CWB WELDING INSPECTOR EXAMINATION TEST
QUESTIONS AND ANSWERS 2025/2026
✔✔What type of power output is FCAW? - ✔✔DCEP Constant Voltage
✔✔What are some advantages to FCAW? - ✔✔- high quality weld
- high disposition rates
- more tolerant to parameter changes and contaminants
- Good penetration
- Out of position welding
✔✔What are some disadvantages to FCAW? - ✔✔- lots of fumes
- Slag Removal
✔✔What is the ideal welder technique for FCAW? - ✔✔20° to 30° drag (pull)
✔✔What is a good power output for SAW? - ✔✔DCEP - provides good bead control
and deeper penetration (most common)
DPEN - Less Penetration with more flaws
✔✔What are some advantages to SAW? - ✔✔- high productivity, high disposition, high
duty cycle
- Low hydrogen process
Dis - flat and horizontal positions only
✔✔What are the two types of flux? - ✔✔Fused and Bonded
✔✔How is Fused Flux Made? - ✔✔by melting together various ingredients, place on a
chill table, crushed and screened
- resistant to moisture
- easy to recycle
- difficult to add deoxidizers
✔✔How is Bonded Flux Made? - ✔✔Finely grind individual components, mix, add
binder (potassium), bake, ground to size
- easy to add deoxidizers
- prone to pick up moisture
✔✔What are three types of flux? - ✔✔Basic - Calcium & Manganese oxide
Acidic - Silicon oxide
Neutral - he ratio of Basic and Acidic are equal
✔✔Where do the mechanical properties come from with SAW? - ✔✔The flux
, ✔✔What is resistance welding (RW)? - ✔✔Electrodes are placed in contact with the
material, and electrical resistance heating is used to raise the temperature of the
workpieces and the interface between them. The same copper electrodes that supply
the current also apply the pressure
- Fluxes and filler metals are not generally used
- good for carbon steels and Stainless steels
✔✔What is Electro Slag Welding (EBW)? - ✔✔- heat is generated by the electrical
resistance of the molten slag. Melts the base metal and the consumable
- electrode is fed through a guide tube to the bottom of a vertical joint, side walls are
parallel tot he electrode. Arc is initiated under a bed of flux. Flux becomes molten to
make a slag bath. Arc extinguishes once molten slag is formed
- has a consumable tube
- material from 75mm to 300mm thick
✔✔What is Diffusion welding (DW)? - ✔✔- produces an atomic bond between two
surfaces with pressure and heat
- joining happens below melting point
contacting surfaces is produced at loads insufficient to cause micro deformation
- brittle surface oxides are removed for atom migration
- occurs through 3 stages metallurgical sequence: deformation, diffusion at grains,
volume diffusion at atoms
✔✔What is Explosion Welding (EXW)? - ✔✔produced through high speed impacting of
two or more material
- no extreme heat transfer
- can be higher hardness
✔✔Welding is a joining process that by definition requires the application of:
A) both heat and pressure
B) either heat or pressure
C) both heat and filler metal
D) both pressure and filler metal
E) all of the above - ✔✔C) Both heat and filler metal
✔✔Name two main methods of arc shielding. - ✔✔gases, flux
✔✔In which direction do the electrons flow in an electrical arc - from anode to cathode
or from cathode to anode? - ✔✔Cathode to Anode
✔✔In arc welding, the electric arc is intensely hot with temperatures exceeding:
A) 20000°C
B) 30000°C
C) 33000°C
D) 40000°C - ✔✔B) 30000°C
QUESTIONS AND ANSWERS 2025/2026
✔✔What type of power output is FCAW? - ✔✔DCEP Constant Voltage
✔✔What are some advantages to FCAW? - ✔✔- high quality weld
- high disposition rates
- more tolerant to parameter changes and contaminants
- Good penetration
- Out of position welding
✔✔What are some disadvantages to FCAW? - ✔✔- lots of fumes
- Slag Removal
✔✔What is the ideal welder technique for FCAW? - ✔✔20° to 30° drag (pull)
✔✔What is a good power output for SAW? - ✔✔DCEP - provides good bead control
and deeper penetration (most common)
DPEN - Less Penetration with more flaws
✔✔What are some advantages to SAW? - ✔✔- high productivity, high disposition, high
duty cycle
- Low hydrogen process
Dis - flat and horizontal positions only
✔✔What are the two types of flux? - ✔✔Fused and Bonded
✔✔How is Fused Flux Made? - ✔✔by melting together various ingredients, place on a
chill table, crushed and screened
- resistant to moisture
- easy to recycle
- difficult to add deoxidizers
✔✔How is Bonded Flux Made? - ✔✔Finely grind individual components, mix, add
binder (potassium), bake, ground to size
- easy to add deoxidizers
- prone to pick up moisture
✔✔What are three types of flux? - ✔✔Basic - Calcium & Manganese oxide
Acidic - Silicon oxide
Neutral - he ratio of Basic and Acidic are equal
✔✔Where do the mechanical properties come from with SAW? - ✔✔The flux
, ✔✔What is resistance welding (RW)? - ✔✔Electrodes are placed in contact with the
material, and electrical resistance heating is used to raise the temperature of the
workpieces and the interface between them. The same copper electrodes that supply
the current also apply the pressure
- Fluxes and filler metals are not generally used
- good for carbon steels and Stainless steels
✔✔What is Electro Slag Welding (EBW)? - ✔✔- heat is generated by the electrical
resistance of the molten slag. Melts the base metal and the consumable
- electrode is fed through a guide tube to the bottom of a vertical joint, side walls are
parallel tot he electrode. Arc is initiated under a bed of flux. Flux becomes molten to
make a slag bath. Arc extinguishes once molten slag is formed
- has a consumable tube
- material from 75mm to 300mm thick
✔✔What is Diffusion welding (DW)? - ✔✔- produces an atomic bond between two
surfaces with pressure and heat
- joining happens below melting point
contacting surfaces is produced at loads insufficient to cause micro deformation
- brittle surface oxides are removed for atom migration
- occurs through 3 stages metallurgical sequence: deformation, diffusion at grains,
volume diffusion at atoms
✔✔What is Explosion Welding (EXW)? - ✔✔produced through high speed impacting of
two or more material
- no extreme heat transfer
- can be higher hardness
✔✔Welding is a joining process that by definition requires the application of:
A) both heat and pressure
B) either heat or pressure
C) both heat and filler metal
D) both pressure and filler metal
E) all of the above - ✔✔C) Both heat and filler metal
✔✔Name two main methods of arc shielding. - ✔✔gases, flux
✔✔In which direction do the electrons flow in an electrical arc - from anode to cathode
or from cathode to anode? - ✔✔Cathode to Anode
✔✔In arc welding, the electric arc is intensely hot with temperatures exceeding:
A) 20000°C
B) 30000°C
C) 33000°C
D) 40000°C - ✔✔B) 30000°C
