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Metallurgy & Weld Quality Inspection Flashcards

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

Read the first 7 Metallurgy & Weld Quality Inspection flashcards as text

  1. What effect does increasing heat input have on the coarse-grained HAZ toughness of low-alloy steel?

    Answer: It reduces toughness by promoting grain growth and unfavorable microstructures

    Higher heat input raises the peak temperature and slows cooling, allowing excessive austenite grain growth in the CGHAZ, resulting in coarser, tougher-degrading microstructures.

  2. According to AWS D1.1, what is the maximum permitted depth of individual surface porosity for a CJP groove weld visible on the surface?

    Answer: 3/32 in.

    AWS D1.1 limits visible individual surface porosity to a maximum diameter of 3/32 in. (2.4 mm) with frequency and cluster restrictions.

  3. What is the primary metallurgical reason for preheating high-carbon steel before SAW?

    Answer: To slow the cooling rate and prevent formation of brittle martensite in the HAZ

    Preheat raises the starting temperature of the base metal, slowing the post-weld cooling rate and suppressing martensite formation in the high-carbon HAZ.

  4. A magnetic particle test (MT) on a SAW weld reveals a linear indication at the weld toe. This most likely indicates:

    Answer: A surface or near-surface crack

    MT reveals surface and slightly subsurface discontinuities with a magnetic field; a linear indication at the weld toe is characteristic of a toe crack.

  5. In fracture mechanics, the term CTOD (Crack Tip Opening Displacement) test is used to:

    Answer: Quantify the fracture toughness of a weld or HAZ at various temperatures

    CTOD testing measures the displacement at a crack tip at the point of fracture or plastic instability, giving a direct measure of fracture toughness applicable to weld quality.

  6. Which element, if present above acceptable levels in SAW weld metal, is most likely to cause hot cracking?

    Answer: Sulfur

    Sulfur forms low-melting-point iron sulfide films at grain boundaries during solidification; when present in excess, these films remain liquid as the rest of the weld solidifies, causing hot cracking.

  7. A tensile test of a SAW weld joint fractures in the base metal rather than the weld metal. This indicates:

    Answer: The weld metal meets or exceeds the base metal tensile strength (weld overmatch)

    Fracture in the base metal during a transverse tensile test confirms that the weld metal is at least as strong as the base metal, demonstrating acceptable overmatch.