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Second Year Welding > AIT > Flashcards

AIT Flashcards

1
Q

Smaw fillet welds on mild steel

Hot pass is a first fill

A

.

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2
Q

Electrode angle =

A

Half the included angle

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3
Q

Another term for inclination is

A

Work angle

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4
Q

Smaw electode inclination
Flat and overhead

A

. 5-15

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5
Q

Forehand

A

Flatter wider smoother metal flow less pen

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6
Q

Backhand

A

Deeper pen narrow bead more build up

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7
Q

Inclination for vertical

A

0-10 forehand

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8
Q

6010

A

DCRP - reverse polarity
DCEP

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9
Q

Weave bead should not exceed

A

2-3 times electrode diameter

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10
Q

The herringbone variation eliminates

A

Undercut

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11
Q

Weave techniques

A

Herringbone
Crescent weave
Lazy L
Sawtooth weave

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12
Q

Groove welds must be reinforced at the center of the weld at least….

A

1.6 (1/16) for material buildup
10 percent material thickness

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13
Q

E4310 (E6010)
1/8
Current type
Polarity
Amps

A

DCEP
DCRP reverse polarity
80-140

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14
Q

E4918 (E7018)
3/33
Currently
Polarity
Amps

A

AC DC
DCEP
DCRP
70-120

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15
Q

E4918 (E7018)
1/8
Current
Polarity
Amps

A

AC DC
DCEP
DCRP
80 - 175

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16
Q

Electrode starting methods

A

Scratch
Tapping

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17
Q

Good polarity checking rod

A

6010 bc it only works on DCRP

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18
Q

Electrode with added potassium

A

6011 has added potassium to stabilize the arc for AC welding

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19
Q

25.4 mm = 1”

A
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20
Q

F system
F1. F2. F3. F4.

A

F1 : iron
F2 : Rutile
F3 : Cellulose
F4 : Lime

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21
Q

Hermetically sealed rods
Temp
Re- bake temp

A

7018 - prevent moisture build up
50 - 250 F

Re-bake
500 - 800F

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22
Q

6010 moisture content

A

3-7 percent

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23
Q

7018 polarity

A

AC or DCRP

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24
Q

Short arc in Smaw
Penetration
Amps and volts

A

High amps low bolts
High narrow deep pen

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25
Q

Long arc in Smaw
Penetration
Amps and bolts

A

Low amps high volts
More fluid puddle, blends better
Less pen

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26
Q

Starting arc volts

A

50-100 amps

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27
Q

Maintaining an arc

A

17-40

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28
Q

Electromotive force EMF

A

Voltage

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29
Q

Blow machine out with

A

High volume
Low pressure air

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30
Q

Percentages of carbon and what they make

A

Low - .05-.30
Nails

Mild .15-.30
General fab

Med .30-.45
Preheat needed, engine connecting rods

High .45-.75
Preheat and post head, springs, crankshafts

Very high .75-1.5
Files

Cast iron 2-4.5

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31
Q

CSA and ASTM

A

Structural steel plates and shapes

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32
Q

AISI

A

Steel sheet stock

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33
Q

SAE and AISI

A

Steel bar stock

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34
Q

CSA system
AT

A

Atmospheric corrosion resistant weldable notch tough

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35
Q

CSA
WT

A

Weldable notch tough

36
Q

CSA
R

A

Atmospheric corrosion resistance steel

37
Q

SAE that begins with a number greater than one is

A

Alloy steel

38
Q

Steel is ….. percent iron

A

95 percent
5 percent other

39
Q

Deoxidizers
5

A

Aluminum
Titanium
Manganese
Silicon
Zirconium

40
Q

Hot shortness

A

Brittle at high temp

41
Q

High strength low alloy steels
Percentage addy

42
Q

Positions welding

A
  1. All positions
  2. Flat and horizontal
  3. Flat only
  4. Down hand, overhead, horizontal, flat
43
Q

Major alloy designations
A, B, C, D, G, M, NM

A

A: carbon moly
B: chrome moly
C: nickel
D: manganese moly
G: all other low alloy electrodes
M: military
NM: nickel moly

44
Q

Pig iron is made in a blast furnace with these three ingredients

A

Iron ore
Coke
Limestone

45
Q

Pig iron carbon content

A

4-5 percent

46
Q

Tuyeres

A

Blow oxygen rich air to remove carbon as CO2 that bubbles out in the blast furnace

47
Q

Cast iron furnaces

A

Cupola
Induction furnace (uses electricity)

48
Q

Steel production furnaces

A

Basic oxygen steel making furnace
Electric arc furnace (high quality steels)

49
Q

Cast iron
2-4.5 percent
Types…

A

Grey : excellent wear resistance ability to absorb noise and vibration - engine block

White : not weldable - better wear resistance then grey

Malleable : easy to be cold worked - annealed white cast iron - plumbing fittings

Ductile or Nodular : highest strength and ductility of cast irons alloyed with rare earth elements and manganese

50
Q

Steel classification by deoxidization process

A
  1. Killed steel - fully deoxidized
  2. Semi killed - some deoxidizers added
  3. Rimmed - no deoxidizers added
  4. Capped - no deoxidizers - cap added to slow cooling
51
Q

Non ferrous vs ferrous metals

A

Ferrous metals contain iron

52
Q

GTAW applications

A

Spot welding
Hot wire (wire is preheated with AC current)
Cold wire
High amp (200 + amps)
Orbital Welding

53
Q

GTAW
Adv and disadvantages

A

Metals and alloys
High quality
Excellent mechanical properties
Filler metal not always required

Slow
Gas shielding
Asphyxiation hazard
Not suitable for outdoors

54
Q

GTAW shade

A

11 - aluminum with argon gas go up a shade to 12

55
Q

Chlorinated degreasing solvent and UV make

A

Phosgene gas

56
Q

GTAW machine is

A

Constant current
Drooping volt amp curve

Adv accuracy and repeatability of current levels

57
Q

Flow meter

A

Volume
CFH cubic feet per hour
LPM litres per min

58
Q

Regulator

A

Brings bottle pressure to a working pressure
Steps it down

59
Q

Post purge

A

1 second of purge time per 10 amps

60
Q

GTAW downslope and upslope

A

Downslope - reduces crater size decreases amps from peak to 0
Upslope - from 0 to peak

61
Q

Pulse

A

Good for thin metals
Keeps the HAZ narrow
Better grain structure
The background maintains the arc
Average amps of the background and peak

62
Q

Ionic bombardment

A

Happens during the positive cycle of the sine wave with high frequency AC

63
Q

GTAW
1/16 - DCEN
Penetration

64
Q

GTAW
1/4 DCEP
Penetration

65
Q

Arc rectification

A

Unstable arc not able to break threw the oxide layer on aluminum

66
Q

Water cooled torches

A

200 + amps
60 percent duty cycle
350 amps
100 percent duty cycle
Left hand threads

67
Q

GTAW
Nozzles and size

A

Use the smallest nozzle the lip of which will not melt under the concentrated heat of the arc

Ceramic
Alumina
Fused quartz (glass)
Metal (cross fire with HF AC)

Measured in 1/16ths

68
Q

Argon gas GTAW

A

10-20 CFH
Gas should flow in a LAMINAR fashion

69
Q

Solenoid valve

A

Electronically operated valve that turns on and off the controls for the
Shielding gas
Coolant
Arc
With a foot pedal or hand remote

70
Q

Helium

A

Hose needs to be plastic or it will leak out passed 20 psi

71
Q

GTAW polarity

A

DCEN
Argon gas 10-20 CFH
EWTh-2 Red - industry standard
Conical prep 2-6 x D
Flush or 1/4 “
0-30 forehand

72
Q

GTAW
Inclination

A

0-30 forehand
70 degrees from horizontal

Filler rod 15-30 from base metal
90 degree relation with each other

73
Q

GTAW fit up

A

1/8 - 5/32
Bigger gap to fit filler rod in between the bevels

74
Q

SMAW groove welds
Why do u tack back side

A

Ensure proper fusion
When extinguishing the arc pull vertically out, will eliminate creators known as blisters
Tack length should be equal material thickness

75
Q

SMAW groove welds
1,3,4 G fit up

A

1/2 included joint angle
0-10 backhand for all passes
3/32-1/8 land and gap

76
Q

SMAW groove welds
If u can’t change your heat which two rods weld at same temp

A

1/8 - 6010 ————80-140
3/32 - 7018 ———-70-120

77
Q

SMAW 2 G fit up

A

0-20 backhand
Preset 3-4 degrees
3/32 - 1/8 land and gap
3 pass stringer cap (7 passes)
Low current settings with a long arc will trap slag

78
Q

CWB SMAW
1GF fit up
What is the included angle

A

30 degrees is the included angle
1/2 “ gap
Start weld on fillet side
Grind parallel to the bend (transverse)
1/8 allowance for impurities

79
Q

CWB test plate
Root bends

A

Two root bends on the stop and starts
One face bend in the middle
First stop at 4.5”
Second stop at 1.5”
4-7 passes

2GF gap is 8 mm
1, 3, 4GF gap is 13mm

80
Q

Non permanent backers are made from

A

Carbon
Ceramics
Copper
Fluxes
Removed after weld is finished

81
Q

SMAW Fillet welds
Electrode inclination

A

5-15 backhand

82
Q

Smaw fillet vertical

A

O-10 forehand

83
Q

SMAW fillet
Weave bead

A

Should not exceed 2-3 times electrode diameter

84
Q

SMAW fillet
Herringbone weave

A

Eliminates undercut

85
Q

SMAW filler
Weave patterns

A

Herringbone (flat, vertical, overhead)
Crescent weave (vertical and overhead)
Lazy L (horizontal)
Sawtooth

86
Q

SMAW fillet
Weld size 1/16 material your working on 10 percent material thickness

87
Q

SMAW fillet welds
Starting methods

A

Tapping
Scratch method

Second Year Welding (13 decks)

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