CWI Practical Visual Inspection Questions and Answers — Questions and Answers
Question 1: An inspector is visually examining a completed groove weld on a 1-inch thick carbon steel plate subject to cyclic loading under AWS D1.1. Which of the following discontinuities is strictly prohibited, regardless of its size or location?
- Undersized weld
- Porosity
- Undercut
- Crack (Correct answer)
Correct answer: Crack
According to AWS D1.1, for both statically and cyclically loaded structures, any crack is deemed unacceptable and must be repaired. While other discontinuities like porosity and undercut have acceptable limits based on size and location, cracks are never permissible.
Question 2: During a post-weld visual inspection, which tool is specifically designed to measure the depth of undercut and the height of weld reinforcement?
- Fillet weld gauge
- Hi-Lo gauge
- Bridge Cam gauge (Correct answer)
- Telescoping mirror
Correct answer: Bridge Cam gauge
The Bridge Cam gauge is a versatile tool used by welding inspectors to measure several different aspects of a weld. It is specifically designed to accurately measure weld reinforcement height, undercut depth, pitting, and fillet weld throat dimensions. A fillet weld gauge measures leg length and throat, a Hi-Lo gauge measures internal misalignment, and a mirror is for viewing obstructed areas.
Question 3: A visual inspector identifies a condition where the weld metal has melted the base metal at the toe of the weld, but has not deposited sufficient filler metal, creating a groove. This discontinuity is best described as:
- Overlap
- Underfill
- Incomplete fusion
- Undercut (Correct answer)
Correct answer: Undercut
Undercut is defined as a groove melted into the base metal adjacent to the weld toe or weld root and left unfilled by weld metal. Underfill is when the weld face is below the adjacent base metal surface. Overlap is the protrusion of weld metal beyond the weld toe or root. Incomplete fusion is a lack of union between the weld metal and the base metal or adjacent weld beads.
Question 4: According to ASME B31.3 for Normal Fluid Service, what is the minimum required frequency for visual examination (VT) of completed welds?
- A random 5% of all welds.
- 100% of all completed welds. (Correct answer)
- All welds made by a new welder for the first week.
- Only welds that are also subject to radiographic testing.
Correct answer: 100% of all completed welds.
ASME B31.3, Paragraph 341.4.1(a), requires visual examination of 100% of all fabrication. This includes checking materials, components, joint preparation, alignment, and, after welding, the completed welds.
Question 5: An inspector is performing a pre-weld visual inspection on a pipe joint. Which of the following items is the inspector MOST likely to check at this stage?
- The presence of undercut or overlap.
- The final weld reinforcement height.
- Joint alignment and root opening. (Correct answer)
- The interpass temperature.
Correct answer: Joint alignment and root opening.
Pre-weld inspection occurs before any welding begins. At this stage, the inspector's primary focus is on verifying that the joint preparation is correct according to the WPS. This includes checking the root opening, bevel angle, and the alignment (mismatch) of the components. Undercut, reinforcement, and interpass temperature are all checked during or after welding.
Question 6: While performing visual inspection of a completed fillet weld, an inspector notices insufficient weld metal at the joint, resulting in the weld face being below the surface of the adjacent base material. This condition is known as:
- Excessive convexity
- Underfill (Correct answer)
- Concavity
- Incomplete penetration
Correct answer: Underfill
Underfill is a longitudinal depression in the surface of a weld where the weld metal deposited is insufficient to fill the joint, leaving the weld face below the adjacent base metal surface. While concavity describes the shape of the weld face, underfill specifically refers to the insufficiency of the deposited metal relative to the base material surface.
CWI Practical Visual Inspection Questions and Answers
An inspector is visually examining a completed groove weld on a 1-inch thick carbon steel plate subject to cyclic loading under AWS D1.1.
Which of the following discontinuities is strictly prohibited, regardless of its size or location?