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TWI - Visual Welding Inspector (CSWIP-WI-6-92) Practice Test

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Exam Code: CSWIP-WI
Exam Name: CSWIP Visual Welding Inspector (WI)
Multiple Choice Questions (MCQs)
Practical Examination (Weld Assessment)
Duration: ~2 hours (varies by training provider)
Pass Mark: ~70% (varies slightly)

1. Introduction to Welding Inspection (10-15%)
- Role and responsibilities of a welding inspector
- Importance of visual inspection in quality control
- Welding inspection stages
- pre-weld
- during welding
- post-weld
- Documentation review
- WPS
- PQR
- WPQ

- WPS (Welding Procedure Specification)
- PQR (Procedure Qualification Record)
- WPQ (Welder Performance Qualification)
- NDT (Non-Destructive Testing)
- QA/QC (Quality Assurance/Quality Control)

2. Welding Processes & Defects (20-25%)
- Common welding processes:
- SMAW (Shielded Metal Arc Welding)
- GTAW (Gas Tungsten Arc Welding)
- GMAW (Gas Metal Arc Welding)
- FCAW (Flux-Cored Arc Welding)
- SAW (Submerged Arc Welding)
- Weld joint types (butt, fillet, lap, etc.)
- Weld imperfections vs. defects (acceptance criteria)

- Porosity
- Slag Inclusion
- Lack of Fusion (LOF)
- Undercut
- Cracks (Hot, Cold, Crater)
- Spatter
- Excessive Reinforcement

3. Standards & Codes (15-20%)
- ISO 5817 (Welding quality levels for steel)
- ISO 9606 (Qualification testing of welders)
- ISO 17637 (Visual testing of welds)
- AWS D1.1 (Structural welding code – steel)
- BS EN 1090 (Execution of steel structures)

- Acceptance Criteria
- Fitness for Purpose (FFP)
- Workmanship Standards
- Tolerance Levels

4. Visual Inspection Techniques (25-30%)
- Tools for visual inspection
- gauges
- magnifiers
- rulers
- Measuring weld sizes
- throat thickness
- leg length
- Surface defect identification
- Reporting and recording defects

- Fillet Weld Gauge
- HI-LO Gauge
- Undercut Depth Measurement
- Weld Profile Assessment

5. Welding Symbols & Drawings (10-15%)
- Interpretation of welding symbols
- ISO 2553
- AWS A2.4
- reading engineering drawings
- Weld joint configurations

- Arrow Side / Other Side
- Groove Weld Symbol
- Fillet Weld Symbol
- Supplementary Symbols (Contour, Finish)

6. Safety & Ethics (5-10%)
- Personal Protective Equipment (PPE)
- Workshop safety practices
- Inspector’s code of ethics

- PPE (Helmet, Gloves, Respirator)
- HSE (Health & Safety Executive)
- Confidentiality & Integrity

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TWI
CSWIP
Visual Welding Inspector (WI) - 2025
https://killexams.com/pass4sure/exam-detail/CSWIP-WI
If a welding symbol indicates a "bevel" with a specified angle of 45 degrees and a depth of 8 mm, what is the minimum base metal thickness required to ensure proper welding?
1. 14 mm
2. 10 mm
m er: D
nation: A bevel weld at a 45-degree angle typically requires the base metal to be at least twic f the bevel to ensure adequate support, hence a minimum of 16 mm.
ion: 1314
enario where a crack is identified in a weld, how does the type of crack (hot, cold, or crater) oice of repair method, particularly in terms of temperature considerations?
ter cracks need to be ground out before repair Cold cracks can be repaired without preheating
cracks require immediate cooling types need the same repair method
er: A
nation: Crater cracks typically need to be ground out and repaired carefully to avoid further ning the joint, as they can propagate easily if not addressed properly.
12 mm
3. 16 m
Answ
Expla e the
depth o
Quest
In a sc affect
the ch
A. Cra B.
1. Hot
2. All Answ
Expla weake
Question: 1315
A fillet weld throat is specified as 7 mm, but inspection with a gauge measures 5.5 mm. BS EN 970 Level C allows a reduction of 0.1t (max 1 mm), where t = 7 mm. Is this acceptable?
1. Yes, within tolerance
2. No, exceeds reduction limit
3. No, requires re-welding
4. Yes, if leg lengths are met
Answer: B
Explanation: For Level C, reduction = 0.1t or 1 mm, whichever is less (0.1 � 7 = 0.7 mm). The 1.5 mm reduction (7 - 5.5 = 1.5 mm) exceeds 0.7 mm, making it unacceptable.
Question: 1316
SO 17637, where the fillet weld throat thickness measures 5.8 mm against a specified mini
m. Considering the inspector�s responsibility, what action aligns with maintaining quality rds?
truct the welder to add an additional pass to increase the throat thickness
cept the weld as the deviation is within a 10% tolerance of the specified value
a fillet weld gauge to confirm the measurement and report the shortfall to the welding supe calibrate the gauge and remeasure to account for potential tool error
er: C
nation: ISO 17637 requires inspectors to accurately measure and report deviations from speci sions, such as a throat thickness below 6 mm, using tools like a fillet weld gauge. Reporting isor ensures proper quality control action, whereas accepting deviations, directing repairs, or ing tool error without evidence contravenes the inspector�s defined responsibilities.
ion: 1317
wing per ISO 2553 specifies a K-joint with a welding symbol: a double-bevel groove weld w both sides, a 3 mm root face, and a "weld all around" symbol. The brace is 20 mm thick, a s 25 mm thick. What is the minimum throat thickness per side?
m
A welding inspector is tasked with visually assessing a T-joint weld on a heavy machinery component under I mum
of 6 m standa
1. Ins
2. Ac
3. Use rvisor
4. Re
Answ
Expla fied
dimen to the
superv assum
Quest
A dra ith
s10 on nd the
chord i
1. 20 m
2. 10 mm
3. 3 mm
4. 25 mm Answer: B
Explanation: In ISO 2553, "s10" specifies a 10 mm throat thickness for each side of the double-bevel groove weld in the K-joint. This is the minimum required weld size per side, independent of the brace or chord thickness.
A welding inspector is overseeing a confidential aerospace weld using Plasma Arc Welding (PAW) at 280A. The welder logs detailed process data (e.g., pulse frequency of 120 Hz, peak current 300A) on an unsecured laptop accessible to non-cleared staff. Per ISO 27001 Annex A controls, what should the inspector mandate?A. Encrypt the laptop and restrict access
1. Delete the data and use paper records
ow logging but limit staff proximity er: A
nation: ISO 27001 Annex A requires protection of sensitive data against unauthorized access. ured laptop violates confidentiality, risking exposure of critical PAW parameters. Encryption restriction provide immediate, robust security, surpassing deletion or server transfer, which
r disrupt workflow.
ion: 1319
essing a weld for spatter, what specific surface condition is indicative of excessive spatter tha corrective action?
ooth and shiny surface nimal discoloration form bead appearance
ugh surface with visible droplets er: D
nation: A rough surface with visible droplets indicates excessive spatter, which can affect the tics and potentially the integrity of the weld, requiring corrective action.
Transfer data to a secure server immediately
2. All Answ
Expla An
unsec and
access may
delay o
Quest
In ass t may
require
1. Sm
2. Mi
3. Uni
4. Ro
Answ Expla
aesthe
Question: 1320
While inspecting a Welder Performance Qualification (WPQ) test coupon for a 6G position pipe weld (45� inclined) using Gas Metal Arc Welding (GMAW), you observe that the welder used a short- circuiting transfer mode with a 1.2 mm ER70S-6 filler wire. The test coupon passed visual inspection and radiographic testing per ASME Section IX, QW-302. However, the WPQ documentation indicates qualification for all positions, including vertical down. Is this qualification acceptable based on the test conditions?
1. Yes, the 6G position qualifies all positions including vertical down
2. No, vertical down requires a separate qualification test
3. Yes, provided the WPS allows short-circuiting transfer mode
4. No, GMAW short-circuiting mode disqualifies vertical down welding Answer: B
n still needs distinct qualification.
ion: 1321
lassification of welding consumables, which of the following designations indicates a low gen electrode?
010
013
018
016
er: C
nation: The E7018 electrode is classified as a low hydrogen electrode, suitable for critical ations.
ion: 1322
MAW fillet weld on a 10 mm thick carbon steel T-joint, you measure the leg length using a
Explanation: ASME Section IX (QW-405.3) states that qualification in the 6G position qualifies all positions except vertical down, which requires a separate test due to its unique welding characteristics. The use of short-circuiting transfer mode does not inherently disqualify the test, but the vertical down positio
Quest
In the c hydro
1. E6
2. E6
3. E7
4. E7
Answ Expla
applic
Quest
In an S steel
ruler with 0.5 mm graduations under 1000 lux illumination. The WPS specifies a leg length of 8 mm �1 mm, and you measure 6.5 mm over a 15 mm length. BS EN ISO 5817 Level C requires WPS compliance. What is the correct reporting action?
1. Report: "Leg length: 6.5 mm, minor deviation, acceptable"
2. Report: "Leg length: 6.5 mm, meets Level C standards"
3. Report: "Leg length: 6.5 mm, within ruler tolerance"
4. Report: "Leg length: 6.5 mm, below WPS minimum, reject" Answer: D
Explanation: The 6.5 mm leg length falls below the 7 mm minimum (8 mm - 1 mm) specified by the WPS, which BS EN ISO 5817 Level C mandates compliance with, making it a defect requiring rejection. The steel ruler measurement is accurate, and the report must reflect the shortfall, not a tolerance or standard compliance.
Question: 1323
g inspector notes that the welder is operating at 28 V and 250 A, yielding a heat input of 1.9 exceeding the WPS maximum of 1.5 kJ/mm for a travel speed of 4 mm/s. What is the insp this stage?
ow welding to proceed as the exceedance is within a 30% tolerance
errupt welding and document the heat input exceedance for quality assessment ust the voltage to 24 V to bring heat input within limits
calculate the travel speed to align with the WPS heat input limit er: B
nation: ISO 17637 mandates monitoring welding parameters during the process. A heat input exceeds the WPS limit of 1.5 kJ/mm, requiring the inspector to stop welding and report for control, not continue, adjust settings, or recalculate independently.
ion: 1324
m thick single V-butt weld (40� bevel) has a root gap of 3 mm and root face of 2 mm. Vis tion shows a 4 mm protrusion beyond the root. What is this?
omplete penetration k of fusion
Root concavity
While monitoring the welding of a fillet weld on a 12 mm thick structural component per ISO 17637, a weldin
kJ/mm, ector�s
duty at
1. All
2. Int
3. Adj
4. Re
Answ
Expla of 1.9
kJ/mm quality
Quest
A 15 m ual
inspec
1. Inc
2. Lac C.
D. Excess penetration Answer: D
Explanation: A protrusion beyond the root indicates excess penetration, where weld metal extends past the root face due to a large root gap (3 mm) and thin root face (2 mm). Incomplete penetration lacks fusion depth, root concavity depresses inward, and lack of fusion shows no bonding.
Question: 1325
When interpreting a welding symbol that specifies a "U" shaped groove, what is the primary characteristic of this joint type?
1. It is designed for better penetration
2. It has a uniform depth
3. It requires a backing bar
nation: A "U" shaped groove is designed to provide better penetration for the weld metal, cing the strength of the joint.
ion: 1326
elding with GTAW on magnesium alloys, what shielding gas mixture is typically recomm ieve optimal results?
gon only
gon with a small percentage of helium ium only
rogen with argon er: B
nation: A mixture of argon with a small percentage of helium enhances arc stability and impr ation when welding magnesium alloys.
ion: 1327
It is used for butt joints only Answer: A
Expla enhan
Quest
When w ended
to ach
1. Ar
2. Ar
3. Hel
4. Nit Answ
Expla oves
penetr
Quest
If a welding inspector observes that safety barriers are not appropriately placed around welding operations, what is the immediate risk this poses?
1. Increased visibility for passersby
2. Enhanced communication among workers
3. Improved airflow around the workspace
4. Potential for unauthorized access and accidents Answer: D
Explanation: Improper placement of safety barriers increases the risk of unauthorized access to hazardous areas, leading to potential accidents and injuries.
Question: 1328
A WPS for FCAW on a 30 mm thick plate specifies a wire feed speed of 200�250 mm/min and a contact tip-to-work distance (CTWD) of 15�20 mm. A welder uses 260 mm/min and 25 mm CTWD. Per ASME Section IX, is requalification required?
the changes are within acceptable tolerances
both wire feed speed and CTWD are essential variables if the weld quality meets standards
er: C
nation: ASME Section IX, QW-404.22 (wire feed speed) and QW-409.9 (CTWD), classify t al variables for FCAW, affecting deposition and heat input. Deviations beyond the specified itate requalification.
ion: 1329
a visual inspection of an FCAW butt weld on a 50 mm thick carbon steel plate, you use a f auge to measure the throat thickness under 500 lux lighting. The WPS requires a minimum m, and you record a value of 24.5 mm over a 30 mm length at a 30� angle. AWS D1.1 Ta es WPS compliance for static loading. What is the reporting format?
port: "Throat thickness: 24.5 mm, below WPS minimum, reject" port: "Throat thickness: 24.5 mm, minor deviation, acceptable" port: "Throat thickness: 24.5 mm, within gauge tolerance"
port: "Throat thickness: 24.5 mm, meets AWS standards"
Yes, only the CTWD change is significant
No,
Yes,
No,
Answ
Expla hese as
essenti ranges
necess
Quest
During illet
weld g throat
of 25 m ble 6.1
requir
1. Re
2. Re
3. Re
4. Re
Answer: A
Explanation: The 24.5 mm throat thickness is below the 25 mm WPS minimum required by AWS D1.1 Table 6.1 for static loading, making it a defect requiring rejection. The fillet weld gauge measurement is precise, and the report must reflect the shortfall against the WPS, not a tolerance or standard compliance.
Question: 1330
Which of the following welding processes is most suitable for joining dissimilar metals?
1. FCAW
2. SMAW
3. GTAW
4. SAW
Answer: C
ion: 1331
essing workmanship standards, which specific practice can significantly reduce the likelihood in welded joints?
ng a single welding technique oring minor imperfections
gularly training and certifying welders ducing inspection frequency
er: C
nation: Regularly training and certifying welders can significantly reduce the likelihood of de ded joints, ensuring high-quality workmanship and compliance with standards.
ion: 1332
verseeing the welding of a butt weld on a 15 mm thick plate per ISO 17637, a welding ins res a preheat temperature of 80�C, below the WPS minimum of 100�C, using an infrared eter, with welding already underway. What should the inspector do?
Explanation: Gas Tungsten Arc Welding (GTAW) provides precise control and is ideal for dissimilar metal welding applications.
Quest
In ass of
defects
1. Usi
2. Ign
3. Re
4. Re
Answ
Expla fects
in wel
Quest
While o pector
measu pyrom
1. Allow welding to continue as the difference is within 20�C tolerance
2. Stop welding and report the temperature shortfall to the welding coordinator
3. Increase the preheat to 100�C using a torch and resume welding
4. Recheck the pyrometer calibration to confirm the reading Answer: B
Explanation: During welding, ISO 17637 requires adherence to WPS preheat minimums (100�C). A reading of 80�C necessitates stopping welding and reporting for quality control, not continuing, adjusting
heat, or rechecking without action.
Question: 1333
In a visual inspection of a weld, you find evidence of lamellar tearing. What is the primary material property that helps mitigate this defect?
1. Ductility
nsile strength ld strength
er: A
nation: High ductility in the base metal can help mitigate the risk of lamellar tearing during g.
Hardness
2. Te
3. Yie Answ
Expla weldin

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TWI - Visual Welding Inspector (CSWIP-WI-6-92) Practice Test

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