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During manual examination of a single-V carbon-steel butt weld, a narrow, continuous reflector maps along one bevel face. It peaks strongly when the beam approaches nearly normal to that face, but is much weaker from the opposite side. Upper and lower end responses are reproducible, and the reflector does not intersect the root. Taken together, these findings most strongly support:
Correct answer: C - Lack of sidewall fusion.
An API-UT-1 examination uses a DAC curve whose initial reference peak was set to 80% full-screen height (FSH). At the sound path of a confirmed 0.55-inch-long slag inclusion, the stored DAC is 48% FSH. The indication peaks at 24% FSH while scanning at 6 dB above reference gain; the stored curve does not shift with gain. What are the approximate reference-gain DAC percentage and recording decision?
Correct answer: A - 25% DAC; record the indication.
The wedge gives repeatable reference echoes on a flat block but rocks on the outside of a 2-inch-diameter pipe with a 0.218-inch wall. Echo amplitude changes sharply with hand pressure even after surface cleaning and fresh couplant. Before judging the weld from those echoes, the examiner should:
Correct answer: B - Use a curvature-compatible shoe and verify complete-system calibration on representative geometry.
Crack sizing in a 1.000-inch-thick flat plate confirms an ID-connected crack. Verified tip responses along its length give remaining ligaments of 0.220, 0.180, and 0.310 inch, measured from the OD surface. A separate echo would imply a 0.120-inch ligament, but reference checks identify it as a mode-converted arrival rather than a crack-tip response. The maximum crack height supported by these measurements is:
Correct answer: B - 0.820 inch.
A strong root-region echo persists along a pipe weld. Plotting from both scan directions places it on a measured ID high-low step, and its behavior matches adjacent sound weld with the same offset. Examination of the required volume is complete, calibration is valid, and the measured geometry accounts for the response. How should this finding be handled?
Correct answer: D - Attribute the echo to high-low geometry rather than making a crack or penetration-flaw call.
The calibration log shows that a 1.000-inch sound path reads correctly after a zero adjustment, but a 3.000-inch sound path reads 3.200 inches. Adjusting zero to place the long-path echo correctly moves the short-path echo off its mark. Coupling, echo identity, and wave mode have been verified. Which correction addresses the cause of this disagreement?
Correct answer: C - Perform two-point velocity/zero calibration, then verify both known sound paths.
Low-amplitude, irregular echoes form a localized cloud within the metal of a shielded-metal-arc butt weld. Individual echoes vary independently as the probe is skewed, and the response fades gradually into background at the edges of the affected region. No continuous reflecting plane or reproducible tip pair is found. Which flaw type best fits this pattern?
Correct answer: A - Clustered weld-metal porosity.
After scanning the full length of an OD-connected crack in a 0.750-inch plate, an examiner obtains two different maximum heights. Tip diffraction gives 0.140 inch from both scan directions, with repeatable tip identification and satisfactory before-and-after reference checks. A focused refracted longitudinal-wave (HALT) setup gives 0.220 inch, but its selected echo lies outside the depth interval in which that setup has demonstrated accurate sizing. Which reporting choice is supported?
Correct answer: D - Use 0.140 inch, supported by the validated tip-diffraction measurement.
An existing butt-weld scan plan aims the shear-wave beam perpendicular to the weld axis from each side, with adequate raster overlap through the wall and no along-weld skew. The plan must also detect vertical cracks whose planes run across the weld rather than along it. What coverage is still needed?
Correct answer: C - Add opposing along-weld or suitably skewed beams to interrogate the transverse crack planes.
At the longest inspection paths in a carbon-steel weld, a 5 MHz shear-wave probe cannot produce a usable reference echo. Contact, angle, range, and instrument operation check correctly; scattering and attenuation dominate. A 2.25 MHz probe with suitable geometry is available for a new calibrated setup. What tradeoff should guide the substitution?
Correct answer: C - Improved penetration, with potentially poorer separation of closely spaced reflectors.
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