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Study Questions Flashcards

1
Q

How many welds does API 577 require to be RT’d?

A

None / The # of welds to RT is established by the primary code

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2
Q

Arc Blow

A

Deflection of an arc from it’s normal path due to magnetic forces

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3
Q

Arc Length

A

The distance from the tip of the welding electrode to the adjacent surface of the weld pool.

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4
Q

Autogenous weld

A

A fusion weld made without filler metal

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5
Q

Backing

A

Material placed at back side of joint to support and retain molten weld metal.

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6
Q

Defect

A

Discontinuity(s) that render a part or product unable to meet min applicable standards or specs. The term designates rejectability

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7
Q

Discontinuity

A

An interruption of the typical structure of a material. May or may not be a defect depending on severity.

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8
Q

Inclusion

A

(SOFT) Entrapped foreign solid material such as Slag, Oxide, Flux, Tungsten (SOFT)

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9
Q

Undercut

A

A groove melted into the base metal adjacent to the weld toe or weld root and left unfilled by weld metal.

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10
Q

Corrective action of non-conformance:

A

Based on nature of non-conformance

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11
Q

Which welding process is most widely used

A

SMAW

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12
Q

Describe the SMAW process

A

Arc between covered electrode and weld pool. Heat of arc comes from tip of a consumable covered electrode. Shielding comes from decomposition of the electrode coating

Arc Between Electrode & Pool
Heat comes from electrode
Shielding comes from electrode coating

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13
Q

Basic Functions of the SMAW electrode coating

A
  1. Shielding Gas
  2. Prevent excessive grain growth
  3. Slag blanket to protect weld
  4. Sometimes provides alloy elements

SHIELD
PEG
BLANKET
ALLOY

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14
Q

Advantages of SMAW

A

Simple

Suitable for most commonly used metals

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15
Q

Limitations of SMAW

A

Deposition rates are lower

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16
Q

Advantages of GTAW

A

Produces high purity welds

Little postweld cleaning

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17
Q

Limitations of GTAW

A

Low deposition rates
Low tolerance for contaminants
Difficult to shield

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18
Q

Advantages of GMAW

A

Only consumable that can weld most commercial metals & alloys
High deposition rates
Minimal cleanup

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19
Q

Limitations of GMAW

A

Complex equipment

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20
Q

Advantages of FCAW

A

Metallurgical benefits from flux
Higher deposition and productivity rates
Shielding produced at the surface, more tolerant of wind.

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21
Q

Limitations of FCAW

A

Complex equipment
Requires exhaust equipment
Slag needs to be removed between passes
Backing material required for root pass

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22
Q

Advantages of SAW

A

Very high deposition rates

High quality welds

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23
Q

Limitations of SAW

A

Weld is not visible during the welding process
Expensive equipment
Limited to shop applications and flat position

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24
Q

SMAW stands for

A

Shielded Metal Arc Welding

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25
GMAW stands for
Gas Metal Arc Welding
26
GTAW stands for
Gas Tungsten Arc Welding
27
FCAW stands for
Flux Cored Arc Welding
28
SAW stands for
Submerged Arc Welding
29
Which GMAW transfer mode is "fast-freezing" and tends to have LOF
GMAW - Short Circuit Mode
30
Which process uses a directed stream of discrete drops
GMAW - Spray Transfer Mode
31
Variables required on WPS
Essential, non-essential and supplemental essential when toughness testing is required
32
Variables required on PQR
Essential, non-essential are optional
33
Per Section IX, who supervises the testing of a PQR coupon?
Manufacturer or contractor - the owner of the procedure
34
What are welding materials?
Base metal, filler metal, fluxes & gases
35
What is the purpose of P-Numbers?
Reduce the # of welding procedure qualifications required
36
What is the basis for F-Numbers
Usability characteristics
37
What is the qual limits for a welder who qualifies using an electrode from a specific F-Number family?
Qualified for all electrodes of the same F-Number. With carbon steel, also qualifies for other F-Numbers
38
What alloy is P-53
Titanium
39
What is the A-Number
ANALYZE / Analysis of chemical composition of the weld
40
Where are some electrodes stored
Warm holding ovens
41
Low Hydrogen electrode storage
Separate from other electrodes
42
What to do with wet fluxes or electrodes
Discard
43
Change in WPQ essential variable requires
Welder Requal
44
Which discontinuity is at the toe of the weld?
Overlap, Undercut is also correct but was not one of the 4 choices
45
ET is useful NDE method for which type of joints?
Butt welds
46
How best to find side wall lack of fusion?
UT
47
What is the most extensively used NDE methods for welds?
Visual
48
Visual exam distance
6-24"
49
Visual exam minimum angle
30 degrees
50
Needed light intensity
100 foot candles
51
Use of Bridge Cam gauge
Measure weld prep angle
52
MT - Flux direction best to see a discontinuity
Perpendicular to discontinuity
53
Result of MT Residual magnetism
Deflect Arc
54
PT on SS watch out for
Chlorine and fluorine, Code mentions chlorine, sulfur and halogens but fluroine has been a test answer
55
PT max temp limit
125 F
56
What determines which IQI should be used
Thickness of base metal plus reinforcement
57
Placement of Wire IQI
Perpendicular across weld
58
Typical RT sources
IR 192 and Cobalt 60
59
Iridium 192 use on what wall thickness
1/4-3"
60
Cobalt 60 use on what wall thickness
1.5-7"
61
UT Calibration
Before & After exam
62
UT calibration block temp
w/in 25F of part to be examined
63
UT recalibration
at least every 4 hours
64
Direction of UT angle beam scan for indications transverse to the weld
Parallel to the weld
65
Why use Hardness Testing
Weld & HAZ, & after PWHT to see if mat'l soft
66
Use of FMR (Field Metallography Replication)
Find excessively hard HAZ structure
67
Pressure test typical holding time
at least 30 minutes
68
Weld metal is similar to that of
Castings
69
Ductility Definition
The ability of a material to deform plastically without fracturing
70
Names of hardness tests
Brinell, Rockwell, Knoop & Vickers
71
What is the heat affected zone (HAZ)
Portion of base metal that has not been melted but whose mechanical properties or microstructure has been altered
72
For carbon steels, the HAZ is parent metal NOT melted but exceeded what temperature?
1350 F
73
Define Toughness
Ability of a material to absorb energy and deform plastically before fracturing
74
One of the most common tests for toughness
Charpy Impact test
75
What do low toughness values indicate
Brittle material
76
Primary reason for PWHT
Relive residual stress
77
Test for hardenability
Jominy Bar
78
Hardenability is related to the amount of
Martensite formed during heating & cooling
79
Significant amounts of martensite in the HAZ can lead to
Hydrogen cracking or a loss of Ductility and Toughness
80
Brinell Hardness limit for 1-1/4 chrome - 1/2 moly
225
81
Austenitic welds required how much delta ferrite to resist cracking
5-20%
82
Differences in welding nickel alloys
Tendency to be sluggish
83
Rod type to use when hot tapping:
Low hydrogen electrodes
84
Examples of low hydrogen electrodes:
E7016, E7018 & E7048 "7016,18 & 48"
85
Product flow rate in piping during hot tapping
1.3 - 4.0 ft/sec
86
Maximum rod size to use when hot tapping material less than 1/4" thick?
3/32" diameter
87
Marking in the tail of a weld symbol
Specification or Process
88
Meaning of the first two digits of a SMAW Electrode
Tensile Strength
89
What processes use a rod with designation "ERXXX"
GMAW/GTAW
90
What does "S" mean in electrode designation of GMAW/GTAW
Solid Wire
91
Common SMAW electrode used for root pass on carbon steel welds
E6010

API 577 (1 decks)

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