120103f FCAW & MCAW on mild steel

Question 1

Is it necessary to remove oil and paint from the base metal? Explain your answer

Answer 1

Yes any excess oil, paint or coatings should be removed to prevent contamination of the weld zone and reduce any harmful fumes that may be produced

Question 2

Describe how to execute a weave bead

Answer 2

A weave bead is completed with a side to side motion while moving in the direction of travel is taking place

Question 3

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

c) causes the weld profile to change

Question 4

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

Answer 4

b) indicates the vertical position with a combination groove and fillet weld

Question 5

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

Answer 5

Find on page 50

Question 6

Does welding position have any influence on FCAW machine settings.

Answer 6

Yes, position has significant influence on machine settings.
Vertical settings are likely lower than horizontal.

Question 7

How would you likely do surface welding on a vertical surface using FCAW
a) travel horizontally starting from the top of the surface
b) travel horizontally starting from the bottom of the surface
c) travel vertically uphill starting from the bottom left corner
d) travel vertically downhill starting from the top right hand corner

Answer 7

b) travel horizontally starting from the bottom of the surface

Question 8

What is the main advantage of FCAW over GMAW?
a) deposition rates are higher
b) equipment is less expensive
c) wire is less expensive
d) welding current requirements are lower

Answer 8

a) deposition rates are higher

Question 9

When multi pass welding with FCAW is it necessary to remove the slag between passes. Explain

Answer 9

Yes; the slag could get trapped between the passes

Question 10

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

d) it is difficult to control penetration in an open gap with FCAW

Question 11

How much stickout is recommended when using gas shielded FCAW with .045” wire
a) 1/8” - 3/8”
b) 3/8” - 3/4”
c) 3/4” - 1 1/2”
d) 3/32” - 1/8”

Answer 11

b) 3/8” - 3/4”

Question 12

When welding the fill passes with FCAW on a 1GF using 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

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

Question 13

Most FCAW welding techniques use an electrode inclination of
a) 10° - 30° forehand
b) 40° - 80° forehand
c) 10° to 30° back hand
0° oe dead square

Answer 13

c) 10° to 30° back hand

Question 14

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

a) slag entrapment

Question 15

What type of technique would you likely use on a 3F weld using 3/8” material when doing the cover pass
a) uphill stringer beads
b) uphill weave bead
c) downhill stringer bead
d) downhill weave bead

Answer 15

b) uphill weave bead

Question 16

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 16

c) there is no fillet weld in a 2G test assembly

Question 17

What is the main benefit of FCAW over GMAW

Answer 17

Productivity

Question 18

How is wire selected ?
a) to match the chemical & mechanical properties of the base metal
b) to have the wire thinner than the base metal to have better penetration
c) to have thicker wire than the base metal to fill the gap
d) to add different metal characteristics to the base metal

Answer 18

a) to match the chemical & mechanical properties of the base metal

Question 19

FCAW & MCAW shielding gas flow rates fall within:
a) 7L/min - 10L/min
b) 14L/ min - 23L/min
c) 18L/min - 28L/min

Answer 19

b) 14L/ min - 23L/min

Question 20

What is the most common shielding gas for FCAW
a) 75% Argon, 25% O2
b) 78% Argon, 20% CO2, 2% O2
c) CO2 or 75% Argon 25% CO2
d) 85% argon 15% CO2

Answer 20

c) CO2 or 75% Argon 25% CO2

Question 21

What is the most common shielding gas for FCAW
a) 75% Argon, 25% O2
b) 78% Argon, 20% CO2, 2% O2
c) CO2 or 75% Argon 25% CO2
d) 85% argon 15% CO2

Answer 21

d) 85% argon 15% CO2

Question 22

For FCAW & MCAW what parameters do you need?
a) constant amperage DCEN
b) constant amperage DCEP
c) constant voltage & DCEP
d) constant voltage & DCEN

Answer 22

c) constant voltage & DCEP

Question 23

What does ESO stand for?

Answer 23

Electrode Stickout

Question 24

What is the reccomended ESO for .035 wire?
a) 1/8” - 3/8”
b) 3/8” - 3/4”
c) 3/4” - 1 1/2”
d) 3/32” - 1/8”

Answer 24

b) 3/8” - 3/4”

Question 25

What is the recommended ESO for 5/64” - 1/8” wire?
a) 1/8” - 3/8”
b) 3/8” - 3/4”
c) 3/4” - 1 1/4”
d) 3/32” - 1/8”

Answer 25

c) 3/4” - 1 1/4”

Question 26

What is the description of a herring bone weave pattern?

Answer 26

a sharp zig zag

Question 27

Does slag have a tendency to remelt on the next pass?

Answer 27

No, this is why you need to remove the slag well between each pass

Question 28

Why limit weave size when using FCAW?
a) flux could freeze on the edge before you can return to it
b) slag can be trapped causing lack of fusion
c) tendency to undercut
d) both a& b

Answer 28

d) both a& b

a) flux could freeze on the edge before you can return to it
b) slag can be trapped causing lack of fusion

Question 29

For a 1F weld position what angle is the weld surface tacked at compared to the horizontal plane?
a) 15°
b) 25°
c) 45°
d) 60°

Answer 29

c) 45°

Question 30

If you have the gun pointed straight up and down what is the electrode angle?
a) 15°
b) 25°
c) 45°
d) 60°

Answer 30

c) 45°

Question 31

What is the benefit of using a herringbone weave variation?

Answer 31

Herringbone weave helps prevent undercut on the cap

Question 32

In the 3F position which description is correct?
a) the weld is done vertically in the down hill progression
b) the weld is done vertically in the uphill progression
c) the weld is done horizontal in the forehand progression
d) the weld is done horizontal in the backhand position

Answer 32

b) the weld is done vertically in the uphill progression

Question 33

When using MCAW in the vertical position what metal transfer would you use?
a) globular
b) spray
c) pulse spray
d) short circuit

Answer 33

c) pulse spray
due to the pulse and having the heating and cooling this process is slower than FCAW

Question 34

MCAW welds in the 3F position which is true:
a) the weld is done vertically & downhill
b) the weld is done horizontally & forehand
c) the weld is done vertically & uphill
d) the weld is done horizontally & back hand

Answer 34

c) the weld is done vertically & uphill

Question 35

When performing a multi pass weld where do you place the first weld?
a) the bevel
b) the 90° angle
c) root
d) stringer

Answer 35

b) the 90° angle

Question 36

When incorporating your start and stops how far from the end of the coupon should you start/stop your first two passes?
a) 3/8”
b) 3/4”
c) 1 1/4”
d) 1 1/2”

Answer 36

d) 1 1/2”

Question 37

What CSA Standard requires a stop in each of the fillet and groove passes?
a)W44.1
b)W45.1
c) W46.1
d) W47.1

Answer 37

d) W47.1

Question 38

When placing stringer and weave beads, as a rule of thumb you should achieve penetration into the?
a) Narrowest portion of the joint
b) Widest portion of the joint
c) Ensure gap is the same through out
d) is at the discretion of the welder

Answer 38

a) Narrowest portion of the joint
- is where the coupons make a 90° angle

Question 39

2G fit up with backing how far from the end of the coupons should the start/stops be incorporated?
a) 1/2”
b) 3/4”
c) 1”
d) 1 1/2”

Answer 39

d) 1 1/2”

Question 40

When is the only time you use forehand direction when using FCAW
a) horizontal
b) vertical
c) overhead
d) you dont use forehand with FCAW

Answer 40

b) vertical

Question 41

with a 3GF weld what progression is used for all welds
a) uphill
b) downhill
c) forehand
d) downhand

Answer 41

a) uphill