Certification Examination Practice

Illinois Metallurgical Welding Inspector Certification Examination Practice Questions And Correct Answers (Verified Answers) Plus Rationales 2026 Q&A | Instant Download Pdf

• What is the primary purpose of a welding procedure specification

(WPS)?

• To train welders in safety practices
• To provide detailed instructions on how to perform a weld
• To schedule welding operations
• To inspect welds after completion

Rationale: The WPS provides the specific parameters and instructions

required to produce a weld that meets quality standards.

• Which of the following is the most common non-destructive testing

method for detecting surface cracks? 1 / 4

• Radiographic Testing
• Ultrasonic Testing
• Liquid Penetrant Testing
• Magnetic Particle Testing

Rationale: Liquid penetrant testing is widely used to detect surface-

breaking defects in non-porous materials.

• What is the primary function of a filler metal in welding?
• To reduce heat input
• To protect the weld from oxidation
• To add material to the joint to ensure proper fusion
• To measure welding parameters

Rationale: Filler metal is used to fill the weld joint and ensure

adequate mechanical properties.

• What is the main effect of hydrogen in weld metal?
• Increased toughness
• Increased ductility
• Cracking susceptibility (hydrogen-induced cracking)
• Faster cooling rate

Rationale: Hydrogen can lead to weld metal cracking, especially in

high-strength steels.

• Which welding position is described as flat, with the weld performed

on the upper side of the joint?

• Horizontal 2 / 4

• Vertical
• Overhead
• Flat

Rationale: The flat position is the easiest and most common position

where the workpiece is horizontal and the weld is on the top.

• What is the significance of preheating before welding?
• Speeds up welding
• Reduces the risk of cracking by slowing cooling rates
• Increases weld porosity
• Improves surface finish

Rationale: Preheating reduces thermal stress and prevents hydrogen-

induced cracking.

• What is the standard method for measuring weld reinforcement?
• Visual estimation
• Using a fillet weld gauge
• Ultrasonic measurement
• Radiographic measurement

Rationale: A fillet weld gauge is the standard tool for checking weld

size and reinforcement.

• Which type of defect is characterized by a separation between weld

metal and base metal?

• Porosity
• Undercut 3 / 4

• Lack of fusion
• Slag inclusion

Rationale: Lack of fusion occurs when the weld metal fails to properly

fuse with the base metal or previous weld pass.

• What is the maximum acceptable weld reinforcement height for fillet

welds according to most codes?

• 1/8 inch
• 1/16 inch to 1/8 inch above the surface
• 1/4 inch
• 1/2 inch

Rationale: Excessive reinforcement can lead to stress concentration

and is generally limited by code specifications.

• Which welding process uses a non-consumable tungsten

electrode?

A. SMAW

B. GMAW

C. FCAW

D. GTAW (TIG)

Rationale: GTAW uses a non-consumable tungsten electrode to

produce high-quality welds.

• What does the term "weld penetration" refer to?
• Width of the weld bead
• Surface finish
• / 4