3.2.2 Questions

CSWIP 3.
2 THEORY PAPER Q&A

1. Signing off a product
In an engineering fabrication industry the last activity in the sequence of manufacturing is load out or
dispatch. This activity cannot be initiated unless the product is signed off. As a matter of fact signing
the product off is assurance of quality which is authenticated by a technically competent person such
as Senior Welding Inspector who makes sure that complete manufacturing of product has been
carried out in accordance with applicable standard and sound engineering practices.
However before signing the documents the senior welding inspector should make enquiry which can
give him the in sites of the past while product was being manufactured.
Typical questions can be as followed
1. What was the repair rate during production?
2. Whether any difficulties are encountered within the job?
3. Which is the critical area in this job or product?
4. Whether any concession or waiver were given, if yes why?
5. How were the weather conditions?
6. Whether there were any safety issues, fatalities, major accidents/incident etc?
7. Whether there were any labour problems?
8. What was the general moral and standard of work amongst the inspection team(s)?
Further to this he can start reviewing of documents and he should make sure that he attaches the
following documents as a minimum
1. Quality control plan ensure all stages are completed and signed off
2. Inspection check list ensure all stages are completed and signed off
3. Verify material certificates such as mill test certificates; material traceability records lap
reports etc
4. Verify the following procedures which are to be attached and have all been approved
a. Welding
e. Hardness
b. Repair
f. PMI
c. NDT
g. Hydrotest
d. PWHT
h. Coating/Painting
5. Verify the qualification level and validity of the welder and NDT personnel
6. Verify the inspection reports of following disciplines and ensure that they cover all
appropriate joints and structure
a. Visual
b. NDT
c. Dimensional control etc
7. Verify calibration certificates of equipments and instruments such as pressure gauge,
inspection tools and welding equipments etc
8. Verify hardness test reports
9. Verify PMI reports
10. Verify PWHT reports and charts
11. Verify Hydro test reports and charts
12. Verify painting and coating inspection reports
13. Verify as built drawings are completed
14. Verify weld maps are available for traceability
15. Verify name plate, rubbing details are available when applicable
16. Verify concession request, NCR, site query etc
17. Verify permit to work
18.
19. As a part of his own inspection he may be obliged to witness final hydrotest, visual inspection
of completed parts. As a matter of quality assurance he may view some radiographs at
random and may even conduct radiograph audit.
20.
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CSWIP 3.2 THEORY PAPER Q&A

21. Finally, transit and tie down procedures should all have been approved by the relevant
engineer prior to the final acceptance of the product and issue of any signed certificate of
conformance.
2. Duties of the Senior Welding Inspector
22.
23. Plan
24. It is an agreed pre-determined structural path way that needs specific aim. All projects
inspection needs the following planning.
a. Establishing inspection test plan and plan for all stages of inspection
b. Establish requires WPS and PQR
c. Plan for requires resources. I.e. manpower, inspection tools, etc.,
d. Developing quality control procedures
e. Plan the work schedule i.e. type of inspection and at what times.
f. Communication with superior and others.
25.
26. Organize
27. To make all necessary arrangement required to carry out or fulfil plan, this may involve the
following.
a. Any training and certification required.
b. Staffing plan i.e. assigning work and area to inspectors
c. Procurement of inspection equipment and its calibration
d. Transportation to and fro from site
e. Accommodation and messing
f. Inspectors leave cycle
28.
29. Supervise
30. Once the plan has been organized it is essential that controls are exercised so that the plan is
successfully implemented
a. Supervise and evaluate inspectors work.
b. Check inspection equipment condition
c. Organize the inspection activities to be completed in time
d. Take effective decision for solving quality related problems
e. Share your knowledge with technical discussion with all inspectors
f. Motivate the staff to meet standard of quality
g. Communicate with other department to improve procedure, investigate and advice on quality
problems.
h. Keep a record of day to day inspection activates and pending inspection to be completed
i. Supervise to maintain ISO related documents.
31.
32. Auditing
33. To carry out a periodic and systematic check on a system process to ensure that it has been
carried out as specified
34.
35. Staff
a. All staff to be internal audited to ensure that they are maintaining all documents as per ITP
b. Whether all ISO related documents are maintained
c. Whether all welder details are up to date
36.
37. Equipment
a. Inspection tools to be checked for calibration and condition
b. Welding machine over calibration and condition
38.
39. Documentation
a. Check all inspection documents are maintained as per procedure
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b. Check all NDT records
c. Check welder qualification record
d. Randomly interpret Radiographic for all personals.
3. Describe and sketch the following defects lamination, laps, bands and their differences
40. Lamination
41. Laminations are planes within the steel plate across (through thickness) which there is no
metallic bond (separated in layers). They are typically a result of non-metallic inclusions and
gas pockets formed in the ingot when it has been cast and as it solidifies.
42.
43. In the steel mill the molten steel poured in moulds to form ingots. While solidification is
taking place huge amount of gases are released. It is quite possible that some of these gases
and non-metallic inclusions such as oxide coating of the bubbles, slag inclusions, refractory
inclusions from erosion of the furnace may remain trapped in the solidified steel. This ingot
when rolled the gas pocket and inclusions inside get flattened in the forms of lamination.
44.
45. This discontinuity adversely affects through thickness strength of steel and is not traceable by
MPI or RT. The only way to detect lamination is UT. This discontinuity may also contribute to
lamellar tear in thicker section.
46.
47. Laps
48. Laps are basically chunk of metal that has flown from the desired profile during operations
such as rolling and hot forming. This chunk of material is connected to the base metal at
some locations and overhanging portion of the chunk simply lies on the metal without being
the homogeneous part of it. As it is surface defect it can be found visually and can be
confirmed by MPI.
49.
50. Differences: lamination is a sub-surface defect lap is a surface defect. Lap can be found in
visual inspection and confirm by MPI. Lamination can be confirmed by ultrasonic test only.
51.
52. Bands
53. As the ingot is forged and rolled the segregation are elongated and reduced in cross section.
If further processing is carried out, they may appear as very thin parallel lines of bands and
is generally known as banding. Banding is not usually significant.
54.
4. It has come to your attention that the morale of your inspection team appears to be low,
a. What could you have observed to determine this?
b. What would occur if this was not rectified quickly?
c. What could you do to lift low morale?
55. Low morale can be identified by the following symptoms
1. lack of diligence
2. taking short cuts
3. ignoring safety procedures
4. not starting work promptly
5. taking long breaks
6. talking in groups and grumbling about minor matters
7. higher levels of absenteeism
8. Negligence (poor record keeping, not inspecting the weld etc...)
9. complaints from TPI/Client
56. Low morale may be result in the following
1. lack of control over production activities from quality point of view
2. poor productivity
3. substandard work output
4. delay in work schedule
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5.
57.
1.
2.
3.
4.
5.
6.
7.
8.
9.
lack of credibility to the organization

Observing all above, it is imperative that lifting the low morale this can be done as follows
Arrange the meeting of entire sub coordinates staff for discussion on the subject matter.
From their response I can form a collective opinion for low morale
Further to this I may have private discussion with each individual which can help me to zero
in on his problems.
This problem is then sorted out as general problem and individual problems.
As regard to the personal problems I can assure the team that I will do everything possible in
my capacity to rectify it.
I should bring to the attention of the employees in gentle but firm manner that, their
individual problems must not affect the morale.
I will try to seek companys help for their personal problem.
These they should be noticed that the high morale will reflect in good salary rise, better
facilities etc.
If low morale continues then the management will be obliged warning letters, demotions and
worst case termination also
58.
5. you suspected that a radiographic team under supervision of your inspector has radiographed
the same weld seam and only changing the lead letters
a. What would be your initial course of action? Or what action would you take to confirm
this?
b. If your suspicion is proved to be correct, what would be your further course of action?
Or what action would you take upon your conformation?
59.
60. Actions to confirm
1. Conduct the radiographic audit in the batches and if similar looking radiographs are found
then they should be verified at job against the welds comparing by profile or by any parent
metal marks.
2. If many such suspected radiographs are found then the full audit of all radiographs should be
performed.
3. Physically inspect three or four joints to random mark with correct identification number and
take new radiographs by using new radiographic crew.
4. Evaluate the new radiographs and compare with the previous taken radiographs of the
respective joints.
5. The outcome of this investigation could be of two types
a. Rare case of duplication
b. Occurrence of duplication in many cases
61. In the first case it is most likely to be a human error; hence the matter can be resolved by
making NDT supervisor aware of facts.
62. In the second case it is an intentional action performed to help somebodys interest, which is
obviously a set back to the quality.
63.
64. Actions upon conformation
1. Inform the occurrence to the higher authorities or supervisor and produce objective evidence
2. Identify the crew which has taken with wrong identification
3. Raise NCR
4. Arrange to remove and replace the crew immediately
5. Arrange to reshoot all joints by using new crew
6. Establish proper monitoring system to avoid reoccurrence of such problems
7. Arrange to close NCR
65. A meeting of all inspectors to be conducted and they should be issued a strong warning letter
to improve the level of their performance to avoid such incident in future.
66.
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6. What is the course of investigation for vessel rupture with loud bang?
67. Based on the above information one can construe the failure must be catastrophic in nature,
which means in all likeness mode of failure is to be brittle. However there could be more than
one mode of failure I.e. the initiation could be the fatigue mode followed by brittle. Because
of this reason it is advisable to personality visit the venue of failure to do some visual
inspection of exposed surface to find out the mode of failure. If the failure found be brittle in
nature the following will be the symptoms
1. rough and crystalline surface
2. the chevron mark having V shaped pointing towards the point of initiation otherwise if
failure initiated in fatigue mode then it will be manifested by
3. smooth surface having dull texture
4. half round crescent or beach marks
68. It is also important to note whether the initiation of rupture is in weld/HAZ or in the base
metal then one can further investigate the following avenues
69. If in base metal
1. chemical composition and physical properties certificates supplied by manufacturer (material
test certificates)
2. heat treatment records and lap test reports if any
3. hardness of the base metal and thickness in the rupture zone
4. suitability of material for the given service conditions
70. If in weld/HAZ
1. Check the WPS used for welding
2. Visual inspection reports and weld logs
3. Radiographic reports
4. Heat treatment records and charts
5. Hardness reports
71. Based on the outcome of the above investigation the reason of the failure can be judged.
72.
7. you have overheard a conversation suggestion that a third party inspector who is under your
charge has been allowing repairs of cracks to be made without reporting them qa/qc
department
a. What would be your course of action?
b. If this is found to be correct what would be your course of action?
73. Since it is grave consequence senior welding inspector should go personally to the job site try
to establish facts in a diplomatic way. Once the facts are established and it is been proved
beyond any reasonable doubts, then the prevention action should be taken in such a way that
it will eliminate further occurrence of such events but will not break any relation.
74. For the sake of disciplinary measures first, the TPI should be summoned for a private
discussion and may be questioned about his action and omissions. It is imperative that he
must be made aware of the fact that you are aware of his omission. Further to this a meeting
should be conducted for all inspectors and they should be made alert against such instance
and they should be instructed to report such occurrence if found immediately to QA/QC
department.
75. In order to make higher management aware of the omission of third party inspector, a strong
letter may be drafted and circulated to higher management about the omission of TPI for
their information and action.
76.
8. What is transition joint? What are the problems occur during welding of a transition joint?
Where corrosion will occur in transition joint?
77. A transition joint is a joint between different thickness and or dissimilar metals. It could be of
two categories
1. different base metals
2. different thickness
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78. Assuming that the transition joint in this discussion complied with both of the above two
categories. Following care should be taken during welding
79.
80. Transition joint with different base metal:
1. proper selection of electrode to avoid dilution of the weld metal
2. proper selection of current range and polarity type of current
3. back purging required, if any
4. cleanliness
5. pre-heat, PWHT
6. Welding process
81.
82. Transition joint with different thickness
1. The thicker member should be gradually tapered off to match the thickness of thinner member
such that said taper will not exceed 1:4
2. The completed weld should be blended in such a way it will follow the gradual transition
3. Proper heat treatment should be chosen taking consideration of thickness of thicker member
83. On steels, the HAZ of the weld tends to be more brittle i.e. it has lower notch toughness than
the actual weld metal. The HAZ area is therefore more prone to cracking especially when
hydrogen is induced, although it must be noted that the tensile strength of the HAZ is
normally high in comparison with the weld and parent material. Unfortunately it a fusion
welding process is being used then the HAZ cannot be eliminated.
84. Problems occur during welding a transition joint
1. Consumable selection
2. Hot cracking due to thermal expansion of steel
3. Cold cracking due to uneven expansion and contraction of thick and thin member or different
material properties
4. Corrosion will occur in SS side in HAZ
85.
9. What is lamellar tearing? describe briefly causes and control measures for lamellar tearing
86. Crack type
: lamellar tearing
87. Location
: below the weld, HAZ (T & Corner Joints)
88. Steel types
: High sulphur & phosphorous steel
89. Susceptible microstructure
: cold rolled
90.
91. It is a step like crack occurring in the parent metal or HAZ of steel with poor through
thickness ductility, where the fusion boundary of the weld is parallel with plate surface. It is
usually associated with restrained joints on corner, tee or fillet welds joining thick plate.
92. Causes
1. poor through thickness ductility
2. non-metallic inclusion in the direction of rolling
3. restrained joint
4. through thickness stress
5. high sulphur/phosphorous content
6. presence of hydrogen
93.
94. Lamellar tearing occurs when two conditions exist at the same time:
a. A susceptible rolled plate is used to make a weld joint
b. High stresses act in the through-thickness direction of the susceptible material
(known as the short-transverse direction)
95. Control
1. Reducing the size of weld
2. modify joint design
3. control restraint
4. use of forged materials for critical work
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5. Grind the parent metal and fill with ductile weld metal. A buttering layer of high ductility
weld metal may be deposited where the vertical member is to be welded.
6. Asses the through thickness ductility by short transverse tensile test
7. Inspect the plate for non-metallic inclusions
8. Carry out full chemical analysis to make sure sulphur is less than 0.05%
96.
10. What is solidification crack describe briefly causes and controlling measures?
97. Cracking that takes place during the weld solidification process is termed either hot cracking
or solidification cracking and occurs in all steels which have high sulphur content - sulphur
causes low ductility at elevated temperatures.
98.
99. In order for a crack to develop the solidifying metal must be subjected to a high tensile stress,
this may by present as a result of weld metal contraction combined with high restraint.
Solidification cracks usually occur longitudinally down the centre of the weld because of the
segregation of impurities and have a blunt profile.
100.
101.
Centreline solidification cracks tend to be surface breaking at some point in their
length and can be easily seen during visual inspection because they tend to be relatively wide
cracks.
102.
Solidification cracking occurs when three conditions exist at the same time:
1. Weld metal has a susceptible chemical composition (sulphur and phosphorus)
2. Welding conditions used give an unfavourable bead shape
3. High level of restraint or tensile stresses present in the weld area
103.
Below causes may accelerate Solidification Crack
1. Contamination in weld joint
2. Unfavourable welding condition
3. Improper Width to depth ratio
104.
Control measures
1. Control the sulphur content
2. Use consumable with high manganese
3. Keep manganese-sulphide: carbon ratio as low as possible
4. Minimise restraints
5. Use low dilution process
6. Weld joints are thoroughly cleaned immediately before welding
7. Maintain proper width to depth ratio
8. Use preheat
105.
11. Explain solidification crack in ferritic steels
106.
Solidification cracking is a hot cracking mechanism that caused during solidification
of weld in ferritic steels, containing high sulphur content. During welding sulphur in the
plate may be remelted and will fuse with iron to form iron sulphide (FeS). These ironsulphides are low melting point impurities, so that collect around the grain boundaries, which
are under great stress due to the action of contractional forces. The bonding between the
grains may now be insufficient to maintain cohesion and cracks will result running through
the length of the weld centreline.
107.
108.
Causes
1. Weld metal has a susceptible chemical composition
a. High sulphur
b. High carbon
c. High phosphorus
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6. High dilution process
109.
110.
Control measures
1. Control the sulphur content
2. Limit the heat input, hence minimising expansion and contraction
3. Increase the grain boundaries by adding delta ferritic
12. Explain solidification crack in stainless steel
111.
Solidification cracking is a hot cracking mechanism that occurs during solidification
of weld metal in austenitic stainless steels. Austenitic stainless steels have large grain
structure compared to ferritic steel grains. During solidification low melting point impurities
collect around these large austenitic grain structures in the weld centreline. These large
grains have small gain in boundaries compared to ferritic steels. This lack of grain boundary
area between the grains may be insufficient to maintain cohesion and cracks occur in the
centreline of weld along its length.
112.
113.
Causes
1. Weld metal has a susceptible chemical composition (low melting point impurities)
114.
115.
Control measures
1. Control the low melting point impurities (sulphur/phosphorous)
2. Ensure the weld joints are thoroughly cleaned
3. Limit the heat input, hence minimising expansion and contraction
4. Increase the grain boundaries by adding delta ferritic
13. What is weld decay describe the causes and prevention measures?
116.
Weld decay occurs in unstabilised austenitic stainless steel with 550C to 850C
range of the HAZ. At this temperature range carbon is absorbed by chromium and chromium
carbide precipitated at the grain boundaries as a metal cools down. This precipitation of
chromium carbides consumed the alloying element cause a local reduction in chromium
content, which has the effect of lowering the resistance to corrosive attack and allowing
occurring.
117.
118.
Controlling measures
1. using of stabilised steels (with addition of Ni or Ti)
2. Use low carbon stainless steels i.e. 316L, 304L (carbon content below 0.03%)
3. Heating to about 1100C where chromium carbide will be dissolved. Then steel is normally
quenched from this temperature to stop re-association.
119.
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14. What is liquation cracking describe the causes and prevention measures?
120.
Crack type
: Liquation crack
121.
Location
: HAZ
122.
Steel type
: Low quality sulphur content steels
123.
124.
Liquation cracks occur in steels, which have high sulphur content. When welding low
quality high sulphur content steels, it is possible that areas containing iron-sulphide (FeS) in
the HAZ will liquefy. These low melting point iron-sulphides usually accumulate at the grain
boundaries. If this melting occurs in the presence of high contractional stress, then the
boundaries will be pulled apart and liquation cracks occur.
125.
Causes
1. High sulphur content
2. High restraint
3. High contractional stresses
126.
127.
Control
1. Use high quality refined steel
2. Controlled heat input
3. Minimise restraint
4. Use preheat
128.
15. What is reheat cracking describe the causes and prevention measures?
129.
Crack type
: Reheat cracking
130.
Location
: Coarse grained HAZ and weld metals
131.
Steel type
: Low alloy steel, creep resistance steels
132.
Susceptible microstructure
: Embrittled coarse grains
133.
134.
Reheat cracking is also known as relaxation cracking. It mainly occurs in HAZ of
welds particularly in low alloy steels during post weld heat treatment or service at elevated
temperatures.
135.
136.
Most alloy of steel subject to an increase of embrittlement of the coarse grained
region of the HAZ when heated above 600C. The problem is worse with thicker steels
containing Cr, Cu, Mo, V, Nb and Ti. Sulphur and phosphorus also have an influence. Typical
steels susceptible would be the 2 Cr. Mo. V type. Example creep resistance steels
137.
138.
During post weld stress relief and at high operating temperature the residual stresses
would be relieved by creep deformation which involves grain boundary sliding and grain
deformation. If due to metallurgical conditions these actions cannot occur, then grain
boundaries may be open up into cracks
139.
140.
Causes
1. areas of high stress concentration and existing weld defects
2. the toes of badly shaped fillet welds, incomplete root penetration welds
3. high creep resistance
141.
142.
Control
1. toe grinding, elimination of partial penetration welds
2. rejection of poor weld profile
3. heat quickly through the susceptible temperature 450-550 C
4. use high preheat temperature and stage wise PWHT during welding large fabrication to
reduce the risk of reheat cracking in the final stress relieving
5. use of weld metal with high ductility
143.
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16. Describe the phenomenon of hic or under bead cracking and prevention measures
144.
During fabrication by welding, cracks can occur in some types of steel, due to the
presence of hydrogen. The technical name for this type of cracking is hydrogen induced cold
cracking (HICC) but it is often referred to by other names that describe various
characteristics of hydrogen cracks:
1. Cold cracking - cracks occur when the weld has cooled down
2. HAZ cracking - cracks tend to occur mainly in the HAZ
3. Delayed cracking - cracks may occur sometime after welding has finished (possibly up to
~48h)
4. Under bead cracking - cracks occur in the HAZ beneath a weld bead
145.
146.
These types of cracks often originate from sub-surface locations under the weld in
HAZ. Hydrogen cracking in the HAZ of steel occurs when 4 conditions exist at the same time:
1. Hydrogen level > 15ml/100g of weld metal deposited
2. Stress > 0.5 of the yield stress
3. Temperature < 300C
4. Susceptible microstructure > 400HV hardness
147.
These four conditions (four factors) are mutually interdependent so that the influence
of one condition (its active level) depends on how active the others three factors are.
148.
149.
The phenomenon of HIC is as follows
150.
During welding small amount of free hydrogen is generated due to decomposition of
moisture from the air, electrode coating, shielding gas or contaminations on the surface to be
welded. This hydrogen can dissolve in the molten steel and from there diffuse into extremely
hot but solidified base metal. If the cooling is sufficiently slow, this evolved hydrogen has
enough time to escape to the atmosphere by diffusion. However if the cooling is rapid some
hydrogen may get trapped in HAZ. This hydrogen produces a condition called as Hydrogen
Embrittlement in the locations of its entrapment, which are dislocations and voids between
grains. Also it generates very high hydrostatic pressure in the space of its confinement. This
pressure combined with shrinkage stress due to cooling produce tiny cracks in metal
immediately next to weld bead, which are sub-surface initially but eventually propagate to
surface.
151.
152.
Avoid or Control measures for HICC
153.
Because the factors that cause cracking are interdependent, and each need to be at
an active level at the same time, cracking can be avoided by ensuring that at least one of the
four factors is not active during welding.
154.
Methods that can be used to minimise the influence of each of the four factors as
follows
1. Use of low hydrogen electrodes
2. Electrodes to be baked and should be stored in hot holding oven to avoid moisture pickup
3. Ensuring that the weld zone is dry and free from rust/scale and oil/grease
4. Control moisture in shielding gas
5. Avoiding stress concentrations due to poor fit-up
6. Avoiding poor weld profile (sharp weld toes)
7. Applying a stress-relief heat treatment after welding
8. Increasing the travel speed as practicable in order to reduce the heat input
9. Keeping weld metal volume to an as low level as possible
10. Procuring steel with a CEV that is at the low-end of the range for the steel grade(limited
scope of effectiveness)
11. Using moderate welding heat input so that the weld does not cool quickly (and give HAZ
hardening)
12. Applying pre-heat so that the HAZ cools more slowly (and does not show significant HAZ
hardening); in multi-run welds, maintain a specific inter-pass temperature
13. Post heat to slow down the cooling rate
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155.
17. Describe the under bead cracking and prevention measures in Q/T steels (Quenched and
Tempered)
156.
Q/T steels are normally full alloyed steels which have high hardenability due to high
carbon equivalent. Such steels subsequent to welding if allowed cooling down rapidly
produce brittle microstructure in HAZ. In such circumstances if the hydrogen gets involved in
the process and trapped in brittle microstructure will produce a condition called as
Hydrogen Embrittlement in the location of its entrapment which are dislocations and voids
between grains. Also it generates very high hydrostatic pressure in the space of confinement.
This pressure combined with shrinkage stress due to cooling produce tiny cracks immediately
next to weld bead, which are subsurface initially but eventually propagate to surface. (as
stipulated above in phenomenon of under bead cracking and thereby cause under bead cracks
in Quench and Tempered steels.)
157.
Prevention
1. giving sufficient heat input by means of pre heating
2. maintain proper inter-pass temperature
3. reduce the rate of cooling by means of post heating and adequate PWHT
4. Use low hydrogen process for welding
5. Performing welding in stress free conditions
158.
18. Describe the under bead cracking and prevention measures in hsla steels
159.
Unlike in Q/T steels, HSLA steels are ferritic in nature. The properties of these steels
are achieved by small amounts of alloying elements dissolved in their ferritic structure. For
this very reason they are soft and ductile as compared to QT steels. Such steels, subsequent to
welding if cooled too rapidly, may undergo a change of microstructure from ferritic to
martensitic namely in HAZ. Once martensitic is formed it is hard and brittle. In such
circumstance if any hydrogen pick-up takes place it may very well lead to phenomenon of
HIC or under bead cracking
160.
Prevention
1. ensure that base metals have enough ductility
2. ensure that base metals have sufficient low % of carbon, manganese and other alloying
element which cause appreciable martensite formation
3. reducing the rate of cooling of weldment
4. performing the welding in stress free conditions
5. use of low hydrogen process
161.
19. Describe the three fracture mechanisms
162.
Welds may suffer three different fracture mechanisms:
1. Fatigue
2. Ductile
3. Brittle
163.
Often a complete fracture of a weldment will be a combination of fracture types e.g.
initially fatigue followed by final ductile fracture.
164.
165.
Fatigue
166.
Fatigue fractures occur in situations where loading is of a cyclic nature and at stress
levels well below the yield stress of the material. Typically fatigue cracks will be found on
bridges, cranes, aircraft and items affected by out of balance or vibrating forces. Initiation
takes place from stress concentrations such as changes of section, arc- strikes, and toes of
welds. Even the best designed and made welds have some degree of stress concentration.
167.
168.
Following appearances of exposed surfaces manifests these kinds of fractures.
1. Very smooth fracture surface, although may have steps due to multiple initiation points.
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2. It is encompassed by crescent marks or beach marks
3. Bounded by curved crack front
4. Bands may be visible indicating crack progression.
5. Initiation point opposite curve crack front
6. Surface at 90 to applied loading
169.
Fatigue cracks sometimes stop of their own accord if the crack runs into an area of
low stress. On the other hand they may grow until the remaining cross-section in insufficient
to support the applied loads. At this point final failure will take place by a secondary
mechanism i.e. ductile or brittle.
170.
171.
Ductile
172.
Occur in instances where the strength and the cross-sectional area of the material are
insufficient to carry the applied load. Such fractures are commonly seen on material and
welding procedure tensile test specimens where failure is accompanied by yielding, stretching
and thinning.
173.
174.
A ductile fracture is an outcome of plastic deformation of material to the point of
rupture. It is manifested by
1. Surface is torn and rough
2. Shear lips at 45 applied stress
175.
176.
Brittle
177.
Brittle fracture is result of composition of hard, brittle material and an impulsive
snappy load. It is a fast, unstable type of fracture which can lead to catastrophic failure.
178.
179.
Following factors will increase the risk of brittle fracture:
1. As the temperature (ambient or operational) decreases
2. With the type and increasing thickness of the material
3. Where high levels of residual stresses are present
4. In the presence of notches.
5. Increased strain rate i.e. speed of loading
180.
181.
Distinguishing features of a brittle fracture are:
1. Surface is flat and at 90 to the applied load.
2. Will show little or no plastic deformation
3. The surface will be rough and may be crystalline in appearance.
4. May show V shaped chevrons on the surface which will point back to the initiation source
182.
183.
Out of the above types fatigue is always the first mode of failure. If failure is in
second mode i.e. ductile or brittle, then these failures will always be following fatigue and not
vice-versa. Otherwise there could be purely ductile or purely brittle failures also which
manifested by the appearance as mentioned above.
184.
20. Describe residual stresses
185.
Metals contract during solidification and subsequent cooling, but if this contraction
is prevented or inhibited residual stresses will develop. Most metal products contain residual
stresses, often up to the yield point. Pipe products for example are usually very highly
stressed. The tendency to develop residual stresses when the heating and cooling are
localised. So welding with its much localised heating and the presence of liquid and solid
metal contact can be expected to induce very high levels of residual stressed. Residual
stresses can be difficult to measure with any real accuracy, but a rough guide is that when the
weld metal exceeds 2 inch3 (14 cm3) then the total residual stress is about yield point in
magnitude.
186.
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187.
Normal welds develop residual stresses:
1. along the weld longitudinal residual stresses
2. across the weld transvers residual stresses
3. through the weld short transverse residual stresses
188.
21. Describe distortion
189.
Distortion is caused by stress. Distortion related to the change of shape of a
component, which results from welding. This change in shape may be temporary (elastic) or
permanent (plastic). If two pieces of materials e.g. plates, which are to be joined, are free to
move during welding distortion will occur. If the two pieces of material are not free to move
(restrained) the force will remain as residual stresses (no distortion)
190.
191.
Types of distortion
1. longitudinal shrinkage
2. transverse shrinkage
3. angular distortion
4. bowing
192.
193.
Factor which affect distortion
1. material properties and condition
2. heat input
3. Amount of restraint
4. Joint design
5. Part fit-up
6. Welding procedure
194.
Method of reducing distortion
1. Pre-setting, pre-bending
2. Forced restraint e.g. welding fixtures, flexible clamps, strong backs
3. Using balancing welding technique e.g. back strip welding, back step welding
4. Using by design e.g. Elimination of welding, Weld placement, Reducing the volume of weld
metal, Reducing the number of runs
5. Reducing the heat input
195.
22. Describe distortion in a simple weld with single v preparation
196.
The action of the residual stresses in weld in welded joints is to cause distortion.
Consider a simple weld with single V preparation.
197.
198.
The following movements can be detected
1. contraction in the weld and HAZ along with the length
2. bowing due to the greater volume of weld metal at the top of the weld
3. peaking due to the Vee angle
4. ripple (in sheet) away from the weld
5. contraction in the weld metal and HAZ transverse to the weld
199.
200.
Control of distortion is achieved in one or more of the following ways
1. pre-setting or pre-bending so that the metal distorts into the required position
2. clamping to prevent distortion, but this increases the level of residual stress
3. welding sequence i.e. balanced welding, back step or back strip welding
201.
23. Destructive testing or mechanical testing
202.
The tests are called destructive tests because the welded joint is destroyed when
various types of test piece are taken from it.
203.
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204.
Destructive tests can be divided into 2 groups, those used to:
1. Measure a mechanical property quantitative tests
2. Assess the joint quality qualitative tests
205.
206.
Mechanical tests are quantitative because a quantity is measured a mechanical
property such as tensile strength, hardness and impact toughness.
207.
Qualitative tests are used to verify that the joint is free from defects they are of
sound quality - and examples of these are bend tests, macroscopic examination and fracture
tests (fillet fracture and nick-break).
208.
209.
Test objectives
210.
Various types of mechanical test are used by material manufacturers/ suppliers to
verify that plates, pipes, forgings etc have the minimum property values specified for
particular grades.
211.
Design engineers use the minimum property values listed for particular grades of
material as the basis for design and the most cost-effective designs are based on an
assumption that welded joints have properties that are no worse than those of the base metal.
212.
The quantitative (mechanical) tests that are carried out for welding procedure
qualification are intended to demonstrate that the joint properties satisfy design requirements.
213.
214.
Tensile Test Transverse tensile tests
215.
To measure the transverse tensile strength under static loading
1. A reduced specimen assesses the tensile strength of the joint
2. A radius reduced specimen assesses the tensile strength of the weld meta
216.
Tensile Test Cruciform test
217.
To measure the relative tensile strength of joints with fillet welds under static loading
(Load through welds)
218.
219.
All weld Tensile Test
220.
To measure Yield Strength & Tensile Strength of (% Elongation also measured &
usually also % Reduction of Area)
1. Electrodes of filler wire / flux combinations
2. Quality of the weld metal as deposited
3. STRA Short transverse reduction areas to access lamellar tear
221.
222.
Bend tests (transverse and longitudinal)
223.
To determine the
1. Soundness of weld metal
2. Weld junctions
3. Heat affected zone
224.
All specimens to be removed and prepared without causing significant distortion or
heating
225.
226.
Side bend test
227.
To determine the soundness of a joint in cross section
228.
229.
Charpy V notch test
230.
To determine the energy absorbed at a specified temperature to fracture the
specimen.
231.
232.
Nick break test
233.
To fracture the joint through the weld metal to permit examination of the fracture
surface
234.
235.
Fillet weld fracture test
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236.
To fracture the joint through the weld metal to permit examination of the fracture
surface (Swan notch in compression)
237.
238.
Macro examination
239.
To examine the whole joint for soundness
240.
241.
CTOD (Crack Tip Opening Displacement Test)
242.
CTOD is a test method for the determination of a metals resistance to the initiation of
a crack resulting from notch defects.
243.
CTOD measures the elastic-plastic toughness of the metal in the ductile-brittle
transition. The propagation of a crack in a welded structure depends upon factors including
the materials used. The size and sharpness of any notch present, operating temperature, the
degree of restraint and welding procedure requirements.
244.
245.
CTOD test permits full size specimens to be used irrespective of metal thickness to
which a notch of given width and depth is applied. The specimen is subjected to a high speed
resonance load cycling on a three point bending rig. A clip gauge is fixed to the mouth of the
notch accurately measures the slow opening of the crack and a force sensing device enables
the applied load to be plotted against displacement on a graph.
246.
24. Explain haz heat affected zone
247.
During welding using fusion welding process there is a huge temperature difference
between the weld and parent material. Because of this temperature difference, the material
immediately adjacent to the weld undergoes micro structural changes.
248.
This area which lies between the fusion boundary and the unaffected parent material
is called heat affected zone HAZ. The extent of changes in microstructure will depend on the
following.
1. Material composition especially carbon content
2. Heat input the higher the heat or arc energy, the wider HAZ. Metallurgical properties will
also be affected.
3. The rate of cooling higher the rate of cooling, harder the HAZ especially C.E. of the steel is
high.
249.
The HAZ in a weld zone on steel consist of up to four separate regions, starting from
the area immediately to the weld.
1. Coarse grained region heat between 1100C and melting point
2. Grain refined region - 900C to 1100C
3. Region of partial transformation - 750C to 900C
4. Region of spheroidization just below 750C
250.
25. Describe briefly saw wire/flux + saw consumables
251.
AWS A5.17.89 is a specification for carbon steel electrode and fluxes for SAW. The
coding system shows the flux capabilities when combined with a specific electrode.
252.
Example coding
253.
F7A6 EM12K or EC1 (Trade Name)
254.
F Indicates flux
255.
7 Indicates the weld metals minimum ultimate tensile strength in Kpsi x 10
(7x10=70Kpsi), when using the flux with the electrode identified.
256.
A Designates the condition of heat treatment to the weld or which test were
conducted A is for as welded and P for PWHT
257.
6 Indicates the lowest temperature in degree Fahrenheit x 10 at which a charpy
value of 27 J was achieved.
258.
E Indicates a solid electrode. EC would indicate a composite electrode
259.
M This may be L, M, or H indicating Low, Medium or High manganese content
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260.
12 This may be one or two digits and nominal carbon content of the electrode i.e.
12 = 0.12%, 8 = 0.08%
261.
K Indicates the electrode is made from semi-killed steel.
262.
263.
Additional flux Information
264.
All fluxes to this specification must be of a granular nature and capable of flowing
freely when used. Particle size is to be a matter of agreement between the purchaser and
supplier. The flux must permit the production of smooth with depth of undercut. Fluxes are
classified on the basis of mechanical properties of the weld metal which they produce and
therefore have to be shown in conjunction with the electrode used. Fluxes used to this
specification may contain fusible compounds of various proportions. Some fluxes contain deoxidisers, others do not and fluxes may react differently with different electrodes and are
voltage used. A change of arc voltage during welding will change the amount of flux melted
and may therefore change the composition of the weld metal. The effect of this change allows
fluxed to be described as neutral, active or alloy.
265.
266.
Neutral fluxes
267.
Neutral fluxes are those which do not produce any significant change in the weld
metal chemical analysis irrespective of arc voltage / arc length changes. Fluxes of this type
contain little or no de-oxidisers and rely on electrode for de-oxidation. They are mainly used
for multi-pass welds
268.
269.
Active fluxes
270.
Active fluxes contain manganese and silicon as de-oxidisers and the effect of those on
the weld metal will change as the arc voltage changes. These fluxes are used mainly for
single pass welds.
271.
272.
Alloy fluxes
273.
Alloy fluxes are those which can be used with a carbon steel electrode to produce a
low alloy weld metal as such they come under the scope of AWS a5.23, low alloy steel
electrodes and fluxes for SAW.
274.
275.
Flux basicity or classification
276.
Basic oxides tend to be more stable than acidic oxides. Fluxes for SAW may be
classified as follows
1. acid general purpose use and for dirty (rusty) steel
2. neutral
3. semi basic improving quality
4. basic
5. high basicity maximum weld toughness and performance
277.
26. Describe briefly fused and agglomerated flux for saw
278.
Fused flux
279.
Fused flux are manufactured as follows, the ingredients are mixed and melted at high
temperature, the mixture is then poured on to large chill blocks or directed into a steam of
water to produce granules which have a hard glassy appearance. The material is then
crushed, sieved and packaged.
280.
281.
Advantages
282.
Good chemical mix achieved
283.
They do not attract moisture, (not hygroscopic) this improves handling, storage, use
and weldability. Any moisture present is easily removed by low temperature drying.
284.
It is easy to remove impurities and fine particles etc. when recycling.
285.
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286.
Disadvantages
287.
The main disadvantage is the difficult in adding de-oxidants and Ferro-alloys. These
would be lost during the high temperature manufacture. The maintenance of a controlled flux
depth is considered critical.
288.
289.
Agglomerated flux
290.
All the flux materials are dry mixed and then bonded with either potassium or
silicate. They are then baked at a temperature below the fusion or melting point and therefore
remain as a powder, which is sieved for size and packaged.
291.
292.
Advantages
293.
Can be colour coded
294.
Easy addition of de-oxidants and Ferro-alloys
295.
Flux depth not co critical
296.
297.
Disadvantages
298.
Tendency for flux to absorb moisture and difficult to re-drying procedure
299.
Possibility of molten slag, causing porosity
300.
Difficult recycling i.e. removal of impurities and sieving
301.
27. A failure has been occurred in service at 40c what is your evaluation on this?
302.
Service temperature of the order of 40C tells that the failure most probably has
occurred due to lack of strength or toughness at that temperature. Compared to base metal a
weld is always of irregular shape and hence considered as irregularity or discontinuity in
surface profiles. Any discontinuity serves as a stress raiser when it comes across lines of
stresses. The strength of material / metal would drops at the locations of high stress
concentration especially when temperature drops significantly. In brief metal tends to lose its
notch toughness. Hence our area of investigation should be notch toughness of given weld
at low temperature. This can be approached in following ways.
1. Verifying that WPS has recommended proper consumables to be used and all the essential
variables were adhered to.
1. heat treatment records and lap test reports if any
2. Review batch certificates for consumables used chemical composition and physical properties
certificates supplied by manufacturer (material test certificates)
3. hardness of the base metal and thickness in the rupture zone
4. suitability of material for the given service conditions
2. Location of failure should be inspected and point of initiation should be established
303.
If the location of failure initiation happens to be without any defect viz., undercut or
porosity then failure can be attributed to sheer lack of low temperature strength and
consumable giving higher low temperature strength may be recommended and improvement
in weld profile may also be advised. However if the point of initiation happens to be a defect
such as porosity or any sub surface defect then corresponding radiograph for that section of
weld may be closely examined and interpreted. In such cases more stringent acceptance
criterion may be recommended in addition to recommendations mentioned above.
304.
28. If you detect an arc strike what is the course of action?
305.
If any arc strike is found on the parent metal is should be ground smooth and MPI is
to be conducted on the location, if it is a ferrous material. For S.S PT is to be conducted.
306.
29. What are the documents required to do repair?
307.
Approved repair welding procedure, qualified welders, method of exploration of
defect, method of defect removal, repair report.
308.
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30. What would be the result of using temperature 1300c in heat treatment?
309.
Steel which are overheated above 1200C may suffer a permanent loss of toughness,
distortion and also forms large quantities of mill scale on their surface.
310.
31. What are the differences between a welding procedure approval and a welder qualification
test?
311.
The welding procedure approval test is carried out by a competent welder and the
quality of weld is assessed using non-destructive and mechanical testing techniques. The
intention of the test is to demonstrate that the proposed welding procedure will produce a
welded joint which will satisfy the specified requirement of weld quality and mechanical
properties.
312.
Welder approval test examines a welders skill and ability in producing a satisfactory
weld. The test may be performed with or with a qualified procedure, (Note: without an
approval welding procedure the welding parameters must be recorded.) welder approval must
be done prior to start the welding in production site. Welder should be qualified to do the
task.
313.
32. Can a non-approved welder be employed to perform welding test?
314.
Yes
315.
33. Describe two method of producing approval procedures?
1. By using prequalified procedure
2. By establishing a procedure
3. By doing mock-up or by trial and error method
316.
34. How to improve team spirit?
1. If there are aged and young inspectors in my team I will give more responsibility to aged one
than younger one so that everyone will get equal load with job according to their experience.
2. Off the job, play games like cricket, badminton etc. against inter department which will make
them united.
3. Once in a while call them for meeting to discuss the latest development
4. Motivate them by giving small incentives or gift at the end of project to encourage the team
work.
5. On special occasion arrange social programme against inter department.
6. Help them all personally without partiality
7. Discuss often their site problems
8. Offer them immediate rewards when they completed really risky and effective job
317.
35. Going to sickness it has been necessary for you to replace a very experienced welding inspector
he has been responsible for carrying out all welder approval testing. his replacement has to
come from your existing staff that has not vast experience in this field
a. How would you instruct the replacement in his new duties and what critical points
would you emphasis?
318.
Prior to assigning the job you would assess the inspector knowledge level in the
welder approval test and you would instruct to carry out and observe the following
1. Collect and go through relevant welding procedure specification and other procedures.
2. Prepare the measuring instrument those are required during the test for checking and
inspection tools like tongue tester, temperature indicating crayons, inspection mirror, torch
light weld gauges, measuring tape etc. and check their calibration validity.
3. Check the test piece material specification and dimension as per WPS.
4. Check the welding preparation for correct bevel angle, root face, root gap and mismatch.
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5. Check consumable certificate such as filler wire, electrodes, fluxes and gases going to be
used for welder test.
6. Check fixing position of the test piece that is 1G, 2G, 3G, 4G, 5G and 6G etc.
7. Mark the bottom and top position in case of pipe
8. Measure heat input.
9. Final weld visual inspection
10. Mark welders name date WPS No and position
11. Prepare test report and submit to supervisor for record and NDE processing.
319.
36. Define quantitative test and qualitative test
320.
Quantitative Test
321.
For measuring a quantity (quantity test = a mechanical property)
322.
Typical mechanical testes
- tensile test
- hardness test
- charpy V notch test & CTOD
323.
324.
Qualitative test
325.
For assessing joint quality (quality test = good fusion & free from defects)
326.
Typical qualitative tests
- bend test
- macro examination (micro examination for some metals)
- fillet fracture & nick break test
327.
37. What does a welding procedure consist of?
328.
Welding procedure consist of
1. essential variables
2. non-essential variables
3. supplementary essential variables
329.
330.
Essential variables
331.
A change in welding parameters which effects the mechanical properties of a weld
are called essential variables. E.g. process, type of material, electrode / flux, shielding gas,
preheating, PWHT etc
332.
Non-essential variables
333.
Changes in welding parameters, which will not affect the mechanical properties of
the weld metal, are called non-essential variables. E.g. groove angel, method of cleaning etc.
334.
Supplementary essential variables
335.
Supplementary essential variables are variables that have an effect on the impact
properties of a joint. They are classed as Non-Essential if impact testing is not required. The
welding procedure shall be attached with PQR to show the evidence that the procedure meets
the mechanical properties desired by the code / specification.
336.
38. Give typical example of welder qualification range for a
a. thickness
b. diameter
c. process
337.
Thickness - When welder is tested on thickness T he is qualified to weld two times
the thickness 2T
338.
Diameter when welder is tested on diameter D he is qualified to weld pipe size
D/2 and above
339.
Process welder is qualified to weld only which process he has been tested
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340.
39. Explain why the quality of the parent metal may affect the incidence of weld metal cracking?
341.
Lower quality or dirty contaminated steels have a higher residual content e.g.
sulphur, phosphorus etc. due to the lower melting point of these impurities segregated into the
centreline of the weld pool during the solidification and will form a plane of low ductility
which may crack when acted upon by the normal transverse residual stress.
342.
40. Explain purpose of preheat
343.
Preheating involves heating the base metal, either entirely or just the region
surrounding the joint to a specific desired temperature, called the preheat temperature
344.
Purpose
1. reduce the risk of hydrogen crack
2. reduce the hardness of the weld heat affected zone
3. reduce shrinkage stresses during cooling and improve the distribution of residual
345.
If preheat is locally applied it must extend to at least 75mm from the weld location
and be preferably measured on the opposite face to the one being welded.
346.
The selection of preheat temperature should be based on three factors listed in order
of importance
1. composition and hardenability of the base or parent metal
2. the feasibility of post weld heat treatment
3. the size, thickness and configuration of the part to be welded
347.
The temperature of the part can be checked by use of temperature indicating crayons
(temp-sticks) tough pyrometers or thermocouples.
348.
41. Explain PWHT
349.
Post weld heat treatment is a process in which the metal in the solid state is subjected
to one or more controlled heating cycles after welding. This PWHT is normally carried out
for the purpose of stress relief and ensuring that the HAZ hardness is not too high for
particular steels with certain service applications. PWHT may also be used to produce
certain properties such as softening after cold working.
350.
Few more advantages of PWHT
1. Improve the resistance of the joint to brittle fracture
2. Improve the resistance of the joint to stress corrosion cracking
3. Enable welded joints to be machined to accurate dimensional tolerances
351.
Because the main reason for (and benefit of) PWHT is to reduce residual stresses,
PWHT is often called stress relief.
352.
The following variables for PWHT must be carefully controlled
1. Maximum heating rate
2. Soak temperature range
3. Minimum time at the soak temperature (soak time)
4. Maximum cooling rate
42. Terms & definitions
353.
Quality assurance
354.
All the planned and systematic actions and activities required providing an adequate
level of confidence in a product, what is wanted?
355.
356.
Quality control
357.
The operational techniques and activities used to fulfil quality. What must be done /
controlled, in order to achieve what is wanted
358.
359.
Quality control inspection
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360.
Quality control inspection as an activity such as measuring, examining, testing or
gauging one or more characteristics of a product or service, and comparing the results with
specified requirements in order to establish whether conformity is achieved for each
characteristic.
361.
362.
In-process inspection
363.
Inspection & surveillance carried out during production
364.
365.
Non-compliance
366.
A written report that states that a clause or instruction in the contract documents,
code or standard cannot be or was not met.
367.
368.
NCR
369.
A non-conformance report documents the details of a non-conformance identified in
a quality audit or other process review. The objective of the report is to make an
unambiguous, defensible, clear and concise definition of the problem so that corrective action
can and will be initiated by management.
370.
371.
Concession
372.
An agreed deviation (with the customer or client) from a pre-agreed path, or
specification
373.
374.
Inspection specification
375.
A document containing or referring to all information required in the level of
inspection for a product.
376.
377.
Certificate of conformance
378.
A signed certificate, declaring that a product has been produced in accordance with a
specification
379.
380.
Defect
381.
A welding imperfection that falls outside of a level of acceptance criteria in an
applied standard
382.
383.
Minor defect
384.
Unlikely to cause failure of the product
385.
386.
Major defect
387.
Likely to cause failure, but small risk of loss of life
388.
389.
Critical defect
390.
Extremely likely to cause failure, with high risk of loss of life
391.
392.
Audit compliance
393.
It determines quality system complies with the applicable quality control procedures
394.
395.
Material specification
396.
The specification applicable to a raw material which is used in the fabrication of a
product
397.
398.
Auditor
399.
The certified quality auditor is a professional who understands the standards and
principles of auditing and the auditing techniques of examining, questioning, evaluating and
reporting to determine a quality systems adequacy and deficiencies.
400.
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401.
Calibration:
402.
Operations for the purpose of determining the magnitude of errors of a measuring
instrument, etc.
403.
404.
Validation:
405.
Operations for the purpose of demonstrating that an item of welding equipment, or a
welding system, conforms to the operating specification for that equipment or system
406.
407.
Accuracy:
408.
Closeness of an observed quantity to the defined, or true, value
409.
43. As a team leader what steps you will take for improving quality?
a. If a member has to be replaced what all things to do?
b. What are the things you will brief in start of a job for your new member?
410.
Actions to Improve quality
1. I conduct periodic and systematic audit, based on audit finds such non-conformance, any
other quality related issues, take preventive actions and avoid such things occur in future.
2. Conduct quality related meetings with inspectors, other department members, and look for
any ideas to improve quality or any quality related concerns they have in their job, take
necessary preventive actions.
3. Any complaints from clients / TPI or feedback from clients, take necessary preventive actions.
4. Technical information related to quality; circulate to all concern departments members
5. Conduct training programs for specialized jobs and critical jobs
6. Provide motivation, motivated employees provide a better working environment in addition to
the product or service output benefits
411.
412.
Actions with replacing member
413.
Get hand over note from replacing member including the following
1. Hand over note including completed status, which was handled by him, current job status,
any quality related issues such as site query, concession request, NCR log etc.
2. Document management etc.
3. Contact details of client representative, contractor personal email address, contact telephone
numbers
4. Contact details of replacing member for future reference
414.
415.
Actions for new member
1. Welcome and introduced to all staff including higher authority
2. Safety induction explain minimum PPE, emergency exit, and emergency contact numbers
3. Brief explain about work system organization chart, reporting channels etc.
4. Brief explain about project specification, quality control procedure, ITP, method statements,
safety procedures, quality management system and location available of those documents
5. Brief explain about site query, NCR log, WPS, PQR, and WQT records etc.
416.
44. Misunderstand between NDT inspector and QC inspector, why is it rectified? How will you
rectify? explain briefly
417.
Reasons to rectify
1. It will lead to miscommunication which will affect the quality of NDT such as wrong
identification of weld joint, wrong NDT method, wrong weld details.
2. Back log in work, substandard work output, work delay in schedule
418.
Rectification measures
1. Conduct the meeting with QC inspector and NDT inspector
2. Open discuss with them, find actual problem
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3. May have technical problem, communication problem like language problem or personal
problem like leave overdue, sick family reason
4. Analysis the root cause of problem and solve
5. Verify the correct system is followed, it not establish the system
6. Continuous monitoring the inspectors activities
419.
45. Give brief describe of the difference between macro and micro examination also state the
purpose of the examination?
420.
Differences
1. macro examination magnification is 10x or lower
2. micro examination magnification is greater than 10x usually 100x or higher
3. macro specimen need rough and ground with 80 grit finish
4. micro specimen need very fine grinding at 600 grit and polish / etching to produce a mirror
finish
421.
Purpose of examination
1. Macro examination: to determine depth of fusion, depth of penetration, effective throat, weld
soundness, degree of fusion, presence of discontinuity, weld configuration, number of weld
pass etc.
2. Micro examination: to determine micro structural constituents, presence of inclusions,
presence of microscopic defects, and nature of cracking etc.
422.
46. Describe briefly the duties of senior welding inspector
423.
A senior welding inspector may be required to manage and control and lead a team
of welding inspectors who will look to him for guidance, especially on subjects of a technical
nature. The SWI will be expected to give advice, handle problems, take decisions and lead
from the front. The SWI will therefore require leadership skills in addition to technical
experience. Senior welding inspector is responsible for the following
1. Signing off the product
2. Prepare department budgets for personnel facilities and supplies
3. Assign work to the inspectors
4. Supervise and evaluate their work
5. Motivate staff to meet standards of quality and efficiency
6. Interlink with other departments to improve procedure and advice on quality problems
7. Receive complying item, understand the problems and establish corrective measures
8. Review plant equipment condition, inspection reports for fitness to use during service
9. Prepare scrutinize documentation for quality
10. Participate in inspection and planning, reviewing and approve procedure which is prepared
by inspection department
11. Develop teak work, advice on training and other personnel qualification requirements
12. Ensure adequate safety precaution for all personnel
424.
In other circumstances he may have a more technically demanding role that requires
detailed knowledge or particular activities
425.
The technical skills required are:
1. Knowledge of technology
2. Knowledge of code of practice
3. Knowledge of planning
4. Knowledge of organization
5. Knowledge of auditing
426.
Knowledge of technology required is similar to the welding inspector but with
additional cope and depth of
1. Commonly used NDT technique
2. Radiographic interpretation
3. QA/QC knowledge
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4. Basic metallurgy of commonly used welded materials including assessment of fracture
surfaces.
427.
Knowledge of code and practice the SWI should be aware of common standards
applied in the welding industry
428.
Knowledge of planning planning of inspection will be required for all phase of
inspection (pre-in-service-post)
429.
Knowledge of organization organization skills are necessary to ensure their
inspection requirement of any plan can be met on time using the correct personnel for the job
430.
Knowledge of auditing the knowledge of audit may involve in detailed checks of
very limited area of inspection to ensure that documentation produced meet the requirement
of the specification
431.
Leadership requires:
1. Ability to if so required
2. Willingness to direct
3. Acceptance of responsibility
4. Understand of problems
5. Ability to delegate willingness to trust staff
6. Commitment to oneself
432.
47. A. on a material certificate following abbreviations APPEARS
a. What do they mean?
1. Re
2. Rm
3. Rp0.2
4. Z%
5. A%
6. CEV or CEQ
b. answer the below given questions
1. In a cross joint tensile test what dimensions and readings are taken?
2. Show how these are used to determine the tensile strength
3. Where would you normally expect the specimen to break?
c.
d. Re means yield stress Reu = upper yield stress Rel = lower yield stress
e. Rm means ultimate tensile strength
f. Rp0.2 means proof stress 0.2% of gauge length
g. Z% means reduction of area at the point of fracture or transverse ductility (>20% = high
resistance to lamellar tear)
h. A% means elongation of the gauge length or elongation ductility
i.
j. To approve a butt welding procedure most of specifications such as ISO 15614 and ASME
SEC. IX require tensile tests to be carried out.
k.
l. These are generally cross joint (transverse) tensile tests of square or rectangular cross
section that as the name suggests, are oriented across the weld so that both parent
metals, both heat affected zones and the weld metal itself are tested. The tensile test piece
typical of the type specified by European standards, such us EN 895, that specify the
dimensions of the test pieces require all excess weld metals to be removed and the surface
shall be free from scratches. Test pieces may be machined to represent the full thickness
of the joint but for very thick joints it may be necessary to take several transverse tensile
test specimens to be able to test the full thickness.
m.
n. While it is possible to measure the yield strength, the elongation and the reduction of area
of transverse tensile test specimens the fact that there are at least three different areas
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with dissimilar mechanical properties makes such measurements inaccurate and
unreliable, although this is sometimes carried out purely for information purpose.
o.
p. The specifications mentioned above require the UTS and the position of the fracture to be
recorded.
q. If the test piece breaks in the weld metal, it is acceptable provided the calculated strength
is not less than the minimum tensile strength specified, which is usually the minimum
specified for the base metal material grade.
r. In the ASME IX code, if the test specimen breaks outside the weld or fusion zone at a
stress above 95% of the minimum base metal strength the test result is acceptable.
s.
t. In most situations the weld metal stronger than the parent metal it is overmatched so
that failure occurs in the parent metal or the HAZ at a stress above the specified
minimum.
u.
v.
w.
x.
y.
z.
On a material certificate following terms may APPEARS:

normalised
quenched and tempered
as rolled
z quality
aa. What are the meanings of these terms?
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ab.
ac. Normalised
ad. It is a process of heating steel to about 40-50C above upper critical temperature
holding for proper time and then cooling in still air on slightly agitated air to room
temperature. The resultant microstructure should be pearlite. It is done for grain
structure refinement, homogenization, removal of residual stress and improved
machinability. For plain steel the temperature for normalizing is 860-915C, and for
alloy steels it is 870-925C
ae.
af. Quenched and Tempered
ag. Quenching is a process of rapid cooling from austenising temperature, which results in
the transformation of austenite to martensite. During cooling, heat musts be extracted at
a very fast rate from the steel piece; and is possible when a steel piece is allowed to come
in contact with some medium which absorbs heat from steel within short period. The
medium use for quenching is known quench out. The quenchants used are liquids, air and
gases are used in special case.
ah. Quenching is a hardening treatment which develops maximum hardness, excellent wear
resistance and high strength levels in the steel, at the same time it adversely affects
properties such as ductility. Toughness and impact strength and also imparts brittleness
because of internal stress developed by quenching. Such a process, which consists of
heating hardened steel below the lower critical temperature, followed by cooling in air is
known as tempering. Tempering lowers strength and wear resistance of the hardened
steel marginally.
ai. As rolled
aj. As rolled means having improved low temperature toughness. A high strength steel plate
of improved low temperature toughness useful for making an grade line pipe provided
with the addition of 0.8 -2% by weight of nickel and 0.0005 0.0040% by weight of Ca.,
which may be used in the as rolled state and manufactured through tow step controlled
rolling the secondary step rolling of which is carried out at a temperature lower than
conventional rolling.
ak.
al. Z Quality
am. Z quality means low sulphur steel with a tested level of ductility through the Z axis
of the plate as opposed to the transverse on longitudinal axis, Z quality is determined
by through thickness tensile test hence sometimes known as through thickness tested
plate.
an.
ao. On a construction site a member of your staff has issued an instruction that all MMA
electrodes have to be baked at 250C before use. the electrode in question are of the
following types:
ap. aws 5.1 e6013
aq. bs en 499 e423b (in standard packing)
ar. bs en 499 e425ni b (in vacuum packs)
as. bs en 499 e352c
1.Do you agree with this instruction?
2.give reasons for your answer
at.
au. I would not agree the instructions given that the above mentioned MMA electrodes to be
baked at 250 degree Celsius before use
av. The reasons for my answer as described below:
1. the first given electrode details are AWS 5.1 E6013, it is a rutile electrode, since they have
high combined moisture and also contains up to 10% cellulose they cannot be baked as they
will not give a low Hydrogen weld deposit.
2. The second electrode is BS EN 499 E423B (in standard packing), it is a basic electrode and it
should be baked at 350 degree Celsius for up to 2 hours, since the packing is not sealed they
will not reach the end user a guaranteed low hydrogen condition, and should follow
manufacturer instructions.
3. The third electrode BS EN 499 E425Ni B (In vacuum pack), it is a basic electrode and need
no baking since it is vacuum packed.
4. The fourth electrode is BS EN 499 E352C, since it is a cellulose electrode it does not require
baking
aw.
ax. Describe briefly
ay. What are the principle reasons for specifying preheat and interpass temperatures in a
welding procedure?
az. how these temperature may be applied and controlled
ba. Undercut has occurred along the top edge of a butt weld made by mma using 4mm
electrodes in the pc position in 25mm thick c/mn steel plate.
1.the preheat specified for the joint was 50c
2.The welder proposes to apply a cosmetic pass, to correct the defect using a
2.5mm electrode should he used no preheat, the same preheat as the original
weld or a higher preheat for this repair? justify your answer
a. the principle reason for specifying preheat and interpass temperature in welding procedure is
to reduce internal stresses and solidification cracks during and after welding
b. Preheat: before starting of the welding heat the weld face with flame /coil till the
temperature reaches to the specified in the WPS then stop the heating and start the root
welding. If preheat is locally applied it must extend to at least 75mm from the weld location
and be preferably measured on the opposite face to the one being welded. Interpass
Temperature: Once the root is welded allow the weld to cool the job to required interpass
temperature mentioned in the WPS. And maintained the temperature till the welding is
completed for subsequent passes. This can be maintained by automatic heating system or
manual heating. The temperature range can be measured by temple sticks (Temperature
indicating crayons or touch pyrometers or thermocouples)
c. Whatever preheat temperature mentioned in WPS has to be applied even for repair
procedures also to control the weld properties.
bb.
a.
b.
c.
d.
e.
a.
b.
c.
d.
e.
bc. List five items of information that could be recorded on an ultrasonic test report, which
would be never present on radiographic report?
couplant type
probe details: type, angle, size and frequency
scanning method/type
correction sensitivity (+2db)
db (disable)
bd.
be. What is the consideration for qa/qc and inspection department if it is required to
increase the toughness and tensile strength of welds on a specific type of component?
Select high tensile and toughness welding consumables and alloying elements which will
increase the toughness and tensile strength of the component.
Select the welding parameters to control the heat input and followed by PWHT, this will
increase the tensile strength and toughness.
Select suitable welding process.
Select the suitable joint design.
Make sure all the required parameters are followed in production.
bf.
a.
b.
c.
d.
e.
f.
bg. Without approval of drawing piping fabrication has been completed. What will be your
course of action?
Raise a non-conformance report.
Check with approved drawing. If minor changes noted, which will not affect the product
design requirement accept as it is provided a deviation request to be raised and approved.
The changes to be incorporated in the as build drawing.
If any major changes noted compared with approved drawing, to be refabricated as per
approved drawing.
Concern person involved, to issues a warning letter,
Conduct meeting with all inspectors and make them awareness, such as things recur in future.
bh.
bi. During an audit no material certificate was found. How would you proceed?
bj. If material test certificate not available ask the supplier to provide it. If it is not available
with supplier then material should be sent to lab for verifying its chemical and
mechanical properties. The lab report shall be attached instead of MTC.
bk.
bl. Why it is desirable to seal in a lamination which is found to break during edge
preparation?
bm. Lamination is to be seal welded prior to welding because these areas will open up during
welding due to the heat produced while welding.
bn.
bo. In a welder approval test should the procedure be explained to the welder?
bp. No. it is not necessary.
bq.
br.
bs.
bt.
bu.
State the objectives of

A reduced transverse tensile test
A radius reduced transverse tensile test
A reduced transverse tensile test specimen assesses the tensile strength of the joint. A
radius reduced transverse tensile test specimen assesses the tensile strength of the weld
metal.
bv.
bw. What is the purpose of all weld tensile test and a radius reduced tensile test?
bx. An all weld tensile test is to measure the tensile strength of electrodes/flux combination
and quality of weld metal as deposited.
by. A radius reduced tensile test is to assess the tensile strength of the weld metal.
bz. State three factors which contribute to or control the mechanical properties of wrought
steel?
ca. Wrought steel grain much refinement during the hot/cold working and many defects are
also removed. This improvement is marked in the rolling direction but is usually results in
a loss of strength through the thickness.
cb.
cc. What is the metallurgical production cause of lamellar tearing?
cd. Lamellar tear could cause due to the presence of inclusions of sulphur, phosphorus and
higher percentage of carbon.
ce.
cf. Does a wrought plate contain residual stresses due to manufacture?
cg. Yes.
ch.
ci. Give the composition for tool steel?

cj. 0.8%Cr, 1.0%Mn, 0.4%C, 0.3%Mo + Ti or Al + residuals
ck.
cl. If bend test failure has occurred what would be your course of action?
cm. Set aside the piece, take one more test piece and repeat the test. Assess the failure,
whether the failure is within the weld metal, weld junction or in the HAZ. A retest is very
much needed in case of failure.
cn.
co. In which steels can it be expected that hydrogen induced cracking is found in the weld
metal if present at all?
cp. High strength Mn steels
cq.
cr. State four mechanisms of cracking, which may be found in the weld metal of ferritic
steel weldments?
cs. Hydrogen induced cracking
ct. Solidification cracking
cu. Solidification pipe or void
cv. Reheat cracking
cw.
cx.
cy.
cz.
da.
db.
dc.
dd.
de.
df.
dg.
State six methods of procedure to avoid solidification or centreline cracking?

Control the sulphur content
Use consumable with high manganese
Keep manganese-sulphide: carbon ratio as low as possible
Minimise restraints
Use low dilution process
Weld joints are thoroughly cleaned immediately before welding
Maintain proper width to depth ratio
Use preheat
dh.
di.
dj.
dk.
State three methods of procedure for avoiding solidification pipe in weld metal?
Correct depth to width ratio
Correct bead shape
Correct surface chilling effect due to
1.No slag covers process
2.Gas not heated
3.Flow rate too high
dl.
dm. State the four factors which give rise to hydrogen cracking and suggest how control
can be exercised?
dn. Factors which raise the risk of hydrogen crack
do. Stress
dp. Hardness
dq. Hydrogen and
dr. Temperature
ds. Control methods
dt. Minimise stress by
a. Pre-setting
b. Back stitch welding or back skip welding
c. Stringer bead
d. Improve joint design (using double side joint instead of single joint)
e.
du.
a.
b.
dv.
a.
b.
Reduce restraints (J preparation reduce included angle)

Minimize hardness by
Lower C.E
Limit heat input to 1.7kj/m ( avoid grain enlargement) use BS 5135 for preheat
Minimize hydrogen presence in three ways
Removal by a combination of preheat heat input (interpass temperature) and PWHT
Prevent entry by selection of process, consumable control, surface cleanliness and
welding technique (short arc)
c. Making hydrogen acceptable by control of formation of microstructure. Use austenitic or
nickel weld metal.
dw. Temperature
a. Use post heating to maintain temperature and hydrogen defuse
b. Control the cooling rate
dx.
dy. Why are austenitic SS electrodes sometimes specified for the welding of steels which
might be susceptible to hydrogen cracking?
dz. Austenitic stainless steel can absorb more hydrogen than carbon steel.
ea.
eb. In what way does the thickness of the metal influence hydrogen cracking?
ec. Increases rate of cooling, larger volume of hydrogen and greater stress
ed.
ee. In what steel group is PWHT almost always used?
ef. Group 4 high carbon steel
eg.
eh. The high carbon no alloys the carbon content is critical. State the % of carbon which
the welding becomes very difficult?
ei. Carbon content in excess of 0.45% becomes very difficult to weld.
ej.
ek.
a.
b.
c.
el.
State two results which may be expected from stress relief of welded products?
Will reduce internal stresses
Hydrogen is diffused
Grain refinement
em. State two types of cracking which can result from heat treatment?
a. Stress relief cracking or reheat cracking in steels containing chromium
b. Thermal cracking
en.
eo. What is the main advantage of using austenitic electrodes (for weld repair)?
ep. The advantage of using austenitic stainless steel electrodes for repairs that hydrogen
entering the weld metal during welding is held in the weld metal and so will not diffuse in
to the hardening HAZ. Hence hydrogen cracking in the HAZ is unlikely to happen.
eq.
er. What is the main problem of weldability when using 18/8 type austenitic electrodes to
repair ferritic steels?
a. Solidification cracking
b. Weld decay
c. Reduces the corrosion resistance of weld metal
es.
et. Why it is recommended that 29/10 is used for buttering and 18/8 is used to fill when
using austenitic electrodes for repair?
eu. To avoid cracking, it is desirable (at least in joints with high restraint) to butter with an
electrode with high dilution tolerance and to make the closing weld with low strength
electrodes.
ev.
ew. Explain why the depth to width ratio of the bead is important?
ex. To take care of residual stresses in welds which developed
ey. Longitudinal along the weld
ez. Across the weld
fa. Through the weld
fb.
fc. Outline metallurgical features of weld decay?
fd. Weld decay: steels with high carbide forming characteristics such as these will react if
the temperature is allowed to dwell about 550C. If this occurs then the chromium is no
longer available for combination with oxygen for the reformation of the protective oxide
and corrosion may result.
fe. Weld decay: depletion of chromium carbides in stainless steel.
ff.
fg.
fh.
fi.
fj.
fk.
State three methods of avoiding weld decay?

Reduce the carbon content i.e. SS316L
Heat treatment 1100C and quench
To stabilize the steel by added Ti or Nb (to form carbides in preference to Cr carbides)
fl. Why backing gases are often specified when welding stainless steel?
fm. To avoid contamination
fn. To prevent formation of porosity
fo. To avoid formation of oxides
fp.
fq. Why carbon di oxide not normally uses as a shielding as when welding stainless steel?
fr. To maintain low carbon
fs.
ft. When stainless steel is welded to mild steel buttering is recommended why?
fu. To seal carbon in
fv. To stop dilution
fw.
fx. When welding SS to a large root gap (3mm) are often used why?
fy. Distortion closes gap
fz.
ga. What is the essential feature of a stainless steel?
gb. Chromium content (minimum 11%Cr is required to form SS and 29% is maximum) it
react with oxygen and produce chromium oxide which is protect the steel from rust.
gc.
gd. What is the principle reason for the development of residual stresses in metals?
ge. Metals contract during solidification and subsequent cooling, but if this contraction is
prevented or inhibited residual stresses will develop.
gf.
gg.
gh.
gi.
gj.
gk.
gl.
Name three directions of residual stresses in weld joints?

Normal welds develop residual stresses
Along the weld longitudinal residual stress
Across the weld transverse residual stress
Through the weld short transverse residual stress
gm. What causes distortion in welded products?

gn. The action of the residual stresses in the welded joints is to cause distortion
go.
gp.
gq.
gr.
gs.
gt.
gu.
Give four consequences of using excessive current?

Excess spatter
Excess metal profile
Center line cracking
Undercuts
gv. Give four consequences of using excessive arc length?

gw. Unstable arc
gx. Lack of penetration
gy. Uneven profile bead
gz.
ha. State the defects which occur when the tack weld is not correctly incorporated into the
weld?
hb. Lack of penetration or fusion
hc.
hd. Give three consequences of incorrect electrode angle?
he. Undercut
hf. Spatter
hg. Lack of penetration or fusion
hh.
hi. Give one consequence of a) too fast travel speed and b) too slow travel speed?
hj. Lack of penetration or fusion
hk. Slag inclusion
hl.
hm.What defect associated with excessively large size electrodes?
hn. Lack of penetration
ho.
hp. What defect is caused by inadequate cleaning between runs?
hq. Slag inclusion
hr.
hs. What defects can be caused by use of high welding speeds in saw process?
ht. Lack of penetration or fusion
hu. Undercut
hv.
hw. What defects can be caused by the use of excessive gaps in saw process?
hx. Excess penetration or burn through
hy.
hz. What are likely causes of slag in the weld metal?

ia. Slag inclusions, insufficient inter-run cleaning, poor bead profile (convex shape)
ib.
ic. What adjustment must be made in submerged arc welding to reduce the bead width?
id. Lower the voltage
ie. Increase the travel speed (if still within the parameters)
if.
ig. What defects can be caused by a plate having poorly cut joint preparation?
ih. Lack of penetration or fusion
ii.
ij. A weld is to be made on a close square butt joint with excessively high current, what
defect would occur?
ik. Excess weld metal
il.
im. What is the likely defect to be caused by an excessive flux burden?
in. Porosity
io.
ip.
What is the critical level of hydrogen in a weld; can it be measured at any time or after
stress relief?
iq. 5ml per 100gm of weld metal
ir. All weld metal hydrogen diffusion test possible but not for the actual weldment
is.
it.
Describe how and why hydrogen increases the incidence of hydrogen cracking?
iu. Hydrogen in the weld/HAZ builds up internal pressure which could be higher than yield
point of metal low hydrogen would cause residual stresses.
iv.
iw. Describe a heat treatment designed to remove hydrogen, when the treatment must is
applied?
ix. PWHT for 10-20-30 hours
iy.
iz.
Why basic hydrogen controlled electrodes must be kept at 150C?

ja. Prevents reabsorbing of moisture (Hydrogen)
jb.
jc.
What are the causes of lamellar tearing?

jd. Lamellar tearing is a defect in the parent metal of a weldment due to high through
thickness residual stresses and a low through thickness strength and ductility of the
material arising from elongated inclusions and bands within the steel.
je.
jf.
Where lamellar tearing is found in a weldment?

jg. The crack is stepped and parallel to the surface of the plate.
jh.
ji.
How do bands (segregation) within steel influence the incidence of lamellar tearing?
jj. Low through thickness strength and ductility are arising from bands within the steel and
of high residual stress.
jk.
jl.
Can susceptibility to lamellar tearing be assessed by ultrasonic NDE?

jm. No. (But I feel yes)
jn.
jo.
Can lamellar tear be detected by NDE?

jp. Before welding cant be detected, after welding can be detected by ultrasonic NDE.
jq.
jr.
State three methods of avoiding lamellar tearing?

js. Reduce the residual stress by low restraints i.e. pre-setting rather than clamping by use of
gaps.
jt. Buttering
ju. Change the joint design
jv.
jw. Name three types of stainless steel?

jx. Martensitic
jy. Austenitic
jz. Ferritic
ka.
kb. State the main weldability problem of the Fe11% chromium steels?
kc. Hydrogen cracking
kd.
ke. Name two methods of avoiding hydrogen cracking in martensitic stainless steel?
kf. Control by hydrogen limitation i.e. the use of TIG welding process
kg. Control by hardness, normal preheat and heat inputs, so select a very low carbon grade.
kh.
ki.
Why do micro alloyed steels suffer hydrogen cracking in the weld metal?
kj. In the micro alloyed steels the hydrogen is held in the weld metal and so hydrogen tends
to be located there also.
kk.
kl.
What are the factors which give rise to hydrogen cracking in alloyed steels?
km. In the HAZ the tensile residual stresses are across the weld, so the hydrogen cracks are
along the length of the weld. In the weld metal the tensile residual stresses are along the
weld so the hydrogen cracks are across the weld.
kn.
ko. What are the two types of SAW flux?

kp. Fused
kq. Agglomerated
kr.
ks. Why are the hydrogen cracks in the weld metal positioned across (transverse) the width of
the weld?
kt. Hydrogen cracking is typically formed at right angles to the stress and is positively
identified by its transgranular appearance when viewed at X100 magnification. In ferritic
steels hydrogen which enters the weld metal during welding moves into the HAZ and due
to, gas forming characteristics and the residual stress, cracking may result.
ku.
kv. State three items which may contribute to excessive hardness in a weldment?
kw. Grain size
kx. Quenching
ky. C.E carbon and alloys

kz.
la.
State two elements which cause centreline cracking?

lb. Sulphur
lc. Phosphorous
ld.
le.
State the methods of minimizing solidification cracking?

lf. Increase weld metal
lg. Reduce the welding speed
lh. Increase the manganese content of the weld pool
li. Use of cooling bars
lj. Control the sulphur content
lk. Keep manganese-sulphide: carbon ratio as low as possible
ll. Minimise restraints
lm. Use low dilution process
ln. Weld joints are thoroughly cleaned immediately before welding
lo. Maintain proper width to depth ratio
lp. Use preheat
lq. Reduce the amount of metal melted out of the parent metal by
1.skill/technique of the welder
2.reduce the amperage
lr.
ls.
A crack is observed along the centreline of the weld metal. Give two reasons for its
formation?
lt. When the weld metal has been deposited and its contracts during solidification it is vital
that the contraction and be fed by the depression of the outer surface
lu. Contraction fed by the weld metal surface
lv.
lw. Give three reasons why pipe may form in the weld metal?
lx. Premature freezing of the surface
ly. Excessive depth of bead related to width
lz. Bad bead shape
ma.
mb. Give three reasons which contribute to premature freezing of the weld pool surface?
mc. Premature of the surface due to
md. No slag covers i.e. the process
me. Gas not heated
mf. Flow rate too high
mg.
mh. Why ferritic material is usually added to austenitic electrodes?
mi. To avoid centreline cracking
mj.
mk. Why are austenitic electrodes used for welding carbon manganese steel?
ml. To control the hydrogen level i.e. making the hydrogen level acceptable to avoid hydrogen
cracking
mm.
mn. When ferritic is added to electrodes what are two possible consequences?
mo. It tends to avoid solidification cracking it does induce magnetism and makes the weld
metal avoid so reducing the corrosion resistance.
mp.
mq. Why are small stringer beads usually recommended for SS weldments?
mr. To reduce the level of heat input and avoid cracking
ms.
mt. Describe the thermal conditions which give rise to weld decay in austenitic SS weldments
mu. 550 degree C for six seconds
mv.
mw. State the special mechanical properties of 25%Cr in Fe alloys?
mx. Ferritic SS is poor weldability due to cracking brittleness and temper embitterment. It is
a single phase alloy which is ferritic at all solid temperatures, so solidification cracking
is a problem.
my.
mz. What is a specification?
na. Specification is a description of what to use in the making of a product i.e. type of
material type of process and type of consumables.
nb.
nc. What is the extent of approval in a procedure?
nd. Extent of approval is the range over which certain variables may alter without requiring
new procedure i.e. when there is a limitation in the welding qualification i.e.
ne. The minimum and maximum diameter of the pipe that the test sample covers e.g. two inch
test piece would allow down 1 and upto 4
nf. The test may only allow welding of consumables in the same grouping, any other
consumable would require retest
ng. The use of set electrical characteristics would not allow change without retest
nh. The direction of welding if changed may require retest
ni. Change of material to be tested would require retesting
nj.
nk. When is a procedure to be re-established?
nl. When there is change in following essential variables
nm. Change of welding process
nn. Change of shielding gases or fluxes
no. Change of direction of welding
np. Change in parent metal to be welded
nq. Change in joint design
nr. Change in welding consumables
ns. Change welding parameter range
nt.
nu. State the four factors which must be satisfied for good welds:
nv. Fusion welding factors
nw. Fusion (melting) the metal must be melted which requires a high intensity of heat
source.
nx. The process must remove any oxide and other contaminants from the joint faces
ny. Contamination by the atmosphere must be avoided
nz. The welded joint must possess adequate properties
oa.
ob. If visual examination of weld is not possible how will you ensure that the joint is okay?
oc. It can be examined by appropriate NDT methods like RT or UT etc
od.
oe. What are minor defects?
of. Misalignment (linear & angular), slag, porosity etc
og.
oh. What are the major defects?
oi. Lack of side wall fusion, overlap, lamination, lack of inter-run fusion, lack of penetration
and incomplete fusion
oj.
ok. What is the course of action if the weldment has been accepted or rejected?
ol. Inspection results to be recorded in an approved format. If the sample is rejected then the
type of defect and the location has to incorporated in a sketch and the report to be given
for further remedial action
om.
on. What features of steel determine its weldability?
oo. Carbon content & carbon equivalent
op.
oq. What is the main advantage of using 29/10 type austenitic electrodes to repair ferritic
steels?
or. The defects of dilution will be lower the alloy content of the weld metal during cooling so
it is advisable to use it.
os.
ot.
What is the difference between inspection for quality control and inspection for fitness for
purpose?
ou.
ov.
ow.
ox.
oy. Describe the relationship between the four essential factors involved in the formation of
hydrogen induced cold cracking.
oz.
pa.
pb.
pc.
pd.
pe.
pf.
pg.
ph.
pi.
pj.
pk.
pl.
pm.
pn. Discuss the reasons for the existence of arc blow and state possible methods of minimising
arc blow.
po. Welder used cellulose electrode instead of low hydrogen electrode. Suggest corrective
action and your course of action in it?
a. Raise Non conformity report
b. Further investigation to be done to identify any other joints welded.
c. Analysis and identify the root cause for this incident
d. Check with approved drawing, product specification and welding procedures specifications.
If welding procedure specification available for this electrode and product design
requirement accept as it is provided a deviation request to be raised and approved.
e. If the specifications not allowed, the entire joints which is identified to be refabricated as per
approved specification.
f. The changes to be incorporated in the as built drawing.
g. Move welder for training and requalification
h. Issue a strong warning letter to Concern person involved.
i. Conduct meeting with all inspectors and make them awareness, such as things recur in future.
j. Document all the above and close the NCR
pp. Name four commonly used NDT methods and list their advantages and disadvantages?
pq. ND
pr. ADVANTAGES
ps. DISADVANTAGES
T
ME
TH
OD
pt. Visu
pu. Inexpensive Highly
pv. Surface discontinuities
al
portable Immediate
only Generally only large
results Minimum training
discontinuities
Minimum part
Misinterpretation of
preparation
scratches
pw. Dye
px. Portability
qe. Locates surface breaking
Pen
py. Inexpensive
defects only Little
etra
pz. Sensitive to very small
indication of depths
nt
discontinuities
qf. Direct visual detection of
qa. Simple to use
results required
qb. Quick results
qg. Penetrant may
qc. Can be used on any noncontaminate component
porous material
qh. Surface preparation
qd. Low operator skill
critical
required
qi. Post cleaning required
qj. Potentially hazardous
chemicals
qk. Mag
ql. Can be portable
qs. Surface must be
netic
qm. Low cost
accessible
Part
qn. Sensitive to small
qt. Rough surfaces interfere
icle
discontinuities Immediate
with test Part preparation
results
required (removal of
qo. Moderate skill required
finishes and sealant, etc.)
qp. Detects surface and
qu. Semi- directional
subsurface
requiring general
discontinuities
orientation of field to
qq. Relatively fast

qr. No harm to test piece
discontinuity Ferromagnetic materials only

qv. Part must be
demagnetized after test.
qw. Edd
y
Curr
ent
qx. Portable
qy. Detects surface and
subsurface discontinuities
qz. Moderate speed
ra. Immediate results
rb. Sensitive to small
discontinuities Thickness
sensitive
rc. Accurate conductivity
measurements
rd. Can detect thorough
several layers
re. Can be automated
rf. Can detect thorough
surface coatings
rg. Little pre-clean required
rp. Ultr
ason
ic
rq. Portable
rr. Inexpensive
rs. Sensitive to very small
discontinuities Immediate
results
rt. Little part preparation
ru. Wide range of materials
and thickness can be
inspected
ry. Radi
ogra
phic
Test
rz. Permanent record

sa. Internal flaws
sb. Can be used on most
materials
sc. Direct image of flaws
sd. Real time imaging
se. Minimum part
preparation
rh. Surface must be

accessible to probe
ri. Very susceptible to
permeability changes
rj. Only works on conductive
materials
rk. Will not detect defects
parallel to the surface
rl. Not suitable for large
areas and /or complex
geometry
rm. Signal interpretation
required
rn. No permanent record
(unless automated)
ro. Skill and training
required
rv. Surface must be
accessible to probe
Rough surfaces interfere
with test Highly sensitive
to sound beam
discontinuity orientation
rw. High degree of skill
required to set up and
interpret
rx. Couplant usually required
sf. Health hazard
sg. Sensitive to defect
orientation
sh. Limited ability to detect
fine cracks
si. Access to both sides
required
sj. Limited by material
thickness
sk. High degree of skill and
experience required for
exposure and
interpretation
sl. Relatively slow
sm. Depth of discontinuity not
indicated
sn. High capital outlay and
running costs
so. Explain hardness and hardenability

a. Hardness is the property of a material that enables it to resist plastic deformation,
penetration, indentation, and scratching.
b. Hardenability is a term used to describe a material's ability to be hardened when it is exposed
to heat and then quenched, or cooled rapidly.

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On a material certificate following terms may APPEARS:

State the objectives of

ci. Give the composition for tool steel?

State six methods of procedure to avoid solidification or centreline cracking?

Reduce restraints (J preparation reduce included angle)

State three methods of avoiding weld decay?

Name three directions of residual stresses in weld joints?

gm. What causes distortion in welded products?

Give four consequences of using excessive current?

gv. Give four consequences of using excessive arc length?

hz. What are likely causes of slag in the weld metal?

Why basic hydrogen controlled electrodes must be kept at 150C?

What are the causes of lamellar tearing?

Where lamellar tearing is found in a weldment?

Can susceptibility to lamellar tearing be assessed by ultrasonic NDE?

Can lamellar tear be detected by NDE?

State three methods of avoiding lamellar tearing?

jw. Name three types of stainless steel?

ko. What are the two types of SAW flux?

ky. C.E carbon and alloys

State two elements which cause centreline cracking?

State the methods of minimizing solidification cracking?

qq. Relatively fast

discontinuity Ferromagnetic materials only

rz. Permanent record

rh. Surface must be

so. Explain hardness and hardenability

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