Page 1 of 145
AWS D17.1 Aerospace Welding Exam QUESTIONS
AND VERIFIED ANSWERS WITH RATIONALES JUST
RELEASED
AWS D17.1 Aerospace Welding Exam
10-Point Exam Coverage — Mostly Tested Areas
1. Aerospace Welding Code Requirements — AWS D17.1/D17.1M requirements, code
terminology, applicability, responsibilities, acceptance criteria, and use of approved procedures.
2. Welding Procedure Specification (WPS) and Qualification — WPS requirements, essential
variables, procedure qualification, test assemblies, qualification ranges, and changes requiring
requalification.
3. Welder and Welding Operator Qualification — Welder qualification tests, continuity,
qualification limits, performance variables, test positions, and documentation.
4. Aerospace Materials and Base Metals — Aluminum, nickel alloys, titanium, stainless steels,
magnesium, heat-resistant alloys, material identification, thickness considerations, and material
compatibility.
5. Joint Design and Fit-Up — Joint types, dimensions, alignment, root conditions, joint
preparation, tack welding, tolerances, access, and preweld inspection.
6. Welding Processes and Equipment — GTAW, GMAW, resistance welding, equipment setup,
shielding gases, polarity, current, voltage, travel speed, and machine controls.
7. Welding Technique and Process Control — Arc control, heat input, shielding, interpass
conditions, filler metals, cleaning, torch/electrode control, distortion control, and welding
sequence.
8. Inspection and Nondestructive Examination — Visual inspection, dimensional inspection,
radiographic testing, ultrasonic testing, liquid penetrant testing, and applicable inspection
requirements.
9. Weld Discontinuities and Acceptance Criteria — Cracks, porosity, lack of fusion, incomplete
penetration, undercut, overlap, tungsten inclusions, arc strikes, oxidation, and rejection/repair
requirements.
10. Quality Assurance, Safety, Records, and Repair — Welding records, inspection records,
traceability, calibration, repair procedures, reinspection, corrective actions, contamination
control, and aerospace quality requirements.
.
1.
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During an aerospace welding job, why must the welder follow the approved welding procedure instead
of changing settings based only on personal experience?
A. Personal experience always produces excessive penetration
B. The approved procedure controls important welding variables and helps produce repeatable weld
quality
C. Aerospace welding does not allow experienced welders to make decisions
D. Welding machines cannot operate without a written procedure
Answer: B
Rationale: An approved procedure establishes controlled variables needed to produce consistent and
acceptable aerospace welds.
2.
Before welding an aerospace component, what is the main reason for checking the base metal
identification and material specification?
A. To select the correct cleaning color
B. To determine the correct material compatibility, procedure, and filler requirements
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C. To reduce the number of inspection steps
D. To determine the welder's certification expiration date
Answer: B
Rationale: Correct material identification is necessary because welding requirements vary between
different aerospace alloys and material groups.
3.
A welder discovers that the joint preparation is different from the approved drawing before starting
production welding. What should happen first?
A. Weld the joint and correct it later
B. Increase welding current to compensate
C. Stop and obtain clarification or correction before welding
D. Remove the joint from inspection records
Answer: C
Rationale: A joint that does not match the approved requirements should be resolved before welding
begins.
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4.
Why is cleanliness especially important when preparing aerospace components for welding operations?
A. Contamination can cause weld defects and reduce the required weld quality
B. Clean parts always require less filler metal
C. Clean parts automatically eliminate distortion
D. Cleaning is only required for appearance
Answer: A
Rationale: Oil, moisture, oxides, dirt, and other contaminants can interfere with welding and produce
unacceptable discontinuities.
5.
When GTAW is used on an aerospace component, what is the primary purpose of shielding gas around
the welding area?
A. To increase electrical resistance
B. To protect the molten weld metal from atmospheric contamination
C. To cool the welding machine
D. To increase joint thickness
AWS D17.1 Aerospace Welding Exam QUESTIONS
AND VERIFIED ANSWERS WITH RATIONALES JUST
RELEASED
AWS D17.1 Aerospace Welding Exam
10-Point Exam Coverage — Mostly Tested Areas
1. Aerospace Welding Code Requirements — AWS D17.1/D17.1M requirements, code
terminology, applicability, responsibilities, acceptance criteria, and use of approved procedures.
2. Welding Procedure Specification (WPS) and Qualification — WPS requirements, essential
variables, procedure qualification, test assemblies, qualification ranges, and changes requiring
requalification.
3. Welder and Welding Operator Qualification — Welder qualification tests, continuity,
qualification limits, performance variables, test positions, and documentation.
4. Aerospace Materials and Base Metals — Aluminum, nickel alloys, titanium, stainless steels,
magnesium, heat-resistant alloys, material identification, thickness considerations, and material
compatibility.
5. Joint Design and Fit-Up — Joint types, dimensions, alignment, root conditions, joint
preparation, tack welding, tolerances, access, and preweld inspection.
6. Welding Processes and Equipment — GTAW, GMAW, resistance welding, equipment setup,
shielding gases, polarity, current, voltage, travel speed, and machine controls.
7. Welding Technique and Process Control — Arc control, heat input, shielding, interpass
conditions, filler metals, cleaning, torch/electrode control, distortion control, and welding
sequence.
8. Inspection and Nondestructive Examination — Visual inspection, dimensional inspection,
radiographic testing, ultrasonic testing, liquid penetrant testing, and applicable inspection
requirements.
9. Weld Discontinuities and Acceptance Criteria — Cracks, porosity, lack of fusion, incomplete
penetration, undercut, overlap, tungsten inclusions, arc strikes, oxidation, and rejection/repair
requirements.
10. Quality Assurance, Safety, Records, and Repair — Welding records, inspection records,
traceability, calibration, repair procedures, reinspection, corrective actions, contamination
control, and aerospace quality requirements.
.
1.
, Page 2 of 145
During an aerospace welding job, why must the welder follow the approved welding procedure instead
of changing settings based only on personal experience?
A. Personal experience always produces excessive penetration
B. The approved procedure controls important welding variables and helps produce repeatable weld
quality
C. Aerospace welding does not allow experienced welders to make decisions
D. Welding machines cannot operate without a written procedure
Answer: B
Rationale: An approved procedure establishes controlled variables needed to produce consistent and
acceptable aerospace welds.
2.
Before welding an aerospace component, what is the main reason for checking the base metal
identification and material specification?
A. To select the correct cleaning color
B. To determine the correct material compatibility, procedure, and filler requirements
, Page 3 of 145
C. To reduce the number of inspection steps
D. To determine the welder's certification expiration date
Answer: B
Rationale: Correct material identification is necessary because welding requirements vary between
different aerospace alloys and material groups.
3.
A welder discovers that the joint preparation is different from the approved drawing before starting
production welding. What should happen first?
A. Weld the joint and correct it later
B. Increase welding current to compensate
C. Stop and obtain clarification or correction before welding
D. Remove the joint from inspection records
Answer: C
Rationale: A joint that does not match the approved requirements should be resolved before welding
begins.
, Page 4 of 145
4.
Why is cleanliness especially important when preparing aerospace components for welding operations?
A. Contamination can cause weld defects and reduce the required weld quality
B. Clean parts always require less filler metal
C. Clean parts automatically eliminate distortion
D. Cleaning is only required for appearance
Answer: A
Rationale: Oil, moisture, oxides, dirt, and other contaminants can interfere with welding and produce
unacceptable discontinuities.
5.
When GTAW is used on an aerospace component, what is the primary purpose of shielding gas around
the welding area?
A. To increase electrical resistance
B. To protect the molten weld metal from atmospheric contamination
C. To cool the welding machine
D. To increase joint thickness
