CWB Welding Inspector Level 2 Exam 2026/2027 -
All Modules Covered with 100% Correct Questions
& Graded A Answers
— MODULE 1: CODE & STANDARD MASTERY —
1.
A fabricator proposes to use a pre-qualified WPS from CSA W59 for a complete joint
penetration (CJP) groove weld connecting a beam (ASTM A992) to a column (ASTM
A572 Gr. 50). The weld is in a seismic moment frame. According to CSA W59:2026,
Clause 5, what is a critical verification the inspector must make before approving its
use?
A) Verify the welder is certified to CSA W47.1.
B) Confirm the base metals are both listed in Table 5.1 (Pre-qualified Base Metal
Combinations).
C) Ensure the welding consumable is identical to that used in the supporting PQR.
D) Check that the joint design matches the detail in the structural drawings.
Correct Answer: B
Correct Answer Text: Confirm the base metals are both listed in Table 5.1 (Pre-qualified
Base Metal Combinations).
Rationale: Pre-qualified WPSs in CSA W59 are valid only for base-metal combinations
explicitly listed in the standard’s tables. A992 to A572 Gr. 50 is common, but the
,inspector must verify its inclusion. Welder certification (A) is separate. The consumable
(C) is governed by the WPS itself. Joint design (D) is important but not the specific
clause governing pre-qualification validity.
2.
During an audit, you find a company using a WPS qualified by a PQR that used 15 mm
thick test coupons. Production involves welding 40 mm thick plates. The essential
variables (joint design, process, etc.) are unchanged. Is this acceptable per CSA
W47.1-2026?
A) Yes, qualification on 15 mm qualifies for all greater thicknesses.
B) No, the PQR must qualify a thickness at least equal to the production thickness.
C) Yes, but only for materials with a P-Number 1 grouping.
D) No, the qualification range is only 1.5× the test coupon thickness (22.5 mm).
Correct Answer: B
Correct Answer Text: No, the PQR must qualify a thickness at least equal to the
production thickness.
Rationale: CSA W47.1 (and ASME Section IX) generally require the test coupon
thickness to qualify thicknesses up to 2× the test coupon, but only if the test coupon is
3/8" (≈10 mm) or greater. For thicker materials, the PQR coupon must be at least as
thick as the production weld to qualify the procedure for that thickness. This is a
common exam point testing precise knowledge of qualification ranges.
— MODULE 2: WELDING PROCESSES & PROCEDURE CONTROL —
3.
, A WPS for SAW (Submerged Arc Welding) lists a voltage of 28–32 V and a travel speed
of 40–45 cm/min. During surveillance, you measure 33 V and 38 cm/min. What is your
correct action as the Level 2 Inspector?
A) Stop welding immediately; both parameters are outside the qualified range.
B) Allow welding to continue; voltage is slightly high but speed is within range.
C) Document the deviation as a minor non-conformance but allow welding to continue.
D) Stop welding; voltage is an essential variable for SAW and is outside the qualified
range.
Correct Answer: D
Correct Answer Text: Stop welding; voltage is an essential variable for SAW and is
outside the qualified range.
Rationale: For SAW, arc voltage is typically classified as an essential variable. Operating
outside the range specified on the qualified WPS invalidates the procedure qualification.
The weld must be stopped, and the procedure must be re-qualified or amended. Travel
speed may be a non-essential or supplementary essential variable, but the voltage
violation alone is sufficient to halt production.
4.
A GMAW WPS lists 1.2 mm diameter ER70S-6 electrode, 28 V, 280 A, 0.45 m/min WFS,
6.0 mm CTWD. Production switches to 1.0 mm diameter wire (same classification) but
keeps all other parameters identical. Is this acceptable?
A) Yes—same electrode classification means the change is non-essential.
B) No—electrode diameter is an essential variable; requalification is required.
All Modules Covered with 100% Correct Questions
& Graded A Answers
— MODULE 1: CODE & STANDARD MASTERY —
1.
A fabricator proposes to use a pre-qualified WPS from CSA W59 for a complete joint
penetration (CJP) groove weld connecting a beam (ASTM A992) to a column (ASTM
A572 Gr. 50). The weld is in a seismic moment frame. According to CSA W59:2026,
Clause 5, what is a critical verification the inspector must make before approving its
use?
A) Verify the welder is certified to CSA W47.1.
B) Confirm the base metals are both listed in Table 5.1 (Pre-qualified Base Metal
Combinations).
C) Ensure the welding consumable is identical to that used in the supporting PQR.
D) Check that the joint design matches the detail in the structural drawings.
Correct Answer: B
Correct Answer Text: Confirm the base metals are both listed in Table 5.1 (Pre-qualified
Base Metal Combinations).
Rationale: Pre-qualified WPSs in CSA W59 are valid only for base-metal combinations
explicitly listed in the standard’s tables. A992 to A572 Gr. 50 is common, but the
,inspector must verify its inclusion. Welder certification (A) is separate. The consumable
(C) is governed by the WPS itself. Joint design (D) is important but not the specific
clause governing pre-qualification validity.
2.
During an audit, you find a company using a WPS qualified by a PQR that used 15 mm
thick test coupons. Production involves welding 40 mm thick plates. The essential
variables (joint design, process, etc.) are unchanged. Is this acceptable per CSA
W47.1-2026?
A) Yes, qualification on 15 mm qualifies for all greater thicknesses.
B) No, the PQR must qualify a thickness at least equal to the production thickness.
C) Yes, but only for materials with a P-Number 1 grouping.
D) No, the qualification range is only 1.5× the test coupon thickness (22.5 mm).
Correct Answer: B
Correct Answer Text: No, the PQR must qualify a thickness at least equal to the
production thickness.
Rationale: CSA W47.1 (and ASME Section IX) generally require the test coupon
thickness to qualify thicknesses up to 2× the test coupon, but only if the test coupon is
3/8" (≈10 mm) or greater. For thicker materials, the PQR coupon must be at least as
thick as the production weld to qualify the procedure for that thickness. This is a
common exam point testing precise knowledge of qualification ranges.
— MODULE 2: WELDING PROCESSES & PROCEDURE CONTROL —
3.
, A WPS for SAW (Submerged Arc Welding) lists a voltage of 28–32 V and a travel speed
of 40–45 cm/min. During surveillance, you measure 33 V and 38 cm/min. What is your
correct action as the Level 2 Inspector?
A) Stop welding immediately; both parameters are outside the qualified range.
B) Allow welding to continue; voltage is slightly high but speed is within range.
C) Document the deviation as a minor non-conformance but allow welding to continue.
D) Stop welding; voltage is an essential variable for SAW and is outside the qualified
range.
Correct Answer: D
Correct Answer Text: Stop welding; voltage is an essential variable for SAW and is
outside the qualified range.
Rationale: For SAW, arc voltage is typically classified as an essential variable. Operating
outside the range specified on the qualified WPS invalidates the procedure qualification.
The weld must be stopped, and the procedure must be re-qualified or amended. Travel
speed may be a non-essential or supplementary essential variable, but the voltage
violation alone is sufficient to halt production.
4.
A GMAW WPS lists 1.2 mm diameter ER70S-6 electrode, 28 V, 280 A, 0.45 m/min WFS,
6.0 mm CTWD. Production switches to 1.0 mm diameter wire (same classification) but
keeps all other parameters identical. Is this acceptable?
A) Yes—same electrode classification means the change is non-essential.
B) No—electrode diameter is an essential variable; requalification is required.
