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CWI D1.1 Qualification practice questions

Applying AWS D1.1 Clause 5 (prequalified WPSs) and Clause 6 (WPS, welder and welding operator qualification) to real situations. This domain is about 30% of the exam. Try each question, then open the answer.

Read the D1.1 Qualification study guide

Question 1

An inspector wants to confirm whether a contractor's WPS can be used without qualification testing. Which D1.1:2020 clause should be checked first?
  1. Clause 5, Prequalification of WPSs
  2. Clause 4, Design of Welded Connections
  3. Clause 9, Stud Welding
  4. Clause 11, Strengthening and Repair of Existing Structures
Show answer

Answer: A. Clause 5, Prequalification of WPSs

Clause 5 lists the conditions a WPS must meet to be prequalified: processes, base and filler metals, joint details, preheat and other variables. In D1.1:2015 this was Clause 3.

Source: AWS D1.1/D1.1M:2020, Clause 5 (Clause 3 in D1.1:2015)

Question 2

Under AWS D1.1:2020, a welder's qualification remains in effect indefinitely unless which condition occurs?
  1. More than 6 months without using the process, or cause to doubt the welder's ability
  2. Any change of employer, or a gap of more than 3 months in using the process
  3. More than 30 days without using the process, or a repair rate above 5%
  4. A qualification test date more than 1 year old, whatever the welder's recent work
Show answer

Answer: A. More than 6 months without using the process, or cause to doubt the welder's ability

D1.1:2020 sets no fixed expiry for welder qualification. It lapses if the welder goes more than six months without using the process. It also lapses if there is a particular reason to doubt the welder's skill. See the period of effectiveness provisions in Clause 6.

Source: AWS D1.1/D1.1M:2020, Clause 6, Part A, period of effectiveness

Question 3

A face bend specimen from a D1.1 welder test shows one open discontinuity measuring 3/16 in. on the convex surface. How should it be judged?
  1. Accept: it is within the 1/4 in. limit for open discontinuities
  2. Accept: only cracks count against a bend specimen
  3. Reject: it exceeds the 1/8 in. limit for one discontinuity
  4. Accept, provided the companion root bend passed
Show answer

Answer: C. Reject: it exceeds the 1/8 in. limit for one discontinuity

The Clause 6 bend test acceptance criteria limit the largest single open discontinuity on the convex surface. The limit is 1/8 inch, and a 3/16 inch indication is over it. See the bend test acceptance criteria in Clause 6, Part B.

Source: AWS D1.1/D1.1M:2020, Clause 6, Part B, acceptance criteria for bend tests

Question 4

A WPS is qualified by testing a CJP groove weld in 1 in. thick plate under AWS D1.1:2020. What range of base metal thickness is qualified?
  1. 1/8 in. and over, unlimited
  2. 1/8 in. through 2 in.
  3. 1/2 in. through 1 in. only
  4. 1 in. only
Show answer

Answer: A. 1/8 in. and over, unlimited

Check the Clause 6, Part B WPS qualification table for CJP groove welds on plate. A test plate 1 inch or thicker qualifies 1/8 inch and over, with no upper limit.

Source: AWS D1.1/D1.1M:2020, Clause 6, Part B, WPS qualification table for CJP groove welds

Question 5

In D1.1 prequalified joint designations, what does 'B-U2a' indicate?
  1. Butt joint, PJP, single-bevel-groove weld, variation a
  2. Bevel-groove weld with backing, made in 2 passes, option a
  3. Butt joint, CJP of limited thickness, square-groove weld
  4. Butt joint, unlimited-thickness CJP, single-V groove
Show answer

Answer: D. Butt joint, unlimited-thickness CJP, single-V groove

A Clause 5 joint designation reads left to right. First comes the joint type (B = butt), then penetration and thickness (U = CJP of unlimited thickness). Next is the groove type number (2 = single-V), then a trailing letter for a variation. See the legend that goes with the prequalified joint detail figures in Clause 5.

Source: AWS D1.1/D1.1M:2020, Clause 5, prequalified CJP and PJP joint detail figures (joint designation legend)

Question 6

For a prequalified SMAW WPS under AWS D1.1, what is the maximum single-pass fillet weld size in the horizontal position?
  1. 1/4 in.
  2. 5/16 in.
  3. 3/8 in.
  4. 1/2 in.
Show answer

Answer: B. 5/16 in.

The Clause 5 prequalified WPS requirements table sets a size limit for single-pass SMAW fillet welds. In the horizontal position the limit is 5/16 inch. Larger fillets in that position need multiple passes or a WPS qualified by test. Read the SMAW row and the horizontal column.

Source: AWS D1.1/D1.1M:2020, Clause 5, prequalified WPS requirements table (Table 3.7 in D1.1:2015)

Question 7

Under AWS D1.1:2020, a welder passes a 2G CJP groove test on plate. Which positions are qualified for plate groove welds?
  1. Flat and horizontal
  2. Horizontal only
  3. Flat, horizontal and vertical
  4. All positions
Show answer

Answer: A. Flat and horizontal

A 2G plate groove test qualifies groove welds in the flat and horizontal positions. Vertical needs a 3G test, and overhead needs a 4G test. See the Clause 6, Part C table of welder positions qualified.

Source: AWS D1.1/D1.1M:2020, Clause 6 (Clause 4 in D1.1:2015), Part C, table of production welding positions qualified for welders

Question 8

A welder qualified with a 3G test welded vertical-up. Production calls for vertical-down welding with the same process. Under AWS D1.1:2020, what applies?
  1. The welder must requalify for vertical-down
  2. Qualification carries over if the WPS allows downhill
  3. Only a macroetch of a production weld is needed
  4. The 3G test covers both progressions automatically
Show answer

Answer: A. The welder must requalify for vertical-down

For welders, a change in the direction of vertical progression is an essential variable. A vertical-up test does not cover vertical-down work, so a new test is needed. See the Clause 6, Part C table of welder qualification essential variables.

Source: AWS D1.1/D1.1M:2020, Clause 6 (Clause 4 in D1.1:2015), Part C, table of welder qualification essential variables

Question 9

In the D1.1 prequalified joint designations, what does 'BC-P5' describe?
  1. A butt joint with backing, CJP, single-U-groove weld
  2. A T- or corner joint, PJP, single-J groove
  3. A butt or corner joint, CJP, flare-bevel groove
  4. A butt or corner joint, PJP, double-bevel groove
Show answer

Answer: D. A butt or corner joint, PJP, double-bevel groove

BC means a butt or corner joint, P means partial joint penetration, and 5 is the double-bevel groove. See the legend for the prequalified joint details in Clause 5.

Source: AWS D1.1/D1.1M:2020, Clause 5 (Clause 3 in D1.1:2015), prequalified joint detail figures (joint designation legend)

Question 10

An inspector needs the prequalified detail for a CJP single-bevel groove weld in a T-joint, unlimited thickness. Which designation should be looked up?
  1. TC-P4
  2. B-U4a
  3. TC-U4a
  4. TC-U5a
Show answer

Answer: C. TC-U4a

TC is a T- or corner joint, U is CJP of unlimited thickness, and 4 is the single-bevel groove. TC-U4a is one variation of that detail. See the legend for the prequalified joint details in Clause 5.

Source: AWS D1.1/D1.1M:2020, Clause 5 (Clause 3 in D1.1:2015), prequalified joint detail figures (joint designation legend)

Question 11

A contractor has a D1.1 WPS qualified by test for SMAW. It now wants to make the same joints with FCAW. Under AWS D1.1:2020, what is needed?
  1. Nothing, since the same joint and base metal are used
  2. Only a revision to the electrode line of the existing WPS
  3. Approval from the welders who will use the FCAW process
  4. A new WPS qualified with FCAW, or a prequalified FCAW WPS
Show answer

Answer: D. A new WPS qualified with FCAW, or a prequalified FCAW WPS

A change of welding process is an essential variable for WPS qualification. The contractor needs a WPS for FCAW, either qualified by test or meeting every prequalification condition. See the Clause 6, Part B table of PQR essential variables.

Source: AWS D1.1/D1.1M:2020, Clause 6 (Clause 4 in D1.1:2015), Part B, table of PQR essential variables

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