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CWI D1.1 Fabrication practice questions

Applying AWS D1.1 Clause 7: consumables, preheat, welding environment, joint fit-up tolerances, weld profiles and repairs. This domain is about 30% of the exam. Try each question, then open the answer.

Read the D1.1 Fabrication study guide

Question 1

Under AWS D1.1:2020, what is the permitted atmospheric exposure time for E8018 low-hydrogen electrodes (no moisture-resistant designator)?
  1. 2 hours
  2. 4 hours
  3. 1 hour
  4. 1/2 hour
Show answer

Answer: A. 2 hours

The exposure limit gets shorter as electrode strength rises, because higher-strength weld metal is more sensitive to hydrogen cracking. For E80XX without a moisture-resistant designator, the limit is 2 hours. See the Clause 7 table of permissible atmospheric exposure.

Source: AWS D1.1/D1.1M:2020, Clause 7 (Clause 5 in D1.1:2015), table of permissible atmospheric exposure of low-hydrogen electrodes

Question 2

Under AWS D1.1:2020, below what ambient temperature is welding not permitted?
  1. 32 degrees F (0 degrees C)
  2. 50 degrees F (10 degrees C)
  3. -20 degrees F (-29 degrees C)
  4. 0 degrees F (-20 degrees C)
Show answer

Answer: D. 0 degrees F (-20 degrees C)

D1.1 prohibits welding when the ambient temperature is below 0 degrees F. It also prohibits welding when surfaces are wet or exposed to rain, snow or high wind. The exception is a heated or protected enclosure that gives suitable conditions for the welder and the work.

Source: AWS D1.1/D1.1M:2020, Clause 7 (Clause 5 in D1.1:2015), welding environment, minimum ambient temperature

Question 3

A 1/2 in. plate is butt welded to a 1 in. plate. Under AWS D1.1:2020, what is the maximum allowed offset (misalignment) from the theoretical alignment?
  1. 0.10 in.
  2. 1/8 in.
  3. 0.05 in.
  4. 1/4 in.
Show answer

Answer: C. 0.05 in.

D1.1 limits butt joint misalignment to 10% of the thickness of the thinner part joined, but not more than 1/8 inch. Here 10% of 1/2 inch is 0.05 inch.

Source: AWS D1.1/D1.1M:2020, Clause 7 (Clause 5 in D1.1:2015), tolerance of joint dimensions, butt joint alignment

Question 4

A fillet weld has a face width of 1/2 in. Under the AWS D1.1:2020 weld profile requirements, what is the maximum convexity?
  1. 1/16 in.
  2. 3/16 in.
  3. 1/4 in.
  4. 1/8 in.
Show answer

Answer: D. 1/8 in.

The Clause 7 weld profile schedule sets maximum fillet convexity by the face width, W. A 1/2 inch face width falls in the middle band, which allows 1/8 inch. See the weld profile table and schedule in Clause 7.

Source: AWS D1.1/D1.1M:2020, Clause 7 (Clause 5 in D1.1:2015), weld profiles (table and figure of acceptable and unacceptable profiles)

Question 5

Under AWS D1.1:2020, on which weld layers is peening NOT permitted (except where specifically approved)?
  1. The root layer and the surface (final) layer
  2. Any intermediate layer of a multipass weld
  3. Every layer of a fillet weld
  4. Only layers deposited with SMAW electrodes
Show answer

Answer: A. The root layer and the surface (final) layer

Clause 7 allows peening of intermediate layers to control shrinkage stress and distortion. Peening is not allowed on the first or last layer, or on the base metal at the weld edges. Caulking, which can hide discontinuities, is not allowed. See the Clause 7 provisions on peening and caulking.

Source: AWS D1.1/D1.1M:2020, Clause 7 (Clause 5 in D1.1:2015), peening and caulking

Question 6

Under AWS D1.1:2020, what is the smallest radius allowed where a reentrant corner is cut into a plate?
  1. 1/4 in. (6 mm)
  2. 1/2 in. (12 mm)
  3. 2 in. (50 mm)
  4. 1 in. (25 mm)
Show answer

Answer: D. 1 in. (25 mm)

Sharp reentrant corners concentrate stress and can start cracks, so Clause 7 sets a 1 in. minimum radius for them. Weld access holes have their own dimensional rules. See the Clause 7 provision on reentrant corners.

Source: AWS D1.1/D1.1M:2020, Clause 7 (Clause 5 in D1.1:2015), reentrant corners

Question 7

A bag of SAW flux on a D1.1 job got wet. Under AWS D1.1:2020, what should be done with the flux?
  1. Dry it at 250 degrees F and use it
  2. Mix it with fresh flux to dilute the moisture
  3. Use it only for the root pass
  4. Do not use it
Show answer

Answer: D. Do not use it

D1.1 does not allow flux that has been wet to be used, whatever is done to it afterward. See the Clause 7 provisions on SAW electrodes and fluxes.

Source: AWS D1.1/D1.1M:2020, Clause 7 (Clause 5 in D1.1:2015), SAW electrodes and fluxes

Question 8

Two 2 in. thick plates are butt welded and are effectively restrained against bending from misalignment. Under AWS D1.1:2020, what is the maximum offset allowed?
  1. 1/16 in.
  2. 1/8 in.
  3. 3/16 in.
  4. 0.20 in.
Show answer

Answer: B. 1/8 in.

The offset may not exceed 10% of the thinner part, with an absolute cap of 1/8 inch. Ten percent of 2 inches is 0.20 inch, so the 1/8 inch cap governs. See the Clause 7 provisions on butt joint alignment.

Source: AWS D1.1/D1.1M:2020, Clause 7 (Clause 5 in D1.1:2015), tolerance of joint dimensions, butt joint alignment

Question 9

A weld has excessive porosity and slag inclusions. Under AWS D1.1:2020, what is the repair method?
  1. Deposit a cosmetic pass over the surface
  2. Peen the weld to close the pores
  3. Remove the unacceptable portions and reweld
  4. Grind the weld face until the pores are gone
Show answer

Answer: C. Remove the unacceptable portions and reweld

Excessive porosity, excessive slag and incomplete fusion are repaired by removing the unacceptable portions and rewelding. Covering or closing the defects is not a repair. See the Clause 7 provisions on repairs.

Source: AWS D1.1/D1.1M:2020, Clause 7 (Clause 5 in D1.1:2015), repairs (contractor options)

Question 10

Weld tabs were used at the ends of a CJP groove weld on a cyclically loaded member. Under AWS D1.1:2020, what is required after welding?
  1. Leave the tabs in place unless the Engineer asks for removal
  2. Cut the tabs off but leave the stubs unground
  3. Remove the tabs and grind the weld ends flush with the edges
  4. Remove the tabs only if they are not the same steel as the base metal
Show answer

Answer: C. Remove the tabs and grind the weld ends flush with the edges

On cyclically loaded structures, weld tabs are removed after the weld cools. The weld ends are then made smooth and flush with the edges of the parts. On statically loaded work they may stay unless the Engineer requires removal. See the Clause 7 provisions on weld tabs.

Source: AWS D1.1/D1.1M:2020, Clause 7 (Clause 5 in D1.1:2015), weld tabs

Question 11

A 2 in. thick plate edge is thermally cut. Under AWS D1.1:2020, what is the maximum surface roughness allowed for a cut surface on a member subject to calculated stress?
  1. 250 microinches
  2. 500 microinches
  3. 1,000 microinches
  4. 2,000 microinches
Show answer

Answer: C. 1,000 microinches

For material up to 4 inches thick, D1.1 limits thermally cut surfaces to a roughness of 1,000 microinches. Roughness is judged against the AWS C4.1 sample. Thicker material and members without calculated stress have a looser limit. See the Clause 7 provisions on thermal cutting.

Source: AWS D1.1/D1.1M:2020, Clause 7 (Clause 5 in D1.1:2015), thermal cutting processes, roughness requirements

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