Welding Inspector
Welding Inspector
Welding Inspector
Management
System Manual
Revision: 0
Date of Issue: 23 May 2011
Page 1 of 9
QUESTION 1
1.1
What is the difference between Quality Assurance, Quality Control and Testing
6 marks
1.2
What is the difference between a Welding Procedure Specification (WPS) and a Procedure
Qualification Record (PQR)?
6 marks
A WPS is a document that describes how welding is to be carried out in production. They
are recommended for all welding operations and many application codes and standards
make them mandatory. It contains sufficient details to enable any competent person to apply
the information and produce a weld of acceptable quality. The amount of detail and level of
controls specified on a WPS is dependant on the application and criticality of the joint to be
welded.
Tests are performed to determine if the weld made to the procedure specification meets
certain standards as established by the code or specification. If the destructive tests meet
the minimum requirements the procedure then becomes a Procedure Qualification Record.
1.3
8 marks
Essential Variables are variables that have a significant affect on the mechanical properties
of a joint. They must not be changed except within the limits specified by this code. e.g.
Material thickness range, Material Group etc.
1.4
Material.
Filler Metal Specification and Classification (size may vary within limits).
Current Type and Polarity
Shielding Gas composition
Position of Welding
Wire feed speed range
Arc voltage
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QUESTION 2
2.1
(i)
Calculate the filler material cost per meter for a welding job given the following data, as
below.
10 marks
DATA
convert mm to metres
Weight of weld
= Volume x Density
= 0.000072 x 7.85 x 1000 = 0.5652 kg
Actual wire used
= Weight of weld metal Deposition efficiency
= 0.5652 0.9 (90%) = 0.628 kg
Total cost of consumables
= Cost per kg x Actual weight of consumable used
= 0.628 x $8 = $5.02
ii)
5 marks
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System Manual
2.2
Calculate the labour cost and the filler metal cost for a welding job given the following data, as
below.
10 marks
DATA
Weld Joint type: T joint
Single pass fillet welds on both sides of equal length (no preparation)
Weld leg length: 8 mm (equal)
Total weld length on each side: 1500 mm
Material: Carbon steel
Welding Process: GMAW
Wire diameter = 1.2 mm
Deposition Efficiency = 95%
Deposition Rate = 4.1 kg/hr
3
3
Density of steel = 7.85 x 10 kg/m
Cost of filler material = $5/kg
Hourly labour rate (including overhead) = $50
Operator Factor = 40%
Area of the cross section of a fillet weld
= x Base x Height
= x 0.8 x 0.8 = 0.32 cm
Volume of weld metal
= Area of cross section x Length
= 0.32 x 150 = 48cm
Weight of weld metal
= Density x Volume
= 7.85 x 48 1000 = 0.38kg
Actual weld metal deposited
= Weight Deposition efficiency
= 0.38 0.95 = 0.4kg
Filler metal cost
= Actual weld metal x Cost of filler metal
= 0.4 x 5 = $2.00
Arc on time
= Weld metal deposited Deposition rate
= 0.4 4.1 x 60 (mins) = 5.9 mins
0.8 is 8mm in cm
divide 8mm by 10
to give 0.8cm
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Date of Issue: 23 May 2011
Page 4 of 9
Labour hours
= Arc on time Operator factor
= 5.9 0.4 = 14.75
Labour cost
= Labour hours x Labour rate
= 14.75 60 (mins) x 50 ($) = $12.29
Therefore for both welds of the same size
Filler metal cost total = $2.00 x 2 = $4.00
Labour cost = $12.29 x 2 = 24.58
2.3
What would be an effective way of reducing the overall cost of producing the welds in question 2.2?
Justify your answer with a sample calculation.
4 marks
Increase the operator factor up from 40% by either automating the process or by motivating the
welder eg. Increase from 40% to 50%
Labour hours = Arc on time / Operator factor = 5.9/0.5 = 11.8 mins
Labour cost = Labour hours x Labour rate = 11.8/60 x 50 = $9.83
Therefore for both welds of same size:
Filler metal cost total = $2.00 x 2 = $4.00
Labour cost = $9.83 x 2 = $19.66
Total cost = $23.66 vs $28.58, save 17% on the cost of producing the weld. Other changes
such as increasing deposition rate or reducing labour rate.
QUESTION 3
3.1
8 marks
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3.2
List three mechanical tests that could be used in qualifying a welding procedure.
3.2
Revision: 0
8 marks
List three alternatives to assessing a welded test piece that could be used in qualifying a welding
procedure.
6 marks
The possible methods are specific to each standard/code and include:
Welding and assessing a (production) component or special test piece that replicates
production welds. Also known as a pre-production welding test.
Previous experience. Relevant evidence is required such as authentic documentation
(typically a WPS and/or test and inspection results).
Standard welding procedure. A procedure qualified by an authority (e.g. an examining
body) and made available to a fabricator/manufacturer.
Prequalified. A procedure is developed in accordance with the requirements of the
standard/code, minimal testing is required (a macro only for AS/NZS 1554).
Qualification based on the use of tested welding consumables. Similar to prequalified
method, applicable to materials that do not deteriorate significantly in the heat
affected zone.
3.3
List two specific weld/material defects that can be found using each of the following NDT methods
and give two advantages and two limitations of each NDT methods.
a)
ii)
iii)
2 marks
Two limitations
b)
Two advantages
2 marks
2 marks
Radiographic Inspection.
i)
Porosity
Tungsten inclusions
Underfill
Lack of penetration
Crack and lack of fusion if orientated correctly to the energy beam
2 marks
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ii)
iii)
2 marks
Three limitations.
Revision: 0
3 marks
.
QUESTION 4
4.1
List two specific weld/material defects that can be found using each of the following NDT methods
and give two advantages and two limitations of each NDT methods.
a)
ii)
iii)
2 marks
2 marks
2 marks
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b)
Ultrasonic Inspection.
(i)
(ii)
iii)
4.2
Revision: 0
i)
2 marks
2 marks
Very sensitive.
Can detect defects too small to be discovered by other methods.
Portable equipment.
Access required to only one side.
Two limitations of ultrasonic inspection.
2 marks
4 marks
A surface intersecting form of hot cracking in the crater of the weld stop.
ii)
4 marks
Crater cracks occur in the crater when the welding arc is improperly terminated. An incorrect
manipulative technique is applied that does not allow for crater shrinkage. Prevent by:
Improve the welding technique for crater fill
Use run off tabs
Use devices that provide for the incremental decrease of welding current
iii)
Detect by:
Visual inspection or by surface NDT methods
Also by radiography and ultrasonic examination
Repair by grinding/gouging followed by NDT
2 marks
Management
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Revision: 0
Date of Issue: 23 May 2011
Page 8 of 9
QUESTION 5
5.1
Regulations typically require employers to manage significant hazards in the place of work. Identify
the measures that can typically be used by an employer:
4 marks
5.2
5.3
5.4
2 marks
4 marks
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Date of Issue: 23 May 2011
Page 9 of 9
QUESTION 6
The following questions have multiple-choice answers and are worth 2 marks each.
Only one answer is correct. Tick only one. If two boxes are ticked, no mark will be awarded.
6.1
How would operational techniques that are used to fulfil the requirements for the outcome of weld
quality be defined?
a.
b.
c.
d.
Quality Audit
Quality Assurance
Quality Control
Quality management
6.2
6.3
6.4
6.5
Which of the following tests is not generally required when qualifying a WPS according to ISO
15614-1 or AS/NZS 1554.1?
a.
Tensile test
b.
Bend test
c.
Chemical analysis
d.
Visual inspection
6.6
6.7
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Date of Issue: 23 May 2011
Page 10 of 9
6.8
According to which criteria would you select the level of protective lens shade in a welding helmet:
a.
According to the light conditions in the workshop.
b.
According to the level of back scattered infrared radiation
c.
According to the welding process used.
d.
According to the instructions of the welding supervisor.
6.9
6.10
For ultrasonic testing, what is the name of the indication that is caused by the opposite side of the
test piece?
a.
Initial pulse.
b.
Back wall echo.
c.
Flash back.
d.
Main sound beam.
6.11
6.12
After a defect has been found and ground out, which method would be best to confirm that the
defect has been fully removed:
a.
Dye penetrant or magnetic particle testing.
b.
Acoustic emission.
c.
Radiography.
d.
Ultrasonics.
6.13
6.14
6.15