ITI Welder Viva Questions and Answers
In the welder practical, the examiner looks at your bead and joint, then asks how you set the current, chose the electrode, and avoided defects. These are the questions asked most often, with short answers.
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A uniform bead without porosity, undercut or slag inclusion, and correct joint preparation. Then your knowledge of electrodes, current, gas welding equipment and safety.
Welder viva questions with answers
Arc welding
How did you select the current for your electrode?
Roughly 40 amperes per millimetre of electrode core diameter as a starting point (about 120 to 130 A for a 3.15 mm electrode), then adjusted for position and plate thickness.
How to say it: Give the rule and the setting you used.
Why is the electrode coated (flux)?
The coating produces a gas shield and slag that protect the molten metal from air, stabilises the arc, and can add alloying elements.
What is arc length, and what happens if it is too long?
The gap between the electrode tip and the job, about equal to the core diameter. Too long gives spatter, poor penetration and porosity.
Why are some electrodes baked before use?
Low-hydrogen electrodes absorb moisture, which causes hydrogen cracking and porosity, so they are dried in an oven before use.
Gas welding
What are the colours of oxygen and acetylene cylinders?
Oxygen cylinders are black; acetylene cylinders are maroon.
What are the three types of flame?
Neutral (equal oxygen and acetylene, for most welding), carburising (excess acetylene) and oxidising (excess oxygen, used for brass).
Why is a flashback arrestor used?
It stops a flame travelling back through the hose into the regulator or cylinder.
Joints and defects
Name the basic types of joints.
Butt, lap, tee (fillet), corner and edge joints.
What is undercut, and what causes it?
A groove melted into the base metal at the edge of the weld and left unfilled. Caused by too high current, too long an arc, or wrong electrode angle.
What causes porosity?
Gas trapped in the weld: damp electrodes, rust, oil or paint on the job, or too long an arc.
What is slag inclusion and how do you avoid it?
Slag trapped inside the weld. Clean each run thoroughly with a chipping hammer and wire brush before the next pass.
Safety
Why is a welding helmet with the right filter glass necessary?
The arc gives off intense ultraviolet and infrared light that causes arc eye and burns. A shade of around 10 to 12 is common for manual arc welding.
What safety steps do you take with gas cylinders?
Keep them upright and chained, away from heat, check for leaks with soap solution, never use oil on oxygen fittings, and close valves after work.
Your opening answer to practise
Copy the lines that are true for you, replace every [bracket] and delete the rest. Every number should be one you can repeat in a practical test.
Opening answer for the Welder viva
- My name is [name], roll number [number], trainee of ITI Welder, [ITI name], session [year].
- Today my practical job was [e.g. a butt joint in flat position with a 3.15 mm electrode].
- I followed the safety steps: [PPE worn], [tools checked], [area cleaned after work].
- The result: [measurement / test reading / output], within [tolerance / expected value].
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Common questions
What questions are asked in the ITI welder viva?
Current setting, electrode coating and baking, arc length, gas cylinder colours, flame types, flashback arrestor, joint types, weld defects and their causes, and welding safety.
What is the most common viva question for welders?
How you selected the current for your electrode and what causes undercut or porosity.
Will they check my bead in the viva?
Yes. The examiner looks at the bead for uniformity, penetration and defects, and asks you to explain them.
Can I get these viva questions as a PDF?
Open the page, choose Print in your browser menu, then Save as PDF. The page prints without menus.
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