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CWI Weld Examination practice questions

Visual inspection before, during and after welding, discontinuity types and causes, gauges and measuring weld size and profile. This domain is about 12% of the exam. Try each question, then open the answer.

Read the Weld Examination study guide

Question 1

Which inspection activity is best done DURING welding?
  1. Verifying preheat and interpass temperature and cleaning between passes
  2. Checking the mill test report against the purchase order
  3. Reviewing welder qualification records
  4. Final dimensional check of the weldment
Show answer

Answer: A. Verifying preheat and interpass temperature and cleaning between passes

During welding, the inspector checks that WPS variables are followed: preheat and interpass temperature, filler metal, technique, root quality, interpass cleaning and back gouging. Many problems, such as slag left between passes, cannot be seen once the weld is finished.

Source: AWS Welding Inspection Handbook, 4th ed., chapter on visual inspection (during welding)

Question 2

Slag inclusions are LEAST likely with which process?
  1. Gas tungsten arc welding
  2. Shielded metal arc welding
  3. Submerged arc welding
  4. Flux cored arc welding
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Answer: A. Gas tungsten arc welding

Slag inclusions come from flux-producing processes: SMAW, FCAW, SAW and ESW. GTAW uses no flux, so slag inclusions are not a typical problem; its typical inclusion is tungsten.

Source: AWS Welding Inspection Handbook, 4th ed., chapter on discontinuities (slag inclusions)

Question 3

A crack runs lengthwise along the center of a SAW weld bead and appeared as the weld solidified. Which factor most likely contributed?
  1. A wide, shallow bead
  2. Too much preheat
  3. Hydrogen from damp electrodes
  4. A bead with a high depth-to-width ratio
Show answer

Answer: D. A bead with a high depth-to-width ratio

Centerline (solidification) cracks are hot cracks. A deep, narrow bead makes the grains meet at the center, where low-melting impurities such as sulfur and phosphorus collect. Lower current or higher voltage to widen the bead helps prevent them.

Source: AWS Welding Inspection Handbook, 4th ed., chapter on discontinuities (cracks)

Question 4

Laminations in rolled plate are best detected before welding by:
  1. Magnetic particle testing of the plate surface
  2. Radiography perpendicular to the plate
  3. Visual examination of the plate face
  4. Straight-beam ultrasonic testing
Show answer

Answer: D. Straight-beam ultrasonic testing

Laminations are flat separations parallel to the plate surface. A straight-beam (longitudinal wave) UT signal reflects strongly from them. They can also show up as lines on cut edges.

Source: AWS Welding Inspection Handbook, 4th ed., chapter on NDE (ultrasonic testing)

Question 5

Which tool is designed to measure internal misalignment (high-low) of pipe joints before welding?
  1. Fillet weld gauge
  2. Temperature-indicating crayon
  3. Protractor
  4. Hi-lo gauge
Show answer

Answer: D. Hi-lo gauge

A hi-lo gauge measures internal misalignment between pipe ends, along with root opening and wall thickness. Misalignment beyond code limits can cause incomplete penetration and stress concentrations.

Source: AWS Welding Inspection Handbook, 4th ed., chapter on inspection tools

Question 6

Which discontinuity is generally considered most harmful to a weld subject to cyclic loading?
  1. Scattered spherical porosity
  2. A crack
  3. Spatter on the base metal
  4. Slight convexity within code limits
Show answer

Answer: B. A crack

Cracks are planar with sharp tips, so they concentrate stress and grow under cyclic loading. Most codes reject cracks of any size. Rounded porosity is volumetric and less damaging.

Source: AWS Welding Inspection Handbook, 4th ed., chapter on discontinuities (significance)

Question 7

Which inspection method is the most widely used and lowest-cost way to find weld problems?
  1. Radiographic testing
  2. Ultrasonic testing
  3. Visual examination
  4. Acoustic emission testing
Show answer

Answer: C. Visual examination

Visual examination is the most widely used inspection method and costs the least. Done before, during and after welding, it catches most problems early, when they are easiest to correct.

Source: AWS B1.11M/B1.11, Guide for the Visual Examination of Welds; AWS Welding Inspection Handbook, 4th ed.

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