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Topics covered in this module include:
Module 1: Theory & Technology (Paper A)
- The role and responsibilities of welding supervisors (and inspectors)
- Welding safety
- Welding, cutting, and related processes
- Welding equipment
- Welding practice and production
- Welding inspection and testing
- Basic metallurgy
Section 1: Multiple-Choice Questions (25 Questions)
Here you can take free AS 2214 Welding Supervisor Part A Exam Practice test with the latest Question and Answers
18 Short Answer / Fill-in-the-Blank Questions for Paper A: Welding Theory & Technology (Closed-Book)
- Responsibilities of a Welding Supervisor
Q: What is one key responsibility of a welding supervisor in a fabrication workshop?
A: Ensuring compliance with the welding procedure specification (WPS).
Explanation: A supervisor ensures that welders follow approved procedures to produce quality welds in accordance with standards like AS/NZS 1554.
- Inspection Role
Q: The main duty of a welding inspector is to verify _______?
A: Compliance with specifications and standards.
Explanation: The inspector checks welds against codes and client requirements to ensure structural integrity.
- PPE for Eye Protection
Q: During arc welding, operators must wear a helmet fitted with ______ to protect their eyes.
A: A welding filter lens.
Explanation: Welding arc emits UV and IR radiation, requiring protective filters to avoid eye damage.
- Fire Hazard Control
Q: Name one method of reducing fire risk during gas welding.
A: Use fire-resistant blankets or shields.
Explanation: Hot sparks and slag can ignite nearby materials; fire-resistant barriers offer protection.
- Shielding Gas for TIG
Q: The most commonly used shielding gas for TIG welding of stainless steel is ______?
A: Argon.
Explanation: Argon protects the weld pool from atmospheric contamination and provides stable arc characteristics.
- Cutting Process
Q: Oxy-fuel cutting requires a fuel gas and ______ to sustain the cutting flame.
A: Oxygen.
Explanation: Oxygen reacts with metal at high temperatures, enabling rapid oxidation and cutting.
- MMA Welding Power Source Type
Q: Manual Metal Arc (MMA) welding uses a ______ type power source.
A: Constant current (CC).
Explanation: MMA requires stable current to maintain a consistent arc despite fluctuations in arc length.
- Wire Feed System
Q: In MIG welding, the wire is fed through a ______ system.
A: Motor-driven roller.
Explanation: The wire feed mechanism pushes consumable wire to the torch at a preset speed.
- Welding Defect from Fast Travel
Q: Excessively fast travel speed during welding can lead to which defect?
A: Lack of fusion.
Explanation: Fast travel reduces heat input, preventing proper fusion between base metals.
- Welding Position
Q: The term “overhead position” refers to welding done from ______ the joint.
A: Below.
Explanation: In overhead welding, gravity pulls molten metal downward, making it one of the most challenging positions.
- Preheat Purpose
Q: One main purpose of preheating steel before welding is to reduce the risk of ______?
A: Hydrogen-induced cracking.
Explanation: Preheating slows down cooling, allowing hydrogen to escape and reducing hardness.
- Root Gap
Q: In butt joint preparation, the root gap helps ensure full ______?
A: Penetration.
Explanation: A root gap allows access for the arc to reach the joint’s root and melt through.
- Visual Inspection Tool
Q: Name a tool commonly used for visual weld inspection.
A: Welding gauge.
Explanation: It measures weld size, leg length, throat, and undercut.
- Non-Destructive Testing Method
Q: UT in NDT stands for ______?
A: Ultrasonic Testing.
Explanation: UT uses high-frequency sound waves to detect internal defects.
- Macro Test Purpose
Q: A macroetch test is used to examine the ______ structure of a weld.
A: Macro (grain or fusion line).
Explanation: It reveals fusion, penetration, and heat-affected zone (HAZ) after etching.
- Effect of Alloying Elements
Q: Chromium in steel improves resistance to ______?
A: Corrosion.
Explanation: Chromium forms a passive oxide layer, protecting stainless steels.
- Weldability Definition
Q: Weldability is defined as the ease with which a material can be ______ by welding.
A: Joined.
Explanation: It includes factors like cracking tendency, metallurgical changes, and mechanical properties.
- Heat Affected Zone (HAZ)
Q: The HAZ is the area of base metal not melted but ______ affected by welding heat.
A: Metallurgically.
Explanation: HAZ properties change due to temperature without melting.
10 Calculation-Based Questions with Answers and Explanations for Paper A: Welding Theory & Technology (Closed-Book)
- Heat Input Calculation
Q1: Calculate the heat input for the following welding parameters:
Voltage = 24 V, Current = 200 A, Travel speed = 5 mm/s, Efficiency = 0.8
Explanation: This measures energy input per unit weld length, affecting cooling rate and microstructure.
- Carbon Equivalent (CEQ) for Mild Steel
Q2: Given: C = 0.18%, Mn = 1.2%, Cr = 0.5%, Mo = 0.2%, V = 0.1%, Ni = 0.3%, Cu = 0.2%
Explanation: CEQ assesses weldability and the likelihood of cracking.
- Minimum Preheat Temperature (Using CEQ)
Q3: If CEQ = 0.45, thickness = 20 mm, find the recommended minimum preheat temperature range.
Answer:
From typical welding tables:
For CEQ = 0.45 and t = 20 mm, preheat ≈ 100–150°C.
Explanation: Higher CEQ and thickness increase cracking risk, so preheat is applied to reduce the cooling rate.
- Fillet Weld Leg Size and Throat Area
Q4: Calculate the effective throat size of a fillet weld with a leg length of 8 mm.
Explanation: The throat is the shortest distance from the root to the face of the weld, used in strength calculations.
- Weld Metal Deposition Rate
Q5: An electrode deposits metal at 5.0 g/min. How much metal is deposited in 15 minutes?
Answer: 5.0×15=75 Grams
Explanation: Deposition rate helps plan productivity and cost.
- Duty Cycle Calculation
Q6: A machine operates for 6 minutes in every 10-minute period. What is the duty cycle?
Explanation: Duty cycle indicates how long a welder can operate continuously without overheating.
- Arc Energy (Heat Input without Efficiency)
Q7: Current = 180 A, Voltage = 22 V, Travel speed = 6 mm/s
Explanation: Arc energy influences weld bead shape and cooling rate.
- Cooling Rate Impact
Q8: Faster cooling rate leads to which metallurgical problem?
Answer: Formation of martensite or hydrogen-induced cold cracking (HICC) in the HAZ.
Explanation: Quick cooling traps hydrogen and forms brittle microstructures.
- Interpass Temperature Monitoring
Q9:If preheat is 120°C and interpass max is 250°C, is welding at 260°C acceptable?
Answer: No.
Explanation: Exceeding interpass limits can cause grain coarsening and weld degradation.
- Weld Volume Calculation
Q10: For a 6 mm fillet weld, 500 mm long, calculate weld metal volume.
Explanation: Weld volume is important for estimating filler consumption.
2 Diagram/Sketch-Based Questions with Answers and Explanations for Paper A: Welding Theory & Technology (Closed-Book)
Diagram-Based Question 1: Weld Symbols Interpretation
Q1: Refer to the welding symbol below and answer the following:
The symbol shows:
- A fillet weld on both sides
- 6 mm leg length
- Arrow side and the other side
Q1a: What type of weld is indicated?
Q1b: What is the throat thickness of this weld?
Q1c: Why would this symbol be used instead of a square butt weld?
Answer Q1a:
Double-sided Fillet Weld — 6 mm leg length on both sides of the joint.
Answer Q1b:
Effective Throat Thickness = 0.707 × Leg size
=0.707×6=4.24 mm= 0.707 × 6 = 4.24 \text{ mm}
Answer Q1c:
A fillet weld is used when:
- Access is available from both sides
- Simpler preparation is desired
- Not full penetration is required
- Economical over butt welding for certain loads
Explanation:
The symbol shows two triangular fillet welds placed symmetrically on both sides of the joint. The leg size and throat thickness are essential for calculating strength. Fillet welds are quicker and cheaper but have less fatigue strength than full penetration welds.
Diagram-Based Question 2: Macrostructure Zones of a Weld
Q2: Study the diagram below showing a cross-section of a welded joint and label the zones:
Base Metal | HAZ | Fusion Zone | Weld Metal | Fusion Zone | HAZ | Base Metal
Q2a: Name and define each of the three key zones of a welded joint.
Q2b: Which zone is most affected by rapid cooling and prone to cracking?
Q2c: What is the main difference in grain structure between HAZ and Weld Metal?
Answer Q2a:
- Base Metal (BM): Unaffected parent material away from the weld.
- Heat-Affected Zone (HAZ): Area near the weld affected by heat but not melted.
- Weld Metal (WM): Filler metal melted and solidified during welding.
Answer Q2b:
Heat-Affected Zone (HAZ) — Most susceptible to cold cracking due to high cooling rates and residual stresses.
Answer Q2c:
- Weld Metal: Has a cast grain structure due to solidification.
- HAZ: Has refined or coarse grains, depending on peak temperatures reached during welding.
Explanation:
Understanding these zones is vital for controlling welding defects and selecting preheat or PWHT. The HAZ can have martensitic transformation in high-carbon steels if cooling is too fast, requiring careful control.
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