AWS-CWI Exam sample test Questions-answers

The AWS Certified Welding Inspector (CWI) exam is a grueling six-hour marathon. With a historically low pass rate for first-time candidates, walking into the testing center unprepared is an expensive mistake.

The exam is divided into three distinct two-hour sections:

• Part A (Fundamentals): A closed-book test of your general welding knowledge.
• Part B (Practical): A hands-on evaluation using plastic weld replicas, inspection tools, and a fake “Book of Specifications.”
• Part C (Code Book Application): An open-book test testing your ability to navigate a specific code (like AWS D1.1 or API 1104) under extreme time pressure.

To pass, you need a minimum score of 72% on each individual part. Below, we have broken down sample questions for all three sections, complete with the detailed logic and rationales you need to train your brain for exam day.

The AWS Certified Welding Inspector (AWS-CWI) certification recognizes an individual’s knowledge, skills and abilities to perform visual inspection of welded joints andtheir compliance with applicable codes and standards. The AWS-CWI exam tests an individual’s knowledge of:

• Welding processes and techniques
• Visual inspection procedures and techniques
• Welding codes and standards
• Non-destructive examination methods

Part A: Fundamentals (Closed-Book)

Part A consists of 150 questions. You have roughly 48 seconds per question. This section tests your foundational knowledge of welding processes, metallurgy, NDT, symbols, and safety.

Question 1: Welding Processes & Equipment

Question: A welding machine has a duty cycle of 60% at 300 amps. How many consecutive minutes can the machine be operated at 300 amps within a 10-minute period before it must be allowed to cool?

• A) 4 minutes
• B) 6 minutes
• C) 10 minutes
• D) 60 minutes

Answer: B Explanation: In the United States, duty cycle is based on a 10-minute time period. A 60% duty cycle means the machine can weld continuously at the rated amperage for 6 minutes (60% of 10) and must idle and cool for the remaining 4 minutes to prevent thermal overload.

Question 2: Nondestructive Testing (NDT)

Question: Which of the following nondestructive testing methods relies on the principle of capillary action to detect surface-breaking discontinuities?

• A) Magnetic Particle Testing (MT)
• B) Ultrasonic Testing (UT)
• C) Liquid Penetrant Testing (PT)
• D) Radiographic Testing (RT)

Answer: C Explanation: Liquid Penetrant Testing (PT) utilizes a low-surface-tension fluid that is drawn into surface-breaking defects via capillary action. MT relies on magnetic flux leakage, UT relies on high-frequency sound waves, and RT relies on the absorption of penetrating radiation.

Question 3: Welding Metallurgy

Question: When welding high-carbon steel, what is the primary purpose of applying preheat to the base metal?

• A) To increase the deposition rate of the filler metal.
• B) To slow down the cooling rate and prevent the formation of brittle martensite.
• C) To increase the depth of penetration.
• D) To burn off surface rust and mill scale.

Answer: B Explanation: High-carbon steels are highly susceptible to cracking. Preheating reduces the thermal gradient between the weld zone and the base metal, which slows the cooling rate. A slower cooling rate prevents the formation of a hard, brittle microstructure known as martensite, significantly reducing the risk of hydrogen-induced cold cracking.

Part B: Practical (Hands-On)

Part B is the most unique portion of the exam. You are given a toolkit (calipers, micrometer, fillet weld gauges, V-WAC gauge), plastic weld replicas, and a customized “Book of Specifications.” You must answer 46 questions based only on the provided book, not real-world codes.

Question 4: Visual Inspection & Tool Usage

Question: You are using a standard fillet weld gauge to verify the size of a convex fillet weld. To ensure the weld meets the specified size, the gauge must verify:

• A) That the maximum convexity is not exceeded.
• B) That the theoretical throat is flush with the gauge blade.
• C) That both the vertical and horizontal legs touch the base metal while the gauge profile contacts the weld face.
• D) That the actual throat is less than the theoretical throat.

Answer: C Explanation: When measuring a convex fillet weld, the standard gauge is designed to check the leg length. If the legs of the gauge touch the base metal and the curved cutout clears or lightly touches the face of the weld, the minimum specified leg size has been met.

Question 5: Book of Specifications Application

Question: (Scenario: You are reading the exam’s Book of Specifications). The specification states: “Undercut shall not exceed 1/32 in. (0.8 mm) for statically loaded structures, but shall not exceed 0.01 in. (0.25 mm) for cyclically loaded structures.” You are inspecting a cyclically loaded replica. Using your V-WAC gauge, you measure an undercut of 1/64 in. (0.4 mm). What is the disposition of this weld?

• A) Acceptable
• B) Rejectable
• C) Acceptable only if blended by grinding.
• D) Cannot be determined.

Answer: B Explanation: This tests your reading comprehension and measurement conversions. The structure is cyclically loaded, so the strict limit is 0.01 in. You measured 1/64 in. Since 1/64 inch equals 0.0156 inches, your measurement (0.015) is greater than the allowed 0.01 inches. Therefore, the weld is rejectable.

Part C: Code Book Application (Open-Book)

Part C contains 46 to 60 questions (depending on the code) and you have 2 hours. This is an open-book test, but you will fail if you try to read the book during the exam. You must use the Index and Table of Contents to navigate swiftly.

Question 6: AWS D1.1 (Essential Variables)

Question: According to AWS D1.1, when a Welding Procedure Specification (WPS) is qualified by testing using the SMAW process, which of the following is considered an essential variable requiring requalification?

• A) A decrease in groove angle by 5 degrees.
• B) A change from an F4 to an F3 filler metal.
• C) A change in stringer bead to weave bead technique.
• D) A change in the brand of the electrode.

Answer: B Navigation Strategy: You would navigate to the “Qualification” clause in D1.1, and locate the table for “PQR Essential Variable Changes Requiring WPS Requalification” for SMAW. A change in F-number (filler metal grouping) fundamentally changes the chemistry and mechanical properties of the weld, making it a strict essential variable.

Question 7: API 1104 (Radiographic Acceptance)

Question: According to API 1104, when evaluating a radiograph for a pipeline weld, what is the maximum acceptable length for a single crater crack (star crack)?

• A) 1/8 in. (3.2 mm)
• B) 5/32 in. (4.0 mm)
• C) 1/4 in. (6.4 mm)
• D) No cracks of any kind are permitted.

Answer: B Navigation Strategy: Go to the “Acceptance Standards for NDT” section in API 1104, find “Visual” or “Radiographic” acceptance criteria, and look for “Cracks.” API 1104 prohibits all cracks except for shallow crater cracks (star cracks) that do not exceed 5/32 in. (4.0 mm) in length.

Top 3 Tips for Exam Day Success

1. Do Not Get Stuck: All questions are worth the same amount of points. If you cannot find an answer in Part C within 2 minutes, mark it, guess an answer, and move on. Come back if you have time.
2. Read the Footnotes: In the open-book sections, AWS loves to test you on the tiny text at the bottom of the tables. If a question seems too easy, check the footnotes for exceptions.
3. Trust Your Gauge, Not Your Eyes: In Part B, a replica might “look” like it has terrible porosity, but if the pores do not exceed the dimensional limits set in the Book of Specifications, you must accept it. Remove your personal field experience and follow the book literally.

Sample AWS-CWI Exam Questions:

1. What does the acronym AWS stand for?
   A. American Welding Society
   B. Association of Welding Specialists
   C. American Welding Standards
   D. None of the above
   Answer: A
2. What is the minimum thickness for a fillet weld?
   A. Leg size of the weld
   B. Throat size of the weld
   C. Leg size divided by 2
   D. Throat size divided by 2
   Answer: B
3. What is the most common weld defect?
   A. Undercut
   B. Porosity
   C. Lack of fusion
   D. Slag inclusions
   Answer: A
4. Which welding process uses a non-consumable tungsten electrode?
   A. Shielded metal arc welding
   B. Gas tungsten arc welding
   C. Flux-cored arc welding
   D. Submerged arc welding
   Answer: B
5. Which element is added to steel to make it deoxidize and increase strength?
   A. Manganese
   B. Carbon
   C. Chromium
   D. Nickel
   Answer: A

6. What is the melting point of mild steel?
   A. 1500°C
   B. 2500°C
   C. 3000°C
   D. 3500°C
   Answer: A
7. What is the most common shielding gas used in arc welding?
   A. Carbon dioxide
   B. Argon
   C. Helium
   D. Nitrogen
   Answer: B
8. What is the role of flux in welding?
   A. It produces gas to shield the weld
   B. It prevents oxidation of the weld pool
   C. It reduces porosity by controlling arc characteristics
   D. Both B and C
   Answer: D
9. What is the highest possible hardness of a steel?
   A. Rockwell C 60
   B. Rockwell C 70
   C. Rockwell C 85
   D. Rockwell C 100
   Answer: D
10. Which code covers the requirements for welding mild steel?
    A. ASME Section VIII Div 1
    B. AWS D1.1
    C. API 1104
    D. None of the above
    Answer: B

11. Which welding position has the least penetration?
    A. Flat position
    B. Vertical position
    C. Overhead position
    D. Horizontal position
    Answer: C
12. Which type of joint is the strongest?
    A. Lap joint
    B. Butt joint
    C. Corner joint
    D. Edge joint
    Answer: B
13. Which welding process uses slag to shield the weld pool?
    A. SMAW
    B. SAW
    C. FCAW
    D. GTAW
    Answer: B
14. Which type of welding produces coalescence of metals with the heat obtained from an electric arc?
    A. Forge welding
    B. Solid-state welding
    C. Laser beam welding
    D. Arc welding
    Answer: D
15. In which welding process does the arc moves along the joint line?
    A. SMAW
    B. SAW
    C. GMAW
    D. GTAW
    Answer: C
16. Which welding position has the maximum penetration?
    A. Flat position
    B. Vertical position
    C. Overhead position
    D. Horizontal position
    Answer: B
17. Which welding process uses a consumable wire electrode and shielding gas?
    A. SMAW
    B. SAW
    C. GMAW
    D. FCAW
    Answer: D
18. In which type of joint do the parts overlap to produce weld?
    A. Butt joint
    B. Lap joint
    C. Corner joint
    D. Edge joint
    Answer: B
19. What is the full form of SMAW?
    A. Shielded metal arc welding
    B. Submerged metal arc welding
    C. Self-shielded metal arc welding
    D. Solid metal arc welding
    Answer: A
20. Which weld has a triangular cross-section?
    A. Fillet weld
    B. Groove weld
    C. Plug weld
    D. Slot weld
    Answer: A

---