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Visual Welding Inspector (WI) - 2025
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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?
14 mm
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.
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.
16 m
Answ
Expla e the
depth o
In a sc affect
the ch
A. Cra B.
Hot
All Answ
Expla weake
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?
Yes, within tolerance
No, exceeds reduction limit
No, requires re-welding
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.
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.
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
of 6 m standa
Ins
Ac
Use rvisor
Re
Answ
Expla fied
dimen to the
superv assum
A dra ith
s10 on nd the
chord i
20 m
10 mm
3 mm
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
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.
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.
All Answ
Expla An
unsec and
access may
delay o
In ass t may
require
Sm
Mi
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Ro
Answ Expla
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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?
Yes, the 6G position qualifies all positions including vertical down
No, vertical down requires a separate qualification test
Yes, provided the WPS allows short-circuiting transfer mode
No, GMAW short-circuiting mode disqualifies vertical down welding Answer: B
n still needs distinct qualification.
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.
MAW fillet weld on a 10 mm thick carbon steel T-joint, you measure the leg length using a
In the c hydro
E6
E6
E7
E7
Answ Expla
applic
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?
Report: "Leg length: 6.5 mm, minor deviation, acceptable"
Report: "Leg length: 6.5 mm, meets Level C standards"
Report: "Leg length: 6.5 mm, within ruler tolerance"
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.
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.
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
kJ/mm, ector’s
duty at
All
Int
Adj
Re
Answ
Expla of 1.9
kJ/mm quality
A 15 m ual
inspec
Inc
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.
When interpreting a welding symbol that specifies a "U" shaped groove, what is the primary characteristic of this joint type?
It is designed for better penetration
It has a uniform depth
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.
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.
Expla enhan
When w ended
to ach
Ar
Ar
Hel
Nit Answ
Expla oves
penetr
If a welding inspector observes that safety barriers are not appropriately placed around welding operations, what is the immediate risk this poses?
Increased visibility for passersby
Enhanced communication among workers
Improved airflow around the workspace
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.
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.
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"