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Autobody Technician Year 3 > Exam 1 > Flashcards

Exam 1 Flashcards

1
Q

The base metal used on resistance spot welders are made up of ______.

A

Copper

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2
Q

Fusible plugs in acetylene cylinders are located in the ___ and _____ of the cylinder.

A

Top and Bottom

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3
Q

What is the temperature of an acetylene flame?

A

800 C (1472 F)

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4
Q

Spray transfer is used for joining materials (_/__”) and greater in thickness.

A

3/32”

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5
Q

What does MIG stand for?

A

Metal Inert Gas

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6
Q

There are two types of welding wire or filler wire metal that can be used in the GMAW process:

_____ wire

___ ___ wire

A

Solid wire

Flux Core Wire

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7
Q

____ cycle is the number of minutes out of a __-minute time period that welder can be operated at it maximum rated output.

A

Duty cycle

10-minute

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8
Q

The maximum safe pressure for acetylene is considered to be __PSI.

A

15 PSI

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9
Q

What does the chemical symbol/formula look like for Acetylene?

A

C2H2

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10
Q

Acetylene cylinders must always be used in an _____ position,

A

Upright

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11
Q

_____ ____ are installed in the cylinder to allow a controlled release of acetylene in the event of fire.

A

Fusible Plugs

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12
Q

What should you do before heating or cutting?

A

Let others know

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13
Q

If the material being heated or cut contains cadmium or lead, A _____ ___ respirator must be used.

A

Fresh Air

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14
Q

Acetylene and oxygen hoses must be able to withstand a minimum burst pressure of ___PSI.

A

400PSI

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15
Q

A carbonizing flame can be used for heating, but adds _____ to steel (hardens it).

A

Carbon

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16
Q

If ___ or _____ is exposed to pure oxygen, an explosion can occur without a flame or spark present.

A

Oil or Grease

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17
Q

When using oxygen the valve must always be _____ open.

A

Fully

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18
Q

The ______ the number is the darker the lens will be.

A

Higher

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19
Q

When and oxygen container is full at room temperature __ºC (__ºF), a standard-sized oxygen cylinder has a pressure of ____ psi and holds a volume of _._m³

A

21ºC 70ºF 2200 PSI 6.9m³

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20
Q

A _______ attachment is designed to preheat the metal to its kindling temperature.

A

Cutting

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21
Q

A ____ ____ also known as a ______, is a tangle of wire located between the feed rollers and the liner.

A

Birds nest

Pileup

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22
Q

_______ are electrical components that convert input alternating current (AC) line voltage to direct current (DC) voltage.

A

Rectifiers

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23
Q

With an aluminum contact tip, the tip should be 0.005” ______ than the size of the wire.

A

Larger

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24
Q

Rotate the regulator pressure-adjusting screw clockwise to ______ pressure ; rotate it counter-clockwise to ______ the pressure.

A

Increase pressure Decrease Pressure

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25
Q

Acetylene is very unstable when compressed beyond __PSI. The critical pressure for acetylene is __ PSI.

A

15 PSI 28 PSI

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26
Q

STRSW are created by combining ____, pressure and ____.

A

Heat, pressure and time

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27
Q

A tip should be operated in ___-working range, which is between smoke range and _______.

A

mid-working blowoff

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28
Q

When welding attach the ____ lead connection as _____ as possible to the welding location.

A

work

close

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29
Q

When welding aluminum manufacturers recommend using a minimum #__ shade lens.

A

10 shade lens

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30
Q

A ________ occurs when the flame goes inside the torch and continues to burn.

A

flashback

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31
Q

When using oxyacetylene equiptment for heating, the acetylene regulator is adjusted to the pressure used when ________ the torch.

A

balancing

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32
Q

Non-fusion welding is an _______ process not a _____ process.

A

Adhesion Fusion

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33
Q

Most welding manufacturers suggest a gas flow rate between __ and __ cfh.

A

15 and 35 cfh

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34
Q

_______ is an alcohol derivative that has the ability to absorb acetylene.

A

Acetone

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35
Q

When cutting with the torch, thinner materials require more _________ than thicker materials.

A

inclination

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36
Q

What does MAG stand for?

A

Metal Active Gas

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37
Q

Can you weld steering or suspension components on a vehicle? Why?

A

NO, you don’t know what properties may be changed or destroyed by welding.

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38
Q

The acetylene valve must ___ be ____ open.

A

Not Fully

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39
Q

As cylinder pressure decreases, the outlet pressure from a pressure regulator remains _______.

A

constant

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40
Q

Spray transfer occurs when using _____ ______ _____ ______ (DCEP).

A

Direct-current Electrode Positive

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41
Q

All components are tightened enough that they will not ____ when ____-tested.

A

Leak Leak-tested

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42
Q

What is the most suitable welding lens for cutting and welding light gauge metal?

A

4 Green

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43
Q

Pull type welder systems are usually hand-held units called _____ guns.

A

Spool

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44
Q

The _______ transfer occurs when the weld metal passes through an open arc in the form of large globules.

A

Globular

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45
Q

_________ is the length of the welding wire or electrode as measured from the contact tip.

A

Stickout

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46
Q

The regulator connection on a welding gas cylinder valve is ____-___ thread.

A

Right-hand thread

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47
Q

A longer stick out ________ the electrical resistance in the circuit and reduces the current available for maintaing the arc

A

increases

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48
Q

What does AWS stand for?

A

American Welding Society

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49
Q

On a cutting torch the acetylene pressure should be set to _ PSI and oxygen to __ PSI

A

5 PSI 20 PSI

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50
Q

______ welding requires the base metal to be fully melted into the area of the joint.

A

Fusion

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51
Q

When an acetylene tank is full at a room temperature __º C (__ºF), a standard-sized acetylene cylinder has a pressure of 1725 kPa (___PSI).

A

21ºC 70ºF 250 PSI

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52
Q

It is estimated that __% to __% of oem welds on unibody cars are done with STRSW

A

90% to 95%

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53
Q

The voids within the porous material inside an acetylene cylinder are filled with liquid ______.

A

Acetone

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54
Q

One part of an oxygen valve contains a ______ or ___ ____ to prevent excessive pressure in the cylinder.

A

Frangible Burst Disk

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55
Q

Do not permit ___ or ______ to come in contact with oxygen cylinders, valves, regulators or other fittings.

A

Oil or grease

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56
Q

A torch can also be referred to as a _____ _____.

A

Torch Handle

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57
Q

_______ tips use more gas, produce larger flames and therefore generate more ____.

A

Larger Btu’s

58
Q

Fusible plugs melt out at ___ºC.

A

100ºC

59
Q

Which form of metal transfer ideal for joining light-gauge metals for fit-ups or wide gaps?

A

Short circuit

60
Q

Plasma Arc equipment is used for ______.

A

Cutting

61
Q

_______ is described as gas pores in the solidified weld bead.

A

Porosity

62
Q

The heat output of a tip is measured in?

A

British Thermal Units (BTU)

63
Q

Regulators perform 2 functions, name them.

A
  1. Reduce cylinder pressure to a usable working pressure 2.Maintain constant pressure, regardless of pressure changes in the cylinder.
64
Q

_________ are electrical devices that transform a high input voltage to a low working voltage.

A

Transformers

65
Q

Acetylene gas can be smelled at a concentration of _% in the air.

A

1%

66
Q

_______ is formed when he oxygen in the atmosphere comes in contact with the intense ultraviolet ligh radiation produced by an open arc.

A

Ozone

67
Q

When the welding or cutting operation is completed, close the torch valves according to the ____________ recommended procedures or the practices adhered to by your ____.

A

Manufacturer’s recommended Shop

68
Q

The regular connection on an oxygen cylinder valve has a _____-___ thread.

A

Right-Hand Thread

69
Q

What does GMAW stand for.

A

Gas Metal Arc Welding.

70
Q

____ welding fuses two pieces of metal together by forcing a molten puddle through the top layer of metal and onto the bottom layer.

A

Tack welding

71
Q

In GMAW short-circuit welding with a _._ mm (3/8) stickout is most often recomended to start with.

A

9.6mm

72
Q

Which light ray can cause eye strain or even temporary blindness?

A

Visible Light Ray

73
Q

Where the problem may involve repairs to the internal electical circuits, repairs must be done by a qualified _____ technician.

A

Repair

74
Q

Lack of penetration, also called ____ lapping, and occurs when there is a lack of fusion between the weld metal and the surface of the workpiece.

A

Cold lapping

75
Q

The _______ welding mode uses a series of pre-timed arc-on/arc-off sequences to allow for cooler welding.

A

Stitch Welding

76
Q

A hole that measures approximately _ mm (1/8”) in diameter must be formed by tearing.

A

3mm

77
Q

When cutting ferrous metals without coatings, iron oxide fumes are given off. ______ shop ventilation should be adequate.

A

Normal

78
Q

If back flow prevention isn’t in place and the acetylene torch valve is faulty, the higher pressure _____ may force its way into the acetylene passages and create a dangerous situation.

A

oxygen

79
Q

Ray produced by the arc can be __ times stronger than the sun.

A

10 times

80
Q

The light rays given off by oxyacetylene are both ______ and _________.

A

Visible and Invisible

81
Q

The burst disc on a welding cylinder, sometimes known as a frangible disk, will rupture at ____ psi.

A

3200 psi

82
Q

________ is defined as the melting away of the plate metal and failure to fill it back in with weld metal.

A

Undercut

83
Q

The most suitable lens for heating, cutting and welding light gauge metal is a __ or __ in a green shade.

A

4 or #5

84
Q

Occasionally, you will need to use oxyacetylene equipment for _______, _______ or _______.

A

Heating Cutting Welding

85
Q

Tack welds are places approximately 13mm _/_” in from the ends of the weld and are spaced approximately 25mm to 30mm _” to 1 _/_” apart along the entire length of the weld

A

1/2”

1” to 1 1/4”

86
Q

Oxygen used for oxyacetylene equipment is __._% pure oxygen.

A

99.5%

87
Q

When leak-testing set the acetylene pressure to _ psi and the oxygen pressure to __ psi.

A

4 psi 15 psi

88
Q

An extension on the nozzle beyond _._mm (1/8”) is not recommended, as the shielding gas envelope may become ineffective at protecting the weld puddle.

A

3.0mm

89
Q

_________ is the process of ridding the molten weld puddle of oxygen.

A

Deoxidization

90
Q

If acetylene pressure is increased, the flame will leave the tip. This is referred to as _______.

A

Blowoff

91
Q

What is the temperature of a neutral flame?

A

3232 C 5850 F

92
Q

The purpose of the _______ ___ is to transfer the welding current to the wire.

A

Contact Tip

93
Q

The _____ directs shielding gas onto the weld zone to prevent atmospheric contamination of the molten puddle.

A

Nozzle

94
Q

Which style of GMAW travel produces a flatter bead shape and less penitration?

A

Forehand

95
Q

What is the temperature of a Carbonizing flame?

A

3149 C 3177 F

96
Q

What is the flame called that has equal parts of acetylene and oxygen?

A

Neutral Flame

97
Q

The regulator on a welder is measured in _______ flow, _____ feet per _____ (CFH) or _____ per minute (L/min).

A

Volumetric flow

Cubic feet per hour

Litres per minute

98
Q

When heating or cutting metal with galvanized coating, zinc oxide fumes are given off. An __ ______ respirator is best.

A

Air Supplied

99
Q

For a lap joint, one peice of metal is laid on top of another, overlapped by _mm to __mm.

A

6mm to 12mm

100
Q

The way that weld metal transfers across the arc from the end of the electrode of the weld zone is called the ____ __ _____ _______.

A

Mode of Metal Transfer

101
Q

When doing a straight cut always attempt to start a cut from an ____, projection or hole.

A

edge

102
Q

The ____ weld is produced by drilling or punching a 6mm to 8mm hole in the top layer of metal.

A

Plug weld

103
Q

The battery should always be ______ to protect the vehicle’s electrical components.

A

disconnected

104
Q

Use only ______ gas whe welding aluminum and keep the volume on the regulator between __ and __ CFH.

A

Argon

30 and 50 CFH

105
Q

Spray transfer uses atleast __% argon, and by increasing the welding current above the critical value called the ________ current.

A

85%

Transision Current

106
Q

When cutting a nut or bolt, hold the prehead flame _mm from the nut.

A

3mm

107
Q

The ______ speed feed motor is usually opertated by ____ _____ (DC) and is controlled by an electronic governer connected to the control system.

A

Variable speed

Direct Current

108
Q

What are the other names used for a Carbonizing flame?

A

Carburizing ; Reducing

109
Q

A ________ is momentary extinguishment of the flame..

A

backfire

110
Q

What does CSA stand for?

A

Canadian Standards Association

111
Q

Name the types of flames in order. 1. 2. 3. 4.

A

Acetylene Flame Carbonizing Flame Neutral Flame Oxidizing Flame

112
Q

Non-Ferrous metals such as aluminum, copper, nickel and bronze and alloys of these materials _______ be cut using oxyacetylene equipment.

A

cannot

113
Q

___ ____ (amps) and ____ (volts) controls are usually located on the front of the machine.

A

Wire speed (amps)

Heat (volts)

114
Q

When a cylinder requires refilling, it should be marked with the letter __.

A

MT

115
Q

Which light ray is both ultraviolet and infrared?

A

Invisible Light Ray

116
Q

___ ___ wire is a type of welding wire that requires no external shielding gas.

A

Flux Core Wire

117
Q

The high-pressure gas cylinder valve is a _____-seat valve.

A

Double-seat

118
Q

Hold the torch with both hands and bring the tips of the preheat flames to within __mm of the material surface.

A

1.5mm

119
Q

____ oxide is present in all welding applications.

A

Iron

120
Q

Welding guns are usually angled at a __° angle to the handle.

A

45

121
Q

Where can you find the contents of a cylinder?

A

WHMIS Label

122
Q

A welding cylinder pressure at room temperature is ____ psi.

A

2000 psi.

123
Q

What is the temperature of an oxidizing flame?

A

3482 C 6300 F

124
Q

Which type of flame removes carbon and iron from the steel?

A

Oxidizing

125
Q

Both AWS and CSA recommend an AWS-___-_ (0.023”) wire for the autobody industry.

A

AWS-E70S-6 (0.023”)

126
Q

The ____ lead is the ground connection.

A

Work

127
Q

______ are considered the most serious of all weld defects because they often lead to complete failure of the weld.

A

Cracks

128
Q

The use of correct _____ ________ (slope in the direction of travel) is important to both the quality and speed of the cut.

A

Torch inclination

129
Q

Short-circuiting metal transfer will short circuit __ to ___ times/second.

A

20 to 200

130
Q

_____ and ____ shielding gasses are the only true inert gasses used in GMAW.

A

Argon and Helium

131
Q

___-_____ welding does not involve the melting of the base metal.

A

Non-Fusion

132
Q

_______ are lengths of unmelted wire protruding from the underside of the weld.

A

Whiskers

133
Q

The term ____ ____ refers to the maximum volume of acetylene that can be taken from the cylinder without drawing acetone liquid along with the acetone gas,

A

Draw Limit

134
Q

Acetone can absorb ___ times its own volume of the acetylene gas.

A

420 Times

135
Q

A ____ type drive welder has a wire drive system house in or on top of the machine and pushed the welding wire into the cable assembly.

A

Push type drive

136
Q

An oxygen regulator has ____-___ threads and acetylene regulators have ____-___ threads.

A

Right-Hand Threads Left-Hand Threads

137
Q

____-______ is defined as excessive penetration in a localized area.

A

Burn-Through

138
Q

The regulator connection on an acetylene cylinder valve has a ___-___ thread.

A

Left-Hand Thread

139
Q

Before oxyacetylene equipment is put to use, all fittings should be leak tested with ___-______ ____ and ______.

A

Non-detergent Soap Water

140
Q

When you start a weld and the wire comes in contact with the base metal and fails to start an arc immediately, you are experiencing a condition known as ______.

A

Stubbing

141
Q

Aluminum _______ must be removed prior to welding; otherwise, it will contaminate the weld.

A

Oxidization

142
Q

Whats the method called that only transfers filler wire when in direct contact with the base metal?

A

Short-circuit metal transfer

Autobody Technician Year 3 (4 decks)

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