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120103k Flashcards

1
Q

Describe and explain the principles of operation of SAW

A

SAW uses an electric arc established between a continuously fed bare metal consumable electrode or electrodes and the work. Shielding is provided by a granular, useable flux material usually brought to the work area using a flux fled system.

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2
Q

What positions can SAW be used in?
a) flat position only
b) flat and horizontal positions
c) flat and vertical positions
d) flat, horizontal, and vertical positions

A

b) flat and horizontal positions

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3
Q

Name 4 types of materials that SAW can be used on.

A

carbon
alloy steels
stainless steels
nickel alloy

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4
Q

List 7 basic equip components required for SAW set up briefly explain the functions

A
  1. The welding power source provides welding current
  2. The welding head assembly includes the wire feeder, torch assembly and travel carriage (machine and auto operation)
  3. The fixtures and positions position the work piece for welding
  4. Spooled filler wire provides shielding, shapes the bead and allows alloys to be added
  5. The flux provides shielding, shapes the bead and allows alloys to be added
  6. the flux feed and recovery equip conveys flux to the weld zone and collects unused flux
  7. The work lead completes the welding current circuit to the work piece
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5
Q

What are the advantages of using a screw type work clamp with SAW

A
  • it provides a strong and positive contact to the work
    it minimizes heat build up
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6
Q

What type of output slope do SAW power sources use?
a) CC
b) CV
c) variable potential
d) CC & CV

A

d) CC & CV

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7
Q

What duty cycle rating is recommended for most SAW power sources
a) 40%
b) 60%
c) 80%
d) 100%

A

d) 100%

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8
Q

SAW may be used in the semi automatic or automatic operation modes
true/ False

A

True

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9
Q

What is the advantage of using an ac power source for SAW?
a) It uses less power than DC equip
b) the arc is more stable than dc current
c) it minimizes arc blow with multiple wire setups
d) AC power sources have higher duty cycle ratings than dc machines

A

c) it minimizes arc blow with multiple wire setups

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10
Q

What will usually result if the drive roll pressure is set to low
a) the wire electrode will slip and feed erratically
b) the wire can pile up inside the wire feed unit
c) the wire will stub the work piece
d) the wire will freeze to the work piece

A

a) the wire electrode will slip and feed erratically

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11
Q

How will the arc react if the flux layer is to shallow?
a) the weld bead will appear rough and ropy
b) the weld bead will have worm holes in it
c) the weld will be flashing and will likely result in porosity
d) the space between two unrestrained loops of wire

A

d) the space between two unrestrained loops of wire

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12
Q

Which is helix:
a) straightening of the wire before it enters the drive roll assembly
b) the diameter of a single loop of wire
c) the turning action of the wire as it unrolls
d) the space between 2 unrestrained loops of wire

A

d) the space between 2 unrestrained loops of wire

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13
Q

What type of drive rolls are normally used with SAW?
a) angled
b) U-groove
c) flat or smooth faced
d) knurled or V-groove

A

d) knurled or V-groove

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14
Q

What type of wire feed set up is used with CV power sources?
a) constant speed
b) voltage sensing
c) amperage sensing
d) arc force controlled

A

a) constant speed

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15
Q

List 6 of the main SAW operating variables and their effects.

A
  1. amperage controls penetration and rate of deposit
  2. Voltage affects arc length
  3. Travel speed affects the penetration and well bead profile
  4. Electrode diameter has a direct effect on the weld bead shape, depth of penetration and weld metal deposition rates
  5. Electrode extension affects rate of metal deposition and affects rate of metal deposition rates
  6. Electrode extension affects rate of metal deposition and affects flux layer depth
  7. Width and dept of flux layer has an influence on arc action, bead appearance and weld metal soundness
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16
Q

To increase arc length when you are welding with SAW, you would
a) use a longer contact tip
b) increase WFS
c) increase arc voltage
d) use a shorter contact tip

A

c) increase arc voltage

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17
Q

When using SAW an increase in the arc voltage produces
a) wider arc stream and shallower penetration
b) wider arc stream and deeper penetration
c) narrower arc stream and shallower penetration
d) narrower arc stream and deeper penetration

A

a) wider arc stream and shallower penetration

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18
Q

When is DCEN used with SAW
a) when deeper penetration is required
b) when welding on nonferrous materials
c) when shallower penetration is required
d) for applications requiring more than 1500 amps

A

c) when shallower penetration is required

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19
Q

Why are wire cast and helix requirements placed in CSA and AWS specifications for SAW filler metals?

A

They ensure that the electrode wire will feed smoothly to the weld zone

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20
Q

What diameters are SAW electrode wires available in?
a) 1/16” - 1/4”
b) 3/32” - 3/8”
c) 1/8” - 1/2”
d) 5/32” - 3/4”

A

a) 1/16” - 1/4”

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21
Q

What is the main difference between the CSA and AWS classification system
a) CSA uses the imperial system to measure tensile strength values
b) AWS uses the metric system to measure tensile strength values
c) CSA uses the metric system to measure tensile strength values
d) AWS uses yield strength values, while the CSA uses tensile strength values in their classification system,

A

c) CSA uses the metric system to measure tensile strength values

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22
Q

Interpret the AWS classification for
F7AZ-EL12K
a) F
b) 7
c) A
d) Z
e) E
f) L
g) 12
h) K

A

F7AZ-EL12K
a) F - flux
b) 7 - min tensile strength of 70,000 psi
c) A - as welded condition
d) Z - no impact properties specified
e) E - electrode
f) L - low Mg content
g) 12 - nominal carbon content (0.12%)
h) K - made from full killed steel

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23
Q

Interpret the CSA classification for the F49AZ- EM14K flux wire designation
a) F
b) 49
c) A
d)Z
e) E
f) M
g)14
h) K

A

F49AZ-EM14K
a) F - flux
b) 49 - min tensile strength of 490 mPa
c) A - as welded condition
d) Z - no impact properties specified
e) E - electrode
f) M - medium Mg content
g)14 - nominal carbon content ( 0.14%)
h) K - made from fully killed steel

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24
Q

Which type of flux can be re-used?
a) bonded
b) agglomerated
c) fused
d) rutile- based

A

c) fused

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25
Q

Which type of SAW flux is generally used for the addition of alloying elements?
a) active flux
b) fused flux
c) recycled flux
d) neutral flux

A

a) active flux

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26
Q

What should be done with SAW fluxes after they have become exposed to moisture?
a) they should be discarded
b) they should be dried or rebaked according to manufacturer specifications
c) they should only be used for non critical welds
d) they should be used at 35 arc volts or higher to allow moisture and gasses to escape the weld before solidification

A

b) they should be dried or rebaked according to manufacturer specifications

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27
Q

Name 4 processes related causes of an unstable arc

A

Any of the 4 following are correct
1. joint dirty with scale or rust
2. incorrect electrical stickout
3. insufficient flux coverage
4. to much wire cast or helix causing poor wire feed
5. worn contact tube
6. incorrect voltage/ amperage settings

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28
Q

Name 3 things you should check for when the wire feed motor operates but the wire fails to feed

A
  1. insufficient drive roll pressure
  2. incorrect drive rolls
  3. excessive pressure on wire spool brake
  4. drive rolls are dirty or clogged
  5. blockage in the liner or torch
  6. plugged wire guide tubes
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29
Q

Are higher deposition rates obtainable with the SAW process

A

Yes

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30
Q

Is SAW easily done in all positions?

A

No

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31
Q

Is SAW the only wire process to use AC current?

A

Yes, MCAW, FCAW, GMAW all use DC only

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32
Q

What does SAW stand for ?

A

Submerged Arc Welding

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33
Q

SAW used what type of flux?
a) flux fused to the consumable electrode
b) granular flux
c) paste
d) SAW doesn’t require flux

A

b) granular flux

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34
Q

Why was SAW so readily adopted in the industry?
a) high penetration capabilities
b) high deposition rates
c) high production rates
d) portability

A

c) high production rates

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35
Q

The use of flux with SAW is limited to flat and horizontal
T / F

A

True

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36
Q

What is another name for SAW?

A

Sub Arc

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37
Q

Is the following statement true or false?
SAW fuses metal with an electric current established between continuously fed bare metal consumable electrode(s). Shielding is provided by a granular fusible flux material usually brought to the work area with a flux feed system.

A

True

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38
Q

SAW flux must be carefully selected because it can influence:
a) arc stability
b) mechanical and chemical properties of weld deposit
c) the presence of structural discontinuities and impurities of the weld zone
d) all of the above

A

d) all of the above

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39
Q

The saw process is capable of making welds using currents of up to ______ amps ac or dc. Both currents can be used on the weld at the same time.

A

a) 1000 amps
b) 1500 amps
c) 2000 amps
d) 2500 amps

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40
Q

SAW can use what type of filler metals:
a) single wires
b) multiple wires at once
c) strips of filler metal
d) all of the above

A

d) all of the above

41
Q

What is SAW meant for
a) thin metals & vertical welds
b) thin metals & flat or horizontal positions
c) thick metals & flat or horizontal position
d) this metals in all positions

A

c) thick metals & flat or horizontal position

42
Q

Can SAW weld joints?

A

Yes but there must be enough room for the welding head to have full access to the joint.

43
Q

Factors to consider when choosing whether to use SAW or not.

A

Thickness of parent metal
joint accessibility
position of weld needed
volume or frequency of welding to be performed
mechanical requirements of the final weld
Chemical composition of the final weld needed

44
Q

How can a SAW system be used
a) manual
b) manual & semi automatic
c) semi automatic and fully automatic
d) manually adjusted, semi automatic and fully automatic

A

d) manually adjusted, semi automatic and fully automatic

45
Q

What equipment is specialized and specific to SAW

A

a supply of granular flux
flux feed and recovery equip

46
Q

What currents is SAW compatible with?
a) CC
b) CV
c) DC
d) both a & b

A

d) both a & b

47
Q

Explain why with SAW you would use the following
DCRP
DCSP

A

DCRP (DCEP) - direct current reverse polarity ( +) - max penetration

DCSP (DCEN) - direct current straight polarity (-) - max deposition
- also used to control arc blow

48
Q

What does SAW use to move along the weld zone?
a) tracks
b) travel carriage
c) rollers
d) SAW can only weld 1 section at a time before the operator moves the equipment

A

b) travel carriage

49
Q

What modes is SAW generally used?
a) machine, automatic
b) machine, semi automatic
c) machine only
d) semi automatic only

A

b) machine, semi automatic

50
Q

Is using positions and fixtures often used with tilting / rotating positioners?

A

Yes as they are on speed trunnion type rolls those positioners enable the welder to be in the correct position

51
Q

Flux feed systems are available as a gravity fed system, or as a pressurized pneumatic flux feed system on fully automatic system True or False

A

True

52
Q

What is typically used as a flux recovery unit?

A

vacuum

53
Q

What is used to keep flux in a useable state?
a) a heater system to keep the recovered flux dry
b) screens to remove slag or other impurities
c) magnets to remove metalic impurities
d) all of the above

A

d) all of the above

54
Q

What type of work lead is recommended for SAW

A

Screw type work lead

55
Q

The CV machine with a constant feed speed wire drive unit is recommended for small diameter wire electrodes 5/64” - 1/8” because :
a) fast response time is required for stable arc
b) fast response time is needed to start the arc
c) fast response needed to push the arc to the base metal

A

a) fast response time is required for stable arc

56
Q

A CC machine coupled to a voltage sensing wire feeder has a very stable arc when using ________ diameter wire electrodes and larger.
a) 5/16
b) 5/32
c) 3/16
d) 5/16

A

b) 5/32
CC used for large wire
CV used for small wire

57
Q

When multiple wires are fed into the weld zone _______ can become a problem when using DC current.
a) arc hunting
b) arc blow
c) slag fusion to electrode
d) voltage hunting

A

b) arc blow

58
Q

What duty cycle are most SAW power sources?

A

100% duty cycle as SAW is generally a high current process

59
Q

What are 3 things you must consider when choosing a power source for SAW?

A
  • rated output
  • duty cycle rating
  • primary power compatibility with the input power requirements of the welding power source
60
Q

What are 5 welding head assembly components

A

Any of the following are correct
- controll unit
- variable speed electric motor and gear box
- wire straightener
- drive roll assembly
- a torch assembly
- wire feed setups
- flux feed and recovery systems

61
Q

Wire straightener is designed to take some of the _____ our of the wire before it enters the drive roll assembly.
a) cast
b) helix
c) protective coating
d) none of the above it just adds an extra point for the wire to go through so it stays straight going into the main unit.

A

b) arc blow

62
Q

Since SAW can use both CC & CV power sources what type of wire feeders are used ?
a) constant speed wire feeder
b) voltage sensing vire feeder
c) amperage sensing wire feeder
d) constant speed wire feeder and voltage sensing wire feeder

A

d) constant speed wire feeder and voltage sensing wire feeder

63
Q

A flux recovery unit is a large vacuum that picks up unused flux from the weld seam as the SAW weld progresses
True or False

A

True

64
Q

What is the most influential SAV variable due it controlling the penetration and burn off rate of the electrode
a) voltage
b) amperage
c) ESO
d) flux type

A

a) voltage

65
Q

on CV power sources with a constant speed wire drive, the wire speed has a direct relation to output amperage

A

Wire speed

66
Q

A CV power source automatically adjusts the wire speed is adjusted.

A

amperage

67
Q

Most CC power sources feature a single current control that sets the amperage by the wire feed
True or False

A

True

68
Q

_________ directly affects the penetration and weld bead profile at a given voltage and amperage.

A

travel speed

69
Q

As a general rule, a good starting point for SAW is an ESO of ___ the diameter of the electrode.
a) 4X
b) 6X
c) 8X
d) 10X

A

c) 8X

70
Q

The width and depth of the ______ influences arc action, bead appearance and weld metal soundness
a) weave pass
b) ESO
c) flux layer
d) none of the above

A

c) flux layer

71
Q

If the flux layer is too deep, the arc is too restricted which results in
a) concave weld
b) overly convex weld bead
c) rough looking weld and ropy bead appearance
d) smooth weld with lots of cold lap

A

c) rough looking weld and ropy bead appearance

72
Q

If the flux layer is to shallow, the arc will only be partially submerged which results in flashing and sputtering and may lead to _____ due to lack of gas coverage

A

porosity

73
Q

As a general rule the appropriate depth of flux is reached:
a) 10x the width of the electrode
b) 15x the width of the electrode
c) once the weld coverage appears good
d) once the welding arc is fully submerged with no flashing

A

d) once the welding arc is fully submerged with no flashing

74
Q

DC electrons flows in one direction only
a) positive to negative
b) negative to positive

A

b) negative to positive

75
Q

When using SAW 2/3 of the arc energy is associated with the ______ side of the welding circuit.
a) positive
b) negative
c) neutral
d) the percentage is 50/50 positive and negative

A

b) negative

76
Q

Are all of the following statements True or False
DCEP is generally used with SAW
- 2/3 of the energy is with the base metal
- the electrode burns off somewhat cooler
- narrow metal flow is quite general unless the arc is lengthened
- deeper penetration

A

Yes, all of these statements are correct
DCEP is generally used with SAW
- 2/3 of the energy is with the base metal
- the electrode burns off somewhat cooler
- narrow metal flow is quite general unless the arc is lengthened
- deeper penetration

77
Q

Are all of the following statements True or False
DCEN is sometimes used with SAW when shallower penetration is desired
- 2/3 of the arc energy is in the electrode
- the electrode burns off hotter
- wider metal flow is noticed
- penetration is shallower

A

Yes, all of these statements are correct
DCEN is sometimes used with SAW when shallower penetration is desired
- 2/3 of the arc energy is in the electrode
- the electrode burns off hotter
- wider metal flow is noticed
- penetration is shallower

78
Q

Active Flux - flux that is largely dependant on the welding variables
Neutral Flux - flux that will not cause significant change in the weld metals chemical composition when there is a large change in arc voltage
* Neutral flux is reusable

A
79
Q

Do filler metals for SAW need to be manufacture to match each base metal, or can you purchase filler metals that will work with a variety of base metals

A

SAW needs its filler metals manufacturered for each specific base metal

80
Q

SAW electrodes are available in
a) bare solid wire
b) composite metal cored
c) stranded electrodes
d) all of the above

A

d) all of the above

81
Q

Which section of the CSA standard would you find SAW electrode information
a) W48-14
b) W48-16
c) W48-18
d) W48-20

A

a) W48-14

82
Q

Saw flux and electrode are identified together. The AWS and CSA systems identify the _____ in the first part of the classification followed by the _____.
a) electrode, flux
b) flux, electrode
c) base metal, electrode
d) electrode, base metal

A

b) flux, electrode

83
Q

Interpret the AWS specification of F7A3-EL12K
F -
7 -
A -
3 -
E -
L -
12 -
K -

A

F - Flux
7 - 70,000psi min tensile strength
A - as welded
3 - 30°F
E - Electrode
L - “Low” manganese content
12 - 12% carbon content
K - killed steel

84
Q

Interpret the AWS specification of F49P4-EM12K
F -
49 -
P -
4 -
E -
M -
12 -
K -

A

F - flux
49 - 49,000psi min tensile strength
P - post weld heat treated
4 - -40°F
E - electrode
M - medium manganese content
12 - 12% carbon content
K - killed steel

85
Q

Interpret the AWS specification of F7A3-EH12K
F -
7 -
A -
3 -
E -
H -
12 -
K -

A

F - Flux
7 - 70,000 psi min tensile strength
A - as welded
3 - -30°F
E - electrode
H - high manganese content
12 - 12% carbon content
K - killed steel

86
Q

Interpret the AWS specification of F7P4-EC1
F -
7 -
P -
4 -
E -
C -
1 -

A

Interpret the AWS specification of F7P4-EC1
F - flux
7 - 70,000psi min tensile strength
P - post weld heat treatment
4 - -40°F
E - electrode
C - composite
1 - specified chemistry

87
Q

True or False
SAW flux is classified in 2 distinct ways
1. keyed to its manufacture
2. relative to its effect on the alloy content of the weld deposit

A

True

88
Q

Submerged arc welding fluxes that have 2 categories
a) neutral, reactive
b) bonded , neutral
c) fused, bonded
d) fused, neutral

A

c) fused, bonded

89
Q

Fused fluxes are manufactured by combining a mixture of silica sand, metal oxides and a small amount of halide salt.
how are these components combined?

A

In a electric furnace to form metallic silicate glass

90
Q

Fused fluxes typically _____ ferrous alloys or deoxidizers & are not likely to change drastically from their original chemistry and can be _____ for welding
a) do not contain, recycled
b) do contain, recycled
c) do contain, reused
d) do not contain, reused

A

d) do not contain, reused

91
Q

Classifying fluxes based on their ability to change the alloy content of the weld deposits. The 3 types of fluxes according to this classification method are?
a) neutral, deactivated, wrought
b) neutral, active, alloy
c) negative, active, wrought
d) neutral, deactivated, alloy

A

b) neutral, active, alloy

92
Q

______ do not significantly change the weld metal chemical analysis.
_______ contain deoxidizers to improve resistance to porosity and weld cracking
_______ generally contain enough alloy metal in their composition to produce an alloy weld using a carbon steel electrode

A

Neutral flux : do not significantly change the weld metal chemical analysis.
Active flux: contain deoxidizers to improve resistance to porosity and weld cracking
Alloy Flux: generally contain enough alloy metal in their composition to produce an alloy weld using a carbon steel electrode

93
Q

When using an active flux the transfer of _____ & _____ is proportional to the arc voltage and the amount of flux used
a) magnesium, silicone
b) manganese, silicon
c) zinc, magnesium
d) zinc silicon

A

b) manganese, silicon

94
Q

Tight control of the voltage is critical to maintain desired weld metal composition especially for ______ welds.
a) single
b) multi pass
c) stringer
d) cap

A

b) multi pass
Active Flux is generally used for single pass welds as the flux is generally not reusable

95
Q

Alloy fluxes generally contain enough ______ in their composition to produce an alloy weld using carbon steel electrode.
a) alloy metal
b) wrought
c) manganese
d) silicates

A

a) alloy metal

96
Q

Some flux hoppers are ______ to keep the flux dry

A

heated

97
Q

Troubleshooting SAW Equipment. Issues fall into 1 of 3 categories.
Process, Electrical, Mechanical.
For each of the below issues state which category it falls under.

Unstable arc - incorrect ESO - incorrect flux coverage - worn contact tube - incorrect volt/amp settings

Stubbing - excessing WFS - arc voltage to low - insufficient flux coverage

Wire hang up - wire straightener needs adjusted

Wire feeds but no arc - poor ground connection - loose cable connections

A

Process, Electrical, Mechanical.
For each of the below issues state which category it falls under.

PROCESS - Unstable arc - incorrect ESO - incorrect flux coverage - worn contact tube - incorrect volt/amp settings

PROCESS - Stubbing - excessing WFS - arc voltage to low - insufficient flux coverage

MECHANICAL - Wire hang up - wire straightener needs adjusted

ELECTRICAL - Wire feeds but no arc - poor ground connection - loose cable connections

98
Q

When comparing SAW to SMAW, GMAW, FCAW, MCAW, SAW Which of the following statements are an advantage to SAW and which are a disadvantage to SAW.

  1. SAW is largely restricted to flat and horizontal
  2. used on 3/16 or thicker unless backing is provided
  3. Joints can be prepared with shallower and narrower V-groove - less filler metal used
  4. high speeds and deposition rates possible
  5. Flux can be used to supply alloying elements to the weld
  6. welding parameters must be precisely controlled
  7. low hydrogen- quality weld metal can be deposited
  8. high quality welds are obtained for many critical applications and tested by x-ray
  9. deviations in arc voltage can cause changes in weld composition when using the flux as an alloy source
  10. operations require special training
  11. multiple wire setups are possible for very heavy welds
A
  1. disadvantage
  2. disadvantage
  3. advantage
  4. advantage
  5. advantage
  6. disadvantage
  7. advantage
  8. advantage
  9. disadvantage
  10. disadvantage
  11. advantage

Welder 1 (37 decks)

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