Welding Inspector CWI Exam Questions & Answers 2026 (1–10)

Question 1

AWS D1.1 is the primary structural welding code that governs welding of what base material?

TheoryPractice · Accepted Answer

Steel. AWS D1.1 is titled 'Structural Welding Code – Steel' and covers the welding of steel structures. Other AWS codes address aluminum (D1.2) and stainless steel (D1.6).

Question 2

AWS D1.1 applies to structures with a base metal minimum thickness of:

TheoryPractice · Accepted Answer

3/16 in (4.8 mm). AWS D1.1 generally applies to structural steel 3/16 in (4.8 mm) and thicker. Thinner material falls under sheet-metal or other codes such as AWS D1.3.

Question 3

A prequalified WPS under AWS D1.1 does NOT require:

TheoryPractice · Accepted Answer

Qualification testing (procedure qualification). Prequalified WPSs comply with all AWS D1.1 prequalification requirements and therefore do not require procedure qualification testing. They still must be documented in writing with all essential variables.

Question 4

Which of the following welding processes is listed as prequalified in AWS D1.1?

TheoryPractice · Accepted Answer

Submerged arc welding (SAW). SAW is listed as a prequalified process in AWS D1.1. GTAW and PAW are not prequalified under D1.1. ESW requires qualification testing.

Question 5

For prequalified fillet welds using SMAW under AWS D1.1, the maximum size of a single-pass fillet weld in the flat or overhead position is:

TheoryPractice · Accepted Answer

1/4 in (6.4 mm). AWS D1.1 limits single-pass SMAW fillet welds in the flat (1F) and overhead (4F) positions to 1/4 in (6.4 mm) maximum. The 5/16 in limit applies to the horizontal position. Exceeding these sizes requires multiple passes.

Question 6

Under AWS D1.1, which condition would disqualify a joint from being prequalified?

TheoryPractice · Accepted Answer

Using a joint configuration not listed in the D1.1 prequalified joint details. Only joint configurations explicitly listed in AWS D1.1's prequalified details may be used without qualification testing. Any deviation — such as a non-listed geometry or dimension — requires procedure qualification by testing.

Question 7

When a WPS cannot meet prequalification requirements under AWS D1.1, the welder must qualify the procedure using:

TheoryPractice · Accepted Answer

A procedure qualification record (PQR) based on test weld results. A PQR documents the actual test weld results and supports a qualified WPS when prequalification requirements cannot be met. It is not just paperwork — it requires physical testing of weld specimens.

Question 8

For AWS D1.1 procedure qualification of a CJP groove weld, the minimum test plate thickness that qualifies unlimited production thickness is:

TheoryPractice · Accepted Answer

1 in (25 mm). Under AWS D1.1, a CJP groove weld PQR test plate of 1 in (25 mm) or greater qualifies the procedure for unlimited production thickness above 1 in.

Question 9

Which essential variable change in AWS D1.1 ALWAYS requires requalification of a WPS?

TheoryPractice · Accepted Answer

A change in the welding process. Changing the welding process is always an essential variable requiring requalification. Changes within the same process classification (e.g., electrode diameter or number of passes) may be non-essential or supplementary essential depending on the code requirements.

Question 10

In AWS D1.1 Table 4.5 (procedure qualification test), which mechanical test is NOT required for a CJP groove weld test plate?

TheoryPractice · Accepted Answer

Charpy V-notch impact test. Charpy V-notch impact testing is required only when specified by the Engineer for fracture-critical or low-temperature applications; it is not a standard mandatory test in the base D1.1 procedure qualification test matrix.

Welding Inspector CWI Exam Questions & Answers 2026 (1–10)

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