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Welder 1 > 120103e > Flashcards

120103e Flashcards

1
Q

Is it necessary to remove scale and rust from the bas metal? Y/N
Explain

A

Yes
removal prevents contamination of the weld zone and reduces harmful fumes

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2
Q

Describe a stringer bead

A

a single pass weld made with NO side to side motion

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3
Q

How should you lay beads when surface welding for build up work?
a) space them so they are 1/8” apart
b) blend them together so they form a solid layer of weld metal
c) space them 1/4” apart
d) the toe of one bead should meet the toe of the next bead

A

b) blend them together so they form a solid layer of weld metal

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4
Q

In what positions can you do surface welding with GMAW using short circuiting metal transfer ?
a) flat only
b) flat and horizontal only
c) all positions except vertical
d) all positions

A

d) all positions

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5
Q

What is the normal electrode angle when doing a single pass 1F weld?
a) 90* to the joint angle
b) 45* to the joint angle
c) 15-20 to the joint angle
d) 180* relative to the welders position

A

b) 45* to the joint angle

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6
Q

How is work positioned for a 1F Tee joint?
a) 90* and 0* to the horizontal plane
b) 180* and 360* to the horizontal plane
c) 120* and 60* to the horizontal plane
d) each member at 45* to the horizontal plane

A

d) each member at 45* to the horizontal plane

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7
Q

Given a choice what position should you use to achieve the most productive fillet welding
a) 4F
b) 1G
c) 1F
d) 6F

A

c) 1F

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8
Q

What is the recommended gun angle for the first pass of a 2F weld on 3/8” material with 3 stringer bead passes specified
a) 90* to the vertical plane
b) 90* to the horizontal plane
c) 45* to the vertical & horizontal plane
d) 270* to the welders initial position prior to arc ignition

A

c) 45* to the vertical & horizontal plane

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9
Q

What type of bead is usually used for the cover pass on a 3F weld on 3/8” material?
a) weave bead
b) stringer bead)
c) modified lazy L bead
d) long dwell crown bead

A

a) weave bead

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10
Q

What is the likely weld progression for the first pass on a 3F weld on 3/8” material
a) uphill
b) downhill
c) sleight of hand
d) back step

A

b) downhill

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11
Q

What joint configuration is generally used for a 1G weld with a Vee groove preparation on 3/8” material
a) 5/32” root face, 3/32” gap
b) 5/32” gap, 1/16” root face
c) 5/32” root face , 5/32” gap
d) 1/16” gap, 1/8” root face

A

b) 5/32” gap, 1/16” root face

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12
Q

How many passes are generally used for a 1G weld with a Vee groove prep on 3/8” material using .035 wire
a) 3 or 4 passes
b) 5 or 6 passes
c) 6 or 7 passes
d) 1 or 2 passes

A

a) 3 or 4 passes

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13
Q

What procedure is recommended to complete a 2G weld with Vee grove prep on 3/8” material?
a) completely fill the joint with one large pass
b) use 1 root bead followed by one weave bead cover pass
c) Use stringer beads on all fill and cover passes working from the bottom upwards
d) Use stringer beads on all fill and cover passes working from the top downwards

A

c) Use stringer beads on all fill and cover passes working from the bottom upwards

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14
Q

The number and letter combinations of 1F and 2 G represent
a) they type of filler wire and shielding gas to be used
b) the position and type of weld to be completed
c) the joint design and configuration
d) the welding process and joint design to be used

A

b) the position and type of weld to be completed

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15
Q

A WPS allows minor changes in the welding voltage and amperage. T/F

A

True

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16
Q

The root pass is becoming excessively heavy as you weld a pipe in the 1GR position.
What corrective action should you take while welding.
a) work closer to the 12 o’clock position of the pipe
b) work closer to the vertical position progressing downhill
c) slow the travel speed across the centre of the weld
d) incline the electrode more into the direction of travel

A

b) work closer to the vertical position progressing downhill

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17
Q

Single Vee preparations on pipe generally have an included angle within the range of
a) 22.5° to 30°
b) 30° to 45°
c) 45° to 75°
d) 60° to 75°

A

d) 60° to 75°

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18
Q

Do all tack welds become an integral part of the weld? Explain

A

No bridged tacks must be removed as welding progresses.
Tacks in the root that may become part of the root must be fully penetrated and feathered to ensure full fusion

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19
Q

Where should the 4 tack welds be located on 6” pipe to be welded in the 5G position

A

in the 12, 3, 6, & 9 o’clock positions

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20
Q

What is the max length of tack welds used for joining 6” sch. 80 pipe?

A

3/4”

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21
Q

If a pipe is fit so that the gap is not uniform, at what location should the widest portion of the gap be placed in prep for welding

A

The widest gap should be placed at or near the last quarter of the joint to be welded

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22
Q

On a 3” sch. 40 pipe what is the min # and length of tacks required?
a) 2 tacks at 1” long
b) 2 tacks at 1/2” long
c) 3 tacks at 1/2” long
d) 4 tacks at 1/2” long

A

c) 3 tacks at 1/2” long

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23
Q

What is the root gap between the test plates of a CWB 2G test weld
a) 1/4”
b) 5/16”
c) 3/8”
d) 1/2”

A

b) 5/16”

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24
Q

How far are the stop/starts from the edge of the CWB 4GF test plate?
a) 1/2”
b) 3/4”
c) 1”
d) 1 1/2”

A

d) 1 1/2”

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25
Q

What does using the wire guides prevent when you align the wire guides with the drive rolls?
a) feeds the wire straight
b) reduces dammage and scaring of the wire
c) prevents bird nesting
d) prevents unnececary drag

A

d) prevents unnecessary drag

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26
Q

If you require reverse polarity (DECP) do you connect your lead to the positive or negative post?

A

Positive- DCEP is straight polarity

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27
Q

When you use the jog switch to feed the wire, is the wire energized? Y/N

A

No

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28
Q

What part of a wire feed system requires the most maintenance?
a) power source
b) wire feeder
c) drive rolls
d) gun & cable assembly

A

d) gun & cable assembly

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29
Q

Liners plug up and wear out which results in erratic wire feeding, what is another term for this?

A

Arc hunting

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30
Q

For fillet welds what is the electrode angle used?
a) 45°
b) 60°
c) 80°
d) 90°

A

d) 90°
1/2 the included joint angle

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31
Q

If forehand is push angle and back hand is drag angle explain the 2 terms in relation to the direction of travel

A

Forehand is pointed in the direction of travel and is pushing the puddle forward
(electrode is pointed in the direction of travel)

Backhand is pointing back towards the start of the weld and traveling away from it (pointing back at the puddle)

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32
Q

Is this statement true?

Changing of inclination affects all of the following
size & shape of the weld profile as well as the depth of penetration

A

Yes- true

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33
Q

What inclination would you use welding thin metals? why?

A

forehand as it has less penetration - less likely to burn through

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34
Q

What term does this statement describe?
When you start a weld and the electrode comes into contact with the base metal but fails to start an arc immediately

A

Stubbing

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35
Q

List 4 weld defects

A

porosity
inclusions
internal cracking
lack of fusion
lack of penetration
undercut

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36
Q

Match the causes of porosity with their remedies

Causes
1. Lack of gas coverage due to drafts, clogged nozzle or loss of gas flow
2. Excessive tip to work distance
3. Excessive gas flow
4. Foreign material on surface of filler base metal
5. Excessive current or voltage

Remedies
a) Clean and protect the wire from dirt, remove rust, oil and other contaminants from the weld joint
b) Move gun closer to the work to reduce stickout and nozzle to work distance.
c) Check for shielding gas flow, increase gas flow using a wind break, or remove spatter buildup from nozzle
d) use settings recommended for filler metal being used
e) reduce gas flow

A

1- C
2- B
3 - E
4 - A
5 - D

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37
Q

Match the 3 causes of undercut to their remedies
1. Incorrect electrode angle
2. Travel speed to fast
3. Insufficient pause time on edges of weave beads

a) slow down to allow the puddle to blend with the base metal
b) Increase side wall time
c) Point towards the undercut

A

1 - C
2 - A
3 - B

38
Q

_________ is when metals melt together resulting in coalescence.

A

Fusion

39
Q

What weld test is the only way to test a semi automatic weld (GMAW)
a) x-ray
b) radiographic
c) bending
d) mag testing

A

c) Bending

40
Q

Match lack of fusion causes with their remedies
1. Improper manipulation of electrode gun
2. Puddle to large
3. Welding Current to low

a) Reduce wire feed and move wire from the centre of the puddle to the leading edge to increase travel speed
b) Increase current settings or reduce stickout
c) work wire into the sidewall or leading edge of the puddle. Dont allow the puddle to do the fusing

A

1 - C
2 - A
3 - B

41
Q

Match the causes of burn through with their remedies
1. Current set to high
2. Excessive root opening or root face to small
3. Travel speed to slow

a) Increase stickout and weave to control the puddle
b) reduce wire feed speed
c) Increase travel speed to reduce heat output

A
42
Q

What is wire size and grade selected to match?
a) flow rate
b) chemical & mechanical properties
c) electrical stickout
d) job site conditions

A

b) chemical & mechanical properties

43
Q

What is the CFH (gas flow) range when using .035 & .045 wire?
a) 9-17
b) 17-21
c) 35-45
d)20-35

A

d)20-35

44
Q

What polarity is used most for GMAW
DECP or DCEN

A

DECP

45
Q

Can GMAW be used in all positions? Y/N

A

Yes

46
Q

List the requirement for the following parameters when welding a Stringer bead layout

Stick out
Electrode Angle
Electrode Inclination
Travel speed
Transfer Mode
2 gasses that could be used
Electrode type

A
  • Stick out - 1/4” - 3/8”
  • Electrode Angle 1/2 included angle : 90°
  • Electrode Inclination 15° - 30° BH or FH
  • Travel speed - leading edge of the puddle
  • Transfer Mode - Short circuit
  • 2 gasses that could be used
    CO2 or COR/Argon
  • Electrode type - ER70S-6
47
Q

What is the electrode inclination used for all fillet weld roots?
a) 0° - 20°
b) 15° - 30°
c) 0° - 10°
d) 15° - 20°

A

b) 15° - 30°

48
Q

With a 2F weld describe the passes needed

A

Root stringer
fill pass at base of root
cap that only covers top edge of fill pass.
can do as 3 or 6 passes in total

49
Q

With a 3F weld describe the passes needed

A

Root - Stringer DH
Fill & Cap UH
Cap covers entire weld

50
Q

What are the 2 shielding gasses used for fillet welds using GMAW

A

CO2 or CO2&Argon

51
Q

What electrode is most commonly used with GMAW

A

ER70S-6

52
Q

What is the most common non-destructive wed test

A

visual inspection

53
Q

Match the weld abbreviation with the full name
1. 1F
2. 2F
3. 3F
4. 1G
5. 2G
6. 3G
7. 4G

A
  1. 1F - Horizontal fillet weld with the plate at a 45° angle
  2. 2F - Horizontal fillet weld at no angle
  3. 3F - Vertical Fillet weld
  4. 1G - Horizontal Grove (Butt) Joint
  5. 2G - Horizontal Groove (Butt) joint
  6. 3G - Vertical Groove (Butt) Joint
  7. 4G - Overhead Groove (Butt) joint
54
Q

When welding 3G what inclination is used with each pass

A

Root - DH
Fill & Cap - UH
Cap covers entire weld

55
Q

when prepping material for a groove weld answer the following
1. What is the angle the plate is cut?
2. What is the size of land added?
3. What gap is left between the plates?

A
  1. What is the angle the plate is cut? 30°
  2. What is the size of land added? 1/16”
  3. What gap is left between the plates? 5/32”
56
Q

When prepping material for 2G what angle do you preset the coupons to to allow for shrinkage of the welds.
a) 0° - 5°
b) 2° - 3°
c) 3° - 4°
d) 4° - 5°

A

c) 3° - 4°

57
Q

When fitting up for 3G on 10g plate what is size of the root opening?

A

1/8”

58
Q

What is a WPS

A

Welding Procedure Specification

59
Q

Why are WPS’s used

A

to ensure consistently good welds as the variables have already been tested

60
Q

Describe what a single Vee butt joint on pipe in 1G(rotated) position

A

1GR pipe weld the pipe is horizontal and is rolled as the weld progresses.
Welding is done from above the joint

61
Q

What size of bevel is normally used on pipe to be welded using 1GR position
a) 20° - 35°
b) 25° - 37.5°
c) 30° - 39°
d) 30° - 37.5°

A

d) 30° - 37.5°

62
Q

When tacking up pipe what gap should be left?

A

1/8” or 5/32”

63
Q

What are the min number of tacks used on pipes
a) ≤ 4”
b) ≤ 6”

A

a) 3
b) 4

64
Q

Do you have to feather starts and stops the same you do tacks? Y/N

A

Yes

65
Q

What is the number of tacks required on 4” pipe?
a) 2
b) 3
c) 4
d) 5

A

b) 3

66
Q

What is the number of tacks required on 6” pipe?
a) 3
b) 4
c) 5
d) 6

A

b) 4

67
Q

Describe 2 types of tacks

A
  1. a tack that becomes part of the root bead
  2. a bridge tack
68
Q

What is the max length of most tacks
a) 1/4”
b) 3/4”
c) 3/8”
d) 3/4”

A

d) 3/4”
once feathered they are generally 3/8” tacks can not be longer than the thickness of the plate.

69
Q

Are bridge tacks permanent or temporary ?

A

Temporary
They are placed in the joint by using a wire as a spacer that is larger than the root gap. (they must be removed as the welding progresses)

70
Q

When welding pipe using powered spinners what direction and position should be used?

A

Down hill and 1-2 o’clock positions. the spinners turn to allow you to weld back hand.

71
Q

What is the gap used when doing a 2G test (page 41)
a) 1/4”
b) 5/16”
c) 3/8”
d) 3/4”

A

b) 5/16”

72
Q

What is the electrode angle used for 1GF, 2G, 3GF & 4GF welds?
a) 1/4 of the included angle
b) 1/2 of the included angle
c) 3/8 of the included angle
d) 3/4 of the included angle

A

b) 1/2 included angle 45°

73
Q

What gap do you use when fitting up for 1G, 3G & 4G
a) 1/4”
b) 1/2”
c) 5/16”
d) 3/8”

A

b) 1/2”

74
Q

What gap do you use when fitting up 2G
a) 1/4”
b) 1/2”
c) 5/16”
d) 3/8”

A

c) 5/16”

75
Q

What does GF stand for in relation to type of joints

A

Groove/Fillet

76
Q

How many root tacks are required to tack 3” such. 40 pipe for qualification purposes
2 tacks
3 tacks
4 tacks
left to the discretion of the welder

A

3 tacks

77
Q

According to CWB test procedures the first pass on a 1GF S classification test assembly is placed:
a) in the center of the backing bar
b) where the bevel meets the backing bar
c) at the junction forming a 90° angle
d) at the junction forming a 30° angle

A

c) at the junction forming a 90° angle

78
Q

What is the recommended gas flow rate when using C25 with .035” wire in the short circuit metal transfer mode
a) 5-9L/min
b) 9-17L/min
c) 17-21L/min
d) 21-32L/min

A

b) 9-17L/min

79
Q

The 3F position requires weld coupons to be positioned in the ____ plane?
a) flat
b) horizontal
c) vertical
d) overhead

A

c) vertical

80
Q

When performing a 1G weld the fitted plates will form an included angle of?
a) 30°
b) 45°
c) 60°
d) 90°

A

c) 60°

81
Q

When performing GMAW roots in a 1GR position what mode of metal transfer is used?
a) short circuit
b) globular
c) spray
d) pulsed arc

A

a) short circuit

82
Q

What welding positions can be performed with the GMAW short circuiting metal transfer
a) all positions
b) overhead only
c) flat and horizontal
d) vertical down only

A

a) all positions

83
Q

What is the primary factor when placing tacks for a GMAW groove weld
a) tacks must be of good quality
b) tacks must be no longer than 1/2”
c) tacks must bond properly to the base metal
d) tacks should be slightly wider than the weld bead

A

a) tacks must be of good quality

84
Q

Which of the following may be responsible for excessive internal reinforcement after welding a 1GR carbon steel root?
a) rotation of pipe to quick
b) no internal gas purge
c) drag technique
d) weld metal applied in the 12 o’clock position

A

d) weld metal applied in the 12 o’clock position

85
Q

When performing 3F or 3G welds with GMAW the procedure states:
a) root downhill, fill and cap uphill
b) root and fill downhill, and cap uphill
c) root uphill and fill and cap downhill
d) all passes are uphill

A

a) root downhill, fill and cap uphill

86
Q

When performing a 2F weld with GMAW on 3/8” material the electrode angle must remain the same for all 3 passes T/F

A

False

87
Q

The recommended fit up for a 3G 10-gauge weld would include
a) 1/8” root spacing
b) tacks between 1/8” - 1/4”
c) no high low
d) all of the above

A

d) all of the above

88
Q

Which joint configuration would be the best choice for a vee groove preparation on 3/8” material?
a) 5/32” land, 1/16” root opening
b) 5/32” root opening, 1/16” land
c) 5/32” land, 3/32” root opening
d) 1/16” root opening, 3/32” land

A

b) 5/32” root opening, 1/16” land

89
Q

What is the recommended technique for a 2G root pass using GMAW short-circuit metal transfer
a) stringer technique
b) weave technique
c) sawtooth technique
d) drag technique

A

c) sawtooth technique

90
Q

What is the recommended procedure used to reduce distortion, when welding in the 2G position
a) place a 1/2” root tack in the joint
b) preset the joint 3°- 4°
c) reduce the number of passes in the joint
d) preheat the joint before welding

A

b) preset the joint 3°- 4°

91
Q
A

Welder 1 (37 decks)

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