WorksheetsWelding Safety and Techniques Quiz
Total questions: 50
Worksheet time: 25hrs 0mins
What does PPE stand for in welding safety?
Personal Protective Equipment
Professional Protective Environment
Personal Performance Evaluation
Proper Protective Elements
The color of an oxygen cylinder is usually:
Red
Green
Black
Yellow
Which polarity is commonly used for E7018 in SMAW?
DCEN
DCEP
AC only
Both AC and DCEN
A fire extinguisher labeled “ABC” is safe for:
Only paper fires
Electrical, flammable liquid, and combustible fires
Metal fires only
Only welding gas fires
Convert 5/16” to decimal:
0.3125
0.4375
0.2500
0.5000
In oxy-fuel cutting, the preheat flame is adjusted until:
Feather disappears
Cone turns green
Gas flow stops
No sparks are visible
What is the tensile strength of an E6010 electrode?
60,000 psi
70,000 psi
80,000 psi
100,000 psi
The abbreviation “IP” on a blueprint means:
Interpass
Inside Pitch
Inspection Point
Initial Pass
Which joint type is created when two plates are edge to edge?
Lap joint
Tee joint
Butt joint
Corner joint
If a student welds 12” per minute for 15 minutes, how many inches total are welded?
120”
150”
160”
180”
What does the flux coating on SMAW electrodes do?
Speeds up weld cooling
Produces shielding gas and slag
Makes arc strike harder
Adds porosity intentionally
The maximum safe working pressure for acetylene is:
10 psi
15 psi
20 psi
30 psi
Which electrode is fast-freeze?
E7018
E7024
E6010
E6013
GMAW with 100% CO₂ tends to produce:
Smooth spray arc
Harsh arc with more spatter
No penetration
TIG-like bead
In FCAW, “self-shielded” means:
Argon gas is required
Flux core creates shielding gas
Wire has no flux inside
Only indoor use allowed
Why is preheat used on thick carbon steel?
Increases weld spatter
Slows cooling to reduce cracking
Reduces tensile strength
Increases distortion
If a 1/4” fillet weld is specified 6” long both sides, total weld length is:
6”
12”
18”
24”
What symbol indicates a weld must be made in the shop, not the field?
Flag
Circle
Tail
No symbol
A WPS provides:
Directions for how a weld must be made
Inspector’s visual notes
AWS Code rules
Weld repair log
What’s the typical argon flow rate for GTAW on carbon steel?
2–5 cfh
10–20 cfh
50–60 cfh
100+ cfh
Which process uses a non-consumable electrode?
SMAW
GMAW
GTAW
FCAW
The GMAW transfer mode used for thin sheet metal is:
Spray transfer
Short circuit transfer
Globular transfer
Pulsed spray transfer
Hydrogen-induced cracking is most likely in:
Aluminum GTAW
Mild steel with low hydrogen electrodes
High-strength steels without preheat
Stainless steel GMAW
Interpass cleaning is especially critical in:
E6010 stringers
E7024 drag rods
GMAW spray transfer
FCAW with flux build-up
Which discontinuity is most dangerous for fatigue loading?
Undercut
Overlap
Porosity
Spatter
A backing strip on a groove weld is used to:
Strengthen the weld face
Reduce need for cleaning
Ensure full root penetration
Make code compliance easier
A correctly adjusted TIG arc length is typically:
Equal to electrode diameter
Twice electrode diameter
Touching base metal
As long as possible
When inspecting fillet weld size, the “leg” is measured:
From root to toe
Across the throat
Face width
Bead reinforcement
Which AWS document covers structural welding in steel?
D1.1
D1.3
D17.1
A5.1
A groove weld symbol with no root opening shown implies:
No prep required
Must follow WPS for root details
Use fillet weld instead
Groove angle = 90°
Which discontinuity is typically detected best by ultrasonic testing?
Surface porosity
Internal slag inclusions
Burn-through
Spatter
A heat-affected zone (HAZ) is:
Only visible under microscope
The portion of base metal altered by welding heat
The area of filler metal dilution
The weld face
Low hydrogen electrodes must be stored in ovens around:
150°F
250°F
450°F
650°F
A CWI performing visual inspection must ensure:
Correct filler metal
Weld meets acceptance criteria in codebook
Machine amperage is always maxed out
Inspector welds sample plates
The throat of a fillet weld is the:
Distance from root to face
Length of bead
Distance across leg
Root opening
Which welding defect appears as long linear cracks along bead edges?
Hot cracking
Cold lap
Wormhole porosity
Arc strikes
Which element in steel primarily increases hardness but reduces toughness?
Carbon
Nickel
Chromium
Copper
Weld procedure qualification requires destructive tests such as:
Nick break and bend tests
X-ray film review only
Visual inspection
Hardness spark test
If interpass temperature is too high, welds may:
Become more ductile
Lose toughness and mechanical properties
Show better bead contour
Self-stress relieve
Which process is most often used for aerospace aluminum welding?
SMAW
GTAW
FCAW
SAW
You’re welding a 3G groove with E7018, but porosity keeps appearing. Best fix?
Increase arc length
Reduce arc length and clean thoroughly
Increase amperage
Switch to 6010
If a print shows a 1/4” intermittent fillet weld 2” long every 6”, total weld length on a 36” joint is:
10”
12”
14”
18”
A welder qualification test fails bend testing when:
Slight convexity appears
Fracture shows slag inclusions
Grind marks are visible
Weld reinforcement is high
What is the minimum preheat for 1” thick high-strength low-alloy steel?
100°F
225°F
400°F
Refer to WPS/code
Which NDE test uses fluorescent dye and UV light?
PT
UT
RT
MT
Why is carbon equivalent (CE) important in welding?
Determines bead width
Predicts weld cracking tendency
Measures penetration depth
Sets amperage automatically
If a 2F fillet weld has excessive convexity, it may cause:
Undercut
Stress concentration
Lack of fusion
Increased toughness
Which transfer mode in GMAW allows high deposition with low spatter and deep penetration?
Globular
Spray transfer
Short circuit
Stick-out transfer
A welder submits coupons with grinding marks across face bend areas. Inspector’s action?
Accept, cosmetic only
Reject – improper prep
Bend test anyway, grind marks irrelevant
Rewrite WPS
Why is hydrogen cracking often delayed (appears hours after welding)?
Hydrogen migrates through microstructure over time
Cooling rate is too fast
Tungsten contamination occurs
Shielding gas absorption continues
