AWS CWI Exam Study Guide based on the 2015 AWS D1.1

PASS YOUR AWS WELDING EXAM with a QuickPass to over 1700 study questions. This program is a valuable study aid for anyone looking to take their Certified Welding Instructor exam. Also useful for Associate and Senior Welding Inspectors as well as suitable for the Welding Certification test!

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All questions suitable for CWI Welding Certification and Welding Inspector Exams.

We began with the QuickPass Certified Welding Inspector AWS CWI Study Guide. Then, for ease of use, we moved all the Windows PC CD-based practice test questions and practice exams ONLINE!

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Course Outline

TEXTBOOK: QuickPass Certified Welding Inspector AWS/CWI Study Guide – based on AWS D1.1 – 2015 edition: This publication deals with Welding Certification and Welding Inspection Exams. Primary emphasis is focused on the Structural Welding Code for Steel.

This is because Welding Inspection involves far more than just looking at welds. A welding inspector must additionally have both a wide range of knowledge and skills and an understanding of the welder’s work.

The Textbook provides both novices as well as experienced welders and inspectors with the information that will assist them in passing the necessary exams.

Code References:

  • AWS D1.1 – 2015
  • AWS D1.2 – 2014
  • AWS D1.3 – 2018
  • AWS D1.4 – 2011
  • AWS A2.4 – 2012
  • AWS A3.0 – 2010
  • API 1104 – 2013

This program is useful for anyone taking exams given by the American Welding Society or other agencies that cover:

  • Examination
  • General Knowledge
  • Inspection
  • Nondestructive Testing
  • Performance
  • Process
  • Responsibilities
  • Safety
  • Symbols
  • Technology

UPDATED: New Online Testing Environment! (1Year Access)
We proudly announce the release of our new ONLINE Study Center.

Pass CWI Welding Test - AWS welding certification online test | CWI Exam
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Gain access to CWI Exam practice questions and specific online content relating to your chosen exam(s). Choose between online chapter reviews, and AWS practice questions, then test your knowledge with simulated timed TLC practice exams.

Use our online chapter reviews, virtual flashcards, and sample questions to verify your knowledge. Our simulated final exams will demonstrate your readiness to pass your ICC exam!

Flash Card Study Mode. Flashcard study mode allows you to view individual practice questions, as well as keep track of your progress. Additionally, you can focus your study by toggling answers you have mastered to study only questions requiring more review.

Exam Simulation Mode. Exam simulation mode enables you to take timed simulated exams formatted similarly to the actual ICC Inspector Exam. When you consistently pass our randomized ICC certification practice test, you are ready to schedule your ICC Test.

The Online Study Center works from any device with Internet access. Instantly log on from your PC or Apple Computer, Notebook, Tablet, Cellphone.

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Home Study Materials

TEXTBOOK: AWS/CWI Exam Manual + CD:

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Over 1700+ ONLINE study questions. Use any device with internet access.

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The CD-ROM for offline access is compatible with Windows only. Mac users must have a Windows emulator to use this program.

Laminated Welding Quick-Cards

Laminated Welding Quick-Cards

Purchasers of our Quick-Pass, ONLINE certified welder study aid often find the following Quick-Cards to be valuable as well.

We provide these Six Page laminated full color quick cards as both a study aid as well as a handy refrence for future use. These Cards put must-know welding information instantly and durably at your fingertips.

Now you can instantly identify essential welding symbols, lookup tables and typical notation formats are also included. Aso provided is a quick refrence guide for the basics, identification, and uses of reinforcing bar.

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Course Outline

Purchasers of our Quick-Pass certified welder study aid often find the following Quick-Cards to be valuable as well.

Welding Symbols Quick-Cards

Welding Symbols Quick-Card. This six-page, full-color card puts essential welding symbols used in architectural plans and engineering drawings at your fingertips. Includes several quick lookup tables,

including;

  • Typical welding symbols.
  • ISO symbols
  • AWS symbols
  • Structural Steel Shapes
  • Types of weld joints and positions
  • Designation of welding and cutting processes by letters
  • Dozens of common abbreviations used in plans and drawings related to welding

In most cases, symbols are shown for plan view, and where alternatives are commonly in use, multiple symbols are shown. Typical notation formats are also included.

ISBN: 1889892742 / 9781889892740

Steel Reinforcing Bars Quick-Card

Steel Reinforcing Bars Quick-Card – Based on the CRSI, the ACI, and the ASTM Standards. This is a quick reference for the basics, identification, and uses of reinforcing bar.

Sections Include:

  • Reinforcing Bars (Rebar) Basics & Identification
  • ASTM Reinforcing Bars (Metric & Inch-Pound)
  • Reinforcing Bar Deformation Requirements
  • Diameter, Tensile Requirements & Specialty Bars
  • Overall Reinforcing Bar Diameters
  • Reinforcing Bar Grades & Tensile Requirements
  • Specialty & Corrosion Resistant Steel Reinforcement
  • Ties & Hooks
  • Types of Ties at Reinforcing Bar Intersections
  • Standards End Hooks
  • 90-degree and 135-degree Stirrup & Tie Hooks
  • 180-degree Stirrup/Tie Hook Dimension
  • Seismic Stirrup/Tie Hooks
  • Bending, Straightening, Rebending & Field Cutting
  • Min. specified Diameter of bend
  • Reinforcing Bar Placing Tolerances
  • Concrete Cover (inches)

ISBN: 1622702034 / 9781622702039

Practize Quiz - Part 1

Of the following aluminum alloys, the ones with a percentage of magnesium are:

Correct! Wrong!

Different forms and tempers of 6061 aluminum alloy are discussed in the following standards:

ASTM B 209: Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate
ASTM B 210: Standard Specification for Aluminum and Aluminum-Alloy Drawn Seamless Tubes
ASTM B 211: Standard Specification for Aluminum and Aluminum-Alloy Bar, Rod, and Wire
ASTM B 221: Standard Specification for Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Profiles, and Tubes
ASTM B 308: Standard Specification for Aluminum-Alloy 6061-T6 Standard Structural Profiles
ASTM B 483: Standard Specification for Aluminum and Aluminum-Alloy Drawn Tube and Pipe for General Purpose Applications
ASTM B 547: Standard Specification for Aluminum and Aluminum-Alloy Formed and Arc-Welded Round Tube
ISO 6361: Wrought Aluminum and Aluminum Alloy Sheets, Strips and Plates

The duty cycle of a welding machine is:

Correct! Wrong!

Duty Cycle is how long you should run your welder before it’ll shutdown. Duty cycle is given in a percentage out of 10 minutes.

On a 2% tungsten electrode, what is the alloying material?

Correct! Wrong!

Thoriated (Color Code: Red)
Thoriated tungsten electrodes (AWS classification EWTh-2) contain a minimum of 97.30 percent tungsten and 1.70 to 2.20 percent thorium and are called 2 percent thoriated. Thorium increases the electron emission qualities of the electrode, which improves arc starts and allows for a higher current-carrying capacity. This electrode operates far below its melting temperature, which results in a considerably lower rate of consumption and eliminates arc wandering for greater stability. Compared with other electrodes, thoriated electrodes deposit less tungsten into the weld puddle, so they cause less weld contamination.

What is used for an aluminum qualification test?

Correct! Wrong!

T6 temper 6061 has an ultimate tensile strength of at least 290 MPa (42,000 psi) and yield strength of at least 240 MPa (35,000 psi). More typical values are 310 MPa (45 ksi) and 270 MPa (39 ksi), respectively. In thicknesses of 6.35 mm (0.250 in) or less, it has elongation of 8% or more; in thicker sections, it has elongation of 10%. The typical value for thermal conductivity for 6061-T6 at 25 °C (77 °F) is around 152 W/m K. A material data sheet defines the fatigue limit under cyclic load as 97 MPa (14,000 psi) for 500,000,000 completely reversed cycles using a standard RR Moore test machine and specimen.

Note that aluminum does not exhibit a well defined "knee" on its S-n graph, so there is some debate as to how many cycles equates to "infinite life".

Also note the actual value of fatigue limit for an application can be dramatically affected by the conventional de-rating factors of loading, gradient, and surface finish.

Which of the following welding positions is not considered out of position?

Correct! Wrong!

Which technique should a welder use whenever possible?

Correct! Wrong!

In forehand welding, the welding rod precedes the torch. The torch is held at an approximately 30 degree angle from vertical. The flame is pointed in the direction of welding and directed between the rod and the molten puddle. This position permits uniform preheating of the plate edges immediately ahead of the molten puddle. By moving the torch and the rod in opposite semicircular paths, the heat can be carefully balanced to melt the end of the rod and the side walls of the plate into a uniformly distributed molten puddle. The rod is dipped into the leading edge of the puddle so that enough filler metal is melted to produce an even weld joint. The heat reflected backwards from the rod keeps the metal molten. The metal is distributed evenly to both edges being welded by the motion of the tip and rod.

When parts are to be joined by fillet welds, they should be as close together as practicable, but never more than:

Correct! Wrong!

AWS D1.1-98 Structural Welding Code paragraph 5.22.1, states, “The parts to be joined by fillet welds shall be brought into as close contact as practicable... If the separation is greater than 1/16 in (1.6 mm), the leg of the fillet weld shall be increased by the amount of the root opening, or the contractor shall demonstrate that the required effective throat has been obtained.”

Which of the following processes uses non-consumable electrodes?

Correct! Wrong!

Non-Consumable Electrodes: Tungsten is a rare metallic element used for manufacturing gas tungsten arc welding (GTAW) electrodes. The GTAW process relies on tungsten's hardness and high-temperature resistance to carry the welding current to the arc. Tungsten has the highest melting point of any metal, 3,410 degrees Celsius.

Which specifications does structural aluminum have to comply with?

ASTM STANDARDS

B221 Specification for Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Profiles, and Tubes

B557 Test Methods for Tension Testing Wrought and Cast Aluminum- and Magnesium-Alloy Products

B557M Test Methods for Tension Testing Wrought and Cast Aluminum- and Magnesium-Alloy Products (Metric)

B647 Test Method for Indentation Hardness of Aluminum Alloys by Means of a Webster Hardness Gage

B648 Test Method for Indentation Hardness of Aluminum Alloys by Means of a Barcol Impressor

B660 Practices for Packaging/Packing of Aluminum and Magnesium Products

B666/B666M Practice for Identification Marking of Aluminum and Magnesium Products

B807/B807M Practice for Extrusion Press Solution Heat Treatment for Aluminum Alloys

B881 Terminology Relating to Aluminum- and Magnesium-Alloy Products

B918 Practice for Heat Treatment of Wrought Aluminum Alloys

D3951 Practice for Commercial Packaging

E18 Test Methods for Rockwell Hardness of Metallic Materials

E29 Practice for Using Significant Digits in Test Data to Determine Conformance with Specifications

E34 Test Methods for Chemical Analysis of Aluminum and Aluminum-Base Alloys

E527 Practice for Numbering Metals and Alloys in the Unified Numbering System (UNS)

E607 Test Method for Atomic Emission Spectrometric Analysis Aluminum Alloys by the Point to Plane Technique Nitrogen Atmosphere

E716 Practices for Sampling and Sample Preparation of Aluminum and Aluminum Alloys for Determination of Chemical Composition by Spectrochemical Analysis

E1251 Test Method for Analysis of Aluminum and Aluminum Alloys by Spark Atomic Emission Spectrometry
Show hint
Correct! Wrong!

When preparing an edge, which method is NOT recommended?

Correct! Wrong!

AWS-CWI Sample Exam Part 1
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Practice Quiz - Part 3

Shielding gases for GMAW and FCAW welding processes must have a maximum dew point of:

Correct! Wrong!

From information supplied by the manufacturers of shielding gas, it has been determined that a dew point of -40°F [-40°C] is a practical upper limit providing adequate moisture protection. A dew point of -40°F [-40°C] converts to approximately 128 parts per million (ppm) by volume of water vapor or about 0.01% available moisture. This moisture content appears very low but, when dissociated at welding temperatures, could contribute hydrogen to that already associated with the electrode. Therefore, it is mandatory to have -40°F [-40°C] or lower dew point in shielding gas. Shielding gas purchased as certified to AWS A5.32 meets this requirement.

AWS D1.1-2015: Structural Welding Code-Steel
Commentary
C-5. Fabrication
C-5.3 Welding Consumables and Electrode Requirements
C-5.3.1.3 Shielding Gas

On tubular butt joints without backing, what is the maximum root opening for welder qualification?

Correct! Wrong!

Welder or welding operator qualification tests shall use the following details:

(1) CJP groove butt joints with backing or backgouging in pipe. Use Figure 9.22(B)
(2) CJP groove butt joints without backing or backgouging. Use Figure 9.22(A).
(3) CJP groove butt joints or T-, Y-, and K-connections with backing in box tubing. Use Figure 9.22(B) in pipe (any diameter), plate or box tubing.
(4) CJP groove T-, Y-, and K-Connections welded from one wide with backing in pipe. Use Figure 9.22(B) in pipe of the appropriate diameter.
(5) CJP groove T-, Y-, and K-connections welded from one side without backing in pipe. Use Figure 9.25 for nominal pipe diameter of >/= 6 in. [150 mm] or Figure 9.26 for nominal pipe </= 4 in. [100 mm].
(6) CJP groove T-, Y-, and K-connection welded from one side without backing or backgouging in box tubing. The options are the following:
-(a) Figure 9.25 in pipe (any diameter) or box tubing plus Figure 9.27 in box tubing.
-(b) Figure 9.25 in box tubing with macroetch specimens removed from the locations shown in Figure 9.27.
See Table 9.14 for the production ranges of diameter and thickness qualified by the test assembly diameters and thicknesses.

AWS D1.1-2015: Structural Welding Code-Steel
9. Tubular Structures
9.19 CJP Groove Welds for Tubular Connections
Figure 9.22 - Tubular Butt Joint - Welder Qualification with and without backing (see 9.19)

If a welder is attempting to qualify to weld K-, T-, and Y- connections, which pipe welding position test is used?

Correct! Wrong!

All welds shall be classified as flat (F), horizontal (H), vertical (V) and overhead (OH), in accordance with the definitions shown in Figures 4.1 and 4.2.
Test assembly positions are shown in:
(1) Figure 9.17 (groove welds in pipe or tubing)
(2) Figure 9.18 (fillet welds in pipe or tubing)

AWS D1.1-2015: Structural Welding Code-Steel
9. Tubular Structures
9.12 Common Requirements for WPS and Welding Personnel Performance Qualification
9.12.1 Positions of Welds
Figure 9.17 - Positions of Test Pipe or Tubing for Groove Welds (see 9.12.1)

Before welding for the shift or the day, two studs must be welded and visually inspected for 360° flash before being bent approximately ______ degrees.

Correct! Wrong!

In addition to visual examination, the test shall consist of bending the studs after they are allowed to cool, to an angle of approximately 30° from their original axes by either striking the studs with a hammer on the unwelded end or placing a pipe or other suitable hollow device over the stud and manually or mechanically bending the stud. At temperatures below 50°F [10°C], bending shall preferably be done by continuous slow application of load. For threaded studs, the torque test of Figure 7.3 shall be substituted for the bend test.

AWS D1.1-2015: Structural Welding Code-Steel
7. Stud Welding
7.7 Production Control
7.7.1 Pre-Production Testing
7.7.1.4 Bend Test.

In radiographic testing, when is it required to use edge blocks?

Correct! Wrong!

Edge blocks shall be used when radiographing butt joints greater than 1/2 in. [12 mm] thickness. The edge blocks shall have a length sufficient to extend beyond each side of the weld centerline for a minimum distance equal to the weld thickness, but no less than 2 in. [50 mm], and shall have a thickness equal to or greater than the thickness of the weld. The minimum width of the edge blocks shall be equal to half the weld thickness, but not less than 1 in. [25 mm]. The edge blocks shall be centered on the weld against the plate being radiographed, allowing no more than 1/16 in. [2 mm] gap for the minimum specified length of the edge blocks. Edge blocks shall be made of radiographically clean steel and the surface shall have a finish of ANSI 125 μin. [3 μm] or smoother (see Figure 6.10).

AWS D1.1-2015: Structural Welding Code-Steel
6. Inspection
6.17 RT Procedures
6.17.13 Edge Blocks.

What is the maximum length of 1/16 inch deep undercut allowed in a 12 inch length of weld for a fillet weld joining 1/2 inch thick statically loaded nontubular members?

Correct! Wrong!

(A) For material less than 1 in [25 mm] thick, undercut shall not exceed 1/32 in [1 mm], with the following exception: undercut shall not exceed 1/16 in [2 mm] for any accumulated length up to 2 in [50 mm] in any 12 in [300 mm]. For material equal to or greater than 1 in [25 mm] thick, undercut shall not exceed 1/16 in [2 mm] for any length of weld.

AWS D1.1-2015: Structural Welding Code-Steel
6. Inspection
6.9 Visual Inspection
Table 6.1, Visual Inspection Acceptance Criteria (see 6.9)
(7) Undercut

When should an inspector be notified of the start of an operation that must be inspected?

Correct! Wrong!

The Inspector shall be notified in advance of the start of operations subject to inspection and verification.

AWS D1.1-2015: Structural Welding Code-Steel
6. Inspection
6.1 Scope
6.1.7 Inspector Notification.

What is the maximum temperature for straightening distorted members with localized heat, if the steel is not quenched and tempered?

Correct! Wrong!

Members distorted by welding shall be straightened by mechanical means or by application of a limited amount of localized heat. The temperature of heated areas as measured by approved methods shall not exceed 1100°F [600°C] for quenched and tempered steel nor 1200°F [650°C] for other steels. The part to be heated for straightening shall be substantially free of stress and from external forces, except those stresses resulting from a mechanical straightening method used in conjunction with the application of heat.

AWS D1.1-2015: Structural Welding Code-Steel
5. Fabrication
5.25 Repairs
5.25.2 Localized Heat Repair Temperature Limitations.

A fitter and a welder are connecting a misaligned V-groove with a slope of 2" over a 3 foot span, using clamps, fixtures and wedges to fit the joint. After fit-up, what should the welder do?

Correct! Wrong!

Parts to be joined at butt joints shall be carefully aligned. Where the parts are effectively restrained against bending due to eccentricity in alignment, the offset from the theoretical alignment shall not exceed 10% of the thickness of the thinner part joined, or 1/8 in [3 mm], whichever is smaller. In correcting misalignment in such cases, the parts shall not be drawn into a greater slope than 1/2 in [12 mm] in 12 in [300 mm]. Measurement of offset shall be based upon the centerline of parts unless otherwise shown on the drawings. AWS D1.1-2015 Structural Welding Code-Steel 5. Fabrication 5.21 Tolerance of Joint Dimensions 5.21.3 Butt Joint Alignment.

What should be done when a T-joint fit-up for fillet welding shows a 1/16 inch root opening?

Correct! Wrong!

The parts to be joined by fillet welds shall be brought into as close contact as practicable. The root opening shall not exceed 3/16 in. [5 mm] except in cases involving either shapes or plates 3 in. [75 mm] or greater in thickness if, after straightening and in assembly, the root opening cannot be closed sufficiently to meet this tolerance. In such cases, a maximum root opening of 5/16 in [8 mm] may be used, provided suitable backing is used. Backing may be of flux, glass tape, iron powder, or similar materials, or welds using a low-hydrogen process compatible with the filler metal deposited. If the separation is greater than 1/16 in. [2 mm], the legs of the fillet weld shall be increased by the amount of the root opening, or the Contractor shall demonstrate that the required effective throat has been obtained.

AWS D1.1-2015 Structural Welding Code-Steel
5. Fabrication
5.21 Tolerance of Joint Dimensions
5.21.1 Fillet Weld Assembly.

AWS-CWI Sample Exam Part 3
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