SKILLS USA WELDING EXAM | 2026/2027
SkillsUSA Welding Competition Written Exam with Complete Questions & Verified Correct
Answers | Latest Version
Overview
This 2026/2027 updated resource contains the latest SkillsUSA Welding Competition
Written Examination with the exact 100 questions and verified correct answers, following
current AWS (American Welding Society) D1.1 Structural Welding Code, OSHA 29 CFR
1910/1926 safety standards, NCCER (National Center for Construction Education and Research)
curriculum, and industry best practices for welding technology. Key Features
Actual SkillsUSA welding exam format with the official 100 questions
Comprehensive coverage of welding processes, metallurgy, blueprint reading, and safety
Updated 2026/2027 AWS code revisions and OSHA safety regulations
Practical application scenarios and troubleshooting exercises
Industry-standard calculations and measurement techniques
Core Content Areas (100 Total Questions)
● Welding Processes & Techniques (25 Qs)
● Blueprint Reading & Welding Symbols (20 Qs)
● Metallurgy & Materials Science (18 Qs)
● Safety Procedures & OSHA Regulations (15 Qs)
● Quality Control & Inspection (12 Qs)
● Equipment Setup & Maintenance (10 Qs)
Answer Format: Correct answers are marked in bold green and include:
- AWS D1.1 code requirement citations and applications
- OSHA 29 CFR 1910/1926 regulation implementations
- Welding procedure specification (WPS) development steps
- Welding symbol interpretation and application
- Defect identification and remediation techniques
,- Heat input calculations and distortion control methods Updates for 2026/2027
Reflects 2026-2027 AWS D1.1 Structural Welding Code revisions
Updated OSHA respiratory protection and ventilation requirements
Enhanced robotics and automation integration in welding processes
New materials and advanced alloys joining techniques
Revised nondestructive testing (NDT) methods and acceptance criteria
Updated welding procedure qualification records (PQR) standards
New green welding technologies and sustainability practices
Revised personal protective equipment (PPE) requirements and standards
SkillsUSA Welding Written Exam – 100 Questions & Verified Answers with
Rationales
1. According to AWS D1.1, what is the minimum preheat temperature for welding
ASTM A572 Grade 50 steel that is 2 inches thick?
A. 50°F
B. 70°F
C. 150°F
D. 225°F
Rationale: AWS D1.1 Table 3.2 specifies a minimum preheat of 150°F for ASTM A572 Grade 50
when thickness exceeds 1.5 inches. Preheat prevents hydrogen-induced cracking and controls
cooling rate.
2. Which welding process uses a non-consumable tungsten electrode?
A. SMAW
B. GTAW
,C. GMAW
D. FCAW
Rationale: Gas Tungsten Arc Welding (GTAW/TIG) uses a non-consumable tungsten electrode
to produce the weld. Filler metal is added separately if needed.
3. What does the third digit in an E7018 electrode designation indicate?
A. Tensile strength
B. Welding position
C. Type of coating and current
D. Hydrogen content
Rationale: In AWS A5.1, the third digit (e.g., “1” in E7018) indicates welding positions, but the
fourth digit (e.g., “8”) defines coating type and recommended current. However, the third digit
in combination with the fourth defines usability. Clarification: For E7018, “18” together
indicates low-hydrogen potassium coating usable in all positions with AC or DCEP.
4. OSHA requires that oxygen cylinders be stored at least how far from fuel-gas
cylinders?
A. 5 feet
B. 20 feet
C. 30 feet
D. 50 feet
Rationale: OSHA 29 CFR 1910.101(b) states oxygen cylinders must be stored at least 20 feet
from fuel-gas cylinders or separated by a non-combustible barrier at least 5 feet high with fire
resistance rating of ½ hour.
5. In a welding symbol, where is the tail located?
A. At the end of the arrow
B. On the reference line opposite the arrow side
, C. Connected to the reference line, used for supplementary info
D. Below the weld symbol
Rationale: The tail is attached to the reference line and is used to convey supplementary
information such as process, specification, or other references. It is not always present and is
omitted when not needed (per AWS A2.4).
6. Which metal is most susceptible to hydrogen-induced cracking?
A. Aluminum
B. Copper
C. High-carbon steel
D. Austenitic stainless steel
Rationale: High-carbon and high-strength low-alloy (HSLA) steels are prone to
hydrogen-induced cracking due to their hard, brittle microstructures and susceptibility to
hydrogen embrittlement. Austenitic stainless steels are generally immune.
7. What is the primary purpose of post-weld heat treatment (PWHT)?
A. Increase hardness
B. Improve appearance
C. Reduce residual stresses and hydrogen content
D. Speed up production
Rationale: PWHT is performed to relieve residual stresses, reduce hardness in the
heat-affected zone (HAZ), and allow diffusion of trapped hydrogen, thereby minimizing risk of
delayed cracking (AWS D1.1 Clause 5.12).
8. According to OSHA 29 CFR 1910.252, what is the minimum ventilation
requirement for welding in confined spaces?
A. Natural ventilation only
B. 50 CFM per welder
SkillsUSA Welding Competition Written Exam with Complete Questions & Verified Correct
Answers | Latest Version
Overview
This 2026/2027 updated resource contains the latest SkillsUSA Welding Competition
Written Examination with the exact 100 questions and verified correct answers, following
current AWS (American Welding Society) D1.1 Structural Welding Code, OSHA 29 CFR
1910/1926 safety standards, NCCER (National Center for Construction Education and Research)
curriculum, and industry best practices for welding technology. Key Features
Actual SkillsUSA welding exam format with the official 100 questions
Comprehensive coverage of welding processes, metallurgy, blueprint reading, and safety
Updated 2026/2027 AWS code revisions and OSHA safety regulations
Practical application scenarios and troubleshooting exercises
Industry-standard calculations and measurement techniques
Core Content Areas (100 Total Questions)
● Welding Processes & Techniques (25 Qs)
● Blueprint Reading & Welding Symbols (20 Qs)
● Metallurgy & Materials Science (18 Qs)
● Safety Procedures & OSHA Regulations (15 Qs)
● Quality Control & Inspection (12 Qs)
● Equipment Setup & Maintenance (10 Qs)
Answer Format: Correct answers are marked in bold green and include:
- AWS D1.1 code requirement citations and applications
- OSHA 29 CFR 1910/1926 regulation implementations
- Welding procedure specification (WPS) development steps
- Welding symbol interpretation and application
- Defect identification and remediation techniques
,- Heat input calculations and distortion control methods Updates for 2026/2027
Reflects 2026-2027 AWS D1.1 Structural Welding Code revisions
Updated OSHA respiratory protection and ventilation requirements
Enhanced robotics and automation integration in welding processes
New materials and advanced alloys joining techniques
Revised nondestructive testing (NDT) methods and acceptance criteria
Updated welding procedure qualification records (PQR) standards
New green welding technologies and sustainability practices
Revised personal protective equipment (PPE) requirements and standards
SkillsUSA Welding Written Exam – 100 Questions & Verified Answers with
Rationales
1. According to AWS D1.1, what is the minimum preheat temperature for welding
ASTM A572 Grade 50 steel that is 2 inches thick?
A. 50°F
B. 70°F
C. 150°F
D. 225°F
Rationale: AWS D1.1 Table 3.2 specifies a minimum preheat of 150°F for ASTM A572 Grade 50
when thickness exceeds 1.5 inches. Preheat prevents hydrogen-induced cracking and controls
cooling rate.
2. Which welding process uses a non-consumable tungsten electrode?
A. SMAW
B. GTAW
,C. GMAW
D. FCAW
Rationale: Gas Tungsten Arc Welding (GTAW/TIG) uses a non-consumable tungsten electrode
to produce the weld. Filler metal is added separately if needed.
3. What does the third digit in an E7018 electrode designation indicate?
A. Tensile strength
B. Welding position
C. Type of coating and current
D. Hydrogen content
Rationale: In AWS A5.1, the third digit (e.g., “1” in E7018) indicates welding positions, but the
fourth digit (e.g., “8”) defines coating type and recommended current. However, the third digit
in combination with the fourth defines usability. Clarification: For E7018, “18” together
indicates low-hydrogen potassium coating usable in all positions with AC or DCEP.
4. OSHA requires that oxygen cylinders be stored at least how far from fuel-gas
cylinders?
A. 5 feet
B. 20 feet
C. 30 feet
D. 50 feet
Rationale: OSHA 29 CFR 1910.101(b) states oxygen cylinders must be stored at least 20 feet
from fuel-gas cylinders or separated by a non-combustible barrier at least 5 feet high with fire
resistance rating of ½ hour.
5. In a welding symbol, where is the tail located?
A. At the end of the arrow
B. On the reference line opposite the arrow side
, C. Connected to the reference line, used for supplementary info
D. Below the weld symbol
Rationale: The tail is attached to the reference line and is used to convey supplementary
information such as process, specification, or other references. It is not always present and is
omitted when not needed (per AWS A2.4).
6. Which metal is most susceptible to hydrogen-induced cracking?
A. Aluminum
B. Copper
C. High-carbon steel
D. Austenitic stainless steel
Rationale: High-carbon and high-strength low-alloy (HSLA) steels are prone to
hydrogen-induced cracking due to their hard, brittle microstructures and susceptibility to
hydrogen embrittlement. Austenitic stainless steels are generally immune.
7. What is the primary purpose of post-weld heat treatment (PWHT)?
A. Increase hardness
B. Improve appearance
C. Reduce residual stresses and hydrogen content
D. Speed up production
Rationale: PWHT is performed to relieve residual stresses, reduce hardness in the
heat-affected zone (HAZ), and allow diffusion of trapped hydrogen, thereby minimizing risk of
delayed cracking (AWS D1.1 Clause 5.12).
8. According to OSHA 29 CFR 1910.252, what is the minimum ventilation
requirement for welding in confined spaces?
A. Natural ventilation only
B. 50 CFM per welder
