100+ Welding Interview Questions and Answers PDF Download

Download 100+ Welding Questions and Answers in PDF

On this page, you will read more than 100+ interview questions and answers on the welding process. This is the complete QnA material for the welding process. You can also download all the questions and answers in PDF.

Ques: What is welding?

Ans: Welding is the process of joining two or more pieces of metal together by melting, cooling, and solidifying to create a permanent bond.

Ques: What is brazing?

Ans: Brazing is a metal joining process in which two or more metallic elements are joined by heating them above 450°C and fusing a filler metal in the joint.

Ques: What is welding?

Ans: Welding is a process of joining two or more pieces of metal together by heating to a temperature below 450°C and fusing a filler metal into the joint.

Ques: What is the difference between brazing and welding?

Ans: The main difference between brazing and welding is the temperature used to melt the filler metal. Brazing requires a higher temperature than soldering.

Ques: What are the different welding processes?

Ans: The different welding processes include MIG welding, TIG welding, stick welding, seam welding, resistance welding, laser welding, electron beam welding, friction welding, ultrasound and plasma welding.

Ques: What is MIG Welding?

Ans: MIG welding, also known as Gas Metal Arc Welding (GMAW), is a welding process that uses a coil of wire to power the weld joint and shielding gas to protect the weld from contamination.

Ques: What is TIG welding?

Ans: TIG welding, also known as Gas Tungsten Arc Welding (GTAW), is a welding process that uses a tungsten electrode to create an arc and a filler metal to join the workpieces together.

Ques: What is stick welding?

Ans: Stick welding, also known as shielded metal arc welding (SMAW), is a welding process that uses a stick electrode and an electric current to create an arc and melt the base metal.

Ques: What is seam welding?

Ans: Flux-cored welding is a welding process that uses a tubular wire filled with flux to protect the weld from contamination and provide a shielding gas.

Ques: What is resistance welding?

Ans: Resistance welding is a welding process that uses an electric current to heat and join pieces of metal to be welded.

Ques: What is laser welding?

Ans: Laser welding is a welding process that uses a laser beam to melt and join pieces of metal to be welded.

Ques: What is Electron Beam Welding?

Ans: Electron beam welding is a welding process that uses a high-speed electron beam to melt and join the pieces of metal being welded.

Ques: What is Friction Welding?

Ans: Friction welding is a welding process that uses frictional heat to melt and join the pieces of metal being welded together.

Ques: What is Ultrasonic Welding?

Ans: Ultrasonic welding is a welding process that uses high-frequency vibration and pressure to melt and join the metal pieces being welded.

Ques: What is plasma welding?

Ans: Plasma welding is a welding process that uses a plasma arc to melt and join pieces of metal to be welded.

Ques: What is Gas Welding?

Ans: Gas welding is a welding process that uses a flame fueled by oxygen and a combustible gas, such as acetylene, to melt and join metal parts.

Ques: What is oxyacetylene welding?

Ans: Oxyacetylene welding is a type of gas welding that uses a mixture of oxygen and acetylene to create a flame that heats and melts metal parts.

Ques: What is plasma cutting?

Ans: Plasma cutting is a process that uses a plasma torch to cut metal by creating a high velocity stream of ionized gas.

Ques: What is waterjet cutting?

Ans: Waterjet cutting is a process that uses a high pressure water jet to cut materials such as metal, stone or wood.

Ques: What is laser cutting?

Ans: Laser cutting is a process that uses a focused laser beam to cut materials such as metal, plastic or wood.

Ques: What is arc cutting?

Ans: Arc cutting is a process that uses an electric arc to cut metal by melting and vaporizing it.

Ques: What is gas cutting?

Ans: Gas cutting is a process that uses a flame fueled by oxygen and a combustible gas, such as propane or acetylene, to cut metal.

Ques: What is the difference between fusion welding and solid state welding?

Ans: Fusion welding is a welding process that involves melting and joining two or more metal parts together, while solid state welding is a welding process that creates a bond between metal parts without melting them.

Ques: What is the difference between fusion welding and brazing/welding?

Ans: Fusion welding involves melting and joining two or more metal parts together, whereas brazing and welding involves joining metal parts using a filler material that melts at a lower temperature than the target metal. basis.

Ques: What is a solder joint?

Ans: A weld joint is where two or more metal parts are joined by a welding process.

Ques: What are the different types of solder joints?

Ans: The different types of weld joints include butt joints, lap joints, tee joints, corner joints, and edge joints.

Ques: What is a butt joint?

Ans: A butt joint is a type of weld joint in which two metal parts are joined together by placing them next to each other.

Ques: What is a lap joint?

Ans: A lap joint is a type of weld joint where two metal parts are overlapped and joined together.

Ques: What is a T-joint?

Ans: A tee joint is a type of solder joint in which two metal parts are joined at right angles to form a "T" shape.

Ques: What is a corner joint?

Ans: A fillet joint is a type of weld joint in which two metal parts are joined at right angles to form an angle.

Ques: What is a Threaded Joint?

Ans: A fillet joint is a type of solder joint in which two pieces of metal are joined at an angle, usually at a 90 degree angle, forming a triangular cross section.

Ques: What is a spline joint?

Ans: A spline joint is a type of weld joint where two pieces of metal are joined edge to edge with a groove or channel between them.

Ques: What is a plug weld?

Ans: Plug welding is a type of welding in which a hole is drilled or punched into one of the pieces of metal and then filled with solder material, bonding the two pieces together.

Ques: What is a gap weld?

Ans: A slot weld is a type of weld in which a crack or groove is cut into one of the pieces of metal and then filled with solder material, bonding the two pieces together.

Ques: What is spot welding?

Ans: Spot welding is a type of resistance welding in which two or more metal sheets are joined by heating them at the point where they overlap until they melt and fuse together.

Ques: What is a seam weld?

Ans: Bead welding is a type of weld where two pieces of metal are joined along their entire length, creating a continuous, waterproof seal.

Ques: What is a spot weld?

Ans: Spot welding is a type of welding in which a series of short welds is used to join two pieces of metal together, usually in a straight line.

Ques: What is a stud weld?

Ans: Stud welding is a type of welding in which a metal stud is welded to another piece of metal, often used to attach fasteners or brackets.

Ques: What is a projection weld?

Ans: Projection welding is a type of resistance welding where two pieces of metal are joined at specific points where one of the pieces has raised sections, or protrusions.

Ques: What is butt welding?

Ans: Butt welding is a type of resistance welding in which the two ends of two pieces of metal are pressed together and then subjected to a high voltage electric current which causes them to melt.

Ques: What is friction welding?

Ans: Friction welding is a solid state welding process in which a rotating tool is used to soften and mix the two pieces of metal, forming a strong bond.

Ques: What is a thermo-compression weld?

Ans: Thermo-compression welding is a type of welding in which two pieces of metal are heated and pressed together under high pressure, forming a strong bond.

Ques: What is a diffusion bond?

Ans: Diffusion bonding is a solid state bonding process in which two pieces of metal are heated and pressed together until their atoms diffuse and bond at the interface.

Ques: What is a brazed joint?

Ans: A brazed joint is a type of joint in which two pieces of metal are joined by heating them to a temperature below their melting point and then adding a filler metal which melts and flows between them, creating a strong bond.

Ques: What is a welded joint?

Ans: A soldered joint is a type of joint in which two pieces of metal are joined by heating them to a temperature below their melting point and then adding a low-melting point metal, called a solder, which melts and flows between them, creating a strong bond.

Ques: What is a brazing filler metal?

Ans: A brazing filler metal is a metal alloy used in brazing that melts at a higher temperature than the metal to be joined and flows into the joint by capillary action, creating a strong bond.

Ques: What is a solder flux?

Ans: Solder flux is a chemical agent used during soldering to clean and prepare surfaces to be joined, as well as to prevent oxidation and aid in solder flow.

Ques: What are the advantages of welding over other joining processes?

Ans: The advantages of welding over other joining processes include strong and permanent joints, high efficiency and productivity, versatility in terms of materials and applications, and relatively low cost for large-scale production.

Ques: What are the disadvantages of welding?

Ans: The disadvantages of welding include the potential for distortion, porosity, and other defects in the joint, as well as the need for skilled labor, specialized equipment, and proper safety precautions. Welding can also be more time-consuming and expensive for small-scale or one-off projects.

Ques: What are the safety precautions to be taken when welding?

Ans: Safety precautions to be taken when welding include wearing appropriate personal protective equipment (PPE), such as helmet, gloves and clothing, ensuring adequate ventilation and fire fighting measures, inspecting equipment and materials to identify any defects or hazards and compliance with established procedures for handling, storage and disposal of welding materials.

Ques: What are the different welding positions?

Ans: The different welding positions are flat, horizontal, vertical, overhead and inclined.

Ques: What is a welding electrode?

Ans: A welding electrode is a metal wire or rod that conducts current to create a welding arc.

Ques: What is a welding wire?

Ans: A welding wire is a metal wire that is used as a filler material to join two pieces of metal together during welding.

Ques: What is a welding wire?

Ans: A welding rod is a metal rod used as a filler material to join two pieces of metal together during welding.

Ques: What is a welding helmet and why is it important?

Ans: The welding helmet is a protective headgear that protects the welder's face, eyes and neck from harmful radiation and sparks during welding. It is important to prevent welding-related injuries and health risks.

Ques: What is a Welding Shield?

Ans: A welding shield is a protective device that covers the work area and prevents the escape of harmful radiation and sparks during welding.

Ques: What is a welding filter lens and why is it important?

Ans: A welding filter lens is a protective lens that is used in a welding helmet to protect the welder's eyes from harmful radiation and ultraviolet light emitted during welding. It is important to prevent eye damage and loss of vision.

Ques: What is the purpose of a welding ground clamp?

Ans: The purpose of a welding earth clamp is to provide a good electrical connection between the welding equipment and the workpiece to ensure efficient and safe welding.

Ques: What is the difference between alternating current and direct current welding?

Ans: AC welding uses an alternating current to create an arc, while DC welding uses a direct current to create an arc. The choice of AC or DC welding depends on the type of metal to be welded and the welding technique used.

Ques: What is the purpose of a welding gas?

Ans: The purpose of a welding gas is to protect the weld puddle and surrounding area from atmospheric contamination during welding and to provide a stable arc for efficient welding.

Ques: What is a solder flux?

A: Solder flux is a chemical compound used during welding to prevent oxidation and other forms of atmospheric contamination in the weld puddle.

Ques: What is a welding torch?

Ans: The welding torch is a hand-held tool used to heat the metal being welded and to direct the flow of the welding flame or arc.

Ques: What is a welding nozzle?

Ans: The welding nozzle is a welding torch component that controls the flow and direction of the flame or welding arc.

Ques: What is a soldering tip?

Ans: The welding tip is a welding torch component that controls the size and shape of the flame or welding arc.

Ques: What is the difference between a soldering nozzle and a soldering tip?

Ans: A welding nozzle controls the direction of the flame or welding arc, while a welding tip controls the size and shape of the flame or welding arc.

Ques: What is a welding electrode holder?

Ans: The welding electrode holder is a device used to hold and connect the welding electrode to the welding machine. Helps keep the electrode steady while welding.

Ques: What is a welding current generator?

Ans: A welding current generator is a device that supplies the electrical energy required for welding. Converts electrical energy from a power source into a form suitable for welding.

Ques: What is a welding wire feeder?

Ans: A welding wire feeder is a device that feeds welding wire to the welding gun. Helps maintain a constant distance between the electrode and the workpiece.

Ques: What is a welding regulator?

Ans: A welding regulator is a device used to regulate the flow of gas or gas mixture to the welding torch. Maintains a constant flow of gas, ensuring a stable welding arc.

Ques: What is the difference between a welding regulator and a flowmeter?

Ans: A welding regulator controls the pressure and flow of gas to the welding torch, while a flowmeter controls only the gas flow.

Ques: What is a welding consumable?

Ans: A welding consumable is a material that is melted during the welding process to create a joint. These include welding electrodes, wires, rods and filler metals.

Ques: What is the purpose of coating a welding electrode?

Ans: The purpose of the welding electrode coating is to improve the quality and strength of the weld. Provides a protective layer that helps prevent oxidation, reduces spatter and stabilizes the arc.

Ques: What is a weld bead?

Ans: A weld bead is a raised section of metal that forms when molten metal solidifies after the welding process. Form the joint between two pieces of metal.

Ques: What is a weld puddle?

Ans: A weld puddle is a pool of molten metal that forms when the welding process melts the metal in the joint. The weld puddle cools and solidifies to form the weld bead.

Ques: What is a weld pool?

Ans: The weld puddle is the pool of molten metal that forms during the welding process. It is the area where the welding electrode melts and fuses the metal in the joint.

Ques: What is a weld pass?

Ans: A weld pass is a single weld process progression that creates a part of the weld. Multiple passes may be required to create a complete weld.

Ques: What is a Welding Procedure Specification (WPS)?

Ans: A Welding Procedure Specification (WPS) is a written document that provides detailed instructions on how to perform a specific welding process. It includes information about materials, welding positions, welding equipment and welding parameters.

Ques: What is a Welder Qualification Test (WQT)?

Ans: A Welder Qualification Test (WQT) is a test performed to ensure that a welder has the skills and knowledge required to perform a specific welding process. It includes both a practical test and a written test.

Ques: What is a Welding Inspector?

Ans: A welding inspector is a person who inspects and evaluates welding work to ensure that it conforms to the necessary standards and specifications. You may work in a variety of industries including construction, manufacturing and transportation.

Ques: What is a Welding Engineer?

Ans: A welding engineer is a professional who specializes in the design, development and optimization of welding processes. He works to improve the quality and efficiency of welding operations in various sectors.

Ques: What is a Welding Supervisor?

Ans: A welding supervisor is a person responsible for supervising and managing the welding operations in a shop or construction site.

Ques: What is a welding operator?

Ans: The welding operator is a person who uses the welding equipment and performs the welding operations according to specific procedures.

Ques: What is a welder?

Ans: The welder is a craftsman who specializes in joining materials with various welding processes.

Ques: What are the different types of welding certifications?

Ans: The different types of welding certifications include certification of a welder, welding inspector, welding supervisor and welding engineer.

Ques: What is a weld code?

Ans: A welding code is a set of rules and regulations governing the design, manufacture and inspection of welded structures.

Ques: What is a welding standard?

Ans: A welding standard is a document that provides guidelines for welding processes, equipment and materials used in various industries.

Ques: What is a weld symbol?

Ans: The weld symbol is a graphical representation used in engineering drawings to specify the details of a weld.

Ques: What is a weld defect?

Ans: A weld flaw is an imperfection or discontinuity in a welded joint that can affect its strength, durability, or appearance.

Ques: What is a Weld Inspection?

Ans: Weld inspection is the process of examining and evaluating welded joints to ensure they meet specified requirements.

Ques: What is welder qualification?

Ans: Welder qualification is the process of verifying his ability to produce welds that meet the required quality standards.

Ques: What is a welder's certification?

Ans: Welder certification is a process of verifying a welder's skills and knowledge through a series of tests and examinations to ensure that he/she can perform welding operations in accordance with industry standards and codes.

Ques: What is a Welding Procedure Qualification Record (WPQR)?

Ans: A Welding Procedure Qualification Record (WPQR) is a document that describes the specific welding procedure used for a particular welding job and provides evidence that the procedure has been tested and approved for use.

Ques: What are non-destructive testing (NDT)?

Ans: Non-destructive testing (NDT) is a set of techniques used to inspect and evaluate materials and welds without causing damage or destruction to the part being tested.

Ques: What are the different types of NDT methods?

Ans: The different types of NDT methods include visual inspection, liquid penetrant test, magnetic particle test, ultrasound test, radiographic test, and eddy current test.

Ques: What is Destructive Testing (DT)?

Ans: Destructive testing (DT) is a weld or material testing method that involves physically destroying a test piece to evaluate its mechanical properties and performance.

Ques: What are the different types of DT methods?

Ans: The different types of DT methods include Tensile Testing, Bending Testing, Charpy Impact Testing, Hardness Testing and Fatigue Testing.

Ques: What is meant by acceptance criteria for welding defects?

Ans: Weld defect acceptance criteria are established standards and guidelines that determine whether a particular weld defect is acceptable or unacceptable.

Ques: What is the Heat Affected Zone (HAZ)?

Ans: The heat-affected zone (HAZ) is the area of metal around the weld where the temperature has been high enough to change the microstructure of the material, affecting its mechanical properties.

Ques: What is weldability?

Ans: Weldability is the ease with which a material can be welded without defects, such as cracks or porosity, and without causing significant changes to its microstructure or mechanical properties.

Ques: What are the factors affecting the quality of the weld?

Ans: Factors affecting weld quality include type of welding process used, welding parameters, type of material to be welded, cleanliness of materials and welding environment, as well as skill and experience of the welder.