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Weld Discontinuities and Defects Flashcards

7 cards from real CWI practice questions. Tap to flip, then mark Knew It or Still Learning — missed cards come back until you master them.

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  1. Which discontinuity is characterized by a groove melted into the base metal adjacent to the weld toe that is left unfilled by weld metal?

    Answer: Undercut

    Undercut is a groove melted into the base metal at the weld toe or root that is not filled by weld metal, reducing the effective cross-section.

  2. Lamellar tearing in a weld joint is most likely to occur in which orientation relative to the base metal surface?

    Answer: Parallel to the surface

    Lamellar tearing occurs parallel to the plate surface due to through-thickness stresses acting on planes of low ductility inclusions.

  3. A weld that shows excessive convexity is most likely to cause which problem in service?

    Answer: Stress concentration at the weld toes

    Excessive convexity creates stress concentrations at the weld toes due to the abrupt geometric transition, which can initiate fatigue cracking.

  4. Which type of crack propagates along the weld metal centerline, typically caused by solidification shrinkage and low-melting-point constituents?

    Answer: Longitudinal centerline crack

    Longitudinal centerline cracks form along the weld axis as the weld solidifies, driven by shrinkage stresses and segregation of low-melting impurities.

  5. According to AWS standards, which condition describes 'overlap' in a weld?

    Answer: Protrusion of weld metal beyond the weld toe onto base metal without fusion

    Overlap is the protrusion of weld metal beyond the weld toe or root onto the base metal surface without fusion, creating a notch-like condition.

  6. A weld inspector finds scattered porosity throughout the weld. Which cause is LEAST likely responsible?

    Answer: Excessive travel speed

    Excessive travel speed more commonly causes incomplete fusion or underfill rather than scattered porosity, which is primarily caused by gas entrapment from contamination or shielding failures.

  7. Which discontinuity is unique to resistance spot welding and appears as a hollow cavity within the nugget?

    Answer: Shrinkage void (void in nugget)

    Shrinkage voids in resistance spot welding form at the nugget center as the molten metal solidifies and contracts, leaving a hollow cavity.