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Welding Process Quiz

Total questions: 50

Worksheet time: 50mins

Name
Class
Date
1.

Welding is a process of:

a)

Mechanical fastening

b)

Joining metals by pressure only

c)

Permanent joining by heat with or without pressure

d)

Temporary joining

2.

The most commonly used welding process in industry is:

a)

TIG welding

b)

MIG welding

c)

Shielded Metal Arc Welding (SMAW)

d)

Laser welding

3.

The electrode in SMAW is:

a)

Non-consumable

b)

Consumable

c)

Carbon rod

d)

Tungsten rod

4.

Flux coating on an electrode is used to:

a)

Increase arc voltage

b)

Protect molten metal from atmosphere

c)

Increase current

d)

Cool the weld

5.

Which gas is used for shielding in TIG welding?

a)

Oxygen

b)

Nitrogen

c)

Argon

d)

Hydrogen

6.

TIG welding electrode is made of:

a)

Copper

b)

Aluminum

c)

Tungsten

d)

Iron

7.

MIG welding uses:

a)

Flux-coated electrode

b)

Bare wire electrode with shielding gas

c)

Carbon electrode

d)

Tungsten electrode

8.

Which current is commonly used for SMAW?

a)

AC only

b)

DC only

c)

Both AC and DC

d)

High frequency AC

9.

The heat affected zone (HAZ) is:

a)

Fully melted metal

b)

Unaffected base metal

c)

Area altered by heat but not melted

d)

Flux region

10.

The purpose of preheating is to:

a)

Increase hardness

b)

Reduce cooling rate

c)

Increase weld speed

d)

Improve arc stability

11.

Porosity in welds is caused by:

a)

Excess current

b)

Trapped gases

c)

Fast cooling

d)

Thick electrode

12.

Slag inclusion occurs due to:

a)

Improper cleaning

b)

High voltage

c)

Low current

d)

Excess shielding gas

13.

Undercut is a defect that:

a)

Adds metal to weld

b)

Removes metal at weld toe

c)

Cracks the weld

d)

Causes porosity

14.

Which welding process uses no flux?

a)

SMAW

b)

SAW

c)

MIG

d)

Flux-cored welding

15.

Submerged Arc Welding (SAW) is best suited for:

a)

Thin sheets

b)

Outdoor welding

c)

Thick plates

d)

Aluminum welding

16.

Welding current mainly affects:

a)

Weld color

b)

Penetration

c)

Slag formation

d)

Weld length

17.

Arc length is the distance between:

a)

Power source and electrode

b)

Electrode tip and workpiece

c)

Flux and weld pool

d)

Two base metals

18.

Excessive arc length causes:

a)

Poor penetration

b)

Stable arc

c)

Deep penetration

d)

No spatter

19.

Distortion in welding is caused by:

a)

Uniform heating

b)

Uneven heating and cooling

c)

Low current

d)

Short weld length

20.

The welding position 1G refers to:

a)

Vertical

b)

Horizontal

c)

Flat

d)

Overhead

21.

Which joint is most common in welding?

a)

Lap joint

b)

Butt joint

c)

Tee joint

d)

Corner joint

22.

Back gouging is done to:

a)

Remove slag

b)

Improve penetration

c)

Reduce distortion

d)

Clean flux

23.

Which metal is difficult to weld due to oxidation?

a)

Steel

b)

Copper

c)

Aluminum

d)

Cast iron

24.

Cast iron is usually welded using:

a)

Mild steel electrode

b)

Nickel electrode

c)

Aluminum electrode

d)

Tungsten electrode

25.

Post-weld heat treatment is done to:

a)

Increase weld speed

b)

Reduce residual stress

c)

Increase hardness

d)

Improve appearance

26.

Welding symbols are standardized by:

a)

BIS / IS standards

b)

ISO only

c)

AWS only

d)

ASME only

27.

Root gap is:

a)

Distance between weld passes

b)

Space between two plates at root

c)

Height of reinforcement

d)

Depth of penetration

28.

Penetration means:

a)

Width of weld

b)

Depth of fusion

c)

Length of weld

d)

Height of bead

29.

Which defect is most dangerous?

a)

Porosity

b)

Crack

c)

Spatter

d)

Slag

30.

The polarity DCEN means:

a)

Electrode positive

b)

Workpiece positive

c)

Electrode negative

d)

AC supply

31.

Welding helmet protects against:

a)

Heat only

b)

UV and IR radiation

c)

Spatter only

d)

Noise

32.

Which test is non-destructive?

a)

Tensile test

b)

Bend test

c)

Radiographic test

d)

Impact test

33.

Dye penetrant test is used to detect:

a)

Internal defects

b)

Surface cracks

c)

Porosity inside

d)

Slag inclusion

34.

Ultrasonic testing uses:

a)

X-rays

b)

Sound waves

c)

Magnetic field

d)

Heat

35.

Hardness of weld increases with:

a)

Slow cooling

b)

Fast cooling

c)

Preheating

d)

PWHT

36.

Welding of stainless steel requires:

a)

Oxygen shielding

b)

Proper control of heat

c)

High carbon electrode

d)

No shielding

37.

Flux in welding helps to:

a)

Conduct electricity

b)

Remove impurities

c)

Increase metal strength

d)

Increase voltage

38.

Which process gives the cleanest weld?

a)

SMAW

b)

MIG

c)

TIG

d)

SAW

39.

The main cause of weld cracks is:

a)

Residual stress

b)

Low voltage

c)

Long arc

d)

Slag

40.

Welding speed too high results in:

a)

Excess penetration

b)

Poor fusion

c)

Wider bead

d)

Better strength

41.

Edge preparation is done to:

a)

Improve appearance

b)

Reduce welding time

c)

Ensure proper penetration

d)

Increase distortion

42.

Which gas is commonly used in MIG welding of steel?

a)

Argon

b)

CO₂

c)

Oxygen

d)

Nitrogen

43.

Overhead welding position is:

a)

1G

b)

2G

c)

3G

d)

4G

44.

Weld reinforcement should be:

a)

Excessive

b)

Minimal and smooth

c)

Sharp

d)

Uneven

45.

Which electrode is used for mild steel?

a)

E6013

b)

E308

c)

E7018 stainless

d)

Nickel rod

46.

Spatter is caused by:

a)

Correct current

b)

Stable arc

c)

Excessive current

d)

Proper polarity

47.

Welding fumes are hazardous because they contain:

a)

Oxygen

b)

Metal oxides

c)

Water vapor

d)

Nitrogen

48.

Which joint requires least weld metal?

a)

Lap

b)

Butt

c)

Tee

d)

Corner

49.

The primary function of shielding gas is to:

a)

Increase heat

b)

Protect weld pool

c)

Cool electrode

d)

Increase penetration

50.

Indian Welding Society (IWS) mainly promotes:

a)

Manufacturing

b)

Welding education & technology

c)

Steel production

d)

Construction only