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