10.3 Comprehensive Review — 25 Practice Questions
Key Takeaways
Treat this 25-question set as a timed, mixed-domain final checkpoint across all three exam parts, not as reading
All three parts pass independently at 72% — Part A (150 closed-book), Part B (46 practical), Part C (50 code) — you must pass each
Keep a three-column miss log (topic, missed rule, the clue you overlooked) and reread the chapter behind any cluster of misses
Re-derive every formula and recite the discontinuity-to-cause and NDE surface-vs-volumetric maps from a blank page
Exam-day logistics: meet the Jaeger J2 near-vision requirement, arrive early, and pace each part with flag-and-return
Get real rest the night before — fatigue, not knowledge gaps, causes most careless misses on a long exam day
How to Use This Final Checkpoint
These 25 questions sample every major CWI domain — the five processes, metallurgy and heat control, discontinuities, NDE methods, weld symbols, code acceptance criteria, safety, and on-the-job math — across all three exam parts. Treat the set as an active-recall checkpoint, not a reading assignment. Answer the full 25 first, then review explanations. For each miss, write the reason the correct option wins and why the most tempting distractor fails; real exam items retest the same concept with new wording, so understanding the underlying rule transfers, memorized answers do not.
If you miss several questions from one domain, stop and reread that chapter before moving on.
A strong final loop is: timed attempt → explanation review → targeted reread → second attempt after a break. Keep a three-column miss log — topic, missed rule, and the clue you should have noticed (a unit, an absolute word, a loading condition). For calculation or scenario items, say the first step aloud before choosing an option; that one habit stops you rushing into a familiar-but-wrong answer.
Three-Part Pass Structure (Plan Each Independently)
The CWI credential requires passing all three parts, each at 72% — a strong Part A cannot rescue a weak Part C. Plan time and tactics per part:
| Part | Mode | Questions (scored) | Pace | Core tactic |
|---|---|---|---|---|
| A — Fundamentals | Closed book | 150 (+15 pretest) | ~48 s | Memorized recall; flag-and-return |
| B — Practical | Open book (kit + Book of Specs) | 46 | ~2.6 min | Measure precisely; judge to the spec |
| C — Code Application | Open book (D1.1/API 1104/ASME IX) | 50 | ~2.4 min | Tab, navigate, read the code text |
Eligibility and renewal reminders that show up as logistics questions: candidates qualify through combinations of education and welding experience and must meet a near-vision (Jaeger J2) requirement; the credential is maintained on a recertification cycle with periodic eye exams. Bring approved corrective lenses if you use them.
Last-Pass Cram Tables (Re-Derive From Memory)
Before you start the 25 questions, prove you can reproduce these from a blank page — they cover the most-missed Part A clusters.
Electrode classifications (decode the digits):
| Example | Meaning |
|---|---|
| E7018 | 70 ksi min tensile; last digit 8 = low-hydrogen iron-powder coating |
| E6010 | 60 ksi; cellulosic, deep penetration, high hydrogen |
| ER70S-6 | Solid GMAW/GTAW wire, 70 ksi, deoxidizers (Si/Mn) |
| E71T-1 | FCAW tubular, 70 ksi, all-position (1), gas-shielded |
Theoretical fillet throat: throat = 0.707 × leg. A 5/16 in (0.3125 in) equal-leg fillet → 0.707 × 0.3125 = 0.221 in.
Five basic joint types: butt, T-joint (tee), corner, lap, edge — every connection is one of these.
D1.1 prequalified processes: SMAW, GMAW (except short-circuit on CJP), FCAW, SAW. GTAW is NOT prequalified and always needs a PQR.
Whole-Exam-Day Readiness Checklist
- I can recite the five processes' power source, polarity, shielding, and position limits, and decode E7018/ER70S-6/E71T-1
- I can map each discontinuity to its cause and the NDE method that detects it (surface vs volumetric)
- I can write heat input and carbon equivalent and compute fillet throat (0.707 × leg) from memory
- I can state the three HIC conditions and one way to break each, and why preheat reduces cracking
- My code book is tabbed for the allowed edition and I can find any major table in under 30 seconds
- I have practiced Part B gauge readings (fillet, Bridge-Cam, V-WAC, hi-lo) and judge to the Book of Specifications
- I have a pacing plan per part and will flag-and-return rather than stall
- I meet the Jaeger J2 near-vision requirement (with corrective lenses if needed) and have my admission documents ready
- I completed several full-length timed practice sets and reread my weakest domains
- I am rested — fatigue, not knowledge, causes most careless misses on a six-hour day
Work the 25 questions now under timed conditions, then close every gap they expose.
Domain Self-Diagnosis — Read Your Misses
The value of this set is not the score; it is what your misses reveal. Sort every wrong answer into one of these recurring CWI domains and act on the pattern:
| If you miss... | The likely gap | Fix |
|---|---|---|
| Process questions (1, 2, 10, 12, 15, 24) | Power source, polarity, shielding, position, prequalification | Re-recite the five-process table from 10.1 |
| Metallurgy/heat (4, 5, 14, 20) | HAZ, HIC triangle, carbon equivalent, preheat purpose | Re-derive CE; list the three HIC conditions |
| Discontinuity/acceptance (11, 13, 21) | Causes vs limits; crack prohibition; D1.1 Table 8.1 | Re-map discontinuity → cause → NDE |
| NDE (6, 7, 19) | Surface vs volumetric, ferromagnetic limit, lighting | Re-recite the NDE capability table |
| Symbols/joints/math (8, 9, 22, 25) | Arrow side, throat 0.707×leg, five joints, heat input | Re-draw symbols; redo both formulas blind |
| Qualification/safety (16, 17, 18, 23) | Tensile basis, OFC limits, 6-month rule, top hazard | Reread duties and safety sections |
The two-pass rule for this set: take it once cold and timed, then — after rereading the chapters behind your weakest column — retake only your missed items the next day, shuffled in with a few new ones so you are testing the concept, not the answer order. When you can clear the same domain twice without notes, that domain is exam-ready. Repeat until every column is solid; that is what walking in prepared looks like.
- Which welding process uses a non-consumable electrode?
SMAW
GMAW
GTAW
FCAW
- What type of power source does GMAW use?
Constant current (CC)
Constant voltage (CV)
Pulsed AC
Variable frequency
- Which electrode is classified as low-hydrogen?
E6010
E6011
E6013
E7018
- The heat-affected zone (HAZ) is defined as:
The area of base metal that has melted and resolidified
The base metal adjacent to the weld that changed microstructure without melting
The filler metal deposited during welding
The entire base metal plate on which welding was performed
- The three conditions required for hydrogen-induced cracking (HIC) are:
High heat input, low-hydrogen electrodes, and slow cooling
Susceptible microstructure, sufficient diffusible hydrogen, and tensile stress
Porosity, undercut, and incomplete fusion
High carbon content, excessive preheat, and PWHT
- What is the minimum illumination required for visual testing per AWS B1.11?
25 foot-candles
50 foot-candles
75 foot-candles
100 foot-candles
- Which NDE method works ONLY on ferromagnetic materials?
Liquid Penetrant Testing (PT)
Radiographic Testing (RT)
Magnetic Particle Testing (MT)
Ultrasonic Testing (UT)
- A weld symbol placed BELOW the reference line indicates the weld is on the:
Other side of the joint
Arrow side of the joint
Both sides of the joint
Top of the joint
- What is the theoretical throat of a 5/16" equal-leg fillet weld?
0.156"
0.221"
0.313"
0.442"
- SAW (Submerged Arc Welding) is limited to which positions?
All positions
Flat and horizontal only
Vertical up only
Overhead only
- Per AWS D1.1 Table 8.1, undercut deeper than which value is generally restricted on welds?
1/64"
1/32"
1/16"
1/8"
- Which welding process has the highest deposition rate?
SMAW
GTAW
GMAW
SAW
- Cracks in a weld are typically:
Acceptable if less than 1" long
Acceptable on statically loaded structures only
Rejectable regardless of size under most welding codes
Acceptable if found only in the weld metal
- The carbon equivalent (CE) formula is used to predict:
Weld metal tensile strength
Hardenability and cracking susceptibility of steel
The required filler metal classification
The minimum groove angle for a V-groove weld
- Which FCAW variant does NOT require external shielding gas?
FCAW-G
FCAW-S
FCAW-P
FCAW-I
- In a transverse tensile test for procedure qualification, the specimen UTS must be:
Equal to or greater than the filler metal UTS
Equal to or greater than the minimum specified base metal UTS
Within 10% of the base metal UTS
At least 120% of the base metal yield strength
- Oxyfuel cutting (OFC) does NOT work on:
A36 structural steel
A572 Grade 50 steel
Austenitic stainless steel
A992 wide-flange shapes
- Per AWS D1.1, welder qualification expires if the process has not been used within:
3 months
6 months
12 months
24 months
- Which NDE method best detects subsurface planar discontinuities?
Visual Testing (VT)
Liquid Penetrant Testing (PT)
Ultrasonic Testing (UT)
Magnetic Particle Testing (MT)
- The primary purpose of preheat in welding is to:
Increase welding speed
Improve bead appearance
Slow the cooling rate to reduce cracking risk
Increase penetration depth
- Overlap (cold lap) is caused by:
Excessive current and fast travel speed
Slow travel and low current letting weld metal flow over unfused base metal
Using the wrong shielding gas
Excessive preheat temperature
- How many basic joint types are there in welding?
Three
Four
Five
Seven
- The most common welding injury is:
Electric shock
Burns
Fume inhalation
Hearing loss
- Under AWS D1.1, which processes are prequalified?
SMAW, GMAW, GTAW, FCAW
SMAW, GMAW, FCAW, SAW
All arc welding processes
SMAW and FCAW only
- Calculate heat input: V = 24V, A = 180A, travel speed = 8 in/min.
19.4 kJ/in
25.9 kJ/in
32.4 kJ/in
43.2 kJ/in
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