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Semifinal Exam in SMAW 4th Quarter

Total questions: 50

Worksheet time: 25mins

Name
Class
Date
1.

SMAW stands for:

a)

Shielded Metal Arc Welding

b)

Steel Manual Arc Welding

c)

Standard Metal Arc Welding

d)

Shielded Machine Arc Weldin

2.

Which PPE protects the eyes and face from arc radiation?

a)

Apron

b)

Welding helmet

c)

Gloves

d)

Safety shoes

3.

What kind of radiation is emitted by a welding arc?

a)

Gamma rays

b)

Ultraviolet and infrared

c)

X-rays only

d)

Radio waves

4.

Which tool is used to remove slag after welding?

a)

Grinder

b)

File

c)

Chipping hammer

d)

Pliers

5.

What happens to metal when heated and cooled rapidly?

a)

It shrinks only

b)

It expands and contracts

c)

It hardens permanently

d)

It loses weight

6.

In welding variables, the letter C stands for:

a)

Cable

b)

Current

c)

Control

d)

Clamp

7.

The correct arc length helps prevent:

a)

Good fusion

b)

Porosity and spatter

c)

Strong weld

d)

Smooth bead

8.

The angle of electrode mainly affects:

a)

Weld appearance and fusion

b)

Color of slag

c)

Size of machine

d)

Type of helmet

9.

Too high welding current may cause:

a)

Incomplete fusion

b)

Burn-through

c)

Cold weld

d)

Narrow bead

10.

Too low welding current may result in:

a)

Excess penetration

b)

Burn-through

c)

Incomplete fusion

d)

Distortion

11.

Welding defects are:

a)

Welding tools

b)

Welding techniques

c)

Imperfections in a weld

d)

Welding positions

12.

Small gas holes in the weld metal are called:

a)

Undercut

b)

Porosity

c)

Overlap

d)

Crack

13.

A groove melted along the toe of the weld is known as:

a)

Slag inclusion

b)

Undercut

c)

Porosity

d)

Spatter

14.

Slag trapped inside the weld metal is called:

a)

Crack

b)

Porosity

c)

Slag inclusion

d)

Overlap

15.

Excess weld metal flowing over the base metal is called:

a)

Undercut

b)

Overlap

c)

Burn-through

d)

Distortion

16.

Which defect is most dangerous to weld strength?

a)

Spatter

b)

Porosity

c)

Crack

d)

Excess reinforcement

17.

Moist electrodes commonly cause:

a)

Undercut

b)

Porosity

c)

Burn-through

d)

Distortion

18.

Failure to clean between welding passes causes:

a)

Crack

b)

Slag inclusion

c)

Overlap

d)

Undercut

19.

Lack of penetration means:

a)

Too much weld metal

b)

Weld did not reach the root

c)

Weld bead is wide

d)

Weld is cracked

20.

Spatter is described as:

a)

Cracks in weld

b)

Trapped gas holes

c)

Scattered molten metal droplets

d)

Trapped slag

21.

Excessive heat input can cause:

a)

Distortion

b)

Smooth bead

c)

Better fusion

d)

Less penetration

22.

Tack welding is used to:

a)

Finish the weld

b)

Remove slag

c)

Hold materials in position

d)

Test electrodes

23.

In pipe welding, 1G position means:

a)

Pipe fixed horizontally

b)

Pipe fixed vertically

c)

Pipe rolled in flat position

d)

Pipe overhead

24.

In 5G welding position, the pipe is:

a)

Rolled

b)

Fixed horizontally

c)

Fixed vertically

d)

Inclined at 45∘45^\circ

25.

Which pipe welding position is the most difficult?

a)

1G

b)

2G

c)

5G

d)

6G

26.

5G welding involves which positions?

a)

Flat only

b)

Horizontal only

c)

Flat, vertical, and overhead

d)

Vertical only

27.

Root pass in pipe welding is commonly done using:

a)

E6013

b)

E7018

c)

E6011

d)

E7024

28.

Which electrode is commonly used for capping?

a)

E6011

b)

E6013

c)

E308

d)

E7024

29.

Tack welds in pipe welding are commonly placed at:

a)

Random positions

b)

Top only

c)

12, 3, 6, and 9 o’clock

d)

Bottom only

30.

Visual inspection is conducted to check:

a)

Electrode size

b)

Weld appearance and defects

c)

Welding speed

d)

Current setting

31.

Which PPE protects the hands?

a)

Helmet

b)

Gloves

c)

Apron

d)

Safety shoes

32.

Which factor affects weld bead width?

a)

Travel speed

b)

Helmet color

c)

Floor condition

d)

Cable length

33.

Overlap is usually caused by:

a)

High speed

b)

Low current and slow travel

c)

Excess cleaning

d)

Dry electrodes

34.

Undercut weakens the weld because it:

a)

Adds metal

b)

Creates stress concentration

c)

Improves fusion

d)

Increases penetration

35.

Which position simulates actual field pipe welding?

a)

1G

b)

2G

c)

5G

d)

6G

36.

The main challenge in overhead welding is:

a)

Poor cleaning

b)

Gravity pulling molten metal

c)

Low current

d)

Electrode storage

37.

Excess reinforcement means:

a)

Thin bead

b)

Too much weld metal

c)

Poor cleaning

d)

Lack of fusion

38.

Proper travel speed results in:

a)

Good bead appearance

b)

Burn-through

c)

Cracks

d)

Distortion

39.

Which electrode characteristic helps protect the weld pool?

a)

Core wire

b)

Flux coating

c)

Cable

d)

Clamp

40.

Which defect mostly affects appearance but not always strength?

a)

Crack

b)

Slag inclusion

c)

Spatter

d)

Lack of fusion

41.

What should be checked first before welding?

a)

Arc length

b)

PPE

c)

Weld bead

d)

Slag

42.

Incorrect electrode angle may result in:

a)

Undercut

b)

Distortion

c)

Burn-through

d)

Crack

43.

Which industry commonly uses 5G pipe welding?

a)

Furniture making

b)

Shipyards and oil pipelines

c)

Automotive painting

d)

Carpentry

44.

Good welding practice results in:

a)

Many defects

b)

Weak joints

c)

Strong and reliable welds

d)

Excess slag

45.

The best way to minimize welding defects is to:

a)

Increase current

b)

Follow proper welding procedures

c)

Weld faster

d)

Skip cleaning

46.

A student welding a pipe in 5G position notices porosity after welding. The electrode was taken from an open container. What is the most likely cause?

a)

Excessive travel speed

b)

Moist electrode

c)

Wrong welding position

d)

Proper current

47.

During a root pass, slag inclusion appears after the fill pass. Which action will best prevent this problem?

a)

Increase welding speed

b)

Remove slag between passes

c)

Lower electrode angle

d)

Stop welding immediately

48.

A welder increases current when welding thicker pipes. Why is this necessary?

a)

To reduce slag

b)

To increase penetration

c)

To avoid PPE use

d)

To reduce arc light

49.

While welding overhead in 5G position, molten metal keeps falling. What adjustment is most appropriate?

a)

Increase current

b)

Decrease travel speed

c)

Adjust electrode angle and reduce current

d)

Remove PPE

50.

Two welders compare 1G (rolled) and 5G (fixed) pipe welding. Why is 5G more difficult?

a)

The pipe rotates

b)

Welding is done only flat

c)

Welding must be done in multiple positions

d)

Fewer defects occur

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