2024 Edition

Welding Practice Test

Take this free welding practice exam to get a sample of the types of questions on an actual welding exam.

Subject matter covered in actual AWS and other welding examinations include: Shielded Metal Arc Welding, Flux Cored Arc Welding, Self Shielded and Submerged Arc Welding, the arc welding processes protected by flux, along with the gas shielded processes, such as Gas Tungsten Arc Welding, Gas Metal Arc Welding and Flux Cored Arc Welding-Gas Shielded. Brazing and soldering are also covered, along with common mechanical and thermal cutting processes that will aid in material preparation and enhance welding fit-up issues.

To prepare for your welding test, see the Welding Practice Exam Kit with 360 Questions with fully explained answers.

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1.	What is the major function of the coating on an arc welding electrode?
		a. Acts as a scavenger, removes oxides and impurities
		b. Influences incomplete penetration
		c. Liquefies the base metal
		d. Adds moisture and accelerates the cooling rate
The key is major function, and that is to purify the weld pool and weld metal. Incorrect answer. Please choose another answer.

2.	Square wave refers to the ____________.
		a. shape of the filler metal
		b. shape of the tungsten electrode
		c. shape of the output power
		d. shape of the power source control box
The shape of the output wave form from this type power source is referred to as square wave. These type power sources have enhanced performance on a.c. They can control the balance, amplitude, frequency etc… to allow better control of penetration and cleaning action. Incorrect answer. Please choose another answer.

3.	Shielding gases are used to protect the molten metal from _______.
		a. being overheated and cooling to fast
		b. porosity and brittleness
		c. heat and distortion
		d. being too cold and not penetrating
The surrounding air around the weld pool, contains oxygen, nitrogen and hydrogen. These gases get into the molten weld pool and cause gas bubbles to form (porosity) and lead to embrittlement and weld cracking. Incorrect answer. Please choose another answer.

4.	Weld backing is used with a process that uses a separate flux and electrode to _______ .
		a. make the overall weld joint stiffer
		b. provide more weight to the weldment
		c. make the material thicker where it is needed
		d. support the highly fluid weld pool so it will not fall through the joint
Weld backing is used on the back side of the joint to prevent melt through and to assure complete penetration of the weld joint. Incorrect answer. Please choose another answer.

5.	_________ is the weight of a volume of material compared with an equal volume of water.
		a. Mass
		b. Density
		c. Specific gravity
		d. Heft
The density of steel is 490 pounds per cubic foot and its specific gravity is 7.8 times that of water. Water weighs 1000 Kg/m³. Therefore, a cubic meter of steel would weigh approximately 7800 kg depending upon the exact grade of steel being checked. Porosity, slag inclusion or other types of discontinuities would reduce the weight but not the specific gravity. Incorrect answer. Please choose another answer.

6.	A medium carbon steel has a carbon content of what percentage range?
		a. 0.05% to 0.15%
		b. 0.16% to 0.60%
		c. 0.60% to 1.70%
		d. 1.70% to 2.15%
Incorrect answer. Please choose another answer.

7.	If a liquid weld pool is at a very high level of energy, at what approximate temperature will the steel begin to solidify?
		a. 1333 F
		b. 2780 F
		c. 3200 F
		d. 3780 F
When welding, the melting point of steel (approx. 2780⁰F) versus the solidification point of the fast freezing flux or slag (approx. 3200⁰ F) is important to know. Also, it is important to know that the melting point varies with the carbon and alloy content of steel. Steel is magnetic until heated above the transformation temperature of approximately 1333 ⁰F. How fast the metal conducts heat will have a large effect of preheat and inter-pass temperature control. How much the metal expands on heating and contracts when cooling needs to be understood to control buckling and distortion. Incorrect answer. Please choose another answer.

8.	__________ is a groove melted into the base metal next to the weld toe or weld root and has not been filled in.
		a. Cracks
		b. Craters
		c. Under fill
		d. Undercut
Undercut best describes this fashion. Some people want to call it “under fill” but it is not correct, since it is not in the weld being located next to the toe. Incorrect answer. Please choose another answer.

9.	If the weld does not combine with another weld or the base metal it is referred to as:
		a. incomplete penetration
		b. incomplete fusion
		c. incomplete bonding
		d. incomplete inclusion
If the weld does not combine with another weld or the base metal it is referred to as Incomplete fusion. Incorrect answer. Please choose another answer.

10.	To determine if a welder is qualified, the welder must pass a ________________ test.
		a. WPQR
		b. WPS
		c. PQR
		d. Code
WPQR determines if a welder is qualified to a Welding Procedure Specification. Incorrect answer. Please choose another answer.

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11.	Which term best describes the operation where a welder or welding operator has control of a molten weld pool and the weld pool has a side to side motion that is transverse to the travel direction?
		a. Oscilllation
		b. Weaving
		c. Whipping
		d. Both a and c
This welding technique would appear in the welding instructions or in the welding procedure specification. This generally increases the heat input per weld pass, but will generally reduce the total number of weld passes required to fill the joint. Incorrect answer. Please choose another answer.

12.	A broken surface is being observed. A small pore or inclusion type discontinuity appears as a round bright area. Which term fits this description?
		a. Nucleation
		b. Crack
		c. Spider web
		d. Fisheye
A fisheye is caused by the presence of hydrogen in the weld. If this appeared on a break test of some type it may or may not be acceptable. Always verify the acceptance criteria per the code or specification. Incorrect answer. Please choose another answer.

13.	Arc time is:
		a. the time the arc is on during the arc welding operation.
		b. the total time the welder is clocked into work.
		c. the non-arc time.
		d. the total arc and non-arc time.
This is also considered the operating factor and is thought of as the percentage of a shift that a welder/welding operator is actually welding. For robotic and mechanized welding, it can be as high as 90% while for manual and semiautomatic welding it can be as low as 10-20% operating factors. Incorrect answer. Please choose another answer.

14.	What is the difference between back and backing welds?
		a. Equipment used
		b. Sequence of when the welds are made
		c. Materials used
		d. None of the above
Though the weld symbols are identical, the sequence of how the welds are made is different. The back weld is made last and the backing weld is made first. Incorrect answer. Please choose another answer.

15.	What NDE process is indicated in the following description? Detects surface discontinuities only. It can also verify fit-up, joint configuration, weld dimensions and profiles.
		a. PT
		b. RT
		c. MT
		d. VT
VT stands for Visual Examination. This is the most common NDE process and can be used before, during and after welding to assure product quality and productivity. Incorrect answer. Please choose another answer.

16.	Penetrant Testing uses a penetrating liquid dye which is applied to a properly prepared surface. The dye is pulled into the discontinuity by _______ action.
		a. suction
		b. heating
		c. cooling
		d. capillary
Capillary action is the ability of a liquid to flow in a narrow space or root opening. This is accomplished without the assistance of external forces and even in opposition of external forces like gravity. Incorrect answer. Please choose another answer.

17.	Which of the following is an established norm or requirement issued by the federal, state or local government about technical systems?
		a. Welder Continuity Report
		b. Standards
		c. Specification
		d. Recommended Practices
A standard is established for use as a rule or basis of comparison in measuring or judging capacity, quantity, content, extent, value, quality, etc… Incorrect answer. Please choose another answer.

18.	Before welding can be done to an industrial welding standard, the supervisor needs to verify:
		a. the quality metric.
		b. the cost metric.
		c. the safety metric.
		d. that the welding procedure specifications and welder qualifications are in order.
All industrial codes and standards reference the requirement for having qualified procedures. They need to be openly available and the welders need to be trained on their proper use. The welders need to be qualified on those procedures and their qualification must be current. The supervisor needs to do this by verifying the welder's continuity report. Incorrect answer. Please choose another answer.

19.	Normal pant and shirt material worn around welding should be of what material?
		a. Polyester
		b. Rayon
		c. Cotton
		d. Synthetics
Cotton and wool are generally recommended apparel around welding operations. Synthetics like polyester, rayon etc… are not recommended as they melt, creating more of burn hazard. Incorrect answer. Please choose another answer.

20.	What is the minimum oxygen level for a confined space?
		a. 14%
		b. 16%
		c. 19.5%
		d. 23.5%
Incorrect answer. Please choose another answer.

Quality starts with who wrote the material.

Our practice exam writer

Written by:
Edward Bohnart

Ed is an AWS certified master welder and welding educator who has over thirty five years of experience in the welding industry. He has served as a Board member of the American Welding Society for over a decade and was its National President from 1995 – 1996. Ed has lectured at the Massachusetts Institute of Technology, the Colorado School of Mines, Texas A&M and Arizona State University. The AWS has recognized Ed as a Counselor, with the National Meritorious Award, the George E. Willis Award, the Plummer Memorial Educational Lecturer Award and designated him as a Distinguished Member.

This Welding Practice Test is designed to be used as a study method for passing an examination on the fundamentals of welding. It is intended for anyone wishing a career in the welding industry, advancing their technical or engineering level of knowledge. It is also suitable for on the job training and apprenticeship training programs. It can serve as a supplementary training tool in building construction, metalworking and industrial technology training programs. The practice test provides a course of instruction in welding and cutting that will enable students to learn the principles.

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