1,001 Questions & Answers for the CWI Exam: Welding Metallurgy and Visual Inspection Study Guide

1,001 Questions

& Answers for

the CWI Exam

Welding Metallurgy

and Visual Inspection

Study Guide

David Quiñonez

Quality Inspector

Level II UT, MT, PT

Industrial Press

Statement of Non-Liability

The process of welding is inherently dangerous. Welding is often used to assemble pressure vessels, buildings, structures, and equipment whose failure can lead to property damage, structural failure, injury, or death. The author has carefully reviewed all the examination material and checked the information to ensure its accuracy was consistent with all the referenced material used to create this work. The author believes that it is correct and in agreement with welding industry practices and standards. However, the author cannot provide for every possibility, situation, and the actions of others. If you decide to apply the information in this preparatory exam, the author refuses to be held responsible for your actions or the results of your actions. Should you decide to apply the information presented to perform welding, use common sense and have a competent person check your designs, welding processes, and the completed welds themselves. Do not attempt life-critical welds without qualified on-site assistance.

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Author: David Quiñonez

Title: 1,001 Questions & Answers for the CWI Exam: Welding Metallurgy and Visual Inspection Study Guide

Library of Congress Control Number: 2018941403

© by Industrial Press, Inc.

All rights reserved. Published in 2018.

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ISBN (print): 978-0-8311-3629-1

ISBN (ePUB): 978-0-8311-9483-3

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ISBN (ePDF): 978-0-8311-9482-6

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Illustrations: David Quiñonez and American Welding Society

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Contents

Foreword

Introduction

List of Figures

  1 Oxyacetylene Welding and Cutting

  2 Shielded Metal Arc Welding (SMAW)

  3 Gas Metal Arc Welding (GMAW)

  4 Gas Tungsten Arc Welding (GTAW)

  5 Flux Cored Arc Welding (FCAW)

  6 Survey of Other Welding and Cutting Methods

  7 Brazing and Soldering

  8 Controlling Distortion and Heat Treating

  9 Welding Symbols and Joint Preparation

10 Welding Metallurgy

11 Electrical Safety and Power Supplies

12 Welding Positions

13 Inspection and Discontinuities

14 Qualification and Certification

 A Directory

Associations and Organizations

Businesses and Corporations

Labor Unions

Specification Material Sources

 B Acronyms/Abbreviations

AWS Letter Designations for Welding and Allied Processes

Element Symbols and Melting Temperatures

 C Tables and Formulas

Oxyacetylene Welding of Various Metals

Shielded Metal Arc Welding Electrode Classification and Types of Coating

Carbon Equivalent

Tensile Strength

Calculating Shear Strength

Percent Elongation

Coefficient of Thermal Expansion

Heat Input (Estimating Heat Input to a Weld)

Temperature

Ohm’s Law

Watt (Power in a Resistor)

Conversion Factors Commonly Used

Calculating Area

Gauge Thickness

Miscellaneous Measures

Schedule

 D References

Answer Key

Index

Foreword

For those who want to increase their knowledge in the realm of metals and welding, or who intend to take the American Welding Society’s Certified Welding Inspection test, the compilation of questions in 1,001 Questions & Answers for the CWI Exam: Welding Metallurgy and Visual Inspection Study Guide will fortify the knowledge that is needed to pass the fundamentals portion for this difficult test and fulfill aspirations for a great career with the potential to earn a great wage. David Quinonez has provided excellent pictures and illustrations that enhance the understanding of the material. I was enthralled with the depth of the content and actually learned quite a bit from this valuable resource. The topics are categorized into understandable subject areas with an old school style that is comfortable to read and use as a reference.

There are fourteen chapters in total. The first five chapters cover the most common welding and cutting processes, and then there’s a chapter for less common welding and cutting processes. The work continues with brazing and soldering, distortion control, symbols and joint preparation, welding metallurgy, electric safety and power supplies, welding positions, inspection and discontinuities and, finally, qualification and certification. A directory provides an excellent reference with acronyms and abbreviations, associations and organizations, elements with their melting temperatures and tables and formulas. All the answers are conveniently placed in the last section of the book.

I have had the pleasure of working with Dave on many structural projects. I certified him for nondestructive testing and I was and still am impressed with his knowledge and thoroughness with all aspects of material testing and welding inspection. If Dave was dispatched to a project, we knew that all work would be completed competently and on time. Dave rose quickly through the company hierarchy and we became co-managers for nondestructive testing work.

For anyone in the fields of welding or metallurgy, I highly recommend Quinonez’s book. It’s the perfect resource for studying for the CWI exam, and will be a great help for those on the job as well.

Mark Reese, M Ed.

AWS Senior Certified Welding Inspector

ASNT UT & MT Level III

Welding Professor

American River College

Sacramento, California

Introduction

This is a comprehensive and challenging sample exam comprised of essential material on the most common welding processes, survey of other welding and cutting methods, welding symbols, electrical safety, power supplies, inspection, discontinuities, and in-depth welding metallurgy questions.

The material presented has been formatted in an easy-to-read, quick-reference layout, designed for beginning welders, students, educators, welding inspectors, supervisors, and contractors or manufacturers employing welders and inspectors.

Some questions require write-in answers and challenge users to become even more knowledgeable than their respective counterparts. Answers to these questions can easily be found in the supplemental answer key. A detailed index offers the reader the time-saving convenience of being able to quickly locate specific topics.

For candidates seeking to take the American Welding Society (AWS) Certified Welding Inspector (CWI) examination, this material primarily covers the fundamentals (Part A) of the AWS-CWI exam, and should be used only as a guide in addition to the recommended self-study examination preparatory material provided by AWS publications.

David Quiñonez

List of Figures

Chapter 1

Figure 1.1 Oxyacetylene gas fitting nuts

Figure 1.2 Oxyacetylene equipment components

Figure 1.3 I-beam oxyfuel cut

Figure 1.4 Acetylene and oxygen nuts

Figure 1.5 Oxyacetylene equipment identification

Figure 1.6 Effects of an oxyfuel cut

Chapter 2

Figure 2.1 SMAW bead penetration

Figure 2.2 Effects of polarity on SMAW bead penetration

Chapter 3

Figure 3.1 GMAW nozzle components and dimensions

Figure 3.2 GMAW nozzle components and dimensions identification

Chapter 4

Figure 4.1 GTAW electrode preparation

Figure 4.2 GTAW electrode tip shapes

Figure 4.3 GTAW bead penetration

Figure 4.4 GTAW current and polarity effects

Figure 4.5 Effects of current type on bead penetration

Figure 4.6 Identification of current type and electrode polarities

Chapter 5

Figure 5.1 FCAW plate

Figure 5.2 I-beam depth

Figure 5.3 I-beam reinforcement

Chapter 6

Figure 6.1 Fusion weld

Figure 6.2 Pipe square butt joint and welding process

Figure 6.3 Plate weld set-up

Figure 6.4 Structural steel I-beam

Figure 6.5 Identification of components for a plate weld setup

Figure 6.6 Steps for severing a structural I-beam

Chapter 7

Figure 7.1 Braze joints

Figure 7.2 Braze welding coils

Figure 7.3 Capillary attraction

Figure 7.4 Lap joint

Figure 7.5 Braze joint designations

Figure 7.6 Effects of surface conditions on capillary attraction

Chapter 8

Figure 8.1 Pre-weld T-joint

Figure 8.2 Overheated sheet metal cut

Figure 8.3 Oxyfuel cut

Chapter 9

Figure 9.1 Welding example

Figure 9.2 Welded plates

Figure 9.3 Groove weld

Figure 9.4 T-joint

Figure 9.5 T-joint weldment

Figure 9.6 Staggered intermittent fillet welds

Figure 9.7 Plug weld

Figure 9.8 Location for welding symbol elements

Figure 9.9 Multiple reference line welding symbols

Figure 9.10 Welding symbols

Figure 9.11 Round to flat material

Figure 9.12 Multiple reference line welding symbol

Figure 9.13 Bevel groove T-joint

Figure 9.14 Multiple element welding symbol

Figure 9.15 V-groove welding symbol

Figure 9.16 V-groove weld

Figure 9.17 Joint for a plug weld

Figure 9.18 Cross-section of partial weld and overhead view

Figure 9.19 Round stock to plate option

Figure 9.20 Round stock to plate option-2

Figure 9.21 Sheet metal weldment

Figure 9.22 Groove joint samples

Figure 9.23 Degrees of strength for structural pipe welds

Figure 9.24 Structural pipe crack

Figure 9.25 ¹ /4 inch fillet weld, all around

Figure 9.26 V-groove weld with ³ /16 inch melt through

Figure 9.27 Single bevel groove weld with ⅛ inch melt through

Figure 9.28 Fillet weld, both sides

Figure 9.29 Staggered intermittent fillet weld symbol

Figure 9.30 Welding symbol for plug weld

Figure 9.31 Identification of welding symbol elements

Figure 9.32 Plug weld filled to half depth

Figure 9.33 Plug weld to plate

Figure 9.34 Plug weld showing faying surface of ½ inch

Figure 9.35 Spacing for staggered intermittent fillet welds

Figure 9.36 T-joint with different fillet weld sizes

Figure 9.37 Fillet weld with unequal leg size

Figure 9.38 Bevel groove T-joint weldment

Figure 9.39 Graphic drawing for double V-groove weld with a spacer

Figure 9.40 Backing and back weld symbols

Figure 9.41 ⅝ inch V-groove weld

Figure 9.42 ½ inch plug weld

Figure 9.43 Overhead view of fillet weld in a plug

Figure 9.44 Bevel groove prepared to round point

Figure 9.45 Bevel groove prepared to chisel point

Figure 9.46 Structural pipe crack repair

Figure 9.47 Edge shapes

Figure 9.47 Edge shapes

Figure 9.48 Common joint preparations for butt welds 252-253

Chapter 10

Figure 10.1 Steel manufacture

Figure 10.2 Metal forming-1

Figure 10.3 Metal forming-2

Figure 10.4 Crystalline structure-1

Figure 10.5 Crystalline structure-2

Figure 10.6 Oxyacetylene cut on angle steel

Figure 10.7 How adding an alloying element affects tensile strength and elongation

Figure 10.8 Diagram of atoms in a crystal lattice-1

Figure 10.9 Diagram of atoms in a crystal lattice-2

Figure 10.10 Graph for electromagnetic spectrum

Figure 10.11 Closed die forging

Figure 10.12 Effects of adding alloying elements

Chapter 11

Figure 11.1 Electrical circuit

Figure 11.2 Waveform and coil arrangement for generator

Figure 11.3 Electrical component and its electrical symbol

Figure 11.4 Primary and secondary windings through an iron core

Figure 11.5 Electrical symbol-1

Figure 11.6 Electrical symbol-2

Figure 11.7 Three-wire, single-phase power

Figure 11.8 Shielded metal arc welding process

Figure 11.9 Output characteristics for the two main classifications of welding power supplies

Figure 11.10 Controlling output on a welding power supply

Figure 11.11 Direction of current flow in a circuit

Chapter 12

Figure 12.1 Pipe-tee welds

Figure 12.2 Corner joint

Figure 12.3 Horizontal pipe, rolled

Figure 12.4 Vertical pipe, fixed position

Figure 12.5 Horizontal pipe, fixed position

Figure 12.6 Eight examples of various welding positions

Chapter 13

Figure 13.1 Parts of a groove weld

Figure 13.2 Parts of a fillet weld

Figure 13.3 Reinforcing structural pipe

Figure 13.4 Arc welding process—example 1

Figure 13.5 Arc welding process—example 2

Figure 13.6 Arc welding process—example 3

Figure 13.7 Arc welding process and transfer mode—example 1 .

Figure 13.8 Arc welding process and transfer mode—example 2 .

Figure 13.9 Arc welding process and transfer mode—example 3

Figure 13.10 Arc welding process and transfer mode—example 4

Figure 13.11 Welding defects, butt joint

Figure 13.12 Welding defects, T-joint

Figure 13.13 Incomplete penetration

Figure 13.14 Fillet weld on a T-joint

Figure 13.15 Column to base plate fillet weld

Figure 13.16 Repair of cracked C-channel

Figure 13.17 Chamfered pipe end

Chapter 14

Figure 14.1 AWS unlimited structural weld test plate

Figure 14.2 Fillet weld break test

Figure 14.3 Notched-bar impact test

  1

Oxyacetylene Welding and Cutting

1. Oxyacetylene welding (OAW) produces approximately what temperature flame at torch tip?

A. 4,800°F

B. 5,600°F

C. 6,500°F

D. 7,000°F

2. Oxygen cylinder-to-regulator threads are:

A. Standard threads

B. Left-hand threads

C. Right-hand threads

D. Basic minor pitch threads

3. Identify oxygen and acetylene fitting swivel nuts.

Figure 1.1 Oxyacetylene gas fitting nuts

A. ______

B. _____

4. Oxygen at high pressures:

A. Can be safely used to blow work areas free of contaminating debris

B. Can be used without regulators

C. Can accelerate combustion of oil into an explosion

D. Should never be used to blow out dust and grit

E. Both C and D are correct

5. Name at least five advantages of the oxyacetylene (OAW) process:

1. _____________

2. _____________

3. _____________

4. _____________

5. _____________

6. Oxyacetylene welding (OAW) is just one member of the _______family.

A. Shielded metal arc welding (SMAW)

B. Oxyfuel welding (OFW)

C. Air acetylene welding (AAW)

D. All of the above

7. Acetylene cylinder-to-regulator fitting and acetylene hose-to-torch fitting threads are:

A. Right-to-left-handed

B. Right-handed

C. Left-handed

D. The same as oxygen-to-regular fitting threads

8. The oxygen cylinder valves should be opened:

A. Slowly

B. 1½ turns

C. Until valve hits the upper stop and will turn no further

D. Both A and C

E. Both A and B

9. What should the high-pressure, cylinder-side pressure gauges indicate on full cylinders?

A. 2,250 pounds per square inch (psi) or (155 bar) in acetylene and 225 psi (15.5 bar) in oxygen

B. 2,570 psi (160 bar) in acetylene and 235 psi (16.5 bar) in oxygen

C. 2,250 psi (155 bar) in oxygen and 225 psi (15.5 bar) in acetylene

D. 2,570 psi(160 bar) in oxygen and 235 psi (16.5 bar) in acetylene

10. Caution should be taken to never adjust the acetylene regulator pressure above:

A. 10 psi (.75 bar)

B. 30 psi (2 bar)

C. 20 psi (1.5 bar)

D. 15 psi (1 bar)

11. Acetylene can dissolve 25 times its own volume per atmosphere of pressure.

A. True

B. False

12. How may testing the system for leaks at the cylinder-to-regulator fittings and all hose fittings be accomplished?

A. By using special leak detection solutions; bubbles indicate leaks

B. Liquid Penetrant Testing (PT)

C. By checking for odors

D. By temporarily raising the cylinder-to-regulator and line pressures to listen for leaks

13. What are the proper steps for adjusting an oxyacetylene flame? Write answer in three steps.

1. _____________

2. _____________

3. _____________

14. What are the proper steps for shutting down an oxyacetylene torch and its cylinders? Write answer in four steps.

1. _____________

2. _____________

3. _____________

4. _____________

15. Why is acetylene potentially so dangerous?

A. It is no more dangerous than propane or natural gas

B. Because it can easily be confused with oxygen cylinders

C. It forms explosive mixtures with air at all concentrations between 2.5 and 80%

D. It is highly unstable

16. What other fuel gases can be used in place of acetylene?

A. Oxygen, nitrogen, and helium

B. Argon, propane, and helium

C. Propane, oxygen, natural gas, and hydrogen

D. Propane, natural gas, hydrogen, and propylene

17. Oil saturated cloth can be used:

A. To aid in removing grime on cylinder valve-to-regulator fittings

B. Only on regulator-to-torch fittings

C. Only if valves are closed on cylinders and regulators

D. Never on high-pressure gas fittings

18. Identify all of the components of oxyacetylene welding equipment:

Figure 1.2 Oxyacetylene equipment components

A. Torch oxygen valve

B. Torch acetylene valve

C. Acetylene regulator

D. Oxygen regulator

E. Cylinder support

F. Acetylene cylinder cap

G. Oxygen cylinder cap

H. Acetylene cylinder valve

I. Oxygen hose

J. Torch

K. Oxygen safely valve

L. Oxygen cylinder

M. Acetylene cylinder

N. Torch tip

O. Acetylene hose

P. Oxygen cylinder valve

19. What is the odor of acetylene gas?

A. Like alcohol

B. Like fuel gas

C. Garlic odor

D. Onion odor

E. Acetylene gas is odorless

20. How is oxygen made for welding?

A. Atmospheric air is repeatedly cooled and compressed until it becomes a very cold liquid. This liquid is gradually warmed until each component gas reaches its vaporization temperature and separates itself. This is called fractional distillation.

B. Atmospheric air is repeatedly pressurized, raising its temperature, until it becomes a vapor and then allowed to be cooled, separating itself from all the other gas components of air; called fractional distillation.

C. Water (H 2 O) is heated, then cooled to remove its oxygen components and separate all of the other atmospheric gases; called fractional distillation.

D. The same as nitrogen, carbon dioxide, and argon, through fractional distillation.

E. Both A and D

F. Both B and D

G. Both C and D

21. When acetylene is dissolved in acetone, how long does the filling process take as the absorption process occurs?

A. 5 hours

B. 7 hours

C. 6 hours

D. 4 hours

22. Why is acetylene considered the best gas for welding?

A. It mixes with other gases for greater versatility

B. It delivers a higher temperature than all other welding processes

C. It limits the amount of heat transferred to the base metal

D. It delivers the highest concentration of heat of all fuel gases

E. Of all other gasses, it has the highest chemical interaction with the weld pool’s molten metal

23. Oxygen cylinders are seamless vessels of special high strength alloy steel that:

A. Are made from a forged drawing process and contain no welds

B. Are made from a single billet by draw forming and contain no welds

C. Are made from a forged drawing process and contain welds

D. Are made from a single billet by draw forming and are welded

24. Oxygen cylinders are seamless vessels that contain a welded neck ring.

A. True

B. False

25. Acetylene cylinders are:

A. Fabricated