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CSWIP 3.2 Test 3:
Q. 1/30: One of your inspectors asks you what would a typical PWHT temperature be, when applied to this fabrication. Which of the following would be the correct answer when taking into account the material thickness range stated on a C/Mn to C/Mn steel welded join
Approximately 50°C above the upper critical limit of the material stated
Between 600°C to 650°C
Approximately 100°C lower than the lower critical limit of the material stated
2 options are correct
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Q 1/30
Test Progress : 3.33%
Q. 2/30: One of your inspectors suggests to you that lamellar tearing may have occurred in a single bevel butt joint. Would you agree with this comment?
No, this defect can only occur in single v butt welds
No, this type of defect will only occur in C/Mn steels with a CE value >0.48%
Yes, this defect is possible in a single bevel butt, but it would require RT for clarification
All options are incorrect
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Q 2/30
Test Progress : 6.67%
Q. 3/30: You notice from the WPS on certain joints a pre heat of 150°C is required, on other joints the preheat is only 75°C. Why do you think some joints require more pre heat than others?
This would be due to the different thickness of materials being used and the increased chances of solidification cracking
This would be due to the different thickness of materials being used and the increased chances of hydrogen cracking
This would be due to the fact that some welders require more preheat than others as it increases penetration
All options are incorrect; it’s due to lamellar tearing in thicker materials
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Q 3/30
Test Progress : 10.00%
Q. 4/30: One of your inspectors suggests to you that the pre heat temperatures are too low to prevent hydrogen cracking occurring. Which of the following combinations are correct for determining a correct pre heat temperature to be applied prior to welding?
Material thickness, joint design, the amount of hydrogen and welding process
Material thickness, the amount of stress, hydrogen content and material type
Material type and thickness, hydrogen scale and heat input
The amount of stress, welding process, hydrogen content and material type
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Q 4/30
Test Progress : 13.33%
Q. 5/30: One of your inspectors asks you what are the main factors affecting hydrogen cracking. Which of the following would be your best reply?
Temperature, the amount of stress, molecular hydrogen and material composition
Material thickness, atomic hydrogen, material composition and the amount of stress
Sulphur content >0.03%, hydrogen content > 15ml, the amount of stress and material composition
All options have insufficient information given
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Q 5/30
Test Progress : 16.67%
Q. 6/30: During visual inspection one of your inspectors detects a longitudinal crack along the weld centerline approximately 100mm in length. Which of the following would be reasons for the occurrence of this type of crack?
Sulphur contents and manganese contents too low
Sulphur contents too high, manganese contents too low
Sulphur contents too low, manganese contents too high
All options would cause this type of cracking
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Q 6/30
Test Progress : 20.00%
Q. 7/30: One of your welding inspectors informs you that during welding one of the welders is using an excessive long arc length. Which of the following issues could be caused by this situation?
An increase in hydrogen content in the weld
An increased risk of carbide precipitation occurring
An increased risk of solidification cracking occurring
An increased risk of lamellar tearing occurring after welding.
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Q 7/30
Test Progress : 23.33%
Q. 8/30: When inspecting the material certificates you notice some of the materials are classified as Z steels. What does this relate to?
All these materials when welded will be free from solidification issues/cracking
All these materials will have a guaranteed minimum UTS value of 500N/mm2, this will help prevent the formation of hydrogen cracking
All these materials will have a probable freedom from lamellar tearing when welded
All these materials have properties of zero ductility
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Q 8/30
Test Progress : 26.67%
Q. 9/30: Which of the following could be used to prevent the formation of hydrogen cracking?
The use of E8018 electrodes in standard packaging
The use of E8010 electrodes, baked to 350°C prior to use to remove moisture
The use of E6012 electrodes, used in a dried condition will give a lower UTS value which will give an increased elongation value
All options are incorrect
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Q 9/30
Test Progress : 30.00%
Q. 10/30: One of your inspectors suggests increasing the restraint on all single V butt joints to reduce distortion. Which of the following may have detrimental affect of this?
An increase risk of solidification cracking and lamellar tearing
An increased risk of solidification and hydrogen cracking
An increased risk of weld decay and hydrogen cracking
All options are correct
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Q 10/30
Test Progress : 33.33%
Q. 11/30: During the inspection of the materials prior to fabrication one of the NDT inspection personnel reports back to you that he has detected lamellar type defects running in the center of the parent plate, sub-surface. Which of the following is correct?
The defects detected would most likely be plate laminations and definitely not lamellar tearing
Lamellar tearing does not happen sub surface, it is a surface breaking cracking mechanism
If its been located in the center of the plate then it would most likely be solidification cracking
NDT does not locate lamellar tearing it requires through thickness ductility testing to locate it when present
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Q 11/30
Test Progress : 36.67%
Q. 12/30: A failure has occurred at the termination of a fillet weld. Part of the surface condition of the fractured surface shows variations in colour contrast between different parts. This can be described as:
Beach marks
Shear lips
Reduction in area
Crystallization marks
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Q 12/30
Test Progress : 40.00%
Q. 13/30: You discover a thick section failure, with a flat surface, over one metre long. You need to establish the initiation point of this failure. What feature on the failed surface could help you to find this?
Crystalline zone
Chevron marks
Crescent marks
Crack direction line
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Q 13/30
Test Progress : 43.33%
Q. 14/30: Cyclic loading can cause failure over time. What best describes this?
Repeated loading of varying magnitude
Loads above the UTS of the material
Stress above the Rm point
Impact loading at low temperatures
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Q 14/30
Test Progress : 46.67%
Q. 15/30: Brittle failure is consistent with which combinations?
High temperature and static loading
Low temperature and residual stress
Temperatures that vary considerably and a load below Re
Temperatures above ambient and low loading
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Q 15/30
Test Progress : 50.00%
Q. 16/30: On the failed structure, some of the failures show distinct initiation points. Which of the following is more likely to be these points?
Concave weld features
Mitre like weld features
Convex weld features
Unequal leg length features
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Q 16/30
Test Progress : 53.33%
Q. 17/30: Brittle fracture occurs at:
The speed of light
Crack propagation is very slow
The speed of sound
Crack propagation is measured at 10mm per minute
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Q 17/30
Test Progress : 56.67%
Q. 18/30: Which failure combination is most common?
Fatigue to brittle
Ductile to Brittle
Ductile to Fatigue
Fatigue to Ductile
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Q 18/30
Test Progress : 60.00%
Q. 19/30: Which of the following materials does not suffer from fatigue failure?
HSLA
316L stainless steel
Q/T steels
None of the options are correct
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Q 19/30
Test Progress : 63.33%
Q. 20/30: One of the failed joints on the structure, has a torn feature with shear lips at the point of failure. What is the most likely cause of this failure?
Cyclic loading
High residual stress
Over loading
Over loading in combination with low temperatures
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Q 20/30
Test Progress : 66.67%
Q. 21/30: Some of the failures show a smooth flat surface. This is consistent with?
Sudden failure
Slow, progressive crack propagation
Loading above the UTS value
Ductile failure
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Q 21/30
Test Progress : 70.00%
Q. 22/30: One of your inspectors informs you that a batch of E8018 electrodes has arrived on site and requires a heat treatment before use. Which of the ollowing best applies to this type of electrode?
Generally this type of electrode can be used directly from the container with no heat treatments required
In accordance with the TWI Specification, these types of electrodes are not permitted for use on this type of fabrication
This type of electrode can be used providing the electrodes flux has been recycled to a maximum of 50:50 ratios old to new
All options are incorrect
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Q 22/30
Test Progress : 73.33%
Q. 23/30: During welding one of your inspectors informs you that the fabricators are recycling SAW welding flux 30% new to 70% old. Is this permitted in accordance with the TWI Specification?
This would not be permitted as the TWI specification states a ratio of 50:50 shall be applied
SAW fluxes can’t be recycled under any conditions
This would be permitted as it’s in accordance with the TWI Specifications
This decision would generally be up to the welding supervisor
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Q 23/30
Test Progress : 76.67%
Q. 24/30: You are informed that the approved supplier of electrodes cannot make a delivery for two weeks. He asks if another manufacturer can be used, the electrodes are the same specification and size.
No, the electrodes must be from the original manufacturer (Table 7)
Yes, the electrodes can be used as they are the same specification.
It depends on whether the client will accept the change
They can be accepted once an all weld tensile test is completed.
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Q 24/30
Test Progress : 80.00%
Q. 25/30: A large batch of MAG wires has arrived on site, one of your inspectors informs you that the copper coating on some of the wire spools has been damaged during transportation. What is the purpose of the copper coating?
The copper is added to the wire to aid fusion and improve echanical properties of the deposited weld metal.
The copper aides electrical pick up and protects the wire from corrosion
The copper coating promotes weld metal fluidity and improves positional welding
All options are incorrect
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Q 25/30
Test Progress : 83.33%
Q. 26/30: A batch of E46 3 1Ni B electrodes has arrived on site. One of your inspectors asks the question "what is the minimum yield value of these electrodes". Which of the following is correct?
In accordance with AWS A5.1 the minimum UTS value would be 460 N/mm2
In accordance with BS EN ISO 2560 the minimum UTS value would be 720 N/mm2
In accordance with BS EN ISO 2560 the minimum yield value would be 460 N/mm2
In accordance with BS EN ISO 2560 the minimum yield value would be 500 N/mm2
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Q 26/30
Test Progress : 86.67%
Q. 27/30: You notice a batch of cellulosic electrodes in the welding consumable store, which of the following statements is correct for this type of electrode?
These electrodes can be used to control hydrogen levels to below 15ml per 100 grams of weld metal
These electrodes should be baked prior to use
These type of electrodes are especially suited to the PG welding position
2 Options are correct
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Q 27/30
Test Progress : 90.00%
Q. 28/30: During your morning inspection of the welding stores, you notice that certain electrodes are being baked in their original container in correctly controlled baking ovens. In accordance with the TWI Specification is this a correct practice?
Yes, providing the treatment is in accordance with the manufacturers instructions
No, under no circumstances should electrodes be baked
Yes providing after baking the electrodes are stored in such a way as to keep them free from moisture intake
No, not permitted
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Q 28/30
Test Progress : 93.33%
Q. 29/30: A Q&T section is being welded with rutile electrodes. It has been proved that Hydrogen cracking does not occur in this type of parent material. Which of the following statements are true?
If HICC is not a problem in the parent material, rutile electrodes can be used.
Basic electrodes must be used as the cracking occurs in the weld metal
If the rutile electrodes are baked before use, the hydrogen level should not be a problem
Any process that produces less than 20ml of hydrogen per 100 grams of weld metal should stop any HICC occurring.
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Q 29/30
Test Progress : 96.67%
Q. 30/30: One of your inspectors is unsure of the toughness value of an electrode classified as E50 3 2Ni B, which of the following is the correct answer?
Maximum toughness 47J at -30°C
Minimum toughness 50J at -20°C
Minimum toughness 47J at -30°C
Maximum toughness 50J at -20°C
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Q 30/30
Test Progress : 100.00%
Q. 31/30: Tungsten electrodes are considered consumables. Therefore, it is crucial that they are used correctly. Which of the following statements is correct concerning Tungstenelectrodes?
Zirconiated electrodes are used on DC negative as they concentrate the arc
Zirconiated electrodes are used on AC as they can withstand more heat on the positive cycle
Zirconiated electrodes are multi purpose for use on DC and AC
Zirconiated electrodes are designed to be used with a long taper preparation.
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Q 31/30
Test Progress : 103.33%
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