TheoryWelding Inspector CWI Practice Questions
Free Welding Inspector CWI practice questions with answers and plain-English explanations. Browse the PDF, video and online mock test.
Welding Inspector CWI Questions
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Q1AWS D1.1 is the primary structural welding code that governs welding of what base material?
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✓ Correct answer: Steel
AWS D1.1 is titled 'Structural Welding Code – Steel' and covers the welding of steel structures. Other AWS codes address aluminum (D1.2) and stainless steel (D1.6).
Q2AWS D1.1 applies to structures with a base metal minimum thickness of:
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✓ Correct answer: 3/16 in (4.8 mm)
AWS D1.1 generally applies to structural steel 3/16 in (4.8 mm) and thicker. Thinner material falls under sheet-metal or other codes such as AWS D1.3.
Q3A prequalified WPS under AWS D1.1 does NOT require:
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✓ Correct answer: Qualification testing (procedure qualification)
Prequalified WPSs comply with all AWS D1.1 prequalification requirements and therefore do not require procedure qualification testing. They still must be documented in writing with all essential variables.
Q4Which of the following welding processes is listed as prequalified in AWS D1.1?
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✓ Correct answer: Submerged arc welding (SAW)
SAW is listed as a prequalified process in AWS D1.1. GTAW and PAW are not prequalified under D1.1. ESW requires qualification testing.
Q5For prequalified fillet welds using SMAW under AWS D1.1, the maximum size of a single-pass fillet weld in the flat or overhead position is:
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✓ Correct answer: 1/4 in (6.4 mm)
AWS D1.1 limits single-pass SMAW fillet welds in the flat (1F) and overhead (4F) positions to 1/4 in (6.4 mm) maximum. The 5/16 in limit applies to the horizontal position. Exceeding these sizes requires multiple passes.
Q6Under AWS D1.1, which condition would disqualify a joint from being prequalified?
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✓ Correct answer: Using a joint configuration not listed in the D1.1 prequalified joint details
Only joint configurations explicitly listed in AWS D1.1's prequalified details may be used without qualification testing. Any deviation — such as a non-listed geometry or dimension — requires procedure qualification by testing.
Q7When a WPS cannot meet prequalification requirements under AWS D1.1, the welder must qualify the procedure using:
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✓ Correct answer: A procedure qualification record (PQR) based on test weld results
A PQR documents the actual test weld results and supports a qualified WPS when prequalification requirements cannot be met. It is not just paperwork — it requires physical testing of weld specimens.
Q8For AWS D1.1 procedure qualification of a CJP groove weld, the minimum test plate thickness that qualifies unlimited production thickness is:
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✓ Correct answer: 1 in (25 mm)
Under AWS D1.1, a CJP groove weld PQR test plate of 1 in (25 mm) or greater qualifies the procedure for unlimited production thickness above 1 in.
Q9Which essential variable change in AWS D1.1 ALWAYS requires requalification of a WPS?
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✓ Correct answer: A change in the welding process
Changing the welding process is always an essential variable requiring requalification. Changes within the same process classification (e.g., electrode diameter or number of passes) may be non-essential or supplementary essential depending on the code requirements.
Q10In AWS D1.1 Table 4.5 (procedure qualification test), which mechanical test is NOT required for a CJP groove weld test plate?
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✓ Correct answer: Charpy V-notch impact test
Charpy V-notch impact testing is required only when specified by the Engineer for fracture-critical or low-temperature applications; it is not a standard mandatory test in the base D1.1 procedure qualification test matrix.
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