102 review Flashcards
1
Q
Which one of the following would NOT be considered a weld fault?
a) slag inclusions
b) arc blow
c) porosity
d) cracking
A
b) arc blow
2
Q
Which one of the following would NOT be considered a cause of incomplete penetration?
a) poor joint design
b) improper manipulation of electrode
c) poor fit-up
d) short arc length
A
d) short arc length
3
Q
Which of the following is a dimensional weld fault?
a) gas pocket
b) slag inclusion
c) warpage
d) lack of fusion
A
c) warpage
4
Q
Which of the following is NOT a dimensional weld fault?
a) warpage
b) distortion
c) joint mis-alignment
d) lack of fusion
A
d) lack of fusion
5
Q
Fillet welds should have:
A) flat profile
B) concave profile
C) flat to concave profile
D) flat to convex profile
A
D) flat to convex profile
6
Q
Welding codes and standards:
A) are manipulated to serve the welder needs
B) are suggested good practices and need not be followed
C) define acceptance on welds based on service required
D) both A and C
A
C) define acceptance on welds based on service required
7
Q
The three general classes of weld faults are:
A) dimensional, structural and defective properties
B) dimensional, structural and metallic properties
C) dimensional, structural and mechanical properties
D) mechanical, chemical and physical faults
A
A) dimensional, structural and defective properties
8
Q
Which of the following is an example of a dimensional defect?
A excessive cap
B) distortion
C) incorrect fit up
D) all of the above
A
D) all of the above
9
Q
Structural discontinuities are generally caused:
A) before the welding operation (poor fit up)
B) after the welding operation (distortion)
C) during the weld operation
D) by incorrect electrode selection
A
C) during the weld operation
10
Q
Which of the following base metal conditions may cause defective properties?
A) chemical composition
B) mill scale
C) mechanical properties
D) all of the above
A
D) all of the above
11
Q
When we apply a load to an object, the lines of force that run through it are known as:
a) force lines
b) stress flow lines
c) load lines
d) notch lines
A
b) stress flow lines
12
Q
Failure to taper out rapid changes in cross section would:
A) cause a structural discontinuity
B) create a a notch effect
C) change physical properties of weldment
D) all of the above
A
B) create a a notch effect
13
Q
To determine the amount of taper when joining material of different thickness, you would:
A) multiply thickest section by 3
B) multiply thickest section by 2
C) multiply thinnest section by 4
D) multiply difference of thickness by 3
A
D) multiply difference of thickness by 3
14
Q
Which condition should be avoided to reduce notch effect?
A) excessive weld convexity
B) excessive weld concavity
C) sharp corners
D) all of the above
A
D) all of the above
15
Q
Which weld fault would be considered most serious in any weldment?
a) over welding
b) distortion
c) slag inclusion
d) internal cracking
A
d) internal cracking
16
Q
Gaseous inclusions such as porosity can be caused by:
a) oil or paint on surface
b) using a short arc length
c) keeping the puddle very fluid
d) using slow travel speeds
A
a) oil or paint on surface
17
Q
Lack of fusion when arc welding is called:
a) undercutting
b) cold lap
c) convexity
d) concavity
A
b) cold lap
18
Q
Crater cracks are mainly the result of:
a) slag entrapments in the crater area
b) poor joint design or preparation
c) rapid contraction of the metal in the craters
d) wrong electrode angle being used by the operator
A
c) rapid contraction of the metal in the craters
19
Q
Incomplete penetration is usually caused by:
a) welding speed too slow
b) root opening too narrow
c) electrode diameter too small
d) welding current too high
A
b) root opening too narrow
20
Q
Undercut is:
a) caused by poor fusion in the base metal
b) a depression in the base metal at the toe of the weld
c) a crack caused by overheating the electrode
d) caused by wrong electrode wire
A
b) a depression in the base metal at the toe of the weld
21
Q
Dimensional weld faults occur:
A) prior to welding
B) during welding
C) after welding
D) both A and C
A
D) both A and C
22
Q
Dimensional weld faults prior to welding include:
A) incorrect fit up
B) distortion
C) incomplete penetration
D) all of the above
A
A) incorrect fit up
23
Q
Careless or poor material preparation may cause:
A) defective properties
B) structural discontinuities
C) dimensional defects
D) all of the above
A
D) all of the above
24
Q
Which of the following cut surfaces may lead to defective properties in a weld?
A) sheared surface
B) flame cut surface
C) gouged surface
D) all of the above
A
D) all of the above
25
Under CSA W59, the cover pass reinforcement on a butt weld:
A) may exceed the root pass reinforcement by 1/16 inch
B) may exceed the root reinforcement by 3/32 inch
C) may exceed the root reinforcement by 1/8 inch
D) maximum, is the same as the root pass
D) maximum, is the same as the root pass
26
Excessive convexity refers to a bulging profile on a:
A) groove weld
B) lap weld
C) butt weld
D) all of the above
D) all of the above
27
To correct insufficient face reinforcement on a groove weld you could:
A) grind weld deposit down smooth
B) add corrective passes
C) machine weld deposit down smooth
D) all of the above
B) add corrective passes
28
Excessive weld reinforcement on butt welds can be measured with:
A a stringer gauge
B) a thin rule tape
C a metric tape
D) a groove weld gauge
D) a groove weld gauge
29
Excessive convexity in a fillet weld is measured with:
A) a fillet weld gauge
B) a thin rule tape
C a metric tape
D) a groove weld gauge
A) a fillet weld gauge
30
Failure to clean internal undercut during the welding process may result in:
A) internal porosity
B) external porosity
C) internal slag
D) external slag
C) internal slag
31
A surface defect may include:
A) porosity
B) excessive spatter
C) stray arc flash
D) all of the above
D) all of the above
32
Who is responsible for structural discontinuities?
A) designer
B) engineer
C) welder
D) all of the above
C) welder
33
Which two categories do internal defects fall into:
A) longitudinal faults, spherical faults
B) spherical faults, laminar faults
C) lingitudinal faults, transverse faults
D) transverse, spherical
B) spherical faults, laminar faults
34
34. Internal porosity may be detected by:
A) visual inspection
B) radiography
C) liquid dye penetrant
D) all of the above
B) radiography
35
Tungsten inclusions are caused by:
A) insufficient amperage
B) excessive voltage
C) very fluid puddle
D) excessive amperage
D) excessive amperage
36
Copper inclusions are caused by:
A) carbon arc air cutting
B) gas tungsten arc welding
C) oxy-acetylene braze welding
D) all of the above
A) carbon arc air cutting
37
Copper inclusions may be caused by:
A) incorrect grinding discs
B) incorrect buffing wheels
C) damaged welding cables
D) loose stinger
C) damaged welding cables
38
Lack of fusion or cold lap is most common with:
A) SAW process
B) FCAW process
C) SMAW process
D) GMAW process
D) GMAW process
39
The two classes of cracking are:
A) physical, mechanical
B) metallurgical, physical
C) metallurgical, mechanical
D) metallic, mechanical
C) metallurgical, mechanical
40
Hot cracking falls under which class?
A) chemical
B) physical
C) metallurgical
D) mechanical
C) metallurgical
41
Transverse cracks are:
A) along side the weld
B across the weld
C) only in the HAZ
D) only in root beads
B across the weld
42
Cold cracking is caused by:
A) nitrogen
B) hydrogen
C) argon
D) oxygen
B) hydrogen
43
Hydrogen finds its way into welds by:
A) core wire
B) melted electrode coating
C) atmosphere
D) carbon dioxide
B) melted electrode coating
44
Solidification cracking occurs:
A) after weld has cooled
B) as weld is solidifying
C) outside the HAZ
D) during stress relieving
B) as weld is solidifying
45
Crater cracks are prevented by:
A) withdrawing electrode slowly from weld zone
B) withdrawing electrode quickly from weld zone
C) ensuring weld ends are finished to a concave profile
D) all of the above
A) withdrawing electrode slowly from weld zone
46
Under CSA W59, reinforcement on a butt weld:
A) should not exceed 1/16 inch
B) should not exceed 3/32 inch
C) should not exceed 1/8 inch
D) should not exceed 3/16 inch
C) should not exceed 1/8 inch
47
Hot cracking falls under which class?
A) chemical
B) physical
C) metallurgical
D) mechanical
C) metallurgical
48
Which of the following slows the cooling rate of steel:
A) preheat
B) maintain interpass temperature
C) post heat
D) all of the above
D) all of the above
49
Mechanical cracks are caused by:
A) high restraint on joint
B) low restraint on joint
C) stress relieving
D) controlled cooling of weldment
A) high restraint on joint
50
Voltage controls the:
a. burn-off rate and penetration
b. fluidness and burn off rate c. penetration and ease of arc striking
d. ease of arc striking and fluidness
d. ease of arc striking and fluidness
51
What is the force that causes current to flow in a conductor?
a. amperage
b. gravity
c. voltage
d. ohms
c. voltage
52
The pressure in an electrical circuit is called the:
a) resistance
b) voltage drop
c) electromotive force
d) current
c) electromotive force
53
The property in an electrical conductor that opposes the flow of current is:
a. current
b. frequency
c. inductance
d. resistance
d. resistance
54
Voltage controls the:
a. burn-off rate and penetration
b. fluidness and burn off rate
c. penetration and ease of arc striking
d. ease of arc striking and fluidness
d. ease of arc striking and fluidness
55
Are voltage is the:
a. voltage that exists between the electrode and the work
b. voltage that exists between the terminals on the machine
c. voltage that is pre-set before starting to weld
d. final open circuit voltage setting
a. voltage that exists between the electrode and the work
56
Open circuit voltage is the voltage:
a. produced when no welding is being done
b. produced when using a long arc
c. needed to produce proper metal flow
d. needed to produce a smooth bead
a. produced when no welding is being done
57
Which of the following has a direct bearing on puddle flow in the weld?
a. amperage
b. current
c. arc voltage
d. open circuit voltage
c. arc voltage
58
The term CURRENT is referred to as:
a. ohms
b. watts
c. volts
d. amps
d. amps
59
A sine wave is a pictorial way of showing the characteristics of :
a. straight polarity cycles
b. constant potential cycles
c. alternating cycles
d. the machine's duty cycle
c. alternating cycles
60
Straight polarity means:
a. direct current
b. electrode positive
c. electrode negative
d. alternating current
c. electrode negative
61
Reverse polarity:
a. is obtainable with an AC current
b. is used for an E6012 electrode
c. means the ground cable is connected to the positive terminal
d. means the ground cable is connected to the negative terminal
d. means the ground cable is connected to the negative terminal
62
Which of the following would only apply to machines that produce AC current?
a. straight polarity
b. reverse polarity
c. duty cycle
d. cycles per second
d. cycles per second
63
A 60% duty cycle welding machine is capable of maximum output for:
a. 36 minutes out of every hour
b. 6 hours out of every 10 hours
c. 60% of the actual arc time
d. 6 minutes out of every 10 minutes
d. 6 minutes out of every 10 minutes
64
A 400 amp, 70% duty cycle welding machine may be used as a 100% duty cycle machine at amperage settings up to:
a. 400 amps
b. 375 amps
c. 355 amps
d. 280 amps
d. 280 amps
65
Welding machines must have the approval of the following agency:
a. ASME
b. DPW
c. NEMA
d. CWB
c. NEMA
66
The "duty cycle" of a welding machine indicates:
a. the percentage of working time and idling time for which the machine is safely designed
b. the length of time the machine will last under normal working conditions
c. the percentage of large electrodes that can be used as compared to small electrodes
d. that the cycles per second can be adjusted to meet the demands of various electrodes and welding positions
a. the percentage of working time and idling time for which the machine is safely designed
67
The most common AC power frequency in use today is:
a. 25 hertz or cycles
b. 30 hertz or cycles
c. 60 hertz or cycles
d. 120 hertz or cycles
c. 60 hertz or cycles
68
A transformer type of power source produces a welding current that changes direction:
a. 30 times per second
b. 60 times per second
c. 90 times per second
d. 120 times per second
d. 120 times per second
69
What is the open circuit voltage that is needed to start the arc on a constant current welding machine?
a. 4 - 10 volts
b. 10 - 25 volts
c. 25 - 50 volts
d. 50 - 100 volts
d. 50 - 100 volts
70
During arc welding, the arc voltage range would be:
a. higher voltage than
amperage
b. higher amperage than voltage
c. both about the same
d. depends on the position
b. higher amperage than voltage
71
When it is difficult to establish an arc between the electrode and the work, the:
a. resistance is too low
b. amperage is too high
c. voltage is too low
d. cable size is too large
c. voltage is too low
72
A drooping type volt-amp curve is used for:
a. constant current
b. constant voltage
c. constant potential
d. constant amperage
a. constant current
73
Deeper penetration is achieved by:
a. AC currents
b. DC reverse polarity
c. DC straight polarity
d. use of rectifier
b. DC reverse polarity
74
An AC transformer type machine will produce:
a. reverse polarity
b. straight polarity
c. reverse or straight polarity
d. no fixed polarity
d. no fixed polarity
75
An AC transformer welding machine uses which principle?
a. changes polarity from DCRP to DCSP
b. converts low voltage to high welding amperage
c. changes alternating current to direct current
d. converts high voltage to high welding amperage
b. converts low voltage to high welding amperage
76
The most economical electric welder to buy and operate is the:
a. AC generator
b. DC generator
c. AC selenium rectifier welder
d. AC transformer welder
d. AC transformer welder
77
The purpose of a rectifier is to:
a. change alternating current to direct current
b. change from single phase to three phase output
c. increase welding speed on aluminum
d. change direct current to alternating current
a. change alternating current to direct current
78
Rectifier type welding machines are used primarily to obtain:
a. steady voltage AC - regardless of arc length
b. DC current
c. an initial high voltage AC starting the arc
d. adequate DC voltage from a low voltage DC line
b. DC current
79
The most versatile machine for the greatest choice of electrodes would be:
a. AC transformer
b. DC generator
c. AC generator
d. AC-DC rectifier
d. AC-DC rectifier
80
What is the main advantage of a rectifier welding machine?
a. it can be used in a shop that has corrosive conditions
b. it may be used where there are power fluctuations
c. all electrodes may be used
d. a good selection of electrodes can be used
d. a good selection of electrodes can be used
81
One disadvantage of the transformer rectifier welding machine is that:
a. operating costs are high
b. it is usually very noisy
c. it is not readily portable
d. maintenance costs are high
c. it is not readily portable
82
A disadvantage of a rectifier is:
а. arc blow may be a problem
b. operating costs are high
c. maintenance costs are high
d. fewer electrodes may be used
а. arc blow may be a problem
83
How would you change polarity on the AC generator welding machine?
a. interchange cable
b. reverse the rotor
c. an AC generator has no fixed polarity
d. reverse the winding on the commutator
c. an AC generator has no fixed polarity
84
What action will cause a change in polarity on DC machines?
a. reverse the direction of the driving motor
b. reverse the direction of the rotor
c. interchange the brushes on the commutator
d. interchange the welding cables
d. interchange the welding cables
85
Which of the following machines can deliver both alternating and direct current?
a. three phase AC transformer
b. gasoline driven generator
c. DC rectifier transformer
d. electric driven AC generator
c. DC rectifier transformer
86
A DC motor generator will produce what type of welding current?
a. rectified
b. AC current
c. DC current
d. high frequency
c. DC current
87
From a capital and operating total cost factor, the most expensive welding machine on the market today would a (an):
a. AC generator
b. AC transformer
c. DC generator
d. Alternator welding machine
c. DC generator
88
Of the following machine types, which machine would produce NO arc blow:
a. AC motor generator
b. DC generator
c. Rectifier welder set DC
d. Electric motor driven generator
a. AC motor generator
89
Generators can produce which current?
AC only
DC only
AC-DC
Rectified
AC-DC
90
Which of the following welding machines make rod selection a little more difficult:
AC-DC rectifier
DC generator
Rectifier welder set on DC
AC motor generator
AC motor generator
91
One advantage of generator type welding machines is:
higher initial cost
it may be portable
less noise
easier to maintain
it may be portable
92
Which volt-amp curve would be used with a DC generator welding machine for production welding?
rising
flat
straight
drooping
drooping
93
What kind of a welding machine uses an arc force control?
Transformers
Rectifiers and inverters
Generators
Alternators
Rectifiers and inverters
94
One of the benefits of using an inverter power source is:
a. the power source can be used in any environment
b. reduction is size and weight
c. electrical components are more rugged
d. are blow is never a problem
b. reduction is size and weight
95
Which of the following welding machines can be designed to operate on either single-phase or three-phase input power?
Rectifier
Dual continuous generator
AC transformer
Inverter
Inverter
96
What is a disadvantage of an inverter power source?
a. low input requirements
b. electric components are more fragile
c. small and light weight
d. may be CC or CV
b. electric components are more fragile
97
Which of the following welding machines immediately rectifies the incoming AC current to DC?
a. AC high frequency GTAW machine
b. Dual continuous control motor generator
c. Transformer rectifier
d. Inverter
d. Inverter
98
When installing electric powered welding machines, the installation must comply with:
a. Occupational health and safety regulations
b. applicable electrical codes c. welding shop regulations d. welding shop installations requirements
b. applicable electrical codes
99
Welding machines should be located away from corners and walls to reduce:
noise hazard from machine
power supply cable size
dirt collecting in machine
dirt collecting in machine
100
The power input to an AC welding machine must be:
a. 220 volt 3 phase current
b. compatible with the machine's rating
с. single phase with a 50 amp capacity
d. a variable current to meet welding demands
b. compatible with the machine's rating
101
The location of an AC welding machine is important because it requires:
a. 3 phase extension, a permanent base and a remote control
b. a confined space, a dust free atmosphere and a service access
c. correct current supply, adequate ventilation and a ground
d. large stinger cables, an adjustable base pad and a fresh air supply
c. correct current supply, adequate ventilation and a ground
102
Electric powered welding machines must be internally grounded so as to:
a. prevent cable overheating
b. prevent damage to circuit c. breaker avoid shock to operator
c. breaker avoid shock to operator
103
What should the internal parts of a transformer welding machine be cleaned with?
a. detergent and low pressure air
b. a wire brush
c. hand held high pressure air
d. high volume low pressure air
d. high volume low pressure air
104
When cable connections overheat:
a. extend the length of the cable from the work
b. use smaller diameter cables
c. immerse cables in water
d. ensure the connections are tight
d. ensure the connections are tight
105
Electric welding machines should be lubricated periodically:
a. with a good grade motor oil
b. following manufacturer's specifications
c. with any dry type lubricant d. with any wax base lubricant
b. following manufacturer's specifications
106
The main reason for the welder to regularly inspect the ground and lead cable insulation is to avoid:
a. current loss
b. accidental arcing
c. arc flash
d. over heating
b. accidental arcing
107
The minimum voltage necessary to maintain an arc with the SMAW process is:
17 volts
25 volts
32 volts
40 volts
17 volts
108
This term describes a noisy, uncontrollable arc that flares from side to side:
a. arc voltage
b. arc blow
c. inductance
d. resistance
b. arc blow
109
This term describes the influence exerted by a magnetic field on neighbouring bodies without physical contact:
voltage
amperage
frequency
inductance
inductance
110
This is the fundamental unit of electricity that moves through a conductor when current is flowing:
resistors
electrons
conductors
rectifiers
electrons
111
Which term describes the NEMA rating of a welding machine?
duty cycle
direct current
arc voltage
amperage
duty cycle
112
Electrode positive means: a.
straight polarity
reverse polarity
AC transformer
alternating current
reverse polarity
113
The number of __________
never increases or decreases in the atom.
electrons
neutrons
protons
ions
protons
114
Electrons have a
charge.
neutral
12 volt
positive
negative
negative
115
Which term measures the strength of a current of electricity?
amperage
voltage
electron
inductance
amperage
116
A charged atom is called _______
a molecule
an amp
an ion
a volt
an ion
117
What term describes a medium that provides an electrical path for current to flow through?
cycle
circuit
conductor
core
conductor
118
The electron flow theory states that electrons move from _________
positive to negative
negative to positive
negative to positive
119
This term describes a material that can stop current flow through itself:
inductor
inverter
conductor
insulator
insulator
120
The nucleus of an atom has:
electrons and protons protons and neutrons neutrons and electrons only electrons
protons and neutrons
121
Which term describes the voltage output of the machine during welding?
arc rectification
arc blow
arc voltage
inductance
arc voltage
122
When current flows through a coil wrapped around an iron core, what is created?
a magnetic field
reverse polarity
transformer rectifier
duty cycle
a magnetic field
123
This device in a welding machine is designed to have a certain number of turns of wire.
circuit
core
coil
cycle
coil
124
This current flows in one direction only and has either a positive or negative value:
direct current
alternating current
open circuit voltage
arc voltage
direct current
125
Which term describes a piece of equipment used to create electricity of sufficient volume for welding?
inductor
resistor
transformer
generator
generator
126
Which is a graphical illustration that plots the relationship between voltage and amperage output of a welding power source?
open circuit voltage
volt-amp curve
electromotive force
duty cycle
volt-amp curve
127
When no current is flowing in the circuit, but the machine is turned on, you can measure the:
open circuit voltage
constant current
alternating current
volt-amp curve
open circuit voltage
128
The speed at which AC changes direction is called the:
voltage
amperage
frequency
resistance
frequency
129
This term describes the property of an electrical conductor that opposes the flow of current.
resistance
inductance
voltage
amperage
resistance
130
In welding, this term describes what is created when there is enough amperage and voltage to overcome the natural resistance to the flow of the electricity.
amp
volt
cycle
arc
arc
131
132
What phase of power supplies most industrial applications?
single-phase power
two-phase power
three-phase power
four-phase power
three-phase power
133
This term describes one complete revolution of the AC alternator:
circuit
core
coil
cycle
cycle
134
These machines convert high voltage, low amperage to low voltage, high amperage by the use of a primary and a secondary coil.
AC transformer
AC generator
DC generator
AC alternator
AC transformer
135
What does EMF stand for?
electron movement force
elementary motor force electromotive force electromotive factor
electromotive force
136
Which term describes the typical sound of an AC transformer welding machine?
turbine whine
high-pitched scream
buzz box
whisper quiet
buzz box
137
This type of welding machine is capable of changing DC to high frequency AC.
AC generator
DC rectifier
DC generator
inverter
inverter
138
What is the function of the secondary winding on a transformer welder?
a. to induce high frequency current
b. to serve as a backup in case the primary winding fails
c. to step down the voltage
d. to step down the amperage
c. to step down the voltage
139
One advantage of an AC transformer welder is freedom from:
undercut
arc blow
porosity
slag inclusions
arc blow
140
What is one advantage of an AC-DC transformer-rectifier welding machine?
a. arc blow is not a problem
b. the purchase price is lower than for a transformer
c. you have a choice of polarity
d. it does not have to be kept clean and cool
c. you have a choice of polarity
