Flux Welding Exam

Question 1

What power source is required for FCAW?

Answer 1

Constant Voltage

Question 2

What drive rolls required for FC?

Answer 2

Knurled

Question 3

What polarity with dualshield? and Innershield?

Answer 3

Dual - Reverse DC+

Inner - Straight DC-

Question 4

What is tensile strength of E81T-1? E10T-1?

Answer 4

80,000 and 100,000

Question 5

E80T - 11 Positions? E81T-11

Answer 5

0 = Flat and Horizontal, 1 = All positions - The opposite of stick

Question 6

What does Voltage control?

Answer 6

Arc Size - if you turn up the width and length go up

Question 7

What does WFS control?

Answer 7

Penetration - sending more wire in faster - if you shorten you change the # of arcs

Question 8

CFH? IPM? WFS or 0/0?

Answer 8

Cubic Feet Per Hour, Inches Per Minute and Wire Feed Speed

Question 9

How much gas pressure with FC GW?

Answer 9

35-45

Question 10

What types of bottles are these two bottles?

Answer 10

High Pressure - open them all the way

Question 11

What travel angle is used with FCAW? Why do you use this one?

Answer 11

Drag, because there’s flux and you risk trapping the flux if you push

Question 12

What is a regulator called when it’s on a machine instead of a bottle?

Answer 12

Blow Meter

Question 13

What does T stand for? S?

Answer 13

Tubular and Solid

Question 14

What are the 4 consumables and what do they do?

Answer 14

Diffusor - Holds everything together
Insulator - Protects you from the current
Contact Tip - carries current into electrode/wire
Nozzle - Use w/ gas because it forces gas over the weld

Question 15

What causes porosity?

Answer 15

Gas coverage not on the weld, like welding from too high.

Question 16

What is the AWS electrode classification for FCAW - G and FCAW - S

Answer 16

G is E71T-1 and S is E71T-11

Question 17

What drive roll tension is used for FCAW?

Answer 17

3 to 4/ A lil grey showing/ As little as possible

Question 18

What does FCAW-S and FCAW-G stand for?

Answer 18

Flux Core Arc Welding - Self Shield (Innershield)

Flux Core Arc Welding - Gas Shield (Dual Shield)

Question 19

What are the 2 drive roll types?

Answer 19

Smooth and Knurled

Question 20

What 2 gases can be used with FCAW - G?

Answer 20

75/25 or 100% CO2

Question 21

Define bird nesting.

Answer 21

Wire caught in the drive roll system

Question 22

What is the most common cause of bird nesting?

Answer 22

Clogged contact tip

Question 23

Which shielding gas gives you the least amount of penetration? Which gives the most? Which is the most common and why? What are some differences?

Answer 23

75/25, 100% CO2 - and 100% CO2 because it’s cheap, it produces the most penetration, creates a very aggressive arc and produces lotsof sparks and BB’s

75/25 is more stable arc than 100% CO2 - prettier

Question 24

What happens if you use a smooth roll on flux core wire? Why would you use knurled?

Answer 24

It will crush the wire then cause you to bird nest. Knurled gives you more traction with less tension.

Question 25

What’s the difference between travel and work angle?

Answer 25

Travel angle is drag or push, that’s it. Work angle is the degreed angle

Question 26

Why do you use DC+ for Gas Shield?

Answer 26

Straight Polarity puts approx 70% of heat on the part and 30% is on the electrode, Reverse or DC+ is the opposite putting 70% of heat on the electrode and 30% on the part - the electrode can stand up to it

DC- less penetration and DC+ more penetration

Question 27

Why do you use a gas with Flux and Mig gas wires? What two types of gasses are there and give examples.

Answer 27

It protects it from the enviornment -
Inert and Reactive -
Inert - Argon + Helium
Reactive - CO2 and Oxygen

Question 28

What is depostion? What do you balance it with?

Answer 28

How much metal you’re putting down - you balance this with penetration.

Question 29

FCAW - G Settings and some details

Answer 29

Constant Voltage
DC+
Knurled
3/4
75/25 or CO2
23- 24 Volts / 300 IPM
35-45 CFH - Open All The Way

E71T-1

High deposition but can’t do outside, easy in flat but hard in other position

Question 30

FCAW - S Settings?

Answer 30

Constant Voltage
DC-
Knurled
3/4
18 - 19 Volts / 125 - 150 IPM

E71T-11