Question 1

Visual inspection is the most effective inspection method because it:

Accepted Answer

Visual inspection is the only method that can be applied before, during, and after welding. By catching fit-up errors or parameter issues early, it prevents defective welds from being made.

Question 2

According to AWS D1.1, the eye examination for a CWI must verify near vision acuity of:

Accepted Answer

AWS D1.1 (and QC1) requires visual acuity of Jaeger J2 at a distance of not less than 12 inches, with or without corrective lenses.

Question 3

The recommended minimum light intensity for visual inspection is:

Accepted Answer

AWS B1.11 recommends a minimum of 100 foot-candles (approx 1000 lux) at the examination surface for adequate inspection.

Question 4

During the 'Before Welding' phase, the CWI should verify:

Accepted Answer

Before welding begins, the inspector must check material correctness, joint preparation angle, root opening, and alignment (fit-up).

Question 5

For effective visual inspection, the inspector's eye should be within ___ inches of the surface and at an angle of not less than ___ degrees.

Accepted Answer

Standard inspection practice requires the eye to be within 24 inches (600 mm) and at an angle of at least 30 degrees to the surface being inspected.

Question 6

Temperature indicating crayons (Tempilstiks) are used to measure:

Accepted Answer

Temperature crayons melt at a specific calibrated temperature, making them the standard tool for verifying preheat and interpass compliance.

Question 7

During welding, the inspector notices the welder using an electrode that has been exposed to the atmosphere for 8 hours (E7018). The inspector should:

Accepted Answer

E7018 (low hydrogen) has a 4-hour exposure limit per AWS D1.1. 8 hours exceeds this, creating a risk of hydrogen cracking. The electrodes must be removed from use.

Question 8

A CWI observes 'arc strikes' on the base metal outside the weld joint. These are:

Accepted Answer

Arc strikes create hard, brittle martensite spots that can initiate failure. AWS D1.1 requires them to be ground smooth and visually inspected (sometimes MT/PT required).

Question 9

When inspecting a groove weld, 'reinforcement' refers to:

Accepted Answer

Reinforcement is the extra metal on the face (or root) that extends beyond the surface of the plate. It is measured for acceptance (usually max 1/8").

Question 10

Checking for 'Hi-Lo' condition refers to:

Accepted Answer

Hi-Lo is a trade term for the misalignment of the internal surfaces of a pipe joint, checked before welding.

Question 11

If a CWI inspects a multi-pass weld and finds slag trapped between passes, this is:

Accepted Answer

Visual inspection during welding requires verification that slag is cleaned between passes. Trapped slag will become a rejectable slag inclusion defect.

Question 12

Which tool is best for visually inspecting the root of a small diameter pipe weld?

Accepted Answer

Borescopes allow visual access to internal surfaces that are otherwise inaccessible to the eye.

Question 13

When inspecting a tack weld that will be incorporated into the final weld, the CWI should ensure:

Accepted Answer

Tack welds incorporated into the final weld must meet the same quality standards as the final weld (no cracks) and be cleaned.

Question 14

The maximum interpass temperature is verified:

Accepted Answer

Interpass temperature is checked just before the arc is struck for the subsequent pass to ensure the steel hasn't become too hot (or too cold).

Question 15

Overlap is a weld profile discontinuity where:

Accepted Answer

Overlap (cold lap) is the protrusion of weld metal beyond the toe or root without fusion. It creates a sharp notch.

Question 16

Which of the following requires a 5x - 10x magnifier for confirmation during visual inspection?

Accepted Answer

While general inspection is done with the naked eye, suspected cracks or fine fissures often require magnification (5x-10x) for confirmation.

Question 17

Spatter is considered a defect when:

Accepted Answer

Codes vary, but generally spatter is rejectable if it prevents proper inspection, painting, or function. AWS D1.1 requires removal of loose spatter.

Question 18

A 'concave root surface' (suck-back) in a groove weld is acceptable provided:

Accepted Answer

Concavity at the root is acceptable if the resulting weld thickness meets the design requirement (usually the base metal thickness).

Question 19

When inspecting the 'Face' of a fillet weld, the CWI looks for:

Accepted Answer

Visual inspection of the face evaluates surface conditions like profile, size, and surface-breaking discontinuities.

Question 20

Underfill is:

Accepted Answer

Underfill is a depression on the weld face or root surface extending below the adjacent base metal surface (insufficient filler metal).

Question 21

Crater cracks (star cracks) are most commonly found:

Accepted Answer

Crater cracks form in the shrinkage crater left when the arc is terminated abruptly.

Question 22

Visual inspection of a single-V groove weld fit-up should check:

Accepted Answer

Fit-up inspection focuses on geometry: groove angle, root opening (gap), root face (land), and misalignment.

Question 23

For a fillet weld, 'Convexity' refers to:

Accepted Answer

Convexity is the bulge of the weld face. Excessive convexity creates stress risers at the toes and is restricted by code.

Question 24

The CWI notices the welder is not using the shielding gas specified in the WPS. The CWI should:

Accepted Answer

The inspector must ensure compliance with the WPS *during* welding. If a variable is wrong, welding should stop and be corrected immediately.

Question 25

The term 'Piping Porosity' refers to:

Accepted Answer

Piping porosity (wormhole porosity) is cylindrical and elongated, often caused by rapid gas evolution during solidification.

Question 26

In determining the size of a concave fillet weld, which tool is used?

Accepted Answer

For a concave fillet, the leg size does not determine the strength. The throat size controls. Therefore, the throat must be measured (or gauged) to confirm size.

Question 27

Heat-tint on stainless steel welds:

Accepted Answer

Heat tint (discoloration) indicates the oxide layer thickness. Darker tints (blue/black) indicate heavy oxidation and reduced corrosion resistance.

Question 28

A 'Cold Lap' (Overlap) is detected visually by:

Accepted Answer

Overlap appears as a rolling over of the weld metal with a sharp re-entrant angle (notch) where it meets the base metal, indicating no fusion.

Question 29

When inspecting backing bars after welding, they must be:

Accepted Answer

Steel backing bars must be thoroughly fused. Lack of fusion at the backing bar interface is a common defect.

Question 30

Surface roughness of a weld is typically compared to:

Accepted Answer

The AWS C4.1 Surface Roughness Gauge is a plastic replica used to visually compare weld surface finish.

Question 31

Which condition is NOT checked during the 'After Welding' visual inspection?

Accepted Answer

Preheat temperature is checked *before* or *during* welding. It cannot be checked after the weld is complete and cooled.

Question 32

Inspection of a double-V groove weld reveals the root pass on the second side was welded without backgouging. This is:

Accepted Answer

For CJP double groove welds, backgouging to sound metal is typically required before welding the second side to ensure removal of the root defects from the first side.

Question 33

When verifying the fit-up of a T-joint, the 'Root Opening' refers to:

Accepted Answer

For a fillet weld T-joint, the root opening is the gap between the two members. Excessive gap requires increasing the leg size.

Question 34

Undercut is measured by:

Accepted Answer

Acceptance criteria for undercut specify a maximum allowable *depth* (e.g., 1/32 inch).

Question 35

Hammer marks on the base metal near the weld:

Accepted Answer

Severe nicks or gouges (stress risers) from tools must be repaired to prevent fatigue cracking.

Visual Inspection Practice Questions

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