Customized Written Assessment Test Code: 8619 Version: 01

Transcription

1 Manufacturing and Welding Customized Written Assessment Test Code: 8619 Version: 01

2 Copyright 2015 NOCTI All rights reserved

3 Instructions for Taking the Written Assessment 1. Fill in ALL of the information requested on the Participant Answer Sheet with a soft black lead No. 2 pencil. Every field must be completed in order to ensure your answer sheet is scored properly. The test administrator will provide you with instructions for completing the Participant Information and Test Information portions of the answer sheet. 2. Use only as many of the response spaces on the answer sheet as are required for this test. Record your written responses in the section of the answer sheet labeled Written Test and your performance responses in the section of the answer sheet labeled Performance Test. 3. Mark each item by darkening the corresponding circle with a No. 2 pencil for the answer choice you think is correct. 4. Erase completely any answer you want to change and then darken the circle for the answer you believe to be correct. You must erase your first mark completely; failure to do so may result in a wrong reading by the scanner. 5. Mark only one answer for each test item. Items marked with more than one choice are automatically scored as incorrect. You should answer all items to the best of your ability. Items left blank are automatically scored as incorrect. 6. Erase any stray marks on the answer sheet as these may lower your score. 7. If you need to return to a question, place a check in the margin of the test booklet and return to it for additional consideration after you have completed the last question. 8. Look over your answer sheet when you have finished and darken any marks that are not black and shiny. NOTE: the test proctor will announce the time limit for this test.

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5 NOCTI Directions: Each of the questions or incomplete statements listed below is followed by four possible answers. Read each question carefully and completely before you attempt to select an answer. Choose the response that you believe best answers the question or completes the statement. Completely fill in the circle containing the letter of your choice on the answer sheet. If you make a mistake, be sure to erase completely. A nonprogrammable calculator may be used for this test. MANUFACTURING 1. Approved safety glasses should always be worn because they are A. tested and rated to protect you B. required by shop safety rules C. required by OSHA D. all of the above 2. Your ear plugs are misplaced while you are taking your scheduled break. What should you do? A. Finish your break and go back to work. B. Take a pair of ear plugs you see on a locker room bench and go back to work. C. Leave the break room a little early so you can stop by the safety room to get a new pair of plugs, on the way back to work. D. Finish your break, then go to the safety room for some new ear plugs, on your way back to work. 3. In any manufacturing area that requires eye protection, you should wear your safety glasses A. when you are running your machine B. when going and coming from lunch C. whenever you believe they are needed D. at all times, even if you are not actually working 4. While you are walking through the shop, you see someone on the other side of the room working without safety glasses. You should A. walk over there to remind the person to put on safety glasses B. go on with what you are doing C. tell the boss the person is not working safely D. write up a safety violation on the person 5. When SMAW welding with (60-160) amps, the worker should wear an arc welding hood with a A. Number 10 shade lens B. Number 12 shade lens C. clear lens D. pair of goggles 1

6 6. Four safety provisions which should be located when entering the shop are: main power supply disconnect, fire extinguisher, first aid station, and A. exits B. tool room C. water D. storage area 9. Which of the following would be considered a chemical hazard? A. scrap steel left in the middle of the isle B. leftover battery acid stored in a coffee can C. hand soap overflowing on the floor D. a broken light bulb 7. The operations manual for your area calls for steel toe boots to be worn at all times. You forgot your work boots. What should you do? A. Go on to work, nobody will notice. B. Let someone know you are running behind and get some proper boots before you go out on the job. C. Go home. D. Run home, get your boots, hurry back to work and rush out to your job so you will not get too far behind. 8. The sign on the door of the worksite you are visiting says, "Hard hats and eye protection required beyond this point." What should you do? A. Since you are just visiting, the ball cap you are wearing will protect your head and your sunglasses will be fine for eye protection. B. Go to the safety station and get the proper safety equipment. C. Ask an employee if it would be okay to proceed without the safety equipment. D. Since you are just walking through the department, you will not need to worry about it. 10. Which of the following would be considered a biological hazard? A. sparks from a cutting torch B. hot chips from a machining operation C. fumes from welding D. heat from a heat treating oven 11. An extension cord stretched across an aisle is considered a A. biological hazard B. fire hazard C. physical hazard D. chemical hazard 12. After the first pass is made on a practice plate, cool the metal in A. oil B. kerosene C. soap D. water 2

7 13. A stick of 11 gauge 1 inch by 1 inch square tubing comes in 20 foot long length and weighs about 20 pounds. To use proper safety in handling the stock, you should A. use your legs, not your back, to pick up the stock B. find a lift truck driver to move the stock C. find someone to help carry the long piece of stock D. balance the stock on your shoulders 14. Your maintenance crew just finished working on a press. They were running it with an override code in the light curtain for testing the cycles. They forgot to turn the override off. The machine is much easier to run with this light curtain turned off you should A. stop the machine and call maintenance back to turn on the light curtain B. continue to run it like it is until you can get someone to fix it C. find out how they did it and fix it yourself D. go take a break until maintenance fixes it 17. What safety color is used to indicate danger, emergency, or stop controls? A. red B. orange C. yellow D. green 18. Which of the following material is best suited for an arc welding table top? A. wood B. steel C. plastic D. formica 19. A cutting torch should be ignited by A. hot metal B. another torch C. a spark lighter/striker D. a match 20. It is best to pick up hot metal with 15. The safety color used to outline work or walk areas and indicate caution is A. white B. yellow C. black D. red 16. Which of the following colors is used to indicate safety and first aid equipment? A. yellow/purple B. red/white C. green/blue D. black/orange A. pliers B. a chipping hammer C. gloves D. a steel brush 21. When a guard on a machine is damaged or broken, the first action to take is to A. lock and tag the machine out B. continue to use the machine, but be extra careful C. slow down all operations until the guard is repaired D. remove the guard and work as normal 3

8 22. To remove slag, hammer the bead so the chipping is done A. towards your body B. away from eyes and face C. towards the bottom D. towards the top 26. Which fire extinguisher is used on fires involving ordinary combustibles, such as wood, cloth, and paper? A. Class A B. Class B C. Class C D. Class D 23. Which fire extinguisher is used on fires involving energized electrical equipment? A. Class A B. Class B C. Class C D. Class D 27. Which of the following is NOT an element on a fire triangle? A. heat B. oxygen C. combustion D. fuel 24. Which fire extinguisher is used on fires involving liquids, greases, and gases? A. Class A B. Class B C. Class C D. Class D 28. Carbon content in steel is usually expressed in terms of A. decimals B. fractions C. points D. percentages 25. Which fire extinguisher is used on fires involving metals such as magnesium, titanium, sodium, and potassium? A. Class A B. Class B C. Class C D. Class D 29. Which of the following is the correct conversion of 2/8 to a decimal? A B C D millimeters = centimeters A B C D

9 31. When welding with 1/8-inch standard coated rods, the current setting should be close to the diameter of the rod at A. 50 amps B. 75 amps C. 120 amps D. 225 amps 32. A good general rule to follow with arc length shall be slightly less than the diameter of the rod being used. For example, 1/8-inch rod would have an arc length of A. 3/32 inch B. 3/16 inch C. 3/64 inch D. 5/16 inch 33. Identify the adjustable locking pliers from the tools pictured below. A. A B. B C. C D. D 34. Code requires that a weave bead be three times the electrode diameter. Using a 1/8-inch electrode will result in a bead wide. A. 7/16 to 1/2 inch B. 3/8 to 7/16 inch C. 1/8 to 3/16 inch D. 1/16 to 3/32 inch 5

10 WELDING 38. This tool is called a 35. What kind of hammer is used to remove slag? A. ball peen B. claw C. chipping D. carpenter 36. Soapstone is used for A. washing hands B. cleaning electrode C. drawing lines on steel plate D. cleaning the ground clamp A. pliers B. vise grips C. channel locks D. pinch clamp 37. The tool pictured below is commonly called a 39. This tool is known as a A. pinch clamp B. C-clamp C. ground clamp D. welding clamp A. soft face hammer B. ball peen hammer C. chipping hammer D. claw hammer 6

11 40. The tool most likely to be used to clean an oxyacetylene cutting tip is: 43. This is a picture of a/an A. A B. B C. C D. D 41. Which of these is generally used for drilling thicker materials, comes in several types such as variable speed and reversible, and in 1/2- inch, 3/4-inch, and 1-1/4-inch sizes? A. electric grinder B. heavy duty drill C. power roll D. power shear A. chop saw B. electric drill C. bevel machine D. hand grinder 44. This tool is used to cut any length and many types of metal with a continuous cutting blade 42. Which of these is a process where gas is heated to an ionized state to use in cutting? A. oxy/fuel cutting B. oxy/acetylene cutting C. plasma arc cutting D. oxy/mapp cutting A. drill press B. vertical band saw C. horizontal band saw D. power shear 7

12 45. This tool is used to cut metal and may be operated mechanically, hydraulically, or pneumatically 47. Which of the following common welding gas mixtures provided the least available heat? A. air-propane B. oxygen-acetylene C. mapp-oxygen D. oxygen-propane 48. Which welding process uses a continuous consumable wire electrode? A. vertical band saw B. power shears C. power roll D. horizontal band saw A. GMAW B. Oxy/fuel C. GTAW D. SMAW 49. This is used in which welding application? 46. This is a picture of a A. PAW B. GTAW C. GMAW D. SMAW A. vertical band saw B. pedestal grinder C. cut-off saw D. mag drill 8

13 50.Select the picture that represents the GMAW welding process A. A B. B C. C D. D 51. A fillet weld is made on a A. flat surface B. lap joint C. open butt D. grooved joint 52. Beveling weld joint edges will insure A. complete penetration B. proper alignment C. a good fit-up D. ease of welding 53. The weld joint pictured is a/an joint. A. corner B. lap C. edge D. T 9

14 54. The weld joint pictured is a/an joint. 57. What one factor determines if a joint is to have an open or closed root? A. bead conformity B. blueprint specification C. speed of application D. electrode coating 58. According to the information in the title box, what is the allowable tolerance in fractional numbers? A. lap B. T C. edge D. corner 55. The weld joint pictured is a/an joint. A. edge B. T C. corner D. lap A. + or - 1/8 inch B. + or - 5/8 inch C. + or - 3/4 inch D. + or - 1/2 inch 59. The circle in this welding symbol tells the welder 56. What weld profile is used to make a lap joint? A. surfacing B. groove C. plug D. fillet A. to add an extra fillet weld B. the weld is to be made in the field C. to weld all around D. to weld vertical up 10

15 60. If you were building up a worn loader bucket you would expect to see which of the following weld symbols on your prints? A. A B. B C. C D. D 61. Stainless steel contains, along with iron, nickel and specified amounts of carbon, large percentages of A. manganese B. silicon C. sulfur D. chromium 62. The alloying elements in aluminum determine its A. weight B. color C. weldability D. availability 11

16 63. This gray heavy ferrous metal is most likely A. stainless steel B. cast iron C. aluminum D. high phosphor bronze 64. The sparkles in this picture indicate the metal being ground is with carbon content. A. ferrous; low B. ferrous; no C. nonferrous; high D. ferrous; high 12

17 65. What preparation should be performed on mild steel before welding? A. preheated B. clamped C. remove mill scale D. kept at room temperature 66. Which of the structural forms is an angle? A. A B. B C. C D. D 67. Which of the structural forms is an ''I'' beam? A. A B. B C. C D. D 13

18 68. Which of the following structural shapes is known as square tube? A. A B. B C. C D. D 69. Which of the following is flat bar? A. A B. B C. C D. D 70. How can distortion be controlled? A. use of a smaller electrode B. welding slower C. using more current D. using tack welds properly 14

19 71. The greatest range of SMAW is done with electrodes in the 74. Which of the following electrodes is a low hydrogen electrode? A. alloy steel group B. mild steel group C. high carbon steel group D. non-ferrous group 72. In a four digit electrode class number, what do the first two digits mean? A. special manufacturer's characteristics B. all position C. low heat input D. tensile strength 73. A deep penetrating electrode is A B C D A B C D

20 75. This rod will work in which of the following positions? A. A B. B C. C D. all of the choices are correct 16

21 76. What is the tensile strength rating of this electrode? A. 40,000 PSI B. 70,000 PSI C. 100,000 PSI D. This electrode is not rated. 77. The notches cut into the fitting on this hose tell the welder it is A. an oxygen hose fitting B. a quick disconnect C. left hand thread D. an inert gas fitting 17

22 78. If a bottle is hit by an arc strike it must be A. fixed by grinding B. fixed by filing C. discarded D. none of the above 79. The output of a constant current welding machine is stated in A. amperage B. resistance C. ohms D. voltage 18

23 80. When setting up an SMAW machine, what two factors determine the amperage setting? A. electrode length and polarity B. polarity and arc length C. type of machine and length of weld D. thickness of the metal and electrode size 85. When welding out of position, the molten puddle is A. smaller than flat position B. deeper penetrating C. affected by arc blow D. affected by the force of gravity 81. Most welding cables are made of A. aluminum B. copper C. nickel D. magnesium 86. Which of the following is a factor that determines weld quality? A. amperage B. length of the arc C. speed of travel D. all of the above 82. The quality and appearance of an electric arc weld depends on A. the current setting B. the length of arc C. the rate of travel and angle of electrode D. all of the above 83. The rod must be fed downward at a constant rate to maintain the correct arc A. amperage B. length C. resistance D. all of the above 84. A depression at the termination of a weld is called A. a crater B. flux C. a spatter D. porosity 87. To secure a strong weld, the metal deposited from the electrode must fuse completely with the A. slag B. base metal C. pool D. craters 88. During the welding process, the oxygen cylinder valve should be opened A. 3/4 of a turn B. not over 1-1/2 turns C. all the way D. 1 full turn 89. The width of a cut produced by the flame cutting operation is called a A. lap B. kerf C. pass D. cleft 19

24 90. Oxyacetylene cutting equipment CANNOT be used to cut A. low carbon steel B. non ferrous material C. channel iron D. high strength steel 91. When a specific type of material is to be cut, what determines the size of the cutting tip? A. hardness B. thickness C. roundness D. flatness 92. To cut this bevel angle on machine #1 you would have to set a degree angle on adjuster #2. A. 15 B C. 30 D

25 93. How could the size of a gas welding tip be determined if the stamped size marking on the tip could not be read? 96. These flux coated brass rods are probably going to be used to A. length B. diameter of opening C. outside diameter D. volume of flame 94. The main purpose of a filler rod is to A. add strength to weld on a joint B. fill in gaps C. use on auto body work D. weld copper tubing 95. Why should you have a clean metal surface in braze welding? A. heat will be released easier B. provide a stronger bond on base metal C. keep metal from piling up D. penetration will be easier A. GTAW weld, aluminum B. GMAW weld, steel C. FCAW weld, steel D. braze weld, steel 97. What are two methods of metal transfer used by the GMAW process? A. spray arc and short circuit transfer B. fusion and cohesion C. alpha and beta D. argon and carbon 98. What is the most common shielding gas mixture used in short circuit transfer method of GMAW? A. hydrogen B. CO 2 or a mixture of 75% argon and 25% CO 2 C. oxygen D. none of the above 21

26 99. When GMAW welding aluminum, the gun is always pointed in the direction of travel to help keep out of the weld. A. heat B. spatter C. contamination D. soot 102. Which of the following joints is least likely to withstand excessive impact or bending loads? A. square butt joint B. lap joint C. double T joint D. double U butt joint 100. Select the wire diameter range most likely to be used on a 110 volt, 20 percent duty cycle, GMAW welding machine being used to weld thin gauge metal END OF ASSESSMENT A inch to inch B. 1/4 inch to 3/8 inch C. 1/8 inch to 5/8 inch D inch to inch 101. Which of these controls affects amperage? A. speed wire B. voltage 22

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