Quiz- Section 13 Automatic Welding Without Filler Metal Additions- CWI Part C -10 Questions
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Section 13 Automatic Welding Without Filler Metal Additions – CWI Part C Practice Test
Prepare for the AWS CWI Part C Open Book Exam with this free practice test based on API 1104 Section 13: Automatic Welding Without Filler Metal Additions. This section is important because it covers the requirements for automatic welding of pipe without filler metal additions, specifically using the flash butt welding process.
In this quiz, you can take a free practice test with the latest exam-style questions and answers for CWI Part C API 1104 Section 13 Automatic Welding Without Filler Metal Additions.
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This free quiz is designed for AWS CWI candidates, welding inspectors, QA/QC inspectors, welding operators, pipeline welding professionals, and students preparing for the AWS CWI Part C exam using API 1104.
Section 13 focuses on flash butt welding, procedure qualification, operator qualification, welding variables, production weld quality assurance, acceptance standards, repair requirements, and radiographic testing procedures.
Quiz Details
Quiz Name: Section 13 Automatic Welding Without Filler Metal Additions – CWI Part C
Standard Covered: API 1104
Exam Type: AWS CWI Part C Practice Test
Total Questions: 10 Questions
Question Type: Multiple Choice Questions
Level: Exam Preparation Level
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What Is Covered in API 1104 Section 13?
API 1104 Section 13 provides the rules for automatic welding without filler metal additions. This section applies only to the flash butt welding process.
Flash butt welding is different from many other welding processes because no filler metal is added. Instead, the pipe ends are joined through controlled electrical heating, axial movement, upset force, and removal of flash.
This section is important for CWI Part C candidates because the procedure qualification rules, welding variables, operator qualification, and acceptance requirements are different from those of welding processes that use filler metal.
Acceptable Process
Section 13 applies to only one welding process:
Flash Butt Welding
Candidates should remember that Section 13 does not apply to SMAW, GTAW, GMAW, FCAW, SAW, or PAW with filler metal. Those processes are covered in other sections of API 1104.
Procedure Qualification
API 1104 Section 13 requires at least two test welds to be made for procedure qualification.
These test welds must be examined by radiographic testing before destructive testing is performed. Destructive testing includes tension tests, nick break tests, and side bend tests.
If the tests are acceptable, the welding variables used during the two test welds establish the permitted maximum and minimum values for the welding procedure.
Important variables include:
- Welding voltage
- Welding current
- Axial speed
- Time intervals in the weld cycle
- Upset stroke
This is an important exam point because the procedure qualification test establishes the permitted ranges for these key automatic welding variables.
Procedure Qualification Test Specimens
API 1104 Table 10 lists the type and number of test specimens required for flash butt welding procedure qualification.
The number of specimens depends on the outside diameter of the pipe. A larger-diameter pipe requires more test specimens.
The required tests may include:
- Tension tests
- Nick breaks tests
- Side bend tests
For CWI Part C preparation, candidates should understand that specimen requirements are based on pipe size and are shown in the applicable API 1104 tables and figures.
Tension Tests
Tension tests for flash butt welding procedure qualification are prepared, tested, and evaluated using requirements similar to those described in Section 5.
The purpose of the tension test is to verify that the welded joint meets the required strength requirements.
Nick Break Tests
Nick break testing is also required for the flash butt welding procedure qualification.
Because flash butt welding is commonly used on large-diameter and heavy-wall pipe, the nick break specimens are wider than those used in Sections 5 and 12.
For flash butt welding, nick break specimens are typically 2 inches wide, compared with the 1-inch-wide specimens used in other sections.
The specimens include notches on the edges and also notches on the top and bottom of the weld bead. The specimen edges must be polished and macro-etched to reveal the bond line so the notch can be properly located.
This makes Nick’s break testing in Section 13 a key topic for the AWS CWI Part C exam.
Side Bend Tests
For flash butt welding, side bend tests are used instead of face and root bend tests.
This is because flash butt welding is commonly used on larger diameter, heavy wall pipe, where side bend testing is more suitable.
The preparation, testing, and acceptance criteria for side bend specimens are similar to the side bend test requirements described in Section 5.
Records
The details of each qualified procedure must be recorded. The qualification record must include the test results and all data required by the welding procedure specification.
The record of qualification must be retained as long as the procedure is in use.
This helps confirm that the automatic welding procedure was properly qualified and that production welding is performed within the approved range of variables.
Welding Procedure Specification
The welding procedure specification for automatic welding without filler metal additions must list all important variables needed to produce acceptable flash butt welds.
The procedure should include:
- Welding process
- Pipe material
- Pipe wall thickness and outside diameter
- Pipe preparation
- Grinding of pipe seam
- Cleaning of pipe ends
- Welding position
- Preheat requirements
- Cleaning and inspection of electrical contact shoes
- Permitted range of welding voltage
- Permitted range of welding current
- Permitted range of axial speed
- Permitted range of time intervals in the weld cycle
- Permitted range of upset stroke
- Time delay before clamp removal
- Method of removing internal flash
- Method of removing external flash
- PWHT time, temperature, measurement technique, and cooling rate requirements
These details are important because flash butt welding depends heavily on equipment control and repeatability.
Essential Variables
API 1104 Section 13 lists essential variables for flash butt welding procedure qualification. If these variables are changed outside the qualified range, requalification may be required.
Important essential variables include:
- Change in pipe material
- Change in specified pipe wall thickness or outside diameter
- Change in pipe preparation dimensions
- Change in welding position
- Change in preheat requirements
- Change in voltage outside the WPS range
- Change in current outside the WPS range
- Change in axial speed outside the WPS range
- Change in weld cycle time intervals outside the WPS range
- Change in upset stroke distance outside the WPS range
- Change in PWHT conditions
These essential variables are important exam topics because Section 13 is highly dependent on controlled welding machine settings.
Qualification of Equipment and Operators
Each welding operator must qualify by welding a test coupon.
The test coupon must meet the same test requirements used for qualifying the flash butt welding procedure. This means the operator qualification test must satisfy the applicable radiographic and destructive testing requirements.
The purpose is to prove that the operator can use the automatic welding equipment correctly and produce acceptable flash butt welds.
Records of Qualified Operators
A record must be made of the operator qualification tests and results.
The company must maintain a list of qualified operators and the procedures for which they are qualified.
If a question arises about an operator’s competence, the operator may be required to requalify.
This requirement helps maintain control and traceability for automatic welding operations.
Quality Assurance of Production Welds
The company has the right to inspect production welds by nondestructive testing, destructive testing, or both.
The frequency of these inspections is at the discretion of the company.
Production welds may be rejected if the recorded welding variables are outside the ranges listed in the welding procedure specification.
These variables include:
- Welding voltage
- Welding current
- Axial speed
- Cycle time
- Upset stroke
A weld may be rejected during welding or after welding has been completed. Rejected welds must be removed from the line.
Reinforcement Limits
API 1104 Section 13 provides limits for internal and external reinforcement on flash butt welds.
Internal reinforcement shall not exceed 1/16 inch.
External reinforcement shall not exceed 1/8 inch.
If reinforcement exceeds these limits, the weld may be rejected. However, excess flash or reinforcement may be removed if it can be corrected without violating the requirements.
Heat Treatment of Flash Butt Welds
Each flash butt weld must receive an austenitizing heat treatment.
This means the weld is heated above the upper transformation temperature, followed by controlled cooling or still-air cooling.
If there is any deviation in time at temperature, maximum temperature, or cooling rate beyond the welding procedure specification, reheat treatment is required.
This is a very important point for CWI Part C candidates because heat treatment is a specific requirement for flash butt welds.
Acceptance Standards for NDT
API 1104 Section 13 provides acceptance standards for flaws found by radiography or other NDT methods, including visual examination.
A small amount of isolated slag inclusion may be permitted within the limits of the standard.
However, the following discontinuities are causes for rejection regardless of size or length:
- Cracks
- Incomplete fusion
- Porosity
Candidates should remember that porosity in a flash butt weld is not acceptable and cannot be repaired.
Repair and Removal of Defects
Defects that are open to the surface may be repaired by grinding if the pipe’s minimum wall thickness is not violated.
Other defects may be removed by grinding, chipping, gouging, or a combination of these methods, followed by repair welding according to Section 10.
All repair welds must be approved by the company.
Porosity found in a flash butt weld cannot be repaired. A flash butt weld containing porosity is rejected and must be removed from the line.
However, porosity found in a repaired area made with another welding process may be acceptable if it meets the applicable porosity limits in Section 9.
Radiographic Procedure
Radiography of flash butt welds must be performed according to the requirements of API 1104 Subsection 11.1.
This means proper radiographic procedure, image quality, identification, interpretation, and reporting requirements must be followed.
What You Will Learn in This Quiz
This practice test will help you understand:
- Scope of Section 13: automatic welding
- Flash butt welding requirements
- Procedure qualification test requirements
- Radiographic testing before destructive testing
- Tension, nick break, and side bend test requirements
- Welding procedure specification variables
- Essential variables for flash butt welding
- Operator qualification requirements
- Records of qualified operators
- Company quality assurance rights
- Production weld rejection based on welding variables
- Internal and external reinforcement limits
- Austenitizing heat treatment requirements
- NDT acceptance standards
- Repair and removal of flash butt weld defects
- Radiographic procedure requirements
Why Practice Section 13 Automatic Welding Without Filler Metal Additions?
Section 13 is important for AWS CWI Part C exam preparation because it covers a specialized welding process with unique requirements. Flash butt welding has different qualification rules, different essential variables, and different production weld acceptance requirements compared with filler metal welding processes.
Practicing this section helps candidates improve their understanding of automatic welding, procedure qualification, equipment control, operator qualification, NDT acceptance, and repair limitations.
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Quiz – Section 13 Automatic Welding Without Filler Metal Additions – CWI Part C – 10 Questions
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Who Should Take This Practice Test?
This quiz is useful for:
- AWS CWI exam candidates
- CWI Part C API 1104 students
- Welding inspectors
- QA/QC inspectors
- Welding operators
- Pipeline welding professionals
- Welding supervisors
- Welding engineers
- NDT technicians
- Students preparing for open-book code exams
Prepare Better for AWS CWI Part C
If you are preparing for the AWS CWI Part C exam, Section 13, Automatic Welding Without Filler Metal Additions, is an important topic to practice. It explains how flash butt welding procedures and operators are qualified, how production welds are inspected, and how defects are accepted or rejected.
Take the free practice test now and improve your preparation for the AWS CWI Part C API 1104 exam.