AWS CERTIFIED WELDER BRIDGE WELDING (D1.5) EXAM
QUESTIONS AND CORRECT ANSWERS (VERIFIED ANSWERS)
PLUS RATIONALES 2026 Q&A | INSTANT DOWNLOAD PDF
Core Domains:
- Qualification
- Fabrication
- Inspection
- Reports and Records
- Materials and Design
- Fracture Control Plan
- Preheat and Interpass Temperature
- Welding Processes and Consumables
Introduction
This comprehensive examination assesses the candidate's mastery of the
AASHTO/AWS D1.5M/D1.5 Bridge Welding Code. It evaluates
knowledge of qualification requirements, fabrication procedures,
inspection criteria, documentation, materials, design considerations,
and fracture control. Questions are presented in multiple-choice and
scenario-based formats requiring integration of knowledge across
domains. Emphasis is placed on code compliance, critical decision-
making, and real-world application. Successful completion demonstrates
readiness for bridge welding inspection and certification.
SECTION ONE: QUESTIONS 1–100
Question 1
What is the minimum base metal thickness covered by the
AASHTO/AWS D1.5 Bridge Welding Code?
A. 1.5 mm
B. 2.5 mm
,C. 3 mm
D. 5 mm
C. 3 mm
RATIONALE: The D1.5 code applies to welding of base metals 3
mm (approximately 1/8 inch) and thicker. Thinner materials are not
covered by this code.
Question 2
Which of the following is the primary base metal specification for
bridge welding under D1.5?
A. ASTM A36
B. AASHTO M 270 / ASTM A709
C. ASTM A572
D. ASTM A992
B. AASHTO M 270 / ASTM A709
RATIONALE: AASHTO M 270 / ASTM A709 is the standard
specification for structural steel for bridges and is the primary base metal
specification referenced in D1.5.
Question 3
Which welding process is the only one prequalified under D1.5?
A. FCAW
B. SAW
C. SMAW with low-hydrogen electrodes
D. GMAW
C. SMAW with low-hydrogen electrodes
RATIONALE: Only SMAW WPSs with low-hydrogen electrodes
are prequalified under D1.5. FCAW, SAW, and GMAW WPSs require
qualification testing.
,Question 4
What is the primary purpose of preheat in bridge welding?
A. To increase welding speed
B. To prevent cracking
C. To reduce distortion
D. To improve appearance
B. To prevent cracking
RATIONALE: Preheat is used primarily to prevent hydrogen-
induced cracking by slowing the cooling rate and allowing hydrogen to
escape from the weld.
Question 5
Within what distance from the arc must preheat be achieved in all
directions?
A. 1 inch
B. 2 inches
C. 3 inches
D. 4 inches
C. 3 inches
RATIONALE: Preheat must be achieved within 3 inches of the arc
in all directions, including through the thickness of the material being
welded.
Question 6
What is the maximum interpass temperature for A709 Grade 70
and higher?
A. 300°F
B. 350°F
C. 400°F
D. 450°F
, C. 400°F
RATIONALE: The maximum interpass temperature for A709 Grade
70 and higher is 400°F, unless otherwise approved. This limits the heat
input to preserve mechanical properties.
Question 7
What is the heat input formula for welding?
A. (Current × Voltage) / Travel Speed
B. (Current × Voltage × 60) / (Travel Speed × 1000)
C. Current / (Voltage × Travel Speed)
D. Voltage / (Current × Travel Speed)
B. (Current × Voltage × 60) / (Travel Speed × 1000)
RATIONALE: Heat input (kJ/in) = (Amperage × Voltage × 60) /
(Travel Speed in inches per minute × 1000).
Question 8
Increasing travel speed while keeping other variables constant will:
A. Increase heat input
B. Decrease heat input
C. Have no effect on heat input
D. Double heat input
B. Decrease heat input
RATIONALE: Travel speed is inversely proportional to heat input.
Increasing travel speed decreases heat input per unit length of weld.
Question 9
What is the purpose of a backing bar in bridge welding?
A. To increase weld strength
B. To support the molten weld pool and prevent burn-through
QUESTIONS AND CORRECT ANSWERS (VERIFIED ANSWERS)
PLUS RATIONALES 2026 Q&A | INSTANT DOWNLOAD PDF
Core Domains:
- Qualification
- Fabrication
- Inspection
- Reports and Records
- Materials and Design
- Fracture Control Plan
- Preheat and Interpass Temperature
- Welding Processes and Consumables
Introduction
This comprehensive examination assesses the candidate's mastery of the
AASHTO/AWS D1.5M/D1.5 Bridge Welding Code. It evaluates
knowledge of qualification requirements, fabrication procedures,
inspection criteria, documentation, materials, design considerations,
and fracture control. Questions are presented in multiple-choice and
scenario-based formats requiring integration of knowledge across
domains. Emphasis is placed on code compliance, critical decision-
making, and real-world application. Successful completion demonstrates
readiness for bridge welding inspection and certification.
SECTION ONE: QUESTIONS 1–100
Question 1
What is the minimum base metal thickness covered by the
AASHTO/AWS D1.5 Bridge Welding Code?
A. 1.5 mm
B. 2.5 mm
,C. 3 mm
D. 5 mm
C. 3 mm
RATIONALE: The D1.5 code applies to welding of base metals 3
mm (approximately 1/8 inch) and thicker. Thinner materials are not
covered by this code.
Question 2
Which of the following is the primary base metal specification for
bridge welding under D1.5?
A. ASTM A36
B. AASHTO M 270 / ASTM A709
C. ASTM A572
D. ASTM A992
B. AASHTO M 270 / ASTM A709
RATIONALE: AASHTO M 270 / ASTM A709 is the standard
specification for structural steel for bridges and is the primary base metal
specification referenced in D1.5.
Question 3
Which welding process is the only one prequalified under D1.5?
A. FCAW
B. SAW
C. SMAW with low-hydrogen electrodes
D. GMAW
C. SMAW with low-hydrogen electrodes
RATIONALE: Only SMAW WPSs with low-hydrogen electrodes
are prequalified under D1.5. FCAW, SAW, and GMAW WPSs require
qualification testing.
,Question 4
What is the primary purpose of preheat in bridge welding?
A. To increase welding speed
B. To prevent cracking
C. To reduce distortion
D. To improve appearance
B. To prevent cracking
RATIONALE: Preheat is used primarily to prevent hydrogen-
induced cracking by slowing the cooling rate and allowing hydrogen to
escape from the weld.
Question 5
Within what distance from the arc must preheat be achieved in all
directions?
A. 1 inch
B. 2 inches
C. 3 inches
D. 4 inches
C. 3 inches
RATIONALE: Preheat must be achieved within 3 inches of the arc
in all directions, including through the thickness of the material being
welded.
Question 6
What is the maximum interpass temperature for A709 Grade 70
and higher?
A. 300°F
B. 350°F
C. 400°F
D. 450°F
, C. 400°F
RATIONALE: The maximum interpass temperature for A709 Grade
70 and higher is 400°F, unless otherwise approved. This limits the heat
input to preserve mechanical properties.
Question 7
What is the heat input formula for welding?
A. (Current × Voltage) / Travel Speed
B. (Current × Voltage × 60) / (Travel Speed × 1000)
C. Current / (Voltage × Travel Speed)
D. Voltage / (Current × Travel Speed)
B. (Current × Voltage × 60) / (Travel Speed × 1000)
RATIONALE: Heat input (kJ/in) = (Amperage × Voltage × 60) /
(Travel Speed in inches per minute × 1000).
Question 8
Increasing travel speed while keeping other variables constant will:
A. Increase heat input
B. Decrease heat input
C. Have no effect on heat input
D. Double heat input
B. Decrease heat input
RATIONALE: Travel speed is inversely proportional to heat input.
Increasing travel speed decreases heat input per unit length of weld.
Question 9
What is the purpose of a backing bar in bridge welding?
A. To increase weld strength
B. To support the molten weld pool and prevent burn-through
