INTRO TO WELDING PROCESS

1. DC negative when used for MIG/MAG can give smooth arc.

a. True.
b. False.

2. In which of the following process is the use of pressure required to

successfully joint the materials:
a. TIG.
b. MMA.
c. SAW
d. Stud welding.

3. Which of the welding process uses loose granular flux:

a. FCAW.
b. SAW.
c. GTAW.
d. SMAW.

4. In the TIG welding process, gas shielding of the weld pool maybe provided
by which gas(es):
a. Carbon dioxide.
b. Argon and oxygen.
c. Argon and helium.
d. Oxygen and helium.

5. Which is not a factor that should be considered in selecting the best

shielding gas mixture for a given applications:
a. Weld appearance and acceptable spatter level.
b. Thickness, joint design and penetration requirements.
c. The welder’s personal requirements.
 d. Transfer mode.

6. Which is an advantage of an argon/hydrogen gas mixture in TIG of stainless

steel:
a. Lower heat input.
b. Improved toughness.
c. Faster travel speed.
d. Improved mechanical properties.

7. Some MMA electrodes for the welding of stainless steel have a low carbon
steel core wire and the alloying elements in the covering. This is because:
a. The core wire offer lower resistance to the passage of the welding
current.
b. The manufacturer can more conveniently include alloying elements in
the covering than produce special core wires.
c. Both for reasons a and b above.
d. For some reason not listed above.

8. A CC (Drooping Arc) power source is suitable for:

a. MMA – TIG.
b. MIG/MAG – FCAW welding process.
c. SAW – MIG/MAG.
d. MMA – MIG/MAG.

9. In Gas Metal Arc Welding (GMAW), spray Transfer may be achieved using
shielding gases containing:
a. More than 85% argon.
b. Less than 50% argon.
c. 100% carbon dioxide.
d. Less than 75% argon.
10. When welding with a weave technique the heat input using the same
welding parameters (amps and volts) as those used for stringer bead will
be:
a. Lower than that for the stringer bead.
b. Unaffected because techniques has no influence on the heat input.
c. Will be higher than the stringer bead because the travel speed will be
lower.
d. The same as that for the stringer bead.

11. Travel speed is the rate at which the welding gun progress along the joint.
As the travel speed increased:
a. The penetration is increased.
b. The heat input into the joint decreased and the penetration is
decreased.
c. The penetration is decreased and the weld bead becomes higher and
wider.
d. The heat input into the joint is increased.

12. The recommended drying temperatures and time required for producing a
condition below 5ml H2 / 100 grams of weld metal when using basic
electrodes would be:
a. Below 150°C for 1 hour.
b. 250°C for 1 hour.
c. Over 350°C for 1 hour.
d. 600°C for 1 hour.

13. In general, the MIG/MAG mode of transfer best suited for welding thin
sheet is:
a. Short-circuiting transfer.
b. Globular transfer.
c. Spray transfer.
d. Should not use MIG/MAG for welding thin sheet.
14. In general, the MIG/MAG mode of transfer best suited for welding thick
sheet is spray transfer.
a. True.
b. False.

15. When using Gas Metal Arc Welding (GMAW) process, straight argon may be
successfully used as a shielded gas when welding the following material(s):
a. Steel or aluminum.
b. Aluminum.
c. Straight argon is never used.
d. Steel.

16. The primary advantage of a 75% Ar, 25% CO2 gas mixture over pure CO2 in
the GMAW process is:
a. Increase in welding speeds.
b. Very significant reduction in weld spatter.
c. Increase heat input.
d. Decrease in welding speeds.

17. Welding changes the properties of solid steel through:

a. Mechanical changes caused by rolling.
b. Changing the final appearance of the steel.
c. Heating and cooling cycles associated with the welding arc and weld
metal deposit.
d. Metallurgical effects as a result of micrographs.

18. When using the GMAW process for the welding of aluminum, the liner
should made of:
a. Nylon.
b. Graphite.
c. Steel.
 d. A liner should not be used.
19. How will the width of the heat affected zone tent to vary as the heat input
of a weld is increased?
a. Increase
b. Decrease
c. unaffected
21. In the TIG process an arc is formed between:
a. The filler metal rod and the work piece.
b. The tungsten electrode and the filler metal rod.
c. No arc is present.
d. The tungsten electrode and the work piece.

22. Arc energy or weld heat is a function of:

a. Travel speed only.
b. The welders ability and does not depend on the welding parameters.
c. Arc voltage and electrode type.
d. Arc voltage, arc current, and travel speed.

23. In MMA the molten metal is protected by:

a. The molten metal is not protected.
b. External carbon dioxide shielding gas.
c. External argon shielding gas.
d. Gases created from the decomposition of the electrode covering.

24. In the Gas Metal Arc Welding process, the electrical current is transferred
to the electrode via the:
a. Feed rolls.
b. Contact tip.
c. Sleeve.
d. Liner.
25. The three main modes of transfer encountered in Gas Metal Arc Welding
(GMAW) are:-
a. Spray, globular and drooping.
b. Spray, high-arc and drooping.
c. High-arc, globular and short-circuiting.
d. Spray, globular and short-circuiting.

26. Which of the following situations is most likely to produce the greatest
amount of the direct and reflected ultraviolet light?
a. Submerged arc welding.
b. Gas metal Arc Welding aluminum plate.
c. Brazing.
d. Resistance welding two thin sheet steel.

27. Which is not an advantage of Helium/Argon/Carbon dioxide mixtures for

welding stainless steel:
a. Short circuiting transfer can be used for joining thin materials and
welding out of position.
b. The high heat input of helium produces deep penetration.
c. Wetting and bead appearance are good.
d. They can be used on austenitic stainless steel without fear of
hydrogen embitterment.
28. Using manual metal arc welding, which of the following has the shortest run
out length?
a. 6 mm electrode, arc energy 1 kj/mm
b. 5 mm electrode, arc energy 2 kj/mm
c. 4mm electrode, arc energy 3 kj/mm
d. 4mm electrode, arc energy 4 kj/mm
29. Which of the bead of C- Mn steel weld is most likely to have the lowest
toughness?
a. the root of a weld
 b. the HAZ of the root
c. the center of a weld
d. the HAZ of the cap

30. Which statement with regards to open circuit voltage is not true:
a. OCV is the voltage between the terminals when welding.
b. The voltage occurs before welding or without load.
c. AC machine has higher OCV compare to DC current.
d. DC current more safe than AC current due to lower OCV value.

31. Inverters are:

a. Less efficient than conventional machine.
b. Capable of being either CC or CV.
c. Inferior in volt – ampere characteristics.
d. Bulky and heavy.

32. Argon is not generally used as a shielding gas when MIG welding carbon
steel because:
a. The price is too expensive compare with carbon dioxide.
b. Penetration is poor.
c. Argon increase spatter levels.
d. Poor cap profile or weld contour.

33.In CO2 welding, which modes of transfer is the most suitable to be used in
the vertical position:
a. Globular.
b. Axial spray.
c. Dip or short circuiting.
d. All of the above.
34. Before use, electrodes classified as BS 639 : 1986 E 42 43 R 10 or AWS type
E 6013 need to be:
a. Dried for 1 hour at 45°C
b. Dried for 2 hours at above 120°C
c. No drying or what so ever.
d. Dried for 1 hour at 120°C max.

35. Movement of the arc by magnetic forces in MMA welding is termed:

a. Arc deviation.
b. Arc misalignment.
c. Arc blow.
d. Arc eye.

36. Which of the following processes joins metals plastically:

a. Friction welding.
b. Resistance welding.
c. Plasma welding.
d. All of the above.
37. The electrode coating:
(A) improve arc stability
(B) produces a slag blanket
(C) allows alloying elements to be added to the weld metal
(D) increases the weld metal cooling rate
a. Statements A&B is correct
b. Statements B&C is correct
c. Statements A,B and C is correct
d. All statement are correct

38.Heavy rutile electrodes are usually:

a. Used in any welding position
 b. Restricted to flat fillet welds
c. Restricted to flat welds and horizontal – vertical fillet welds
d. Used in the overhead position

39.A common gas / mixture used in MIG welding nickel alloys to combine
good levels of penetration with good arc stability would be:
a. 100% CO2
b. 100% argon
c. 80% argon 20% CO2
d. 98% argon 2% oxygen
40.If the arc length is too short, the arc will:
a. Be erratic
b. Lack direction
c. Lack intensity
d. May short circuit during metal transfer

41.Repair welding is often more difficult than production due to:

a. The material being ingrained with in-service contaminates.
b. Restricted access within the repair area.
c. The possible position of the weld repair.
d. All of the above

42.Welding with higher heat input with carbon manganese steel may not
cause:
a. Higher strength of joint.
b. Higher hardness value.
c. Higher integrity.
d. Higher distortion.

43.Which statement with regards to Open circuit voltage is true:

 a. OCV is the voltage measured during welding.
b. OCV is the input voltage to the power source.
c. OCV value normally above 200 volts.
d. OCV is the voltage without current flow.

44. If the current is less than 200 amps and the voltage is between 15 and
22v, which metal transfer mode, is likely to occur?
a. spray transfer
b. short arc or dip transfer
c. pulsed transfer
d. globular transfer

45. During GTAW process which of the following defect would you not expect
to find:
a. Spatter.
b. Undercut.
c. Slag inclusion.
d. Silica inclusion (Ferritic Steel).
e. A and C answers are correct.

46. In SAW, which parameter give greater control for the depth of
penetration on the welded material:
a. Voltage.
b. Wire feed speed.
c. Wire size.
d. Current.

47. The main function of the choke (inductance) in the MIG/MAG process will
affect:
a. The globular transfer mode to be smoother arc.
 b. Increasing of current rise to the molten metal of wire and reduce the
spatter level in dip transfer.
c. Deposition rate.
d. Arc voltage.

48. In MIG/MAG, compared with MMA welding, which of the following

statements are ture?

(i) the MIG/MAG process allows greater welding continuity

(ii) the MIG/MAG process is better suited to outside applications

(iii) MIG/MAG equipment is more costly and less portable than MMA
equipment

(iv) deeper penetration is possible with MMA than MIG/MAG

a. statement A & B are correct

b. statement A and C are correct
c. statement A, C and D are correct
d. statement B and D are correct
49. Which of the following statements are true with regard to TIG process?

(i) The TIG process is faster than most other welding processes

(ii)Generally the best welding results achieved with DC electrode negative

(iii) Tungsten may contaminate the weld and create inclusions

a. statement A & B are correct

b. statement B and C are correct

c. statement A and C are correct

 d. none of the above statement is correct

50. By adapting to twin welding heads what benefits are gained?

(a) welding time is reduced

(b) less consumables are required

(c) Assuming the number of passes is reduced , distortion is minimized

51. output characteristics of TIG and Plasma TIG set are normally:
a. Constant potential.
b. Flat characteristics.
c. Drooping arc characteristics.
d. Constant voltage.

52. The arc energy during a welding process:

a. Does not affect the toughness of weldment.
b. Must be high in order to avoid lack of fusion.
c. Affects the width of HAZ.
d. All of the above.
53. Which of the following welding process is constant voltage process?
(i) MIG/MAG
(ii) TIG
(iii) MMA
(iv) Electroslag
(v) flux-cored
a. Process A and C
b. Process A, D and E
c. Process C, D and E
d. Process B, C and E
 54. A constant voltage output characteristic would be required for which of
the following welding process?
a. MMA/SMAW
b. TIG/GTAW
c. MIG/MAG/GMAW
d. TAGS
55. A typical arc energy value for a MAG weld run would be?
a. 1.2 kJ/mm
b. 12 KJ
c. 1.2 J/mm
d. 120 kJ/mm

56. Which of the following welding process would give the highest heat input
when using typically parameters?
a. manual metal arc welding
b. shielded metal arc welding
c. submerged arc welding
d. tungsten inert gas welding
57. Which welding process would not be suitable for welding carbon steel?
a. MMA
b. MIG
c. SAW
d. TIG
58. The output characteristic for a TIG/MMA power source would be?
a. constant current
b. constant polarity
c. constant voltage
d. constant pulsing
59. when referring to MIG welding, the shielding gas could be:
a. argon
b. argon + 1% oxygen
c. argon + 20% co2
d. all of the above
60. submerged arc utilizes:
A. deep penetration characteristic
b. high deposition rates on DC+
c. flat welding only
d. none of the above
61. A WPS may specify a maximum width for individual weld beads when
welding c- Mn steels if the width is exceeded it may cause…..
a. Lack of inter-run fusion
b. A reduction in HAZ toughness
c. Lack of sidewall fusion
d. All of the above
62.For TIG welding, what benefit does a current slope – out device have?
a. It reduces tungsten spatter
b. It reduces the risk of crater cracking
c. It reduce the risk of arc strikes
d. It reduces the inter pass temperature
63.Which type of power source characteristic is normally used for manual
welding?
a. Constant voltage
b. Flat characteristic
c. Constant current
d. A motor generator
64.In MMA welding, penetration is principally controlled by
a. arc voltage
b. welding speed
 c. Ferro silicon in the electrode coating
d. current
65. Which of the following units is used to express heat input
A. joules
b. N/mm²
c. J/mm²
d. KJ/mm
66. The polarity used for TIG welding of all materials, except aluminium and
magnesium, is…

a. DC negative

b. DC positive

c. AC

d. any polarity can be used

67. If welding travel speed is doubled, but the current and voltage remain
the same, the heat input will….

A. be reduced 50%

b. be increased by a factor of two

c. be about the same

d. be reduced by approximately

68.Slag inclusions would occur with

a. Manual metal arc
b. Metal inert gas
c. Submerged arc welding
d. Both a and c
69.MIG welding tends to be susceptible to lack of fusion problem. This is
because of:
a. Poor maintenance of equipment
b. Incorrect setting
c. Poor inter-run cleaning
d. All of the above
70.Which of the following is not a fusion welding process?
a. Electro-slag welding
b. Oxy-gas welding
c. Forge welding
d. TIG welding
71.Which of the following statements is true?
a. Electrode d.c positive produces a deep narrow weld pool
b. Rutile means calcium carbonate
c. Porosity is always repaired
d. D.C. electrode positive is used for MAG welding steel
72.During MIG/MAG welding the arc length is most likely to be affected by
a. The wire diameter
b. The current return connections
c. The gas flow rate
d. The torch to work angle
73.Which of the following gas mixtures would you expect to use to give good
weld profile and penetration when MAG welding carbon steels to?
a. 100% Argon
b. 80% Argon+ 20% Co2
c. 98% Helium + 2%Co2
d. 100% Co2
74.MIG/MAG welding using Dip transfer mode is susceptible to:
a. Solidification cracking
b. Slag inclusions
c. Lack of side wall fusion
d. Hydrogen cracking
75.SMAW welding equipment requires what type of output characteristic?
 a. Constant voltage
b. Flat
c. Constant current
d. Constant polarity
76.When MIG welding aluminum alloys in the overhead position which
current type would normally be used?
a. A.C
b. D.C. negative
c. D.C. positive
d. Drooping
77.During TIG welding the arc voltage is controlled by
a. The welder
b. The flat output characteristic of the power source
c. The polarity of the electrode
d. The constant voltage control
78.In arc welding processes, excess weld metal profile is most affected by:
a. Arc length
b. Open circuit voltage
c. Amperage
d. Root gap
79.Which submerged arc welding flux be described as powdery or ball like?
a. Basic
b. Fused
c. Agglomerated
d. Acidic
80.Which of the following would act as de-oxidizers in a tertiary de-oxidized
MAG welding wire?
a. Manganese, silicon, copper
b. Silicon, nickel, aluminum
c. Manganese, silicon, aluminum
d. Manganese, molybdenum, nickel
81.Which of the following best describes a semi- automatic welding process?
a. The welder is responsible for the arc gap and travel speed
 b. The welder is responsible for the travel speed only
c. The power source controls both arc gap and travel speed but
under constant supervision
d. The power source control is both travel speed and arc gap

82.For a given voltage and current setting on a constant current output power
source. When the arc length is shortened:
a. The current will decrease and the voltage will increase
b. The travel speed will increase and the current will decrease
c. The current will increase and the voltage will decrease
d. The current will increase and the travel speed will decrease

83.When welding low carbon steel with the GMAW process on dip transfer,
one purpose of the inductance control is to reduce:
a. Spatter
b. Lack of fusion
c. Porosity
d. Cold lap

84.The main reason for using a back purge when welding 18-8 stainless steel
with the TIG welding process is to
a. Control root penetration
b. Prevent root bead porosity
c. Improve positional welding
d. Prevent oxidation welding of the weld root
85.The heat input during a fusion welding process:
a. Does not affect the grain structure of the material unless it is
very high
b. Must be as high as possible to avoid lack of fusion
c. Affects the width and metallurgy of the HAZ
d. Must be very low to avoid grain growth
86.When hydrogen control is specified for a manual metal arc-welding project
the electrode would normally be:
 a) Cellulosic
b) Iron oxide
c) Acid
d) Basic
87. If submerged welding to be used to make butt welds, which would
you be most critical of:

a) The root gap tolerance

b) The angle of penetration
c) The root face width
d) The gas cut finish

88.A metallurgical problem most associated with submerged arc welding is:

a) Hydrogen cracking in HAZ

b) Solidification cracking in the weld metal
c) Hydrogen cracking in the weld metal
d) Lamellar tearing in the weld metal
89.The flame temperature of oxy/acetylene mixture gas is given as:

a) 3200 C
b) 2300 C
c) 5000 C
d) None of the above
90.Which of the following current types would be used for welding aluminum
with the TIG welding process:
a. Ac
b. Dc +ve electrode
c. Dc –ve electrode
d. All of the above could be used successfully
91.Which of following welding processes may be described as a low H2
process in comparison with MMA welding:
a. TIG
b. MIG
c. MAG
d. All of the above
92.Which of the following welding processes does not uses a consumable
electrode:
a. SAW
b. MMA
c. TIG
d. ESW
93.What is the purpose of a rectifier:
a. To adjust the voltage
b. To adjust the amperage
c. To covert ac to dc
d. To reduce the chance of arc strike
94.Why have a high OCV with MMA welding:
a. To initiate
b. To obtain penetration
c. To avoid lack of fusion
d. MMA welding does not have a high OCV
95.Spatter may be finely controlled during MIG/MAG welding by:
a. Adjusted the inductance control
b. Using CO2 gas
c. Increasing the arc voltage
d. Welding with no gas
96.Submerged arc welding is a process generally gives:
a. Slag free welds
b. Low penetration
c. Low dilution
d. High heat input
97.Why is hot pass so called:
a. Because it is applied at a high amperage
b. Because it is applied when the root is still hot
c. Because it could cause hot shortness
d. Because it heat treats the root
98.Why is a welding arc shielding:
a. To eliminate hydrogen
 b. To retard the cooling rate of the weld
c. To eliminate the atmosphere
d. To ensure maximum heat input
99.Which welding process is considered to be the most versatile:
a. SAW
b. TIG
c. MIG/MAG
d. MMA
100. The TIG welding process utilizes an electrode that is :
a. Cellulosic
b. Non consumable
c. Consumable
d. None of the above
101. Which is the correct arc energy if the amps are 350, volt 32 and
travel speed 310mm/s:
a. 2.16kj/mm
b. 0.036kj/mm
c. 2160kj/mm
d. 36kj/mm
102. When welding a double V butt joint with SAW process of presence
of centerline porosity may be due to:
a. Damp flux
b. Contaminated joint preparation
c. Incorrect stick out lengths
d. All of the above
103. Which is not a possible effects of having a travel speed too fast
a. Low toughness, slag inclusions and undercut
b. High hardness, slag inclusions and a narrow thin weld bead
c. Low hardness, excessive deposition and cold laps
d. Low toughness, poor fusion and slag inclusions

104. What five parameters would be checked when calibrating welding

equipment for mechanized MAG welding:
 a. Joint set up, flux coating, polarity, travel speed and amps volts
b. Amps/volt, WFS, gas flow rate, Polarity and travel speed
c. Amps/volt, WFS, wire diameter, polarity and travel speed
d. Electrode stick out, WFS, amps/volt, polarity and wire
diameter
105. Which of the following statements is true when using a flat
characteristic power source:
a. The electrode is always dc-ve
b. The shielding is always pure argon
c. The wire feed speed remains constant
d. The electrode extension will have no effect on weld quality
106. Which of the following will vary the most, when varying the arc
length:
a. Voltage
b. Amperage
c. Polarity
d. None of the above
107. A multi run MMA butt weld made on C/Mn steel consists of 5
passes using 6mm electrodes. A12 pass weld made on the same joint using
4mm electrode on the same material will:
a. Have a Lower heat input and a higher degree of grain refinement
b. Have a lower heat input and a coarse grain structure
c. Have a higher amount of distortion and a higher degree of grain
refinement
d. Have a higher amount of distortion and a lower degree of grain
refinement
108. Which of the following welding processes would you expect to use
a collet:
a. TIG/TAG
b. MIG/MAG
c. MMA
d. All of the above
109. What are the possible result of having a too lower heat input:
 a. An increase in hardness, lower yield strength and lack of fusion
b. A reduction in toughness, hydrogen entrapment and an
increase in hardness
c. Entrapped hydrogen, an increase in hardness and lack of fusion
d. Entrapped hydrogen, a reduction in carbon content and lack of
fusion
110. SAW in single pass weld will give:
a. Poor profile
b. Burn rapidly
c. Good penetration
d. None of the above
111. In SAW process if voltage and current is increased and travel speed
is decreased. What will be the effect in the profile:
a. Wider weld
b. Higher weld reinforcement
c. Concave weld surface
112. What change will occur on the HAZ during heating of metal caused
by welding:
a. Change in tensile strength
b. Change in hardness
c. Change in grain crystal structure
113. In MIG/ CO2 welding which parameters give the greatest control of
weld appearance during dip transfer or short circuiting welding:
a. Wire stick out length
b. Amperage
c. Wire feed speed
d. Inductance
114. Argon +2% Oxygen is used when welding
a. High carbon steels
b. Austenitic stainless steels
c. Aluminum
d. Marten site stainless steels
115. Increasing the arc energy input of a welded joint will?
 a. Increase the strength of the joint
b. Increase the toughness of the joint
c. Increase the grain size of the weld and HAZ
d. De-crease the width of the HAZ
116. In sub arc welding, excessive flux melting will result from:
a. Increasing the arc voltage
b. Decreasing the arc travel speed
c. Increasing the travel speed
d. Increasing the wire feed speed
117. Which of the following processes would be most prone to lack of
fusion defects:
a. Pulsed arc MIG
b. Spray transfer MIG
c. Dip transfer MAG
d. Submerged arc
118. Adjusting the inductance control in dip transfer MIG/MAG welding.
Will control
a. The pulse rate
b. The gas flow rate
c. The amount of spatter
d. The arc voltage
119. Poor penetration would be found in MIG/MAG welded steels when
using:
a. Argon +20% CO2
b. CO2
c. Pure Argon
d. Argon +5% CO2
120. Welds made with high heat inputs show a reduction in one of the
following properties:
a. Ductility
b. Toughness
c. Fatigue strength
d. Mechanical strength
121. In SAW, the use of excessively high voltage would result in :
a. Insufficient flux melting
b. Excessive flux melting
c. Slag removal difficulties
d. Spatter
122. Welding procedures may require welds to be deposited at a
controlled rate heat input. High heat input would:
a. Have poor profile
b. Have larger grain size
c. Have high hardness in the HAZ
d. Have low elongation properties
123. Three essential factors for producing fusion weld are melting of
materials, removal of surface oxide from the joint surfaces and elimination
of atmosphere from the region of the arc. Name the fourth one:
a. The weld must be free from stress
b. The filler material must match that of the weld
c. The completed joint must at least match the mechanical
properties
d. An arc for a heat source
124. In general it is not easy to mechanize the MMA welding process
because:
a. Short electrode length, the control of the arc length and the
process uses A flat characteristic
b. Short electrode length, the control of the arc length and flux
coverings
c. The control of the arc length, stop start problems and short
electrode length
d. Flux coverings, short electrode lengths and relationship
between amps and volts