Question 1

Which destructive test is primarily used to determine the ultimate tensile strength of a weldment?

Accepted Answer

The transverse tensile test pulls a specimen perpendicular to the weld axis until failure to determine the ultimate tensile strength of the joint.

Question 2

In a guided bend test, the primary property being evaluated is:

Accepted Answer

Bend tests stretch the outer fibers of the weld to evaluate ductility (ability to stretch without breaking) and soundness (revealing discontinuities like lack of fusion).

Question 3

The Charpy V-Notch (CVN) test is used to measure:

Accepted Answer

CVN testing measures the energy absorbed by a notched specimen during fracture, indicating the material's resistance to brittle fracture (toughness).

Question 4

When performing a 'Root Bend' test, the surface of the specimen placed in tension (on the convex side of the bend) is the:

Accepted Answer

In a root bend, the root of the weld is on the outside (convex) radius, subjecting it to the maximum tensile strain to check for root defects.

Question 5

In an AWS D1.1 guided bend test, the specimen is rejected if a discontinuity on the convex surface exceeds:

Accepted Answer

AWS D1.1 Section 4.9.3.3 states that the convex surface shall not contain discontinuities exceeding 1/8 inch (3 mm) measured in any direction.

Question 6

The 'All-Weld-Metal' tensile test is designed to determine:

Accepted Answer

This test uses a cylindrical specimen machined entirely from the weld metal to determine the properties (yield, UTS, elongation) of the filler metal itself, excluding base metal effects.

Question 7

Which hardness testing method uses a diamond cone indenter?

Accepted Answer

Rockwell C (HRC) uses a diamond cone (brale) indenter and a 150 kg load, typically used for harder steels. Rockwell B uses a steel ball.

Question 8

The Fillet Weld Break Test is used primarily to evaluate:

Accepted Answer

The fillet weld break test involves breaking the sample to inspect the fracture surface for root fusion, penetration, and internal defects like slag or porosity.

Question 9

In a Macroetch test, the specimen is polished and etched to reveal:

Accepted Answer

Macroetching (visual examination at low magnification) reveals the weld structure, including penetration, HAZ width, and individual weld passes.

Question 10

The Nick-Break test is used to determine:

Accepted Answer

The nick-break test forces a fracture through the weld metal (by nicking the sides) to expose internal discontinuities like slag inclusions, gas pockets, or lack of fusion.

Question 11

Percent Elongation in a tensile test is calculated by comparing:

Accepted Answer

Percent Elongation = ((Final Length - Original Length) / Original Length) x 100. It measures ductility.

Question 12

Which variable is crucial to control during a Charpy V-Notch test?

Accepted Answer

Impact toughness changes drastically with temperature (DBTT). The specimen must be tested at a specific, controlled temperature to get valid results.

Question 13

In a guided bend test, if the material thickness is 3/8 inch, what is the typical diameter of the plunger (mandrel) for a standard 2T bend?

Accepted Answer

For many standard tests (A36 steel), the bend radius is 2T (twice the thickness) or plunger diameter is 4T. Wait, standard AWS D1.1 plunger for 3/8" plate is 1-1/2" diameter. Let's verify formula. D = A = 1.5 inches for 3/8 plate (Table 4.1).

Question 14

The Brinell Hardness Test typically leaves an indentation that is measured by its:

Accepted Answer

The Brinell test presses a 10mm ball into the surface. The hardness number (HB) is calculated based on the *diameter* of the indentation.

Question 15

A 'Side Bend' test is typically used for:

Accepted Answer

Side bends expose the entire cross-section (root to face) of the weld and are commonly used for thicker plates (>3/8 inch) instead of separate root and face bends.

Question 16

Which tensile property is indicated by the highest point on the stress-strain curve?

Accepted Answer

The highest point on the stress-strain curve represents the maximum load the material sustained, which is the Ultimate Tensile Strength (UTS). It indicates the maximum stress the material can withstand before necking begins.

Question 17

If a tensile specimen breaks in the base metal outside the weld area, the weld is considered:

Accepted Answer

If the break occurs in the base metal, it proves the weld metal and interface were stronger than the base metal.

Question 18

The Vickers hardness test uses which type of indenter?

Accepted Answer

The Vickers test uses a square-based diamond pyramid indenter, suitable for microhardness testing of small areas (like specific HAZ zones).

Question 19

What is the result of 'Peel Testing' usually used for?

Accepted Answer

Peel testing involves mechanically peeling apart two sheets joined by a resistance spot weld to measure the button diameter and fracture mode.

Question 20

Percent Reduction of Area is determined by measuring:

Accepted Answer

Reduction of Area = ((Original Area - Final Area at fracture) / Original Area) x 100. It is a measure of ductility.

Question 21

When taking a hardness test on a weld cross-section (Macro-hardness), where are readings typically taken?

Accepted Answer

A hardness survey traverses the Base Metal, HAZ, and Weld Metal to detect hard spots (martensite) or soft spots.

Question 22

A 'longitudinal' bend test bends the specimen:

Accepted Answer

Longitudinal bends are taken parallel to the weld axis. They are often used when the base metals have significantly different yield strengths.

Question 23

The Drop Weight Test (Nil-Ductility Transition) determines:

Accepted Answer

The Drop Weight Test (ASTM E208) determines the Nil-Ductility Transition (NDT) temperature, below which the steel behaves in a brittle manner.

Question 24

In a metallographic test (micro-etch), 'micro' refers to:

Accepted Answer

Microetching involves high magnification (>50X) to see grain structure, phases, and microscopic inclusions. (Macro is <10X or naked eye).

Question 25

Which etchant is commonly used for carbon steel macroetch specimens?

Accepted Answer

Nital (typically 5-10% nitric acid in methanol/ethanol) is the standard etchant for revealing carbon steel weld structures.

Question 26

Shear strength is typically measured on:

Accepted Answer

Fillet welds are designed to carry shear loads. Transverse or longitudinal shear tests are used to determine their strength.

Question 27

During a tensile test, the 'Yield Point' is detected by:

Accepted Answer

For materials with a distinct yield point (like mild steel), the load stops increasing temporarily while strain continues (drop of the beam).

Question 28

A 'wraparound' guided bend jig is preferred over a plunger-type jig for:

Accepted Answer

Wraparound jigs ensure the specimen follows the radius without sliding friction or kinking, which is critical for softer metals like aluminum.

Question 29

The HAZ hardness of a carbon steel weld is usually:

Accepted Answer

Due to the rapid heating and cooling cycle (quenching effect) of welding, the HAZ often transforms into harder microstructures (like martensite/bainite) compared to the annealed base metal.

Question 30

In a tensile test, if the cross-sectional area is 0.5 sq in and the breaking load is 35,000 lbs, what is the UTS?

Accepted Answer

Stress = Force / Area. 35,000 lbs / 0.5 sq in = 70,000 psi.

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