Page 1 of 143
AWS D1.2 Structural Aluminum Endorsement
Exam QUESTIONS AND VERIFIED ANSWERS WITH
RATIONALES JUST RELEASED
AWS D1.2 Structural Aluminum Endorsement Exam
10 MOST-TESTED EXAM COVERAGE AREAS
1. Aluminum Materials and Metallurgy — alloy identification, temper, heat treatment,
weldability, base-metal properties, filler metals, and effects of welding heat.
2. Design of Aluminum Welds — fillet welds, groove welds, plug welds, slot welds, stud welds,
joints, weld sizes, effective dimensions, and structural details.
3. Welding Procedure Specifications and Qualification — WPS requirements, procedure
qualification, essential variables, test assemblies, acceptance criteria, and PQR documentation.
4. Welder and Welding Operator Qualification — performance qualification, test positions,
process limitations, qualification ranges, retesting, and qualification records.
5. Fabrication Requirements — joint preparation, fit-up, alignment, cleanliness, preheating,
welding sequence, distortion control, tack welding, and workmanship.
6. Welding Processes for Aluminum — GTAW, GMAW, gas shielding, current selection, electrode
and wire selection, arc characteristics, and process controls.
7. Inspection and Acceptance — visual inspection, weld discontinuities, cracks, porosity,
incomplete fusion, undercut, dimensions, and acceptance requirements.
8. Nondestructive Examination — radiographic examination, penetrant examination, examination
procedures, indications, interpretation, and applicable records.
9. Reports and Records — WPS, PQR, welder qualification records, inspection reports, examination
reports, traceability, and documentation.
10. Code Application and Responsibilities — D1.2 scope, drawings, specifications, engineer
responsibilities, inspector responsibilities, fabrication compliance, and code interpretation.
(American Welding Society)
1.
What is the main purpose of AWS D1.2 when aluminum structures are fabricated using welded
structural members?
, Page 2 of 143
A. To regulate aluminum pressure vessels
B. To provide requirements for welding aluminum structures
C. To regulate electrical installations
D. To replace all engineering design calculations
Answer: B
Rationale: AWS D1.2 provides welding requirements for structures made from aluminum structural
alloys within its stated scope.
2.
Which material is specifically outside the normal scope of AWS D1.2 structural welding requirements?
A. Aluminum structural plate
B. Aluminum structural shapes
C. Aluminum pressure vessels
D. Aluminum structural tubing
Answer: C
Rationale: AWS states that D1.2 covers aluminum structural alloys but excludes aluminum pressure
vessels and pressure piping. (AWS Pubs)
, Page 3 of 143
3.
Before an inspector accepts an aluminum weld, what should be checked first when applying a specified
welding procedure?
A. The welder's favorite welding current
B. The approved welding procedure and applicable requirements
C. The color of the welding machine
D. The age of the welding helmet
Answer: B
Rationale: Inspection must be based on the applicable approved procedure, drawings, specifications,
and code requirements.
4.
Why is aluminum surface cleanliness especially important before beginning a structural welding
operation?
A. Dirt can improve weld penetration
B. Oxides and contaminants can interfere with sound weld formation
, Page 4 of 143
C. Cleaning changes aluminum into steel
D. Contamination increases electrical resistance only
Answer: B
Rationale: Aluminum oxide and contaminants can interfere with fusion and contribute to welding
defects.
5.
Which welding process commonly uses a nonconsumable tungsten electrode when welding aluminum?
A. GTAW
B. SMAW
C. SAW
D. FCAW
Answer: A
Rationale: GTAW uses a nonconsumable tungsten electrode and is commonly used for aluminum
welding.
6.
AWS D1.2 Structural Aluminum Endorsement
Exam QUESTIONS AND VERIFIED ANSWERS WITH
RATIONALES JUST RELEASED
AWS D1.2 Structural Aluminum Endorsement Exam
10 MOST-TESTED EXAM COVERAGE AREAS
1. Aluminum Materials and Metallurgy — alloy identification, temper, heat treatment,
weldability, base-metal properties, filler metals, and effects of welding heat.
2. Design of Aluminum Welds — fillet welds, groove welds, plug welds, slot welds, stud welds,
joints, weld sizes, effective dimensions, and structural details.
3. Welding Procedure Specifications and Qualification — WPS requirements, procedure
qualification, essential variables, test assemblies, acceptance criteria, and PQR documentation.
4. Welder and Welding Operator Qualification — performance qualification, test positions,
process limitations, qualification ranges, retesting, and qualification records.
5. Fabrication Requirements — joint preparation, fit-up, alignment, cleanliness, preheating,
welding sequence, distortion control, tack welding, and workmanship.
6. Welding Processes for Aluminum — GTAW, GMAW, gas shielding, current selection, electrode
and wire selection, arc characteristics, and process controls.
7. Inspection and Acceptance — visual inspection, weld discontinuities, cracks, porosity,
incomplete fusion, undercut, dimensions, and acceptance requirements.
8. Nondestructive Examination — radiographic examination, penetrant examination, examination
procedures, indications, interpretation, and applicable records.
9. Reports and Records — WPS, PQR, welder qualification records, inspection reports, examination
reports, traceability, and documentation.
10. Code Application and Responsibilities — D1.2 scope, drawings, specifications, engineer
responsibilities, inspector responsibilities, fabrication compliance, and code interpretation.
(American Welding Society)
1.
What is the main purpose of AWS D1.2 when aluminum structures are fabricated using welded
structural members?
, Page 2 of 143
A. To regulate aluminum pressure vessels
B. To provide requirements for welding aluminum structures
C. To regulate electrical installations
D. To replace all engineering design calculations
Answer: B
Rationale: AWS D1.2 provides welding requirements for structures made from aluminum structural
alloys within its stated scope.
2.
Which material is specifically outside the normal scope of AWS D1.2 structural welding requirements?
A. Aluminum structural plate
B. Aluminum structural shapes
C. Aluminum pressure vessels
D. Aluminum structural tubing
Answer: C
Rationale: AWS states that D1.2 covers aluminum structural alloys but excludes aluminum pressure
vessels and pressure piping. (AWS Pubs)
, Page 3 of 143
3.
Before an inspector accepts an aluminum weld, what should be checked first when applying a specified
welding procedure?
A. The welder's favorite welding current
B. The approved welding procedure and applicable requirements
C. The color of the welding machine
D. The age of the welding helmet
Answer: B
Rationale: Inspection must be based on the applicable approved procedure, drawings, specifications,
and code requirements.
4.
Why is aluminum surface cleanliness especially important before beginning a structural welding
operation?
A. Dirt can improve weld penetration
B. Oxides and contaminants can interfere with sound weld formation
, Page 4 of 143
C. Cleaning changes aluminum into steel
D. Contamination increases electrical resistance only
Answer: B
Rationale: Aluminum oxide and contaminants can interfere with fusion and contribute to welding
defects.
5.
Which welding process commonly uses a nonconsumable tungsten electrode when welding aluminum?
A. GTAW
B. SMAW
C. SAW
D. FCAW
Answer: A
Rationale: GTAW uses a nonconsumable tungsten electrode and is commonly used for aluminum
welding.
6.
