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CWI Welding Processes practice questions

How SMAW, GMAW, FCAW, GTAW, SAW, ESW, plasma, oxyfuel, brazing and soldering work, their equipment, consumables and typical problems. This domain is about 15% of the exam. Try each question, then open the answer.

Read the Welding Processes study guide

Question 1

What does the '1' in E7018 indicate?
  1. Flat and horizontal fillet positions only
  2. A single-pass electrode
  3. The electrode can be used in all positions
  4. Group 1 low-hydrogen electrode
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Answer: C. The electrode can be used in all positions

In E7018, the third digit gives usable positions. A 1 means all positions, and a 2 means flat and horizontal fillet. A 4 means flat, horizontal, overhead and vertical-down. The final '8' identifies a low-hydrogen, iron-powder coating usable on AC or DCEP.

Source: AWS A5.1/A5.1M (classification system)

Question 2

Which is NOT a function of the coating on an SMAW electrode?
  1. Producing a shielding gas
  2. Supplying the welding current to the arc
  3. Forming slag that protects the cooling weld
  4. Adding deoxidizers and alloying elements
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Answer: B. Supplying the welding current to the arc

The core wire carries the current. The coating provides shielding gas, slag, arc stabilizers, deoxidizers and sometimes alloying elements and iron powder.

Source: AWS Welding Handbook, 9th ed., Vol. 2 (Welding Processes, Part 1), chapter on SMAW (electrode coverings)

Question 3

Why is AC commonly selected for GTAW of aluminum?
  1. Its electrode-positive half cycle removes oxide; the negative half cycle gives penetration
  2. AC removes the need for inert shielding gas because the arc cleans the pool itself
  3. AC keeps the tungsten from overheating, so one electrode size suits every current
  4. AC gives deeper penetration than DCEN because the heat is shared by the electrode and work
Show answer

Answer: A. Its electrode-positive half cycle removes oxide; the negative half cycle gives penetration

Aluminum's tough oxide melts far above the base metal. On AC, the electrode-positive portion of each cycle gives a cleaning action that removes it, and the electrode-negative portion heats the work. This balance is why AC is the usual choice.

Source: AWS Welding Handbook, 9th ed., Vol. 2 (Welding Processes, Part 1), chapter on GTAW (alternating current)

Question 4

In the classification ER70S-6, what does the 'S' indicate?
  1. Stainless steel
  2. Short-circuiting transfer only
  3. Solid electrode or rod
  4. Spray transfer only
Show answer

Answer: C. Solid electrode or rod

In AWS A5.18 classifications, ER means the product can be used as an electrode or a rod. The 70 is the minimum tensile strength in ksi, and S means solid wire. The final digit identifies the chemistry; -6 has higher manganese and silicon for welding over mill scale.

Source: AWS A5.18/A5.18M (classification system)

Question 5

In the SAW flux-electrode classification F7A2-EM12K, what does the 'A' indicate?
  1. The flux is active and adds Mn and Si to the weld
  2. The flux-electrode combination is usable in all positions
  3. Properties were tested in the as-welded condition
  4. The flux is an alloy flux that adds Cr or Ni to the weld
Show answer

Answer: C. Properties were tested in the as-welded condition

In AWS A5.17, F7 means flux with 70 ksi minimum tensile strength. A means tested as-welded (P would mean after postweld heat treatment). The 2 means Charpy impact requirements were met at -20 degrees F. EM12K describes the electrode: medium manganese, about 0.12% carbon, killed.

Source: AWS A5.17/A5.17M (classification system)

Question 6

An oxyacetylene flame with about equal volumes of oxygen and acetylene, showing a clear inner cone with no feather, is a:
  1. Carburizing flame
  2. Oxidizing flame
  3. Neutral flame
  4. Soft flame
Show answer

Answer: C. Neutral flame

A neutral flame burns roughly equal volumes of oxygen and acetylene and has a sharply defined inner cone without an acetylene feather. It is used for most steel welding because it neither adds carbon nor oxidizes the pool.

Source: AWS Welding Handbook, 9th ed., Vol. 2 (Welding Processes, Part 1), chapter on oxyfuel gas welding

Question 7

What is arc blow?
  1. A loud popping sound caused by a long arc
  2. Deflection of the arc from its normal path by magnetic forces
  3. The arc going out when the electrode touches the work
  4. Spatter blown from the weld by shielding gas
Show answer

Answer: B. Deflection of the arc from its normal path by magnetic forces

Arc blow is the deflection of an arc by magnetic forces, most common with DC near ends of joints or with uneven ground connections. Switching to AC, moving the work lead, shortening the arc or changing electrode angle can reduce it.

Source: AWS A3.0M/A3.0:2020 (term: arc blow); AWS Welding Handbook, 9th ed., Vol. 2 (Welding Processes, Part 1)

Question 8

Which AWS filler metal specification covers carbon steel electrodes for shielded metal arc welding?
  1. AWS A5.1
  2. AWS A5.18
  3. AWS A5.17
  4. AWS A5.20
Show answer

Answer: A. AWS A5.1

A5.1 covers carbon steel SMAW electrodes and A5.5 covers low-alloy steel SMAW electrodes. A5.18 is carbon steel solid wire for GMAW and GTAW, A5.17 is SAW and A5.20 is FCAW.

Source: AWS A5 filler metal specification series (scopes)

Question 9

In arc stud welding, what is the purpose of the ceramic ferrule placed around the stud?
  1. To insulate the stud from the work so no current passes through it
  2. To concentrate heat, hold the molten metal and shield the arc
  3. To act as filler metal that melts into the joint to form the fillet
  4. To measure the stud length after welding
Show answer

Answer: B. To concentrate heat, hold the molten metal and shield the arc

The ceramic ferrule surrounds the arc, concentrates heat, holds the molten metal in place to form the fillet (flash) and restricts air. It is broken off and discarded after the weld.

Source: AWS Welding Handbook, 9th ed., Vol. 3 (stud welding); AWS D1.1 Clause 9

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