120103f FCAW and MCAW on Mild Steel

Question 1

Question: Is it necessary to remove oil and paint from the base metal?

Answer 1

Answer: Yes, to prevent contamination of the weld zone and reduce harmful fumes.
Explanation: Removing contaminants like oil and paint is crucial for welding integrity and safety.

Question 2

Question: Describe how to execute a weave bead.

Answer 2

Answer: A weave bead is completed with a side-to-side motion while moving in the direction of travel.
Explanation: Weave beads are used for wider welds, requiring lateral movement during welding.

Question 3

Question: Changing the angle of the electrode holder in relation to the joint:
a) changes the voltage.
b) has no effect on the weld.
c) causes the weld profile to change.
d) causes the wire to feed unevenly.

Answer 3

Answer: c) causes the weld profile to change.
Explanation: The angle of the electrode affects the shape and quality of the weld bead.

Question 4

Question: The number/Ietter combination 3GF:
a) represents the type of filler wire and shielding gas to be used for the project.
b) indicates the vertical position with a combination groove and fillet weld.
c) requires the joint to be completed in three passes and ground flat.
d) indicates that a mix of three shielding gases is required.

Answer 4

Answer: b) indicates the vertical position with a combination groove and fillet weld.
Explanation: 3GF refers to a specific weld type and position used in welding practices.

Question 5

Question: Sketch the joint preparation and fit-up of a typical CWB 1GF joint test weld using the FCAW process.

Answer 5

Figure 47 shows the correct configuration.

Question 6

Question: Does welding position have any influence on FCAW machine settings? Explain your answer.

Answer 6

Answer: Yes. Welding position has a significant influence on machine settings. Machine settings in the vertical position are likely to be lower than the same weld in the flat position.

Question 7

Question: How would you likely do surface welding on a vertical surface using FCAW?

Answer 7

Answer: b) travel horizontally starting from the bottom of the surface

Question 8

Question: What is the main advantage of using FCAW over GMAW?

Answer 8

Answer: a) Deposition rates are higher.
Explanation: FCAW generally allows for faster welding speeds due to higher deposition rates.

Question 9

Question: When multi-pass welding with FCAW, is it necessary to remove the slag between passes?

Answer 9

Answer: Yes. The slag could get trapped between the passes

Question 10

Question: Why are back-up bars often employed on FCAW groove welds?
a) Open gaps cause potentially damaging current surges in the main transformer
coils of the power source.
b) FCAW root beads in open gaps are characterized by lack of fusion.
c) Loss of gas coverage is a problem with FCAW in an open gap.
d) It is difficult to control penetration in an open gap with FCAW.

Answer 10

Answer: d) It is difficult to control penetration in an open gap with FC AW

Question 11

Question: How much electrode stickout is recommended when using gas shielded FCAW with 1.2 mm (0.045”) wire?
a) 3.2 mm - 12 mm (1/8”-3/8”)
b) 10 mm - 19 mm (3/8”-3/4”)
c) 20 mm - 40 mm (3/4” - 1-1/2”)
d) 2.5 mm - 3.2 mm (3/32”-1/8”)

Answer 11

Answer: b) 10 mm - 19 mm (3/8”-3/4”)

Question 12

Question: When welding the fill passes with FCAW on a IGF using 10 mm (3/8”) material,
what should the gun angle be in relation to the joint?
a) 10° towards the welder
b) one-half the angle formed at the centre of the bead to be placed
c) any angle that is comfortable to the welder
d) 10° away from the welder

Answer 12

Answer: b) one-half the angle formed at the centre of the bead to be placed

Question 13

Question: Most FCAW welding techniques use an electrode inclination of:
a) 10° to 30° forehand.
b) 40° to 80° forehand.
c) 10° to 30° backhand.
d) 0° or dead square.

Answer 13

Answer: c) 10° to 30° backhand

Question 14

Question: What must you be careful of when placing weave beads in a large groove weld?
a) slag entrapment
b) overheating the power source
c) overheating the gun nozzle
d) running out of wire

Answer 14

Answer: a) slag entrapment.
Explanation: Slag entrapment, often due to improper technique or fast travel speed, is a common defect in FCAW welds.

Question 15

Question: What are the three main safety concerns when welding?

Answer 15

Answer:
a) eye and skin protection,
b) ventilation,
c) set up screens and warning signs.
Explanation: These safety measures are critical to protect against the hazards associated with welding, like UV radiation, fumes, and sparks.

Question 16

Question: What type of technique would you likely use on a 3F weld using 10 mm (3/8”) material when doing the cover pass?

a) uphill stringer beads
b) uphill weave bead
c) downhill stringer beads
d) downhill weave bead

Answer 16

Answer: b) uphill weave bead

Question 17

Question: List the nine items on the startup checklist of any new project.

Answer 17

Answer: The sequence includes:
a) Check helmet for correct shade filter plate.
b) Check all exposed skin.
c) Check wire size and type for suitability to parent metal and position of weld.
d) Check drive roll pressure.
e) Check condition of contact tube, gun nozzle and trigger switch.
f) Check shielding gas supply (if required) and turn on and set flow rate.
g) Check operating parameters on welding procedure (if applicable).
h) Energize power source/wire feeder.
i) Run several beads on scrap metal to fine-tune voltage and wire speed.

Question 18

Question: Where is the fillet weld in a CSA 2G test assembly located?

a) against the bevelled edge
b) against the square edge
c) there is no fillet weld in a 2G Test Assembly
d) the Fillet weld is the cover pass

Answer 18

Answer: c) there is no fillet weld in a 2G Test Assembly