100+ Free ITI/NCVT Welder (Fab & Fit) (AITT Theory) Practice Questions

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Sample ITI/NCVT Welder (Fab & Fit) (AITT Theory) Practice Questions

Try these sample questions to test your ITI/NCVT Welder (Fab & Fit) (AITT Theory) exam readiness. Each question includes a detailed explanation. Start the interactive quiz above for the full 100+ question experience with AI tutoring.

1Which class of fire extinguisher is specifically designed to extinguish metal fires (such as burning magnesium or sodium) in a welding workshop?

A.Class A fire extinguisher

B.Class B fire extinguisher

C.Class C fire extinguisher

D.Class D fire extinguisher

Explanation: Class D fire extinguishers are specifically designed for combustible metal fires, which are common in workshops working with magnesium, titanium, sodium, or potassium. They use dry powder agents like sodium chloride or graphite-based powders to smother the fire and absorb heat. Using water (Class A) or standard CO2 (Class B/C) on metal fires can cause violent explosions or chemical reactions.

2What is the standard color coding of an acetylene gas cylinder used in oxy-acetylene welding and cutting operations in India?

A.Black color

B.Maroon color

C.Blue color

D.Grey color

Explanation: Under standard Indian safety guidelines (IS 393), acetylene gas cylinders are color-coded maroon (or sometimes signal red) to differentiate them from oxygen cylinders, which are color-coded black. This clear identification prevents dangerous cross-connections. Acetylene connections also use left-hand threads, whereas oxygen connections use right-hand threads.

3Which types of harmful non-ionizing radiations are emitted by an electric welding arc, requiring the use of a welding helmet with a filter lens?

A.X-rays and Gamma rays

B.Microwaves and Radio waves

C.Ultraviolet (UV) and Infrared (IR) rays

D.Alpha and Beta particles

Explanation: An electric welding arc emits intense ultraviolet (UV) and infrared (IR) radiations along with visible light. UV rays can cause 'arc eye' (photokeratitis), which is a painful burn of the cornea, and skin burns similar to severe sunburn. IR rays can cause thermal damage to the retina and contribute to cataracts over long exposure. Filter lenses block these harmful rays.

4Why is it critical to ensure that oxygen cylinder valves, regulators, and hoses are kept completely free from oil, grease, or other hydrocarbons?

A.Oil and grease act as electrical conductors and increase shock risk.

B.Hydrocarbons can contaminate the weld metal and cause severe porosity.

C.Oil and grease can spontaneously ignite and cause a violent explosion in the presence of high-pressure oxygen.

D.Hydrocarbons react with oxygen to block the gas flow through the regulator.

Explanation: Pressurized pure oxygen reacts violently with hydrocarbons like oil, grease, or petroleum-based lubricants. This reaction can lead to spontaneous combustion, intense heat, and high-pressure explosions without any external spark or flame. Welding safety rules strictly state that no oil or grease should ever be applied to oxygen cylinders, valves, regulators, or torches.

5What is the primary function of wearing leather leggings and a leather apron during manual metal arc welding (MMAW) operations?

A.To insulate the welder from high-frequency currents

B.To protect the welder from electric shock when changing electrodes

C.To shield the welder's clothing and skin from hot sparks, spatters, and molten slag

D.To keep the welder's body temperature cool under intense arc heat

Explanation: Heavy leather aprons and leggings are designed to withstand high temperatures and resist penetration by hot welding sparks, flying spatters, and molten slag. Leather is naturally flame-resistant and does not melt, making it the ideal protective material for heavy welding and cutting processes where gravity can cause slag to drop onto the welder's lower body.

6Which health hazard is most commonly associated with welding galvanized steel without proper local exhaust ventilation or respiratory protection?

A.Silicosis

B.Metal fume fever

C.Asbestosis

D.Caisson disease

Explanation: Welding galvanized steel vaporizes the zinc coating, producing white zinc oxide fumes. Inhaling these fumes causes 'metal fume fever' (also known as brass chills or welder's ague), which presents with flu-like symptoms including fever, chills, nausea, headache, and muscle aches. It usually begins a few hours after exposure and resolves within 24 to 48 hours, but chronic exposure can be more damaging.

7In the standard classification of plate welding positions, what does the designation '3G' represent?

A.Flat position groove welding

B.Horizontal position groove welding

C.Vertical position groove welding

D.Overhead position groove welding

Explanation: In ISO and AWS standards, groove welds on plates are classified as 1G (flat), 2G (horizontal), 3G (vertical), and 4G (overhead). Therefore, 3G refers to vertical groove welding, which can be performed in either the vertical-upwards (3G-up) or vertical-downwards (3G-down) progression.

8What is the primary advantage of utilizing an inverter-type welding power source compared to a conventional transformer-rectifier welding machine?

A.Inverter machines have lower open circuit voltage, reducing arc start time.

B.Inverter machines are significantly lighter, more energy-efficient, and offer precise arc control.

C.Inverter machines require no cooling fans or heat sinks, making them noiseless.

D.Inverter machines can only output alternating current (AC), which eliminates arc blow.

Explanation: Inverter welding power sources use solid-state electronics to increase the incoming utility power frequency (typically 50 Hz) up to 20,000 Hz or more. This high-frequency switching allows the internal transformer to be extremely small and lightweight. Consequently, inverter units are highly portable, consume less electrical power, and use microprocessors to provide dynamic arc control and stabilization.

9In DC arc welding, what heat distribution ratio occurs between the electrode (anode) and the workpiece (cathode) when using Direct Current Electrode Positive (DCEP) polarity?

A.50% heat on electrode and 50% heat on workpiece

B.33% heat on electrode and 67% heat on workpiece

C.67% heat on electrode and 33% heat on workpiece

D.10% heat on electrode and 90% heat on workpiece

Explanation: Under DCEP (Direct Current Electrode Positive or reverse polarity), electrons flow from the workpiece to the electrode. When these electrons hit the electrode tip, they release kinetic energy as thermal energy. As a result, approximately 2/3 (67%) of the arc heat is concentrated on the electrode, and 1/3 (33%) is on the workpiece. This high electrode heat rate increases deposition speed and is ideal for overhead welding, but requires thick electrodes to prevent overheating.

10Why is the open-circuit voltage (OCV) of a welding machine considered a significant safety hazard for the welder?

A.OCV is the extremely high voltage during welding that causes arc blow.

B.OCV is the voltage present when the machine is on but welding is not occurring, which can cause severe electric shock if the welder touches live parts.

C.OCV represents static charge buildup on the machine frame that can explode gas cylinders.

D.OCV is the high-voltage spike when the machine overheats, causing the thermal overload switch to fail.

Explanation: Open-circuit voltage (OCV) is the voltage measured across the welding terminals when the machine is switched on but no welding arc is active (typically 50V to 100V DC or AC). Since no current is flowing, the voltage is at its maximum. If a welder contacts the electrode holder's live parts and ground simultaneously—especially in wet or sweaty conditions—this voltage is high enough to drive a lethal electrical current through the human body.

About the ITI/NCVT Welder (Fab & Fit) (AITT Theory) Exam

The CTS Welder (Fabrication & Fitting) trade trains candidates in oxygen/acetylene cutting/welding, manual metal arc welding (SMAW), gas metal arc welding (MIG), gas tungsten arc welding (TIG), joint preparation, structural metal marking, layout development of pipe intersections, fitting assemblies, and weld quality control. Coursework includes AWS electrode codification, flame adjustment, polarities, distortion control, and weld inspection methods (NDT). Successful trainees earn the National Trade Certificate (NTC) after AITT.

Assessment

One-year CTS trade (1200 hours + 150 hours OJT/group project), NSQF Level 3, trade code DGT/1028. Summative AITT includes Trade Practical plus Computer-Based Test. Engineering-trade CBT: 75 questions / 150 marks / 2 hours covering Trade Theory (with Workshop Science & Calculation and Engineering Drawing items) and Employability Skills.

Time Limit

2 hours for CBT (AITT July 2026 DGT guidelines). Practical duration follows the DGT/State Directorate schedule.

Passing Score

33% minimum in Trade Theory and in Employability Skills; 60% minimum in Trade Practical and Formative Assessment (DGT CTS pass regulation / AITT July 2026 guidelines). No grace marks.

Exam Fee

CBT fee ₹213 per trainee for AITT July 2026 mains (plus applicable payment-gateway charges). Practical fees are separate — confirm with your ITI. (Directorate General of Training (DGT), Ministry of Skill Development and Entrepreneurship)

ITI/NCVT Welder (Fab & Fit) (AITT Theory) Exam Content Outline

10%

Welding Safety & Equipment Setup

PPE, cylinder safety (oxygen, acetylene), flash-back arrestors, electric shock hazards, arc radiation protection, and welding machine settings.

15%

Gas Welding & Cutting (OAW)

Oxy-acetylene flame types (neutral, carburizing, oxidizing), gas cutting torches, nozzles, and gas welding techniques.

20%

Shielded Metal Arc Welding (SMAW)

Arc length, electrode classification (AWS codification), polarities (DCEP/DCEN), welding positions (1G, 2G, 3G, 4G, 1F, 2F, 3F, 4F), and joint edge preparation.

15%

MIG/MAG & TIG Welding (GMAW/GTAW)

Shielding gases (argon, CO2), tungsten electrode selection, filler wires, wire feed speed, gas flow rates, and operating parameters.

25%

Structural Fabrication & Fitting

Marking, measuring, structural steels (beams, channels, angles), pipe development (T-joints, Y-joints), bolting, riveting, and assembly templates.

15%

Inspection, Defects & Testing

Visual inspection, weld defects (porosity, undercut, slag inclusion, lack of fusion, penetration), non-destructive testing (NDT: dye penetrant, magnetic particle, radiographic) and destructive tests.

How to Pass the ITI/NCVT Welder (Fab & Fit) (AITT Theory) Exam

What You Need to Know

Passing score: 33% minimum in Trade Theory and in Employability Skills; 60% minimum in Trade Practical and Formative Assessment (DGT CTS pass regulation / AITT July 2026 guidelines). No grace marks.
Assessment: One-year CTS trade (1200 hours + 150 hours OJT/group project), NSQF Level 3, trade code DGT/1028. Summative AITT includes Trade Practical plus Computer-Based Test. Engineering-trade CBT: 75 questions / 150 marks / 2 hours covering Trade Theory (with Workshop Science & Calculation and Engineering Drawing items) and Employability Skills.
Time limit: 2 hours for CBT (AITT July 2026 DGT guidelines). Practical duration follows the DGT/State Directorate schedule.
Exam fee: CBT fee ₹213 per trainee for AITT July 2026 mains (plus applicable payment-gateway charges). Practical fees are separate — confirm with your ITI.

Keys to Passing

Complete 500+ practice questions
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Focus on highest-weighted sections
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ITI/NCVT Welder (Fab & Fit) (AITT Theory) Study Tips from Top Performers

1Review the AWS electrode codification system (e.g. E6013: E = electrode, 60 = 60,000 psi min tensile strength, 1 = all positions, 3 = AC/DC welding current with rutile coating).

2Understand weld defects, specifically the causes of undercut (excessive current, fast travel speed) and porosity (inadequate gas shield, damp electrodes).

3Study structural steel profiles (ISA, ISMB, ISMC) and basic pipe development template calculations.

Frequently Asked Questions

What is the difference between DCEP and DCEN polarities in welding?

In DCEP (Direct Current Electrode Positive / Reverse Polarity), the electrode is connected to the positive terminal, concentrating 70% of the heat at the electrode. In DCEN (Direct Current Electrode Negative / Straight Polarity), the electrode is negative, concentrating 70% of the heat at the base plate (ideal for deep penetration).

What is the purpose of a flashback arrestor?

A flashback arrestor is a safety device installed on gas regulators and blowpipes to prevent the flame or reverse gas flow from reaching the cylinder, preventing explosions.

What shielding gas is used for MIG welding of steel?

MIG welding of carbon steel typically uses Carbon Dioxide (CO2) or an Argon-CO2 mixture (e.g. 75% Argon / 25% CO2) as a shielding gas.

100+ Free ITI/NCVT Welder (Fab & Fit) (AITT Theory) Practice Questions

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