Question And Answer Sheet

1 Q. H-LO45 TEST SPECIMNT IN WHICH POSITION FOR HARDNESS TEST?

Ans. PE (Hardness, Macro)
2 Q. WHAT IS COST OF WELD REPAIR ?
Ans. 10Time
3 Q. Which ,Micro structure lead to H2 cracking?
Ans. Micro Structure <400HV (Martinsite)
4 Q. SAW welding mechanisem?
Ans. Full Automatic
5 Q. What is part of tig machine?
Ans.
6 Q. What is essential variable as per 15614 welding procedure?
Ans.
7 Q. What is purpose of disel generator?
Ans. Preffered for site works.
8 Q. What is effect of high voltage?
Ans. Arc Length Increase, Weld Width Increase, Penertation Decrease, Amp Decerase.
9 Q. What is purpose of strong back?
Ans. Prevent angular distortion in plate & help prevent peaking in welding cylindrical shells.
10 Q. What defect not detected in RT?
Ans. Plannar Defect.
11 Q. What is Purpose of Indutance?
Ans. Reduce Spatter.
12 Q. What happen if indutance too high and too low?
Ans. Lack of Fusion, Spatter
13 Q. What happen when polarity change form DC+ve to DC-Ve?
Ans. Weld width increase, Penetration Decrease.
14 Q. Which process to be used for high deposition rate weld?
Ans. SAW
15 Q. What is most likely to solidification crack?
Ans. SAW & Austenitic S.S
16 Q. What is degree for 'J' Grovee?
Ans. 12-15* (10-15*)
17 Q. In which temperature oxy-fuel gas cutting happen & what is the reaction of oxy-fuel gas cutting?
Ans. 700-960* (850*) , Exoythermic
18 Q. COSHH (Safety)?
Ans. Control of Substance hazard to health.
19 Q. What is purpose of transformer?
Ans. Transformer AC-AC for welding & Rectifire AC-DC
20 Q. If materials carbon steel has change to 316L steel, what type of defect can occur?
Ans. Solidification Cracking
21 Q. For checking thickness which ndt method is used?
Ans. UT
22 Q. Principle of MPT?
Ans. Magnetic Flux leackege & Magnetic Partical
23 Q. To weld 2'' outer Dia & 5mm thick pipe which transfer mode is used in Mig/Mag?
Ans. Dip Transfer
24 Q. In all bend tensile what will not be mesured?
Ans. Rp
25 Q. Oxy-fuel is used in?
Ans. Carbon Steel & Alloy Steel
26 Q. When Rm will be mesured ?
Ans. When material Excessive ductile.
27 Q. As per wps find max&min HI?
Ans.
28 Q. As per wps find max.& min. Arc energy?
Ans.
29 Q. In saw process heat input is max. why?
Ans. Arc is insulated, It used more then 1000 Amps.
30 Q. Why porsity occur?
Ans. Damp Or Cantaminated Electrode.
31 Q. What is under cut & why?
Ans. Melting of top edge due to high welding current or high travel speed.
32 Q. Where solificication crack occur?
Ans. Center line of weld metal
33 Q. About Fillet weld?
Ans.
34 Q. Where weld decay occur?
Ans. Haz
35 Q. Flame of oxy-fuel gas cutting?
Ans. Netural, Oxidizing, Carburizing.
36 Q. What is polarity of Mig/Mag?
Ans. DC+Ve
37 Q. Why AC current only in use in Tig Process?
Ans. To remove oxide layer.
38 Q. In which DT, Welder qualification done?
Ans. Fracture and Macro
39 Q. Why vertex angle use in Tig Process?
 Ans. Best Penetration.
40 Q. What is the transistion range of charpy-V Notch?
Ans. 0 to -20*
41 Q. In which weld prepration root radius is pre-set?
Ans. J or U
42 Q. A welder qualify in all position, but except in vertical down which weld progression is this?
Ans. Up hill-PF
(Important Quection)
43 Q. As per AWS 5.1 7018, 8018, Which type of electrode?
Ans. Basic
44 Q. In tig Welding, What are the different of electrode shape?
(Thoriated, Ceriated or lanthanum) Electrode tip or Vertex angle, DCEN Deep Penertation & Good Weld width.
Ans. AC Moderate Penetration & Wide weld width. ( Balled End) (Zirconated), Flat End Not Recommend.
45 Q. What is the gas flow rate of tig welding?
Ans. 10-12 Liter/Min.
46 Q. About the pluse transfer technique?
Ans. V<24V, All Position, Modrate Heat input, Weld >6mm thick, Pulse current- Pinch Effect.
47 Q. What is purpose of post flow?
Ans. To avoid weld pool cantamination.
48 Q. Composition of Mig/Mag welding?

Ans. Mig- Argon/Helium- Spray , Puls, Mag-Co2 100% Dip, Mag-Ar+15-20% Spray, Puls, Mag- Ar+1-5% Spray, puls-S.S
49 Q. What is the CTWD?
Ans. CTWD is the distanc b/w contact tip to work pice,
50 Q. About Globular transfer?
Ans. It give lots of Spatter, Only used in PA position, Required 100% Co2, Thickness-3-6mm
51 Q. What is the thermal Efficency factor of SAW?
Ans. 1.0 (Arc energy is equal to heat input is SAW.
52 Q. Various factor to avoid distortion?
Reduce No. of runs or Passed, Used of balance welding, Reduce weld metal, Use to Back to back Assembly.
Ans. Minimize Welding time.
53 Q. About vicker hardness?
Vickers Hardness is method for hardness testing and is commenly used in industry. Vickers hardness used
Ans. squere based dimond pyramid indector. It is measured HV5, HV10, H25.
54 Q. What happen if pre-heat decresed?
Materials cool faster, Srinkage strees forms, Mositure does'nt remove, Risk of hardend micro structure,
Ans. Hydrogen does'nt diffued.
55 Q. What is HF?
Start is used to initiate the are in Tig welding, it uses apporx.20000 v, Chance of damage electronic equipment
Ans. HF start.
56 Q. What is Sock time?
Ans. It is the time that a joint should be soacked at pick temp. for a period. 1Hr/25.4mm
57 Q. Arc air gauging is used to which materials?
Ans. Both Ferrous and Non Ferrous.
58 Q. About SAW welding?
SAW is high heat input welding process, It is a fully automatic process, Productivity 90%, PA & PB position
Ans. used only.
59 Q. What is RCD?
Ans. RCD Residual Cricuit Devices are used to avoid shock due to residual current in the equipment.
60 Q. What is COSHH?
COSHH to control of sabstance hazard to health, It is the law that required employee to control substance in
Ans. the work place that can cause health.
61 Q. What are the effect of Cadmium?

Cadmium is toxic metal found on steel as a cooling or in silver solder, Cadmium fumes can cause in fatal with
Ans. symptoms like illens similar to flue metal fume fiver, 20min of welding in presence of cadmium cause fatality
62 Q. Pipe bore weld is done by which welding?
Bore welding is welding preocess that reduce the Chamfer of a bore by adding 3-6mm of metals to inside of
Ans. worn bore.
63 Q. Overlap/cold lap are seen by which examination?
Ans. Micro scopic exam.
64 Q. what is the purpose of transfer rectifier?
Ans. It is used to rectify or change AC to DC.
65 Q. Which welding, what happens of HAZ?

Ans. Increased or decreased strangth , loos of corrosion resistance cracking, lower toughness and higher hardness.
65 Q. When is the electrode are not used?
 When welding with electron beam process electrode are not used cyrogynice services also electrode are not
Ans. used.
66 Q. What is the purpose of indutance?
Indutance to used to reduce spatter and resistance to flow of current, It decressed the frequency of short
Ans. circuiting, Indutance too high- lack of fusion & Stubbing, Indutance too Low- Spatter.
67 Q. What is duty cycle?
Ans. Duty cycle is a safety value in a minutes , Duty cycle= Welding time/Total Time X100.
68 Q. What is operating factor?
operating factor is the percentage of a welder working day that is actually spend welding. Operating factor =
Ans. Arc Time/Total Hrs Worked X100
69 Q. What is compound weld?
Ans. Two Different type of Weld in a joint.
70 Q. What happen when root face increase?
Ans. Lack of root penetration occurd.
71 Q. What happen, if V to J?
Ans. Angle of groove reduce and difficult occurd for welding with electrode.
72 Q. How to avoid crater?
Ans. Use slop out device.
73 Q. How to prevent distortion?
Ans.
74 Q. About arc strick?
Arc strick are the local damages to the surface of parent metals adjacent to weld. Arc strick produce Hard HAZ
Ans. which reads to serious cracking increased. Arc strick repaired by grinding.
75 Q. About MPT?
MPT metode which detact surface and sub surface crack by using magnetic force. MPT Principle magnatic flux
Ans. leackege
76 Q. What is Pwps?
Ans. PWPS is the preliminary welding procedure speicfication which is used to qualification of WPS.
77 Q. What are the responsibility of welding inspector?
Inspecting the weld During, Before and After welding, it is the responsibility and welding inspector is to ensure
Ans. all welding associated, action are carried out in accordance with the specification.
78 Q. What is the temperator of Quenching & Tempring?
Ans. 550*C-600*c
79 Q. Duty before welding?
Ans. Check pre heat, Check consuamble
80 Q. Lamellar tearing occur in?
Ans. Parent Metal.
81 Q. Which of the joint has more greatest fatigue life?
Ans. Cancave.
82 Q. Weld Decay occur in?
Ans. HAZ
83 Q. Pre-flow in tig used for?
Ans. Protect of the Weld metal.
84 Q. A welder is welding is PG position, Electrode sutaible is?
Ans. E6010
85 Q. Above electrode name?
Ans. Cellulose.
86 Q. Lack of fusion in which position in mag welding?
Ans. PG.
87 Q. Above referance , resion why?
Ans. Weld pool flow ahead due to Gravity.
88 Q. Can AC polarity be used with general MMA welding machine plant?
Ans. No we cant weld.
89 Q. Hardness sample from HL-045 fixed pipe down hill?
Ans. PE
90 Q. Above referance , resion why?
Ans. Low heat input.
91 Q. Charpy V-notch sample are taken from?
Ans. PF
92 Q. Above referance , resion why?
Ans. High Heat input.
93 Q. Hardness of material increased by?
 Ans. Heat input.
94 Q. Above referance , another resion why?
Ans. Carbon increase. Fast Cooling.
95 Q. What is the use of transformer?
Ans. AC-DC, Low Voltage to High Voltage.
96 Q. Resion Why?
Ans. Decrease surge in current.
97 Q. In which weld prepration root radius is pre-set?
Ans. J'
98 Q. In which profile decrease fatigue life occur?
Ans. Canvax
99 Q. Which prepration have land?
Ans. J (5-15*)
100 Q. Design through thickness formula?
Ans. A=0.707, L=1.41
101 Q. Which fillet weld have high strangth?
Ans. Canvax
102 Q. About Pre-heat which joints?
Ans. Compaund Joint & Tee Joint
103 Q. About Weaving?
Ans. High Heat input. Low Ductility, Decrease Hardness.
104 Q. About Solidification crack?
Ans. Sulphur, Phasphoras.
105 Q. About Lamllar Tear?
Ans. Less Through thickness & ductility <20%
106 Q. Specimen taken from which position for toughness test?
Ans. PF
107 Q. About arc strick?
Ans. Hard and Britile, Area Reduction, Chance of Cracking.
108 Q. About Spatter (Indutance)?
Ans. Too High Indutance - Lack of Fusion, Too Low- Spatter.
109 Q. Example of Qualitative & Quantitative test?
Ans. Qualitative- Bend, Nick Break, Macro, Quantative- Tensile Test.
110 Q. About UTS?
Ans. Ultimate Tensile Strangth (UTL/C.S.A=Nmm2)
111 Q. Calculation of Elongation formula?
Ans. Actual Length/Original length X 100
112 Q. Transistion range in charpy test?
Ans. 0 to -20* Ductile & -20 to -30* Britaile
113 Q. Abount CTOD?
Ans. Measure material property, Fracture toughness test, Cyclice load, Dynamic load.
114 Q. Abount RT test?
Ans. All Materail.
115 Q. On SS which NDT method is used?
Ans. PT & RT
116 Q. Lamination are checked with angle probe ?
Ans. 0* Probe & Comprasion Probe.
117 Q. About 25% high heat input & 25% low heat input?
Ans. High heat input= Impect Requirment, Low heat input= Hardness Requirment.
118 Q. What is the Essential variable for welder qualification ?
Ans. Welding Position.
119 Q. About Alloy elements and their Effect?
C-Strangth, Mn-Toughness, Si- Deoxidiser, Al- Grain Refiner, Cr- Corrosion Resistance, Mo- Creep Resistance, V-
Ans. Strangth, Ni- Low Temp. Application,
120 Q. What is the purpose of transformer?
Ans. AC to DC
121 Q. About OCV Range?
Ans. 50-90V
122 Q. In which electrode fluid slag will come?
 Ans. Basic
123 Q. Purpose of vertex angle?
Ans. Good penetration and Profile.
124 Q. About HAZ Full details?
Ans. SGRPT.
125 Q. If welder change Spray transfer to Dip transfer what is happen?
Ans. Low Penetration, High Spatter, Lack of Fusion.
126 Q. If Shielding gas change from argon to helium what happen?
Ans. Low Penetration.
127 Q. What happen if indutance too high and too low?
Ans. High= Stub End lack of Fusion & Low= More Spatter.
128 Q. If arc voltage increase which defect will come?
Ans. Porisity.
129 Q. In which temperature oxy-fuel gas cutting happen & what is the below melting point?
Ans. 850*C
130 Q. Which Reaction happen in Oxy-Fuel gas cutting?
Ans. Exyothermic.
131 Q. Classification of Electrode?
Ans. E7018, 70=Tensile Strangth, 1=position, 8= flux Coating Type.
132 Q. Diffrence between Agglormated flux & Fused flux?
Ans. Agglormated flux= Non Hygroscopic, High Quality Weld / Fused flux= Hygroscopic, Low Quality Weld.
133 Q. What are the four 4 factor to happen hydrogen cracking?
Ans. a= >15ml/100grm of Hydrogen, Y.S>0.5%, <300* Temp., <250HV Hardness.
134 Q. What is the Pirnciple of MPT?
Ans. Magnetic Flux leackege & Magnetic Partical
135 Q. In which area Weld Decay occur?
Ans. HAZ
136 Q. What is cost of weld repair?
Ans. 10 time.
137 Q. What is purpose of PWHT?
Ans. Stress Relieve
138 Q. What is the purpose of Strong back?
Ans. Control Distortion.
139 Q. Quenching & Tempring?
Ans. 600-650*C
140 Q. In 10mm thickness plate, the PWHT will done to how much length?
Ans. 40M
141 Q. What happen if welder work 20min in cadmium fume?
Ans. Fatality, Death
142 Q. What is the validity of Equipment?
Ans. 6 months
143 Q. About pre-heat thickness for materials
Ans. 20mm
144 Q. Essential Variable for WPS?
Ans. Mechanical Property
145 Q. Which process to be used for high deposition rate weld and also site welding?
Ans. FCAW.
146 Q. Most of Solidification crack occur?
Ans. SAW
147 Q. Design through thickness & Actual Through thickness relation between?
Ans. Canvax.
148 Q. Can we use MMA Process in AC?
Ans. Not sutabile for some electrode, minimize arc blow.
149 Q. Welding variable of MMA?
Ans. Current, voltage, Travel Speed, Ploarity, Type of Electrode.
150 Q. BS EN E50 3B- '3' indicate what?
Ans. Toughness
151 Q. BS EN E50 3B- '50' indicate what?
Ans. Yield Strangth.
152 Q. Why we use Tig process for Alumunium?
Ans. Cathodic cleaning.
153 Q. What is the undesirval element in solidification cracking?
Ans. Sulphur
154 Q. How to avoid solidification crack?
Ans. Use Mn Based Electrode.
155 Q. What is the appearance of lamellar tearing?
Ans. Terraced Appearance.
156 Q. Which is the best method to identify porosity?
Ans. RT.
157 Q. How porosity will come?
Ans. High Voltage.
158 Q. In which materials distortion will take place.?
Ans. Austenitic stainless steel.
159 Q. Which two test required for welder qualification?
Ans. Fracture and Macro
160 Q. In Ferrous material defect testing, which NDT method is applied?
Ans. MPT
161 Q. Which MMA electrode give Canvax profile.?
Ans. 7018
162 Q. Above Reference electrode name?
Ans. Basic
163 Q. In which transfer lack of fusion occur?
Ans. Dip Transfer
164 Q. Resion for it?
Ans. Low Current (High Indutance)
165 Q. Which Electrode is good in PG position for root run welding?
Ans. E7010 Cellulose
166 Q. Which crack occur with it?
Ans. Hydrogen crack
167 Q. About Natural Flame:?
Ans. 50% O2 & Less Fuel Gas (Netural flame is used to cut carbon steel & some low alloy steels.)
168 Q. About Oxidizing Flame?
Ans. More O2 & Less fuel Gas.( Oxidizing flame is used to cut brass & bronze.
169 Q. About Carburizing Flame?
Ans. Less O2 & More fuel Gas ( Carburizing Flame is used to cut lead & Hard materials.)
170 Q. Oxy-fuel gas cutting Quality?
Good Cut, Cut too Slow, Cut too Fast, Preheat flame too low, Pre heat flame too high, Nozzel is too high above
Ans. the works, Irregular travle speed.
171 Q. About Mechanised oxy-fuel cutting?
Ans. Can use portable carriages or gantry type machines high productivity.
172 Q. About Plasma cutting?
Ans. No need promote oxidation and no preheat, Gas-Air, Ar, N2, O2, Mix- of Ar+H2, N2+H2
173 Q. Oxy-fuel cutting applied in which materials?
Carbon Steel & Alloy Steel
174 Plasma cutting applied in which materials?
All Materails. (Mostly/Mainley-Stainless Steel)
175 Arc air gauging is used to which materials?
Ferrous and Non ferrous
176 Manual metal arc gauging applied in which materials?
All Materials (Polarity-DCEN & AC )
Drag & Drop
177 Q. Duties of welding inspector during welding?

Ans. A) Inter pass cleaning. B) Joint Alignment. C) Inter pass Temp. D) Gas flow Rate.
178 Q. Resion for undercut?
Ans. A) Hing Current. B) High Voltage. C) Gas Flow Rate. D) Excessive Weaving.
179 Q. Solidification occur due to………………………..?

Ans. High melting point liquid, Low melting point liquid, Chromium carbid, (High Diluation, High Restrain)
180 Q. …………..Min. intensity of light during visual inspection?
Ans. 300Lux, 350Lux, 500Lux
181 Q. Resion for solidification crack will proceed in which process?
Ans. 121, 131, 135, 141, 136
182 Q. All weld test which is not consider?
Ans. Rm, Rp, Re, A%
183 Q. Resion for it?
Ans. Yield point is difficalt to detrmine for certain material. ( Alumunium)
184 Q. In MMA process, there was no root face, what will occur?
Ans. Excess Penetration, LOF, LOP
185 Q. The worst criteria for under cut?
Ans. Sharpness length & Depth, Depth + Hight, Length+Hight.
186 Q. Resion for it?
Ans. If Sharpness come then stress concetration increase, If Hight come, If Depth come.
187 Q. If change from MMA to FCAW, what will happen?
Ans. Deposition Increase, Distrotion Decrease
188 Q. Do you use AC current directly?
Ans. No, transformer it first then use.
WPS
1 Compaund weld wps, 2 butt weld wps, 1 Fillet weld wps
189 Q. Pipe to plate which wps use?
Ans. Fillet Weld wps
190 Q. Welder Qualification for fillet weld, which test should be done, (No face is done) bend & V.I is done in that WQT?
Ans. Fracture test for fillet weld.
191 Q. Which wps suitable for good root profile & high deposition?
Ans. SAW & TIG WPS
192 Q. In welder qualification which position for welder is not qualified?
Ans. PD & PG (From All 4 WQT)
192 Q. Materials thickness is 12mm which WQT can perform?
Ans. 1, 2, 3, 4
193 Q. Which WPS have lowest hit input?
Ans. WPS with TIG.
194 Q. Which Factor are mention in WPS?
Ans. Pre heat Procedure, Strong Back, Welding Sigment
195 Q. Why support is provided during PWHT?
Ans. To prevent falling due to increase Y.S, For uniform heating, To prevent falling due to increase UTS.
196 Q. Which defect detecated by MPT?
Ans. Internal Prosity, Crack, Internal Slage
197 Q. E7018 What is the '70'?
Ans. Min. TS 70000 PSI
198 Q. Resion of Porosity?
Ans. Voltage, ARC Length.
199 Q. In Tig Sharp Tip is used in which polarity?
Ans. DECN