Technician CRWT Examination

AWS Certified Resistance Welding Technician (CRWT) Examination Practice Questions And Correct Answers (Verified Answers) Plus Rationales 2026 Q&A | Instant Download Pdf

• Which of the following is the primary purpose of resistance welding?

a) To melt the base metal using a torch

b) To join metals using heat generated by electrical resistance

c) To mechanically fasten two metals

d) To solder metals using a filler

Rationale: Resistance welding uses the heat generated by electrical

resistance between the metals to create a weld without melting the base metal completely.

• What type of current is most commonly used in resistance welding?

a) Alternating current only 1 / 4

b) Direct current or alternating current, depending on equipment

c) High-frequency current only

d) Pulsed current only

Rationale: Both AC and DC can be used in resistance welding; DC is often

preferred for steady welds, while AC is common in spot welding machines.

• In spot welding, what is the main factor controlling nugget size?

a) Electrode color

b) Weld current and weld time

c) Cooling water flow

d) Metal thickness only

Rationale: The nugget size is directly influenced by the weld current and

duration of current flow, which control heat input.

• What is the primary function of electrodes in resistance welding?

a) To cool the metal

b) To hold the workpiece in place

c) To conduct electrical current and apply pressure

d) To coat the weld area

Rationale: Electrodes serve a dual role: conducting current through the metal and applying force to hold the pieces together during welding.

5. Excessive electrode force in resistance welding can cause:

a) Proper weld penetration

b) Expulsion of molten metal and reduced nugget size 2 / 4

c) Improved nugget formation

d) Lower electrode wear

Rationale: Too much force can squeeze molten metal out of the weld zone,

reducing nugget size and quality.

• Which material property has the greatest effect on resistance

welding?

a) Color

b) Thermal conductivity

c) Electrical resistivity

d) Density

Rationale: Electrical resistivity determines how much heat is generated in

the weld zone during resistance welding.

• Which of the following is the most common resistance welding

process?

a) Seam welding

b) Projection welding

c) Spot welding

d) Flash welding

Rationale: Spot welding is the most widely used resistance welding

process, especially in automotive and sheet metal applications.

• What does “weld schedule” refer to in resistance welding?

a) The order of electrode replacement 3 / 4

b) The inspection timeline

c) The combination of weld parameters such as current, time, and

force

d) The metal preparation method

Rationale: Weld schedule defines the electrical, mechanical, and timing

parameters needed to produce a proper weld.

• Which of the following electrode tip shapes is commonly used for spot

welding sheet metal?

a) Conical

b) Flat rectangular

c) Truncated cone

d) Spherical

Rationale: Truncated cone tips provide a concentrated current path and

apply uniform pressure for sheet metal spot welding.

• What is the primary cause of expulsion during a resistance weld?

a) Low current

b) High electrode force

c) Excessive weld current or time

d) Poor electrode alignment

Rationale: Expulsion occurs when the heat generated exceeds the metal’s

capacity to contain it, forcing molten metal out of the weld zone.

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