12-11-25 Welding Midterm Review 2025
  • 1. What is the base metal?
A) The weld bead
B) The metal to be welded
C) The shielding gas makes sparks
D) The flux coating
  • 2. What is an arc?
A) A joint type that lets light fly around everywhere
B) Light from welding
C) Flow of electricity through a gaseous space or air gap
D) A type of electrode
  • 3. What is arc length?
A) Length of the rod
B) Length of the weld
C) The distance from the gap between plates and the clamp wire
D) The distance from the electrode to the weld pool
  • 4. What is undercut?
A) A surface crack
B) A groove melted into base metal left unfilled
C) Extra filler metal
D) A grove melted into the base metal that is a misaligned joint
  • 5. What is a crater?
A) A depression in the face of the weld
B) A buildup of slag in the face of the weld
C) A melted rod tip in the face of the weld
D) A porosity pocket in the face of the weld
  • 6. What is the axis of weld?
A) Imaginary line through top of the bead
B) Imaginary line through center of weld metal
C) Imaginary line through weld toe
D) Imaginary line through HAZ boundary
  • 7. What is spatter?
A) Falling flux expelled that do not form part of the weld
B) Gas bubbles expelled that do not form part of the weld
C) Metal particles expelled that do not form part of the weld
D) Arc blow expelled that do not form part of the weld
  • 8. What is slag inclusion?
A) Undercut failure
B) Steel trapped in slag
C) Non-metallic material trapped in weld
D) Hot cracks trapped in the weld pool at the end
  • 9. What is a joint?
A) Location where two or more members are joined
B) The end of the metal piece that is welded first.
C) filler metal
D) a welding defect
  • 10. What is a crater crack?
A) A cold shut
B) A stress fracture formed cause metal was too clean
C) A centerline crack
D) A crack in the crater of a weld bead
  • 11. What is ductility
A) Ability to remain cold.
B) Ability to stay magnetized
C) Ability to deform without failure
D) Ability to resist rust
  • 12. What is duty cycle?
A) Electrode burn rate is working nonstop
B) Arc stability rating
C) Machine lifespan over a 10 min period
D) Percentage of time welders operate at rated output
  • 13. What is filler metal?
A) Metal added to make a welded joint
B) Metal base plate
C) Flux coating
D) Distance fusion extends into base metal
  • 14. What is depth of fusion?
A) Distance bead width extends
B) Distance fusion extends into base metal
C) Rod penetration
D) Weld height
  • 15. What is penetration?
A) Extent weld metal combines with base metal
B) Arc reach
C) Bead surface depth
D) Slag depth
  • 16. What is deposition rate?
A) Weight of metal deposited per unit time
B) Heat generated
C) Amount of slag produced
D) Length welded per hour
  • 17. What does SMAW stand for?
A) Stick Metal Arc Work
B) Solid Metal Arc Welding
C) Shielded Mechanical Arc Welding
D) Shielded Metal Arc Welding
  • 18. What is SMAW?
A) Purely mechanical process
B) Uses tungsten electrode
C) Uses shielding gas
D) Uses heat of an arc between covered electrode and the work
  • 19. Advantage of SMAW?
A) No slag
B) Portable and inexpensive
C) High speed
D) Fully automated
  • 20. Disadvantage of SMAW?
A) It’s slow
B) Requires gas bottles
C) Only works indoors
D) Cannot weld steel
  • 21. 7018 can use:
A) AC only
B) DC only
C) Neither
D) AC or DC
  • 22. What polarity do we weld with?
A) Alternating ground
B) No polarity
C) Straight polarity
D) Reverse polarity
  • 23. Reverse polarity:
A) Electrode is positive, ground negative
B) No polarity exists
C) Electrode negative
D) Ground floats
  • 24. Two safety points:
A) Avoid using gloves never safety glasses
B) Use small rods and low heat
C) Proper ventilation and protective clothing
D) Always weld outside use sitka gloves
  • 25. SMAW electrode:
A) Carbon rod
B) Consumable electrode covered with flux
C) MIG wire
D) TIG tungsten
  • 26. Strength of 7018 rod:
A) 120k psi
B) 18k psi
C) 40k psi
D) 70k psi
  • 27. Meaning of 3rd digit in 7018:
A) Coating type
B) Welding position
C) Rod length
D) Positive polarity rod
  • 28. Meaning of 4th digit in 7018:
A) Diameter
B) Arc length
C) Composition of rod
D) Strength
  • 29. Four rod groups:
A) High carbon, low carbon, stainless, alloy
B) Inert, reactive, passive, active
C) Soft rods, hard rods, hot rods, cold rods
D) Celluosic, Rutile, Basic/low Hydrogen, Iron Powder
  • 30. DCEP:
A) Direct Current Electrode Positive
B) Direct Coil Energy Pulse
C) Dual Current Electrode Phase
D) Direct Current Elevated Pressure
  • 31. Why put rods in oven?
A) sterilize
B) Reduce moisture
C) Prevent Bending
D) heat for penetration
  • 32. Minimum oven temperature?
A) 250°F
B) 100°F
C) 175°F
D) 500°F
  • 33. E stands for:
A) Energy
B) Edge
C) Earth
D) Electrode
  • 34. Rod lengths:
A) 1–2 feet
B) 20–30 inches
C) 9–18 inches
D) 3–6 inches
  • 35. MR or R:
A) Medium rated
B) Moisture resistant
C) Metal rod
D) Machine ready
  • 36. Base metal we use:
A) Cast iron
B) A36 mild steel
C) Stainless steel
D) Aluminum
  • 37. Light produced in welding:
A) Green infrared
B) Electro violet and ultra red light
C) X‑ray emissions
D) Blue spectrum only
  • 38. Five joint types:
A) Lap, butt, edge, corner, T-joint
B) Curve, twist, bend, fold, lock
C) Root, face, toe, leg, web
D) Arc, gas, flux, rod, plate
  • 39. AWS:
A) American Welding Society
B) Arc Welding System
C) Advanced Weld Standards
D) American Wire Service
  • 40. Heat affected zone:
A) Slag-covered area
B) Metal melted completely
C) Joint line
D) Metal altered but not melted
  • 41. PJP:
A) Partial Joint Penetration
B) Parallel Joint Pass
C) Pressure Joint Process
D) Primary Joint Preparation
  • 42. CJP:
A) Cut Joint Position
B) Central Joint Plane
C) Controlled Joint Process
D) Complete Joint Penetration
  • 43. 1F:
A) Flat groove
B) Flat fillet
C) Overhead fillet
D) Vertical fillet
  • 44. 2F
A) Vertical groove
B) Horizontal groove
C) Flat Fillet
D) Horizontal fillet
  • 45. 3F
A) Horizontal groove
B) Flat fillet
C) Vertical fillet
D) Overhead fillet
  • 46. 4F:
A) Vertical fillet
B) Horizontal fillet
C) Flat groove
D) Overhead fillet
  • 47. 1G:
A) Flat fillet
B) Flat groove
C) Vertical groove
D) Overhead groove
  • 48. 2G:
A) Horizontal groove
B) Horizontal fillet
C) Vertical groove
D) Flat groove
  • 49. 3G:
A) Horizontal fillet
B) Vertical groove
C) Flat groove
D) Overhead groove
  • 50. 4G:
A) Flat groove
B) Vertical groove
C) Horizontal fillet
D) Overhead groove
  • 51. Weave:
A) Cleaning motion
B) Slag brushing
C) Weld bead made with transverse movement
D) Root buildup
  • 52. No large amount of ______ should be in the weld
A) Sulphur
B) Hydrogen
C) Oxygen
D) Mercury
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