AWS D1.1 Code Practice Questions

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

Explanation: 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).

Explanation: 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.

Explanation: 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.

Explanation: 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.

Explanation: 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.

Explanation: 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.

Explanation: 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).

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

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

Explanation: 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).

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

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

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

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

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

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

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

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

Explanation: 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).

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

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

Explanation: 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.

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

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

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

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

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

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

Explanation: 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.

Explanation: 4G is the designation for Overhead Groove weld.

Explanation: 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).

Explanation: 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).

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

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

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