g., filling gouges) must be approved by:

Accepted Answer

AWS D1.1 typically grants the 'Engineer' (representing the owner) the final authority on base metal repairs, though the CWI verifies the repair.

Question 15

For a fillet weld to be considered 'continuous', what is the minimum length required by AWS D1.1?

Accepted Answer

The minimum effective length of a fillet weld is 4 times the nominal size. If shorter, the size must be considered 1/4 the effective length (but absolute min length is often cited as 1.5 inches for structural stability).

Question 16

In AWS D1.1, Camber tolerance for a built-up girder (span > 100 ft) is:

Accepted Answer

Dimensional tolerances allow for some positive camber (upward curve) but typically 0 negative camber. For long spans, tolerances increase.

Question 17

Which inspection method is required for the ends of CJP groove welds in tension members (Cyclic Loading)?

Accepted Answer

Cyclically loaded tension members require internal volumetric inspection (RT or UT) to ensure no critical flaws exist at the ends/terminations.

Question 18

Stud welding (shear connectors) must be visually inspected for:

Accepted Answer

Studs are inspected for a full 360-degree flash (fillet) around the base and proper length after welding.

Question 19

If a stud does not show a full 360-degree flash, the D1.1 repair procedure is:

Accepted Answer

The code allows repairing a stud with missing flash by adding a fillet weld (min size specified) to the area lacking flash.

Question 20

The minimum fillet weld size for a T-joint is determined by:

Accepted Answer

Minimum fillet weld size (Table 5.8) is based on the *thicker* part joined to ensure sufficient heat input to prevent cracking (heatsink effect).

Question 21

The 'T-bend' test is associated with:

Accepted Answer

Fillet weld soundness tests often use a T-joint break or bend test to verify root fusion.

Question 22

According to AWS D1.1, surfaces to be welded must be free of scale, rust, and other foreign matter within ___ inches of the weld line.

Accepted Answer

Cleaning is required within 1 inch (25 mm) of the weld toe/root.

Question 23

A WPS is 'Prequalified' if:

Accepted Answer

Prequalification means the procedure is exempt from testing (PQR) because it adheres strictly to the proven parameters and details in Clause 3.

Question 24

Is 'Short Circuiting' GMAW (GMAW-S) a prequalified process under AWS D1.1?

Accepted Answer

GMAW-S is prone to lack of fusion. AWS D1.1 does NOT list it as a prequalified process; it always requires a qualified WPS (by testing).

Question 25

For a prequalified joint, the root opening tolerance 'As Detailed' is typically:

Accepted Answer

Standard detail tolerance is often +1/16, -0 inch. Fit-up tolerance adds to this.

Question 26

Which NDT method is specified by D1.1 for detecting laminar tearing in base metal?

Accepted Answer

Straight beam UT is used to detect laminations and laminar tearing in the base metal thickness.

Question 27

In a bend test for a 1-inch thick plate (WPS qualification), the specimens required are:

Accepted Answer

For plates 3/8 inch and thicker, 4 Side Bends are typically used (or 2 Tensile + 4 Side Bends for full PQR). Side bends cover the full thickness.

Question 28

The essential variable for shielding gas in a WPS includes:

Accepted Answer

Changing gas composition or flow rate beyond specified limits requires requalification of the WPS.

Question 29

What is the 'F-Number' in welding?

Accepted Answer

F-Numbers group electrodes/rods that require similar welder skills (e.g., F4 for low hydrogen SMAW).

Question 30

A PQR (Procedure Qualification Record) serves to:

Accepted Answer

The PQR is the factual record of the test weld (variables used + test results). The WPS is derived from the PQR.

Question 31

If a welder qualifies in the 3G (Vertical) position, they are also qualified for:

Accepted Answer

Qualification in 3G typically qualifies for 1G (Flat), 2G (Horizontal), and 3G (Vertical). It does not qualify for Overhead (4G).

Question 32

A welder qualification continues indefinitely unless:

Accepted Answer

Continuity requires the welder to use the process at least once every 6 months. If a gap > 6 months occurs, qualification lapses.

Question 33

A change in which of the following is an Essential Variable for welder qualification?

Accepted Answer

Essential variables for performance qualification include process, polarity, position, thickness range, and backing removal.

Question 34

When testing a PQR, if the reduced section tensile specimen breaks in the base metal outside the weld interface, the test is accepted if:

Accepted Answer

If the break is in the base metal, D1.1 allows acceptance if the strength is at least 95% of the specified minimum for the base metal.

Question 35

What is the welding position defined as '4G'?

Accepted Answer

4G is the designation for Overhead Groove weld.

Question 36

Which WPS variable change requires requalification?

Accepted Answer

Adding a position that was not qualified (e.g., Vertical) is an essential variable requiring a new PQR/WPS. (Amperage/Speed usually have wider tolerances like +/- 10-25% depending on code, but position is strict).

Question 37

For a welder qualifying on 1-inch thick plate, what is the maximum thickness they are qualified to weld?

Accepted Answer

Under AWS D1.1, a performance qualification test on plate 1 inch or thicker qualifies the welder for Unlimited thickness (Min 1/8 inch to Max Unlimited).

Question 38

Can a welder qualified for CJP groove welds also weld PJP groove welds and fillets?

Accepted Answer

Qualification on CJP groove welds generally qualifies the welder for PJP grooves and Fillet welds in the positions qualified.

Question 39

In a WPS, the 'Electrical Characteristics' section typically specifies:

Accepted Answer

Electrical characteristics define the power source settings essential for the arc energy.

Question 40

A 'Standard' WPS (SWPS) is:

Accepted Answer

SWPSs are industry-standard procedures (AWS B2.1 series) supported by extensive PQR data, purchasable for use without requalification (if accepted by the contract).

AWS D1.1 Code Practice Questions

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