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Quizzes > Quizzes for Business > Manufacturing

Take the Metallurgy and Welding Knowledge Test

Assess Your Metalwork and Welding Proficiency Today

Difficulty: Moderate
Questions: 20
Learning OutcomesStudy Material
Colorful paper art depicting elements of metallurgy and welding for a knowledge test

This Metallurgy & Welding Knowledge Test helps you practice welding processes, safety rules, and metal properties with 15 multiple-choice questions, so you can spot gaps before class, certification, or shop work. When you finish, keep building skill with the engineering welding quiz and the codes and standards quiz .

Which welding process uses a non-consumable tungsten electrode?
MIG welding
TIG welding
Oxy-fuel welding
Stick welding (SMAW)
TIG welding uses a non-consumable tungsten electrode to create the arc, while filler metal is added separately. The inert gas shield protects the weld area from atmospheric contamination.
What is the primary purpose of wearing a welding helmet?
Maintain helmet shape
Protect the eyes and face from arc radiation and spatter
Keep the welding area clean
Improve welding speed
A welding helmet protects against intense UV and IR radiation from the arc, as well as hot spatter. This safety equipment is essential to prevent severe eye and skin damage.
Which joint is formed when two metal plates are aligned in the same plane and welded along their edges?
Corner joint
Tee joint
Lap joint
Butt joint
A butt joint occurs when two plates are placed edge to edge in the same plane and welded at the seam. It is commonly used for welding pipes and sheet metal.
What welding symbol indicates a fillet weld on a drawing?
A circle
A square
A zigzag line
A right-angle triangular symbol
The fillet weld symbol is represented by a right-angle triangle on the reference line. This symbol indicates a triangular cross-section weld between two surfaces.
Which gas is commonly used as a shielding gas in MIG welding of carbon steel?
Helium
Oxygen
Carbon dioxide
Argon
Carbon dioxide is often used as a shielding gas for MIG welding carbon steel due to its deep penetration and cost-effectiveness. Pure CO2 produces a stable arc but more spatter compared to argon mixes.
Which welding process is best suited for high deposition rates on thick section steel?
Flux-Cored Arc Welding (FCAW)
Gas Tungsten Arc Welding (GTAW/TIG)
Gas Metal Arc Welding (GMAW/MIG)
Shielded Metal Arc Welding (SMAW)
FCAW provides high deposition rates and deep penetration, making it ideal for thick section steel. The flux core allows for good shielding and productivity in heavy fabrication.
How does increasing carbon content in steel affect its weldability?
Reduces shrinkage
Improves ductility
Has no effect
Decreases weldability due to hardness and cracking tendency
Higher carbon content increases hardness in the heat-affected zone and promotes cracking. This makes welding more challenging and often necessitates preheat or post-weld heat treatment.
What is the main purpose of preheating metal before welding?
Lower cooling rate to minimize cracking
Reduce electrode consumption
Increase surface hardness
Speed up the welding process
Preheating slows the cooling rate of the weld area, reducing residual stresses and the risk of cold cracking. It is especially important for high-carbon or thick materials.
On a welding symbol, what does a circle at the intersection of the arrow and reference line denote?
Backing weld
Surfacing
Field weld
All-around weld
A circle at the junction of the arrow and reference line indicates an all-around weld. This means the weld is to be applied continuously around the joint.
Which weld defect is characterized by incomplete bonding between adjacent weld beads?
Undercut
Slag inclusion
Lack of fusion
Porosity
Lack of fusion occurs when the weld metal fails to merge with the base metal or previous pass, leading to weak areas. Proper heat input and technique are needed to avoid this defect.
In GTAW of aluminum, which technique helps reduce distortion?
Increasing electrode stick-out
Employing pulsed current welding
Adding more filler metal
Using alternating current (AC)
Pulsed current welding controls heat input and allows the weld pool to cool intermittently, reducing overall distortion. It also improves penetration control and weld bead profile.
What effect does low thermal conductivity of stainless steel have on welding?
Eliminates need for shielding gas
Causes slow cooling and potential distortion
Increases fume production
Weld heat dissipates too quickly
Stainless steel's low thermal conductivity results in slower heat dissipation, increasing the risk of distortion and residual stress. Welders often use controlled heat input to manage these effects.
Which safety protocol specifically controls exposure to welding fumes?
Using arc shields
Wearing heavy gloves
Applying fire-resistant blankets
Using local exhaust ventilation
Local exhaust ventilation captures welding fumes at the source, preventing inhalation of toxic metal oxides. This is a key control measure in welding safety protocols.
What is the primary function of backing bars in weld joint preparation?
Absorb excess weld spatter
Clean the root of the joint
Support molten metal to ensure full penetration
Act as a guide for the welding torch
Backing bars support the molten weld pool at the root of the joint to achieve full penetration and proper bead shape. They also help control heat distribution.
Which code governs welding requirements for pressure vessels?
AWS D1.1 Structural Welding Code
ASME Section VIII
ASME Section IX
ISO 9001
ASME Section VIII details design, fabrication, and inspection requirements for pressure vessels. It sets specific welding procedures, qualifications, and quality standards.
In submerged arc welding of thick plates, what is the main cause of root concavity defects?
Low welding current
Too much flux
Insufficient welding voltage
Excessive travel speed
Excessive travel speed reduces the heat input and penetration at the root, leading to a concave profile. Proper travel speed ensures adequate fusion and bead shape.
How does an increased cooling rate influence martensite formation in the heat-affected zone of welded carbon steel?
It has no effect
It increases martensite formation
It decreases martensite formation
It converts martensite to pearlite
Faster cooling rates transform austenite to martensite, a hard and brittle microstructure. Controlling cooling through preheat or post-weld heat treatment can minimize unwanted martensite.
Which non-destructive testing method is most effective for detecting subsurface welding defects?
Visual inspection
Magnetic particle testing
Dye penetrant testing
Ultrasonic testing
Ultrasonic testing uses high-frequency sound waves to detect internal defects and measure thickness. It is highly effective for identifying subsurface flaws in welds.
On a welding symbol, the designation "E7018" refers to which of the following?
Recommended welding travel speed
Minimum tensile strength and hydrogen level
Shielding gas composition
Electrode diameter in millimeters
In E7018, '70' indicates minimum tensile strength of 70 ksi and '18' signifies a low hydrogen electrode with 0.18% diffusible hydrogen. This classification ensures weld quality and strength.
When welding dissimilar metals such as carbon steel to stainless steel, what additional concern is critical?
Galvanic corrosion between the metals
Difficulty in striking an arc
Excessive surface oxidation
Shielding gas loss
Dissimilar metals can create a galvanic cell in corrosive environments, leading to accelerated corrosion of the more anodic metal. Proper filler selection and post-weld treatments mitigate this risk.
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Learning Outcomes

  1. Identify common welding processes and their applications
  2. Analyse material properties affecting weld quality
  3. Evaluate safety protocols in metallurgy and welding
  4. Apply proper joint preparation techniques
  5. Demonstrate understanding of welding symbols and codes
  6. Master basic troubleshooting methods for weld defects

Cheat Sheet

  1. Primary metal transfer modes in GMAW - The mode you choose changes droplet behavior and heat input, affecting weld penetration and bead appearance. Short”circuiting is ideal for welding thin sheets by minimizing heat, while spray and pulsed”spray modes offer consistent, high”quality deposits for thicker sections.
  2. Key welding processes (GTAW, SMAW, FCAW) - GTAW delivers precise, clean welds on thin materials, SMAW is incredibly versatile and portable for field work, and FCAW combines high deposition rates with flux shielding for outdoor conditions. Understanding when to deploy each process ensures optimal weld quality and productivity.
  3. Effect of carbon content on weldability - Materials with higher carbon content become harder but are more prone to cracking after welding due to increased hardening and reduced ductility. Using the equivalent carbon content formula can help predict weldability and guide preheat and post”weld heat treatments to reduce defects.
  4. Common welding defects - Porosity, slag inclusions and undercut are some of the most common welding defects caused by factors like contamination, incorrect parameters or improper technique. Spotting these issues early and adjusting your setup or process can prevent weak welds and costly rework.
  5. Proper joint preparation - Properly preparing joints - including cleaning out rust, oil and mill scale, as well as precise fit”up - reduces the risk of defects like porosity and lack of fusion. Good preparation streamlines welding and delivers stronger, more consistent results.
  6. Interpreting welding symbols and codes - Welding symbols and codes provide a universal shorthand for weld type, size and finish requirements on fabrication drawings. Mastering these symbols is crucial for accurate communication and ensures every weld meets design specifications.
  7. Residual stresses and distortion - Weld”induced residual stresses and distortion can warp your components and compromise structural integrity. Controlling heat input with proper sequencing, backing bars and stress”relief techniques keeps distortion in check.
  8. Safety protocols and PPE - Safety is non”negotiable: always wear appropriate PPE - helmets, gloves, aprons - and ensure good ventilation or fume extraction. Knowing safety protocols and emergency procedures protects you and your team from burns, UV exposure and toxic fumes.
  9. Role of shielding gases - Shielding gases like argon, carbon dioxide or their mixtures protect the molten weld pool from atmospheric contamination. Choosing the right gas affects arc stability, penetration and bead shape, so match your gas to the material and process.
  10. Basic troubleshooting for weld defects - Troubleshooting weld defects starts with a systematic check of parameters: for porosity verify gas flow and joint cleanliness, for incomplete fusion adjust heat input or travel speed. Developing these problem”solving skills ensures consistent, high”quality welds on every job.
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