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API-577 API Welding Inspection and Metallurgy Exam Free Practice Exam Questions (2025 Updated)

Prepare effectively for your API API-577 Welding Inspection and Metallurgy Exam certification with our extensive collection of free, high-quality practice questions. Each question is designed to mirror the actual exam format and objectives, complete with comprehensive answers and detailed explanations. Our materials are regularly updated for 2025, ensuring you have the most current resources to build confidence and succeed on your first attempt.

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Total 110 questions

What is the minimum liquid level that should be maintained above the area that is to be hot tapped on a storage tank or vessel?

A.

1 ft. (300 mm)

B.

2 ft. (600 mm)

C.

3 ft. (900 mm)

D.

4 ft. (1200 mm)

Where is the weld HAZ assumed to be for purposes of hardness testing?

A.

0.25 inch on either side of the fusion zone

B.

0.25 inch away from the toe of the weld into the base metal

C.

1 inch on either side of the centerline of the weld

D.

Just adjacent to the toe of the weld

Which of the following is a hazard associated with in-service welding on a carbon steel pipe containing chlorine?

A.

Explosion or unstable reaction with the addition of localized heat.

B.

Exothermic decomposition or explosion.

C.

Carbon steel will burn in the presence of chlorine and high heat.

D.

Hydrogen released during welding process can initiate hydrogen-assisted cracking.

What is the liquid flow rate range that should be maintained in piping to be hot tapped?

A.

0.05 - 2.7 ft./sec (0.015 - 0.82 m/sec)

B.

1.3 - 4.0 ft./sec (0.40 - 1.20 m/sec)

C.

2.3 - 3.3 ft./sec (0.70 - 1.00 m/sec)

D.

4.1 - 5.5 ft./sec (1.25 - 1.68 m/sec)

If an individual changes an essential variable in the WPS, the individual must:

A.

Re-qualify the PQR.

B.

Re-qualify the WPS.

C.

Record the change on the existing WPS.

D.

List the change as a supplement to the WPS.

Which of the following is used to determine the soundness and ductility of a groove weld?

A.

Ductility test

B.

Guided bend test

C.

Notch toughness test

D.

Tension test

ACFM is an NDE technique ideal for inspecting:

A.

Nozzles, ring-grooves, and grind-out areas.

B.

Lap joint welds and uphill welding.

C.

Butt welds (single and double bevel) and plug welds.

D.

Fillet welds, J-welds, and seal welds.

Heating a round bar to an elevated temperature and then quenching one end is a test method to determine:

A.

Hardenability.

B.

Temper embrittlement.

C.

Heat treatability.

D.

Thermal conductivity.

For GMAW welding, the last number of the electrode identifies the:

A.

Chemical composition.

B.

Strength of the electrode.

C.

Coating characteristics.

D.

Operating characteristics.

Which of the following is not usually an essential variable on a WPS form?

A.

Welding technique

B.

Groove design

C.

Base metal

D.

Welding position

P-numbers are based on which of the following?

A.

Comparable base metal characteristics

B.

Weldability characteristics of base metal

C.

Electrode characteristics

D.

Chemical composition of the base metal

As a result of welding, metals with a high coefficient of thermal expansion are:

A.

More susceptible to distortion during welding.

B.

Less susceptible to cracking during welding.

C.

More susceptible to brittle fracture.

D.

Less susceptible to brittle fracture.

The weld symbol represents which type of weld groove?

A.

Parallel

B.

Scarf

C.

Flare

D.

Bevel

Rules for qualifying welding operators using radiography on a production weld require what minimum weld length to be examined?

A.

6 in. (150 mm)

B.

12 in. (300 mm)

C.

24 in.(600 mm)

D.

36 in. (900 mm)

What is a discontinuity?

A.

An interruption in the normal physical structure of a material.

B.

An imperfection which is detectable with NDE.

C.

The response or evidence from the application of NDE.

D.

A departure of a quality characteristic from its intended condition.

Any electrodes that have become wet:

A.

Should be placed in a warming oven only if they are low-hydrogen.

B.

Should not be used for jobs requiring low-hydrogen electrodes.

C.

Should be used at a higher amperage than recommended by the manufacturer.

D.

Should be discarded.

API Recommended Practice 577 provides:

A.

A definition of welds that should be inspected in refinery and chemical plant equipment.

B.

A definition of specific techniques and practices that should be used for welding inspection.

C.

Guidance on the extent and scope of inspection required for specific types of welds.

D.

Guidance on welding inspection during the fabrication and repairing of refinery equipment and piping.

Which of the following determines the necessity for preheat and postweld heat treatment?

A.

The percentage of carbon that will be in the completed weld

B.

The as-rolled hardness of the welding components

C.

The carbon equivalent of the steel

D.

The rate of cooling after the welding is completed

Items to be included in the WPS for GMAW process are:

A.

Joint design and test coupon thickness.

B.

Base metal P-number and deposited metal thickness.

C.

Type of welding process and test coupon thickness.

D.

Electrode-flux class and electrical characteristics.

The distance the weld metal extends from the weld face into a joint, exclusive of weld reinforcement is called:

A.

Groove angle

B.

Joint penetration

C.

The weld body

D.

Complete penetration

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Total 110 questions
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