Welding Inspector CWI Exam Questions & Answers 2026 (21–30)

Question 1

Interpass temperature in AWS D1.1 refers to:

TheoryPractice · Accepted Answer

The maximum temperature the weld joint may reach between passes. Interpass temperature is the maximum temperature the weld joint (including the deposited weld metal and HAZ) is allowed to reach between successive weld passes. Exceeding it can degrade toughness and mechanical properties.

Question 2

A complete joint penetration (CJP) groove weld is defined as a groove weld in which:

TheoryPractice · Accepted Answer

The weld metal extends through the full thickness of the joint. A CJP groove weld has weld metal deposited through the complete thickness of the base material, ensuring full fusion from root to face with no unfused root area.

Question 3

For a PJP (partial joint penetration) groove weld made from one side using SMAW in a 60° groove angle, AWS D1.1 defines the effective throat as:

TheoryPractice · Accepted Answer

S minus 1/8 in (3.2 mm). For a PJP groove weld made from one side by SMAW with a groove angle ≥60°, the effective throat = S − 1/8 in (3.2 mm), accounting for the fact that full depth cannot be reliably achieved.

Question 4

Under AWS D1.1, the maximum root face tolerance for a prequalified single-bevel-groove weld (without backing) is:

TheoryPractice · Accepted Answer

+1/16 in, −0 in (+1.6 mm, −0 mm). AWS D1.1 prequalified joint details specify a root face of 0 to 1/16 in (0 to 1.6 mm) for CJP welds without backing. Exceeding the upper tolerance can prevent full root fusion.

Question 5

Under AWS D1.1, the maximum allowable undercut for statically loaded structures (primary tension members) is:

TheoryPractice · Accepted Answer

1/32 in (0.8 mm) for tension members, 1/16 in for compression. AWS D1.1 limits undercut to 1/32 in (0.8 mm) on primary tension members in statically loaded structures, and 1/16 in (1.6 mm) for compression members, because undercut acts as a stress concentrator under tensile loading.

Question 6

AWS D1.1 visual inspection acceptance criteria for groove weld reinforcement (face): the maximum convexity for welds in steel plates ≥1 in (25 mm) wide is:

TheoryPractice · Accepted Answer

3/16 in (4.8 mm). AWS D1.1 limits groove weld face reinforcement to 3/16 in (4.8 mm) maximum for base metal width ≥1 in. Excessive convexity creates stress risers and is a visual rejection criterion.

Question 7

For cyclically loaded (fatigue) structures under AWS D1.1, porosity is limited to a maximum single-pore diameter of:

TheoryPractice · Accepted Answer

3/32 in (2.4 mm). For cyclically loaded structures, AWS D1.1 applies stricter porosity limits — individual pores may not exceed 3/32 in (2.4 mm) diameter, versus the more lenient limits for statically loaded structures.

Question 8

Under AWS D1.1 RT acceptance criteria for statically loaded structures, the maximum allowable length of an individual slag inclusion in a 3/8 in (9.5 mm) thick weld is:

TheoryPractice · Accepted Answer

1/4 in (6.4 mm). AWS D1.1 limits individual slag inclusion length to 2/3 of the weld thickness for welds 3/8–3/4 in thick. For a 3/8 in weld: 2/3 × 3/8 in ≈ 1/4 in (6.4 mm) maximum. Inclusions exceeding this length are rejectable.

Question 9

Which NDT method is most effective at detecting surface-breaking cracks in ferromagnetic welds?

TheoryPractice · Accepted Answer

Magnetic particle testing (MT). Magnetic particle testing (MT) is highly sensitive to surface and near-surface cracks in ferromagnetic materials. It uses magnetic fields and iron particles to reveal discontinuities that interrupt the field.

Question 10

Under AWS D1.1 for RT of groove welds, the minimum image quality indicator (IQI) sensitivity required is:

TheoryPractice · Accepted Answer

2-2T (2% wire or hole IQI, essential wire/hole visible). AWS D1.1 requires 2-2T IQI sensitivity for radiographic testing, meaning a 2% wire or hole-type IQI is used and the essential indicator (2T hole or equivalent wire) must be visible on the film.

Welding Inspector CWI Exam Questions & Answers 2026 (21–30)

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