CRWT Test Prep Exam Questions & Answers 2026 (11–20)

Question 1

What is the most common non-destructive testing method used to evaluate resistance spot welds in production environments?

TheoryPractice · Accepted Answer

Ultrasonic testing. Ultrasonic testing is the most common non-destructive method for evaluating spot welds in production environments because it can quickly determine weld size and detect internal discontinuities.

Question 2

What type of weld failure occurs when the weld nugget completely pulls out from one sheet, leaving a hole?

TheoryPractice · Accepted Answer

Button pullout failure. Button pullout failure occurs when the weld nugget completely pulls out of one sheet during destructive testing, which is generally considered a good indication of proper fusion and weld strength.

Question 3

What is the minimum acceptable nugget diameter for a spot weld according to most industry standards?

TheoryPractice · Accepted Answer

4√t (where t is the thickness of the thinnest sheet). Most industry standards specify that the minimum acceptable nugget diameter should be 4√t (4 times the square root of the thickness of the thinnest sheet being joined).

Question 4

Which of the following defects is caused by excessive welding current in resistance spot welding?

TheoryPractice · Accepted Answer

Expulsion. Expulsion (metal splash) occurs when excessive welding current causes the molten metal to be expelled from the weld zone, resulting in material loss and potentially weaker welds.

Question 5

Which non-destructive test method is based on measuring the electrical conductivity changes in welds?

TheoryPractice · Accepted Answer

Eddy current testing. Eddy current testing works by inducing electrical currents in conductive materials and measuring the changes in electromagnetic field, which can indicate variations in weld quality.

Question 6

What is the purpose of the chisel test for resistance spot welds?

TheoryPractice · Accepted Answer

To determine weld strength and examine failure mode. The chisel test is used to separate spot-welded joints by driving a chisel between the sheets to determine the weld strength and examine the failure mode and nugget size.

Question 7

In resistance welding, what defect is characterized by a lack of fusion between the sheets with only a weak bond at the faying surface?

TheoryPractice · Accepted Answer

Stick weld. A stick weld occurs when insufficient heat or pressure results in a weak bond without proper fusion between the sheets, often causing interfacial failure during testing.

Question 8

What is the primary purpose of cross-sectioning a spot weld for metallographic examination?

TheoryPractice · Accepted Answer

To measure nugget size and examine internal defects. Cross-sectioning allows for direct measurement of nugget size and shape, and examination of internal defects like cracks, porosity, and fusion quality that cannot be seen from the surface.

Question 9

Which of the following is a sign of electrode wear in resistance welding quality inspection?

TheoryPractice · Accepted Answer

Inconsistent weld nugget size. Inconsistent weld nugget size is a primary indicator of electrode wear, as worn electrodes cannot maintain consistent current density and pressure during welding.

Question 10

What does the term 'nugget diameter' refer to in resistance spot weld quality assessment?

TheoryPractice · Accepted Answer

The diameter of the fused zone between the sheets. Nugget diameter refers to the size of the fused zone between the welded sheets, which is a critical measurement for determining weld quality and strength.

CRWT Test Prep Exam Questions & Answers 2026 (11–20)

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