Welder - 1st Semester - Module 1 : Induction Training and Welding Process

Questions: Level 1

1 Which operation is to remove burrs from a

plate after cutting?
A Brushing
B Filing
C Scraping
D Chiseling
2 Which is used for handling hot jobs?
A Tongs
B Shawel
C Poker
D Snips
3 Which part of the hammer fits into the
handle for it’s rigidity?

A Face
B Pein
C Cheek
D Wedge
4 Which is to wear for safety while handling
thin sheets?
A Tongs
B Clamp
C Hand gloves
D Hand screen

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Questions: Level 2 8 What is done to avoid injury to fingers after
hacksawing or chiselling a metal piece?
1 Which part of hammmer is shaped to fit the A Filing
handle rigidly? B Cleaning
A Big hole C Grinding
B Eye hole D De buring
C Key hole 9 What PPE is used when working on the
D Plain hole overhead crane?
A Wear apron
2 What happened if bench vice is over
B Wear helmet
tightened?
C Wear goggles
A Box nut damaged
D Wear leg gaurds
B Spindle damaged
10 Which is the method to control back fire
C Work bench damaged
while welding?
D Work pieces damaged
A Close oxygen control valve
3 What treatment you should give to a person
B Close acetylene control valve
who suffered from electric shock?
C First close the oxygen cylinder valve
A Given an alcoholic drink
D First close the acetylene cylinder valve
B Given a cold drink
11 Which hand tool is used to remove
C Made to walk
excessive adhering slag after gas cutting?
D Keep worm and comfortable
A Chisel
4 How much gap is maintained between the
B Flat file
grinding wheel and the work rest on a
C Chipping hammer
pedestal grinder?
D Cross cut hammer
A 4 to 5 mm
12 What precaution you will follow in gas
B 3 to 4 mm
welding to avoid fire accidents?
C 2 to 3 mm
A Alert to go away
D 1 to 2 mm
B Keep fire extinguishers
5 Which tool is used to open the cylinder
C Keep sand buckets near
valves?
D Keep away the inflammable materials
A Wrench
13 Which injury is to be covered immediately
B Spindle key
by clean cloth on affected porpion of the
C Cutting player
body?
D Adjustable spanner
A Cut injury
6 Which material is used to check the leakage
B Burn injury
of acetylane regulator connections?
C Crush injury
A Salt water
D Broken injury
B Plain water
14 Which material is used to check the leakage
C Soap water
of oxygen regulator connections?
D Chemical water
A Salt water
7 What action to be taken if a person in still I
B Soap water
contact with electric supply?
C Plain water
A Break the contact by hand
D Chemical water
B Break the contact by dry wood
15 Why should a welder clothes be free of oil or
C Break the contact by using iron rod
grease while welding?
D Break the contact by pushing with leg
A To protect the job
B To reflect the arc rays
C To avoid catching of fire
D To protect the welding machine

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Questions: Level 3

1 What are the main causes of accidents

while using a hammer?

A Poorly fitted or broken handle

B Carelessness in using a hammer
C Lack of skill in operation
D Improper methods of handling
2 What are the solutions for the safety in the
gas welding?
A Learn safety instructions
B Check on hose and gauge for damage
C Periodic checking of the cylinder
D Work area free from flammable material
3 What is the treatment to a persomn having
eye irritation caused by arc flashes?
A Use ear drops
B Use eye drops
C Use nose drops
D Use water drops

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 Module 1: Induction Training and Welding Process - Key paper

Questions: Level 1 Questions: Level 2 Questions: Level 3

SL.No Key SL.No Key SL.No Key

1 B 1 B 1 A
2 A 2 B 2 D
3 D 3 D 3 B
4 C 4 D
5 B
6 C
7 B
8 D
9 B
10 A
11 A
12 D
13 B
14 C
15 C

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 Welder - 1st Semester - Module 2 : Welding Techniques

Questions: Level 1 8 What is the name of joint if two members

welded in the same plane?
1 Which type of transformer used in arc A Lap joint
welding? B Tee joint
A Step up C Butt joint
B Step down D Edge joint
C One - to - one 9 What is the easiest position to weld?
D Copable of increasing supply voltage A Flat
2 Which position is advantageous for easy B Vertical
welding? C Over head
A Flat D Horizontal
B Vertical
C Over head
D Horizontal
3 Which one of the following is used to
convert AC to DC supply in a welding
machine?
A Rectifier set
B Motor generator set
C Engine generator set
D Welding transformer
4 What is the metal used to make earth clamp
in a welding machine?
A Iron
B Brass
C Aluminium
D Copper alloy
5 How much current should be set, to weld a
10 mm thick plates, by arc welding?
A 70 Amps
B 80 Amps
C 90 Amps
D 110 Amps
6 What is the term for the depth of fusion,
from the surface of the weld metal plate?
A Leg length
B Fusion zone
C Penetration
D Heat affected zone
7 What should be the angle for a double bevel
butt joint?
A 450
B 350
C 250
D 200

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Questions: Level 2

1 Which type of electrode produces short arc

length?
A Heavy coated electrodes
B Light coated electrodes
C Medium coated electrodes
D Super heavy coated electrodes
2 Which type of arc length produces deep
penentration weld?
A Long arc length
B Short arc length
C Medium arc length
D Too long arc length
3 What is the conversion function of a
rectifier?
A AC to AC
B DC to DC
C AC to DC
D DC to AC
4 Which arc length produces correct fusion?
A Long arc length
B Short arc length
C Normal arc length
D Too long arc length
5 Which type of polarity is used in welding non
ferrous metals?
A AC Transformer
B Reverse polarity
C Straight polarity
D DC Motor generator

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Questions: Level 3

1 Which arc length produes popping sound?

A Long arc length
B Short arc length
C Normal arc length
D Too long arc length
2 What arc length should be used to reduce
the spatter?
A Long arc length
B Short arc length
C Normal arc length
D Too long arc length

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 Module 2: Welding Techniques - Key paper

Questions: Level 1 Questions: Level 2 Questions: Level 3

SL.No Key SL.No Key SL.No Key

1 B 1 A 1 B
2 A 2 B 2 C
3 A 3 C
4 D 4 C
5 D 5 B
6 C
7 A
8 C
9 A

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 Welder - 1st Semester - Module 3: Weldability of Steel

Questions: Level 1 7 What is the defect in the weld joint shown in

figure?
1 What is the current range required for
3.15mm dia MS electrode in arc welding?
A 40 - 50 A
B 50 - 60 A
C 70 - 80 A
D 100 - 110 A
2 What is the name of last bit of an discarded A Overlap
electrode? B Porosity
A Red end C Reinforcement
B Dead end D Lack of penetration
C Stub end 8 Which metal in welding process is subjected
D Waste end to “Weld decay” defect?
3 How many groups of mild steel pipes are A Brass
there? B Copper
C Mild steel
D Stainless steel
9 Which filler rod is used for bronze welding of
cast iron, malliable iron and copper?
A Manganese, Bronze, filler rod
B Copper, Phosperous, filler rod
C Copper, Phosperous alloy filler rod
D Copper, Zinc, Nickel filler rod
A Two groups 10 What does the third digit of AWS
B Five groups codification in EB 5426HJX represent?
C Four groups A Type of current
D Three groups B Type of covering
4 How a pipe is specified? C Type of tensile strength
A Dia only D Type of welding position
B Length only 11 Which accessory is used to protect the eyes
C Outer dia only during gas welding?
D Outer dia x inner dia x length A Helmet
5 What should be the bevel angle for edge B Hand screen
preparation of 6mm thick pipe welding? C Colour goggles
A 30° - 35° D Grinding goggles
B 40° - 45° 12 What is the composition of acetylene gas?
C 60° - 65° A C - 72.3% H - 27.7%
D 70° - 75° B C - 82.3% H - 17.7%
6 What is the purpose of copper coating on C C - 90% H - 10%
mild steel filler rod used in gas welding? D C - 92.3% H - 7.7%
A Rust proof
B Water proof
C Moisture proof
D Increased filler dia

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13 What is the name of the flame shown in 19 What is the name of small metal particles
figure? which are thrown out of the arc during
welding?
A Slag
B Spatters
C Stub end
D Weld metal
A Neutral flame
B Oxidising flame
C Carburising flame
D Oxy-Acetylene flame
14 Which size of CCMS filler rod is to be used
for welding plate of 8mm thick with ‘V’ edge
preparation?
A 3.15 mm ϕ
B 4.0 mm ϕ
C 5.0 mm ϕ
D 6.3 mm ϕ
15 How many segments are to be selected for
welding 50 mm ϕ pipe?
A 3 segments
B 4 segments
C 6 segments
D 8 segments
16 What type of edge preparation is needed,
for gas welding a pipe, with wall thickness
6mm?
A Single “V”
B Single bevel
C Square edge with root gap
D Square edge without root gap
17 How many equal divisions should be made
while developing a “T” pipe joint?
A 4 equal divisions
B 6 equal divisions
C 9 equal divisions
D 12 equal divisions
18 Which metal in welding process is subjected
to “Weld decay” defect?
A Brass
B Copper
C Mild steel
D Stainless steel

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Questions level 2 7 What is the base for selecting the nozzle
size for gas welding of a pipe?
1 What is the defect of metal flowing into the A Groove angle
surface of base metal without fusing it? B Weldig position
A Over lap C Diameter of pipe
B Under cut D Pipe wall thickness
C Lack of fusion 8 Which type of filler rod shall contain higher
D Lack of penetration percentage of iron?
2 What is the type of welding defect shown in A Ferrous
given figure? B Non - ferrous
C Alloy type of ferrous metals
D Alloy type of non - ferrous metals
9 What is the process of heating steel to
specific temperature and cooling suddenly?
A Annealing
B Hardening
A Crack C Tempering
B Blow hole D Quenching
C Burn through 10 What is the main purpose of ‘Normalising’
D Unfilled crater steel?
3 Which one of the defect is caused by low A To control hardness
current in arc welding? B To prevent cracking
A Poracity C To make welding operation easier
B Under cut D To produce fine grain of uniform structure
C Lack of fusion 11 What is the purpose of setting root gap?
D Excessive penetration A To over some under cut
4 What is the cause of hair line separation in B To control distortion
the bead in arc welding? C To get good penetration
A Fast cooling D Gap get closed due to expansion
B Slow cooling 12 Which of the following metals have high
C Long arc length thermal conductivity?
D Wrong selection of electrode A Brass
5 What is the name of the steel material which B Bronze
are not weldable? C Copper
A High carbon steel D Aluminium
B Medium carbon steel 13 What is the process of hot weld joint rapidly
C Austenitic stainless steel hammered to relieve internal stresses?
D Ferrite & martensitic stainless steel A Peening
6 Which is used to cut thin pipes of smaller B Annealing
sizes? C Heat treatment
A Chisel D Straightening
B Hack sawing 14 Which type of cast iron possess higher
C Pipe cutter hardness?
D Lathe parting tool A Grey cast iron
B White cast iron
C Nodular cast iron
D Malleable cast iron

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15 Which type of cast iron is soft? 20 What is the name of the part ‘x’ shown of a
A Grey cast iron portable cutting machine?
B White cast iron
C Nodular cast iron
D Malleable cast iron
16 Which size of filler rod should be used to
weld 2mm thick MS sheet?
A 1.6 mm
B 2.0 mm
C 2.5 mm
D 3.15 mm
17 What is the main function of the flux coating
in electrodes?
A Speed control
A To prevent rusting
B Per-heat control
B To stabilize the arc
C Vertical control
C To control arc temperature
D Horizontal control
D To increase welding current
21 What benefit we get out of a carburising
18 What is the purpose of oxygen lever in gas
flame?
cutting?
A Suitable for bross, copper welding
A Pre heat the base metal
B Suitable for stellite, flame cleaning
B Push the molten metal
C Suitable for mildsteel, stainless steel
C Remove the excess metal
D Suitable for pure aluminium, cast iron &
D Release excess oxygen and to push the
brass welding
molten metal
22 What are the defects in generated acetylene
19 Which nozzle shown in figure represents
gas?
good condition and selected for gas cutting?
A Oxygen, hydrogen & carbon
B Carbon monoxide unburit ash
C Hydrogen, dust particles, ash
D Hydrogen, lime dust, ammonia & water
vapour
23 What is the range of pressure gauge used in
an oxygen cylinder used in gas welding?
A 120 to 150 Kg/cm2
B 110 to 150 Kg/cm2
C 100 to 150 Kg/cm2
D 90 to 150 Kg/cm2
24 What should be the angle of filler rod, by
A Nozzle A
rightward welding?
B Nozzle B
A 30° - 40°
C Nozzle C
B 40° - 50°
D Nozzle D
C 50° - 60°
D 60° - 70°
25 What thickness of plate, gas welding by
forehand technique can be used without
edge preparation?
A Up to 2.5 mm
B Up to 3.15 mm
C Up to 4 mm
D Up to 5 mm

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26 What is the purpose of copper coating in MS 33 What procedure is followed in welding pipe
filler rod? in 5 G position?
A Easy to melt and deposit A Rotate pipe and weld vertically
B To speed up fusion of weld B Pipe not rotated weld verticaliy
C To increase filler rod dia C Pipe not rotated and pipe axis 450
D To prevent rusting of filler rod D Pipe welded 12’o clock to 6’o clock either by
27 What flux is used in welding brass? uphill or downhill method
A Anti - borax
B Borax paste
C Cryolite and berium chloride
D Zinc chloride and potassium dichromate
28 What flux is to be used for gas welding
stainless steel plates?
A Borox flux
B Anti - Borox
C Cryolite and berium chloride
D Zinc chloride and potassium dichromate
paste
29 Which filler rod to be used for gas welding
aluminium?
A Silicon - brass
B Silicon - manganese
C Copper - Silver alloy
D Pure aluminium, 5% silicon aluminium alloy
30 What should be the pre - heating
temperature of aluminium job for gas
welding?
A 200°C - 400°C
B 250°C - 400°C
C 300°C - 400°C
D 350°C - 400°C
31 What is the base for selecting the nozzle
size for gas welding of a pipe?
A Groove angle
B Weldig position
C Diameter of pipe
D Pipe wall thickness
32 What is the welding position asper ASME
for a pipe joint held vertically, welding in a
horozontal line?
A 1G
B 2G
C 5G
D 6G

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Questions Level 3 7 Which heat treatment process causes the
reduction of brittleness in the steel?
1 Why deposited bead is not in uniform size? A By annealing
A Incorrect flame setting B By hardening
B Wrong angle of blow pipe C By tempering
C Wrong angle of filler rod D By normalising
D Variation in speed of travel and angle 8 What is the cause of porosity in arc
2 What is the type of distortion shown? welding?
A Damp electrodes
B Carbon electrodes
C Over size electrodes
D Low hydrogen electrodes
9 What is the welding defect in base metal
gets melted and a groove formed along the
toe of the weld?
A Undercut
A Wide distortion B Blow holes
B Angular distortion C Reniforcement
C Transverse distortion D Lack of penetration
D Longitudinal distortion 10 What is the name of the steel material that
3 Which element is present in contact is not weldable?
electrodes in large proportion? A High carbon steel
A Carbon B Medium carbon steel
B Silicon C Austenitic stainless steel
C Manganese D Ferrite & martensitic stainless steel
D Iron powder.
4 Which size of filler rod should be used to
weld 2.5mm thickplates,using nozzle 5 by
leftward technique?
A 1.60 mm
B 2.00 mm
C 2.50 mm
D 3.15 mm
5 Which process causes the increase in the
strength of part after fabrication?
A Hardening
B Tempering
C Quencling
D Normalising
6 How the repairs of cracks in cast iron
component carrried out?
A By using clamps during welding process
B Similar to arc welding mild steel plate
C Local preheating, leftword welding
technique flame heating each layer
D Cracks repaired using appropriate electrode

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 Module 3: Weldability of Steel - Key paper

Questions: Level 1 Questions: Level 2 Questions: Level 3

SL.No Key SL.No Key SL.No Key

1 D 1 A 1 D
2 C 2 A 2 C
3 A 3 C 3 D
4 D 4 A 4 B
5 A 5 C 5 A
6 A 6 C 6 C
7 D 7 D 7 C
8 D 8 A 8 A
9 D 9 D 9 A
10 D 10 D 10 C
11 B 11 C
12 D 12 C
13 A 13 A
14 C 14 B
15 B 15 A
16 A 16 A
17 D 17 B
18 D 18 B
19 B 19 C
20 A
21 B
22 D
23 A
24 A
25 B
26 D
27 B
28 D
29 D
30 B
31 D
32 B
33 D

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