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Manufacturing and Welding Customized Written Assessment Test Code: 8619 Version: 01
Manufacturing and Welding
Customized Written Assessment
Test Code: 8619 Version: 01
Copyright 2015
NOCTI ®
All rights reserved
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.
THIS PAGE IS INTENTIONALLY BLANK
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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
2
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
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.
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
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
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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
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
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
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
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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
23. Which fire extinguisher is used on fires
involving energized electrical equipment?
A. Class A
B. Class B
C. Class C
D. Class D
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
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
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
27. Which of the following is NOT an element on
a fire triangle?
A. heat
B. oxygen
C. combustion
D. fuel
28. Carbon content in steel is usually expressed in
terms of
A. decimals
B. fractions
C. points
D. percentages
29. Which of the following is the correct
conversion of 2/8 to a decimal?
A. 0.20
B. 0.28
C. 0.22
D. 0.25
30. 35.77 millimeters = _____ centimeters
A. 0.3577
B. 357.77
C. 3.577
D. 0.03577
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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
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WELDING
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
37. The tool pictured below is commonly called a
A. pinch clamp
B. C-clamp
C. ground clamp
D. welding clamp
38. This tool is called a
A. pliers
B. vise grips
C. channel locks
D. pinch clamp
39. This tool is known as a
A. soft face hammer
B. ball peen hammer
C. chipping hammer
D. claw hammer
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40. The tool most likely to be used to clean an oxy-
acetylene cutting tip is:
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
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
43. This is a picture of a/an
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
A. drill press
B. vertical band saw
C. horizontal band saw
D. power shear
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45. This tool is used to cut metal and may be
operated mechanically, hydraulically, or
pneumatically
A. vertical band saw
B. power shears
C. power roll
D. horizontal band saw
46. This is a picture of a
A. vertical band saw
B. pedestal grinder
C. cut-off saw
D. mag drill
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. GMAW
B. Oxy/fuel
C. GTAW
D. SMAW
49. This is used in which welding application?
A. PAW
B. GTAW
C. GMAW
D. SMAW
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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
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54. The weld joint pictured is a/an _____ joint.
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
56. What weld profile is used to make a lap joint?
A. surfacing
B. groove
C. plug
D. fillet
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. + 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
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
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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
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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
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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
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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
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71. The greatest range of SMAW is done with
electrodes in the
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. 6010
B. 6013
C. 7018
D. 7024
74. Which of the following electrodes is a low
hydrogen electrode?
A. 6010
B. 6011
C. 7018
D. 7024
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75. This rod will work in which of the following positions?
A. A
B. B
C. C
D. all of the choices are correct
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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
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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
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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
81. Most welding cables are made of
A. aluminum
B. copper
C. nickel
D. magnesium
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
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
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
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
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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. 27.5
C. 30
D. 45
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93. How could the size of a gas welding tip be
determined if the stamped size marking on the
tip could not be read?
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
96. These flux coated brass rods are probably
going to be used to
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. CO2 or a mixture of 75% argon and 25%
CO2
C. oxygen
D. none of the above
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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
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
A. 0.023 inch to 0.030 inch
B. 1/4 inch to 3/8 inch
C. 1/8 inch to 5/8 inch
D. 0.40 inch to 0.100 inch
101. Which of these controls affects amperage?
A. speed wire
B. voltage
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
END OF ASSESSMENT
