What is the maximum allowed overlap of the cover pass bead on the pipe surface?

• A. 3/16 inch
• B. 3/32 inch
• C. 1/8 inch
• D. 1/4 inch

Answer: (B)

In TIG pipe welding, controlling how much the final cover pass bead overlaps onto the pipe surface keeps the weld surface smooth, with a consistent profile and minimal need for grinding. The maximum overlap is set to a small value so the cover pass seals the weld without creating excessive reinforcement that would distort the surface or hide defects. A 3/32 inch overlap is this tight tolerance—small enough to maintain a near-flush surface and consistent wall thickness, while still providing the finishing cover you need. Larger overlaps, like 1/8 inch, 3/16 inch, or 1/4 inch, would produce a noticeably raised, bulky crown and could complicate inspection and subsequent fit-up or finishing.