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CWI Welding Performance practice questions

Welding procedure specifications, procedure qualification records, welder and welding operator qualification and essential variables. This domain is about 11% of the exam. Try each question, then open the answer.

Read the Welding Performance study guide

Question 1

Which document records the actual variables used to weld a test coupon and the results of testing that coupon?
  1. Welding procedure specification (WPS)
  2. Welder performance qualification record (WPQ)
  3. Procedure qualification record (PQR)
  4. Mill test report
Show answer

Answer: C. Procedure qualification record (PQR)

The PQR records the actual values used to make the test weld, such as base metal, filler, current, voltage, travel speed and preheat. It also records the results of the required tests. It supports one or more WPSs.

Source: AWS Welding Inspection Handbook, 4th ed., chapter on welding procedures; ASME BPVC Section IX, QW-200 (PQR)

Question 2

In welding procedure qualification, what is an essential variable?
  1. A variable that must be written on the WPS but can be changed freely
  2. Any variable the welder can adjust
  3. A variable whose change beyond stated limits requires requalification
  4. A variable that applies only when impact testing is required
Show answer

Answer: C. A variable whose change beyond stated limits requires requalification

An essential variable is one that affects the mechanical properties of the weldment; changing it beyond the code's limits requires requalification. Nonessential variables can be changed by revising the WPS without new tests.

Source: ASME BPVC Section IX, QW-251 (types of variables); AWS Welding Inspection Handbook, 4th ed.

Question 3

Under ASME Section IX, a welder has not welded with a process for more than 6 months. What happens to the welder's qualification for that process?
  1. It stays valid indefinitely
  2. It is reduced to flat position only
  3. It stays valid if the welder used a different process
  4. It expires
Show answer

Answer: D. It expires

Section IX QW-322 says qualification expires when a welder has not welded with a process for 6 months or more. Qualification can also be revoked when there is a specific reason to question the welder's ability. AWS D1.1 has a similar 6-month rule.

Source: ASME BPVC Section IX, QW-322; AWS D1.1:2020 Clause 6 (period of effectiveness)

Question 4

What is the main purpose of P-numbers in ASME Section IX?
  1. To show the base metal's price category
  2. To identify the filler metal that must be used with each listed base metal
  3. To group base metals of similar weldability to reduce qualifications
  4. To give the minimum preheat temperature
Show answer

Answer: C. To group base metals of similar weldability to reduce qualifications

P-numbers group base metals by characteristics such as composition, weldability and mechanical properties. A procedure qualified on one P-number generally covers other metals in the same P-number, cutting down on testing.

Source: ASME BPVC Section IX, QW-420 (P-numbers)

Question 5

During a procedure qualification test, which role is appropriate for the inspector?
  1. Weld the coupon so that it is done correctly
  2. Set the welding variables at the midpoint of the ranges the WPS will cover
  3. Witness the welding, record the actual variables and observe testing
  4. Choose which bend specimens to discard
Show answer

Answer: C. Witness the welding, record the actual variables and observe testing

The inspector's value lies in independent observation. That means confirming the materials and recording the real welding data. It also means witnessing specimen removal and testing, so the PQR is accurate.

Source: AWS Welding Inspection Handbook, 4th ed., chapter on qualification testing

Question 6

Why do most codes limit the range of production thickness a welder may weld, based on the thickness of the welder's test coupon?
  1. Thicker coupons use more filler metal, so the range keeps test costs down
  2. A thin test does not show the multipass skills that thick joints need
  3. Thickness affects the base metal chemistry, which the welder must match
  4. Thickness limits apply to procedures, so welders have no thickness range
Show answer

Answer: B. A thin test does not show the multipass skills that thick joints need

A thick coupon needs many passes, sidewall fusion and cleaning between passes, so it shows more skill than a thin one. Codes therefore let a thick-plate test cover a wide range, often unlimited. A thin-plate test covers only up to a set limit. The exact ranges come from the governing code, such as D1.1 Clause 6.

Source: AWS Welding Inspection Handbook, 4th ed., chapter on welder qualification; AWS D1.1/D1.1M:2020, Clause 6 (thickness qualified for welders)

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