Flux Welding Exam Flashcards
What power source is required for FCAW?
Constant Voltage
What drive rolls required for FC?
Knurled
What polarity with dualshield? and Innershield?
Dual - Reverse DC+
Inner - Straight DC-
What is tensile strength of E81T-1? E10T-1?
80,000 and 100,000
E80T - 11 Positions? E81T-11
0 = Flat and Horizontal, 1 = All positions - The opposite of stick
What does Voltage control?
Arc Size - if you turn up the width and length go up
What does WFS control?
Penetration - sending more wire in faster - if you shorten you change the # of arcs
CFH? IPM? WFS or 0/0?
Cubic Feet Per Hour, Inches Per Minute and Wire Feed Speed
How much gas pressure with FC GW?
35-45
What types of bottles are these two bottles?
High Pressure - open them all the way
What travel angle is used with FCAW? Why do you use this one?
Drag, because there’s flux and you risk trapping the flux if you push
What is a regulator called when it’s on a machine instead of a bottle?
Blow Meter
What does T stand for? S?
Tubular and Solid
What are the 4 consumables and what do they do?
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
What causes porosity?
Gas coverage not on the weld, like welding from too high.
What is the AWS electrode classification for FCAW - G and FCAW - S
G is E71T-1 and S is E71T-11
What drive roll tension is used for FCAW?
3 to 4/ A lil grey showing/ As little as possible
What does FCAW-S and FCAW-G stand for?
Flux Core Arc Welding - Self Shield (Innershield)
Flux Core Arc Welding - Gas Shield (Dual Shield)
What are the 2 drive roll types?
Smooth and Knurled
What 2 gases can be used with FCAW - G?
75/25 or 100% CO2
Define bird nesting.
Wire caught in the drive roll system
What is the most common cause of bird nesting?
Clogged contact tip
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?
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
What happens if you use a smooth roll on flux core wire? Why would you use knurled?
It will crush the wire then cause you to bird nest. Knurled gives you more traction with less tension.
What’s the difference between travel and work angle?
Travel angle is drag or push, that’s it. Work angle is the degreed angle
Why do you use DC+ for Gas Shield?
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
Why do you use a gas with Flux and Mig gas wires? What two types of gasses are there and give examples.
It protects it from the enviornment -
Inert and Reactive -
Inert - Argon + Helium
Reactive - CO2 and Oxygen
What is depostion? What do you balance it with?
How much metal you’re putting down - you balance this with penetration.
FCAW - G Settings and some details
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
FCAW - S Settings?
Constant Voltage DC- Knurled 3/4 18 - 19 Volts / 125 - 150 IPM
E71T-11
