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Shape OF Weel @Sheloiné Gas ® Tes6STen Type © RewityMtiaey satlite the 2téit that each af the Fbileinie have onl © the casT S.MAwl wleWdine 4. Weedivc positions FlaT WELAG is rmeke efficient. Yoel Ca LSE Lake Rods at hiGy wT Va Lues less SULL Receerbecl Ans S wWeucdkee LariGine 2. Type of erecreede Evid is A MG epesizion, Kod used ow the FlaT AiGe) TRoks Pow tle ceaear clr fee pagarion asd 44-up be USE of A T-Geoove Reaudos Less Wed meTAL+ A. Size of Ewerkede - Lace Exécréode with hGH deposition %41e Nesceihe the HAZ and how itis Beane. Deen adyacenst B the wed whith is notmnecred, rhatevel Me riko rbuct© Gud rmbCA/> PE prenes ake Chal gach CS) Rov pl of SHRP cel rvs WAS i esceibe your undetstaddine ae Alsé Gas Meta. Ae we _ weed? Values “felse” betedeent Peak andl back Geouwel Value, with Peek above Tartan! Valer= roa Sika Aches the Ake, and BakGkousd cakeort kesdy to detocn net dhoplet duy KepinG etecrkocle Tia Hot. 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Eccr@odle Cae Hikes will melt past of Base Mera, cool Rapiell asin 2 BuenttinG ok Beithle Coaditioia uch rm ye ay Lea To Chaltin® it) Sekvce, Stoatel*Gecand Srmeoth a Re thSpecteel foe Soundmesse @ Name 4 Basic wed Joists and mecaliy daw ahem. oe | Butt - Joist oedeR Tein [atest teeth gee oa LAP- JoinT~ @ Study the wendise Suembcl avo Ausul \ a T5~150, TS5O tHe Suestienl ad Teleocnteut Fillet wheel LF) LENGTH of filler wWetel 645) : ~ CENTER Te CENTER. of Filler ulet/ L150) Guled the icin dhe by how Locate To. ExPuaw why 2h UT AREER Aoe Siz 68 Lack of Sidedlau_ NE @ SKia disrance oF tess Hav on with Ar asecd 8" 1s closer - 6 bas beltee AnGle Add Gives meee Bom plitudecarthe Sten@ You ane ow the Tob Site whese "R192" 5 habe ussa te RT Wns, Teevtty thee (3) utays fe Pestech youve self Feera the hazaads ‘of Radiation RetizAseD ny “IR N42” )"Reduee exposure time” use the fostest Fim Spee! Guise Ree Recl Seusithid yy uttls SieeresT Soukce Te Filo Gs 7TAance a @)'Reduertons D&ravce” § Loublive dsrance Roles Exposuke Fewe C1) Tranes @ Raclatins hela” Heavy merats Suce As Lad sacl Aeplafgd uranium obsokb Kodatir. Two, one lO mhik plates ate tbe peahoitel, Hen wecdal LeaethR u8ii& NAW Owhad is the aantechin betdeas pesveet aid hydiecert desir) — Faeheat anncleaitis hytlec con citlusiée oct o€ Me wdelel, pitocos the weld ts tool Slowly. Feereat 150% 200° Etiemimabs embiittleenenst @ Mew nib Hydee@en Geb rite the iter) 1» the bas¥ hres - Hydeccen Geveeated eurlra) the 98 Fee Denna ob Gataammalie Electiteles @ what Kid of deeds can tydeeGen) (hase ~ Hydao ben tapped iv Wed avdl HAZ will cause Sevele eembeittleament= @) Descerbe hyws you woutel PeepakO avd test 2 Redacwd erSite test y 12. A shear wave transducer angle in the ultrasoric testing system means.? 1 The angle of the sound beam in the material under test. UK 13, In GTAW, an electrode top can carry a much higher current without overheating when it is used on. DC straight polarity 14. Which of the following is a method of minimizing distortion . Balance welds around the neutral axis, 15.” Which one of the choices below would be the best one to help reduce accessive are blow with SMAW. Switch to AC current A 10mm fillet weld has a nominal throat dimension of: 10mm 1 ‘Area of 10 mm - answer Leg dimension 10 mm - answer Volume of 10 mm Both 1 & 3 are correct yaeyr ‘Which of the following SMAW electrodes are restricted to horizontal and flat position welding. — E 48024 18.” When using magnetic particle upon inspection, a surface crack in the weld cap can be jl Bestlocated when using: ol 1. The crack is transverse to the magnetic line fal 2. The magnetic field is transverse to the crack 0 3 ‘The weld surface is clean. 4. The field follows an obstruction 5. ALL of the above - answer19. A guided root bend test on a weld would show. 1. The weld ductility when measuring the difference in distance between the gage marks. 2. Excessive reinforcement 3. The integrity of the face weld 4. Lack of penetration or fusion - answer 5. HAZ properties Which of the following electrodes is classifiec as a basic electrode E6010 E48014 Acellular electrode ‘One that contains tatania 48016 E 48016 - answer — lasr digit 5,66 of #E indice Gasie Which of the following gases does not produce a spray arc transfer of gas metal arc welding. 1. 80% argon, 20% CO? 2. 100% Argon 3. 98% Argon, 2% OX 4. Helium rich gases 5. 100% Co? answer fedacuirg Go ghecsaito Htansifor ceution Tt a Senng PramspO€ 22. A welding symbol ? od fey Answer #1 a 23. If liquid pentrant examination transfer from excessive penetrant, which comes after the il following penetration steps. = a o 1. Application of developer 2 CT Ae or "x 2 Application of the penetrant ae occ eae YO, ph tare ¢ 3. entrant dyell time - answer ye gevdepe qoypled, 4, Final surface cleaning att oa discon PvE) fat ) 5. Drying of the material ‘ s inn 24. How is an effective throat of a fillet weld calculated. Through its leg length The minimum distance of its root of weld ‘The distance of the root and the weld through to the cap of the weld. The length of the weld times, the size of the weld None of the above yaene 25. Which of the following is the correct joint preparation of the weld symbol #1The weld defect hollow bead is defined as: Linear porosity or a cylinder gas pocket occarring in the root bead. ‘The amount of weld metal required for a fillet weld: Increases as the square in the leg length. - answer Deereases in the square in the leg length Is in proportion to the throat size Is determined by the required depth of penetration None of the above 4.2% The a ngs BM Bk e Lkizcraeco ler inches thick. 025 yeep Ee Impact test are used to: Energy required to break specimen A welding symbol #4 a single bevel groove weld on arrow side followed by a fillet weld on the other side using a coated electrode/a fillet weld on the arrow side, both sides tested using magna particle test 32.0 What is the voltage measurement when the welding machine current is zero #1 open circuit voltage io, x 33. When using the GMAW process the type of transfer depends on which of the following: 4 Current Shielding gas Electrode size Electrode composition All of the above - answer de a veep te 34. Porosity Cwhat is 4 Thue cy 1. Cannot be trapped within a weld (0 © 2. Moves up through latter passes and will show only a final pass. 3. __Isrestricted to the center line of the weld 4. Is developed from fatigue welder technique - answer 5. Can be dissipated with heat treatment When conducting a tensile test the rate of loading up to the yield point is usually limited to some maximum value. What is the reason for this? 1. Because a fast loading rate might increase the yield strength.36. 12 Essay Questions Briefly outline the effect that each of the following have on the cost of SMAW welding. 1, Welding Position 2. Type of Electrode 3. Jointpreparation & fitup 4. Size of Electrode The cost effects of SMAW are as follows: ‘Welding Positions, Flat is the cheapest less welder skill in Flat Position (apprentice is cheaper) bum larger rods, higher current can be used and more weld deposition. Rollers can be used to produce more speed and more production. In the Flat position electrode stubs can be sued right to the end resulting in less waste. No shielding gas is required for the SMAW Process. Type of Electrode: AE7024 electrode will produce a much high deposition rate than an E6010 resulting in more speed and production by using E7024 type of electrode. Joint preparation & Fitup: ‘AJ groove is much more effective than a V groove joint, simply because there is less to fill in the J groove fitup resulting in less weld deposition and faster production. Size of electrode: Generally larger diameter electrodes are used for welding thick materials in the Flat Position so that higher deposition rates can be obtained. Describe the HAZ and how it is formed. HAZis the area adjacent to the weld which has not been melted, but whose micro- structure or mechanical properties have been changed. Describe your understanding of Pulse Gas Metal Arc Welding. Pulse is used for out-of-position welding. Tke current output changes or pulses between apeak value and a background value at a rapii, but controlled rate. The peak current is above the transition value for spray so that in each pulse a drop of metal is detached and transferred across the arc. The current then decreases to the background value, which maintains an arc and keeps the electrode top “ot and ready to detach the next droplet in the next pulse. The background value is in the range of grobular transfer well below the spray transition value, The lower current creates a smaller weld pool and lower heat input which allows out of position welding. This also allows welding of thin materials.39. Stress Strain Curve Fracture stress F w Strain to facture A Ce Tensile strength E ® . Maximum hardness —- \ Necking begins at D Bending stress --- Uniform strain B Off set yield strength C AYRE ena 40. // Explain why Arch Strikes on a weldment might be objectionable and also state 2 possible causes. be Hecaatas OD Feeeteny D welden teeters ED) 7 raistey of Faucry Clectwoole ‘The base metal which is not part of the weld chould not be struck by the are A small part of the base metal may be melted when the arcis initiated. The molten metal which cools rapidly may crack from Quenching or a small surface pore may lead to extensive cracking in service, Any cracks or marks caused by are strikes should be ground smooth and re inspected for soundness. Arc strikes causes a Quenched or Brittle condition. 0 41. Name 4 basic weld joints and neatly draw them. “Module 3, Pg 9. BulTjoint, comer joint, Lapp Joint and Bdge joint. 42.7 Study the welding symbol belw and answer the question. - Straggered intermittent weld is the type = 8 is the size of the fillet ~ 75s the length of the fillet - 150 is the spacing from the center of one fillet weld to the center of the next fillet weld. 43. Given the following information which UT tansducer A or B is in the best position to locate the size or lack of side wall fusion defect. Explain why itis the best position? ‘Assume that a skip distance of less than one will be used to locate the size and defect. & Bis the correct answer B is closer, the better angle, more amplitude on the signal.‘You are on the job site where IR. 192 is being used to RT welds, identify three ways to protect yourself from the hazards of radiation released by IR192. Reduced Exposure Time use the fastest film szeed that gives the required sensitivity and the shortest source to film distance that meets unshapeness requirements. Distance Radiation follows the Inverse Square Law. Doubling the distance reduces radiation four times. Shielding Heavy materials such as lead or depleted uranium absorb radiation. For a given thickness of material, the intensity is reduced by a given fraction. Two, one inch thick plates are to be preheated then welded together using SMAW. 1. What is the connection between preheat and hydrogen diffusion? 2. How might hydrogen get into the weld in the first place? 3. What kind of defects can hydrogen cause? Preheat is used to accelerate the diffusion of hydrogen out of the weld. It also allows the weld to cool slowly. At a preheat of 150° - 209°C, hydrogen has no embrittlement effect on steel. Coated electrodes which are not heated are full of contamination and will cause hydrogen pregnation in the weld. The greatest risk comes form hydrogen generated within the arc from damp or contaminated welding consumables, mainly fluxes or coated electrodes. 3.7 Ifthe weld cools too quickly, significant quantities of hydrogen may be trapped in the 46. weld and HAZ. Hydrogen trapped in steel will cause severe embrittlement. Describe how you would prepare and test a reduced tensile test specimen for “T” welding procedure qualification. Include a drawing of the test specimen in your answer and show the approximate measurements. Tensile Test is used mainly in the Qualification for Weld Procedure. Specimens have a ‘square or rectangular cross-section and are prepared transverse to the weld. This means that both material and weld metal are tested. The reduced section tensile specimen is intended to represent the entire cross-section of the weld. The specimen is equal to the thickness of the welded plates and only the reinforcement is removed. .47. Caloulate the Heat Input of the following parameters voltage =20V amps = AMPs ‘AreTravel Speed = 30 inches per minute Wire Feed Speed = 300 inches per minut Number of passes =3 Heat Input = — YRAX60 PM 20x 10x 60 300 Answer = 400JF Welding Report 1. S points in a welding inspection report that you think are important, they are: jl Materials material specification (ASTM A 355 Grade P22 Stainless Steel 3 Tubing) t ‘We need to know if this is the exact material required to do the job. Another words are ‘we using the right materials, Are the Quantity and dimensions correct. EXAMPLE (4- 20 FT lengths of 6" diameter schedule 80). Are there any special requirements? (heat- treating, QA requirements inspection prior to delivery. Are there requirements to supply mill test certificates. De oe Verification of Welding Procedures Fabrications & construction codes require that welding be carried out in accordance with written procedures and must go on to formalize this requirements by specifying the content and recommending the format of such procedures codes might also require that the Welding Procedure Specification be approved by some appropriate body such as the CWB. WPS isa written Qualified welding procedure prepared to provide direction for making production welds to code requirements. The WPS may be used to provided direction to the welder or welding operator to assure compliance with the code, Are the welders on the job, qualified :o the WPS? ‘Welding personnel are qualified by undertaking welder performance tests as required by the relevant code. This comes in the form of an ID card (ticket) which shows the classification, process position, etc. for which the individual is Qualified.4. é 7 Ap Vn (0 acs fv 5. Watch for any physical signs of non-conformance of the final product. The inspector must be completely familiar with the conditions for conformance, the acceptance criteria and the procedure to be followed in the event of non- conformance. There must be a system in place for: ‘Reporting non-conformance, corrective and repair action ‘Authorizing, monitoring and inspecting repairs. Documenting repairs and other rectification action. Reviewing records for recurring problems and initiating corrective action ‘Verifying that heat treating equipment is working properly and that the procedure is being followed. on A Your inspection report rejected a number of welds and you did not - mention what code they were rejected under. Does this matter, or is it of // marginal importance? Yes, itis very important to follow a code: For example, if there were a number of welds which in ASME31.3 would include socket and seal welds and attachments welds for slip on Flanges, branch reinforcement and supports. The extend of the imperfection in 31.3 for acceptance would be zero for cracks. Also the code layout for ‘Non-Destructive testing methods of visual inspection, RT, MP and Liquid Penetrant. So the crack would be ground out and repaired, then we oculd visual inspect, call for RT and then MT the repair to code. yeep ‘The fundamental job of the inspector is to observe and report. Name three important observations you would report on. Before the welding starts, duties may include checking of equipment materials and consumables to make certain they are in lime with the WPS. Ifusing Basic clectrodes, portable rod ovens operatirg at correct temperatures must be used. Verify that welding parameters confirm to the approved welding procedures. The inspector also deals with the application of RT; verifying where and when it is to be done, checking qualifications and reports as well as looking and discussing interpretation. ‘Your welding report must include information on material prep fit up. Name five items this would include explain the significance of two of them. L yReN Cleaning _internal and external surfaces to be free from paint, oil, rust, scale and other material that would be detrimental to either the weld or the base metal when heat is applied. Root face - an excessively large root face on weld joint preparation depth. End preparation Alignment Root opening As the welding inspector in a Fab shop you are required to witness and report on the welding and report on the welding parameters made with automatic GTAW process, name five of the parameters. Select two and explain their significance to the welding process.10 Five welding parameters are: shielding gas types and flow rate, tungsten type, travel speed, polarity and travel angle. Travel angle should be set at 5-15 degrees. Excessive angle can cause air entrainment which could lead to porosity and electrode contamination. Shielding gas is used at the torch as well as a purge inside the pipe with the objective of protecting the arc and the weld metal form atmospheric contamination. Shielding gases used for GTAW are completely inert since the presence of oxygen or carbon dioxide will oxidize the tungsten electrode and limit its life, Inert gases commonly used are argon, helium and argon-helium mixtures at 99.99% purity. The flow rate at the torch is usually 10-35 CFH and 12-30 CFH for a back purge.ca gota z) i Congect Answer.— an} [\ CoN ae %) ye C iS The CoRRRT ANSWER O-infer apete Arch. o Ane (zeec) IS The CogRecT ASHER. olz 8" 3" ge 35" < ne ge o ni °The well puipaccion indicated athe dyrtall io: nrwn~ Moos JS The cogrect #riwee.