Welding Defects and Prevention: Master Common Defects and Their Solutions

Question 1

Which of the following factors should NOT be considered when selecting a welding process?

Accepted Answer

Welder's age

Answer

Material thickness

Answer

Desired joint strength

Answer

Available equipment

Question 2

What is the main cause of porosity in welds?

Accepted Answer

Entrapment of gases

Answer

Improper shielding gas flow

Answer

Excessive heat input

Answer

Lack of fusion

Question 3

Which welding process is most prone to oxidation defects?

Accepted Answer

Shielded metal arc welding (SMAW)

Answer

Gas metal arc welding (GMAW)

Answer

Gas tungsten arc welding (GTAW)

Answer

Submerged arc welding (SAW)

Question 4

Which of the following is NOT a common welding defect commonly encountered in the welding industry?

Accepted Answer

Overlapping

Answer

Porosity

Answer

Undercut

Answer

Slag inclusion

Question 5

What is the primary cause of porosity in welds?

Accepted Answer

Moisture in the welding environment

Answer

Rapid solidification

Answer

Improper shielding gas

Answer

Excessive heat input

Question 6

Which factor does NOT affect the cooling rate of a weld?

Accepted Answer

Filler metal composition

Answer

Base metal thickness

Answer

Welding speed

Answer

Ambient temperature

Question 7

Which of the following is NOT a common type of welding defect?

Accepted Answer

Corrosion

Answer

Porosity

Answer

Cold lap

Answer

Undercut

Question 8

In welding, what type of defect is characterized by the presence of trapped impurities within the solidified weld metal?

Accepted Answer

Inclusion

Answer

Undercut

Answer

Blowhole

Answer

Cracking

Question 9

Which of the following describes a condition where the weld metal has bonded with only one base metal?

Accepted Answer

Lack of fusion

Answer

Porosity

Answer

Slag inclusion

Answer

Incomplete penetration

Question 10

Identify the welding defect characterized by a groove or trench along the weld's edge.

Accepted Answer

Undercut

Answer

Cold lapping

Answer

Overfill

Answer

Concavity

Question 11

What is the primary purpose of using flux in welding?

Accepted Answer

To protect the weld from oxidation and remove impurities

Answer

To increase the welding speed

Answer

To improve the weld appearance

Answer

To reduce the weld strength

Question 12

Which of the following is NOT a common welding defect?

Accepted Answer

Adhesion

Answer

Slag inclusion

Answer

Cracking

Answer

Undercut

Question 13

What is the primary cause of porosity in welds?

Accepted Answer

Trapped gases

Answer

Excessive heat input

Answer

Cold base metal

Answer

Improper shielding gas

Question 14

What is a common preventive measure against undercut in welding?

Accepted Answer

Proper joint preparation

Answer

Using a larger electrode

Answer

Increasing welding speed

Question 15

Which of the following is a characteristic of a lack of fusion in a weld?

Accepted Answer

Unfused metal at the weld interface

Answer

Excess weld bead on the surface

Answer

Inclusion of slag in the weld

Answer

Penetration into the base metal

Question 16

What is the purpose of post-weld heat treatment?

Accepted Answer

To relieve internal stresses and improve toughness

Answer

To improve weldability of the material

Answer

To increase weld strength and hardness

Answer

To prevent corrosion and oxidation

Question 17

What is the importance of welding procedure specifications (WPS) in defect prevention?

Accepted Answer

They document optimal welding parameters and prevent deviations

Answer

They are only applicable to specific welding processes

Answer

They provide guidelines for post-weld heat treatment only

Question 18

What is the primary objective of weld repair?

Accepted Answer

To restore the structural integrity and serviceability of the welded joint

Answer

To reduce the risk of fatigue failure

Answer

To improve the appearance of the weld

Question 19

Which of the following is a type of crack that occurs along the fusion zone?

Accepted Answer

Hot crack

Answer

Cold crack

Answer

Undercut

Answer

Lamellar tear

Question 20

What is the primary cause of slag inclusions?

Accepted Answer

Incomplete slag removal

Answer

Porosity

Answer

Distortion

Question 21

Which of the following is a preventive measure against undercut?

Accepted Answer

Proper welding technique

Answer

Using a smaller electrode

Answer

Increasing travel speed

Answer

Lowering welding current

Question 22

What is the primary factor that contributes to weld porosity?

Accepted Answer

Entrapment of gases

Answer

Improper welding position

Answer

Insufficient heat input

Answer

High welding voltage

Question 23

Which of the following is a method to prevent distortion in welded structures?

Accepted Answer

Preheating and postheating

Answer

Leaving gaps between welds

Answer

Welding in a vertical position

Answer

Using thicker base metal

Question 24

What is the name of the defect characterized by a lack of fusion between two weld layers?

Accepted Answer

Laminations

Answer

Porosity

Answer

Slag inclusions

Answer

Cracks

Question 25

Which of the following is a preventive measure against cold cracking?

Accepted Answer

Preheat and slow cooling

Answer

Weld in a cold environment

Answer

Use a larger electrode

Answer

Increase welding speed

Question 26

What is the term for the melted base metal that is fused together during welding?

Accepted Answer

Weld pool

Answer

Slag

Answer

Flux

Answer

Porosity

Question 27

Which of the following is a common cause of grain growth in welds?

Accepted Answer

High heat input

Answer

Improper electrode selection

Answer

Low welding speed

Answer

Contaminated base metal

Question 28

What is the role of flux in welding?

Accepted Answer

Protect the weld from the atmosphere

Answer

Bond the weld metal to the base metal

Answer

Remove impurities from the weld pool

Answer

Increase the melting point of the base metal