Fundamentals of Welding Flashcards

1
Q

What is the primary difference between welding and assembly?
a) Welding creates a temporary joint, while assembly is permanent
b) Welding requires mechanical fasteners, while assembly does not
c) Welding forms a permanent joint, while assembly may allow disassembly
d) Assembly is more expensive than welding

A

c) Welding forms a permanent joint, while assembly may allow disassembly

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2
Q

Which of the following is NOT a fusion welding process?
a) Arc welding (AW)
b) Resistance welding (RW)
c) Friction welding (FRW)
d) Oxyfuel gas welding (OFW)

A

c) Friction welding (FRW)

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3
Q

In which process does coalescence occur through the application of pressure alone or with heat below the melting point?
a) Arc welding
b) Solid-state welding
c) Oxyfuel gas welding
d) Autogenous welding

A

b) Solid-state welding

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4
Q

What type of welding is commonly used in the construction of bridges and buildings?
a) Spot welding
b) Diffusion welding
c) Arc welding
d) Ultrasonic welding

A

c) Arc welding

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5
Q

What is the primary risk associated with arc welding?
a) Chemical contamination
b) Ultraviolet radiation
c) Water leakage
d) Thermal expansion

A

b) Ultraviolet radiation

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6
Q

What is the purpose of a filler metal in fusion welding?
a) To increase the thickness of the base metal
b) To act as a heat insulator
c) To provide bulk and added strength to the welded joint
d) To conduct electricity across the joint

A

c) To provide bulk and added strength to the welded joint

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7
Q

Which type of weld is typically used to fill edges in lap, corner, or tee joints?
a) Groove weld
b) Fillet weld
c) Spot weld
d) Seam weld

A

b) Fillet weld

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8
Q

Which of the following is a key disadvantage of welding?
a) It requires complex machinery
b) It cannot be performed outside of factories
c) Welded joints are difficult to disassemble
d) It always requires a filler material

A

c) Welded joints are difficult to disassemble

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9
Q

Which term describes the efficiency of converting power into usable heat at the work surface during welding?
a) Melting efficiency
b) Power density
c) Heat transfer efficiency
d) Heat affected zone (HAZ)

A

c) Heat transfer efficiency

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10
Q

What is the heat-affected zone (HAZ) in welding?
a) The area where molten metal is deposited
b) The zone that remains unaffected by heat
c) The region that undergoes microstructural changes due to heat but does not melt
d) The zone where electrical current flows

A

c) The region that undergoes microstructural changes due to heat but does not melt

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11
Q

Which type of welding uses an electric arc to melt metals?
a) Oxyfuel gas welding
b) Ultrasonic welding
c) Arc welding
d) Resistance welding

A

c) Arc welding

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12
Q

What is the primary purpose of automation in welding?
a) To reduce heat input during the process
b) To enhance safety, productivity, and quality
c) To decrease the weight of welded joints
d) To increase the variety of metals that can be welded

A

b) To enhance safety, productivity, and quality

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13
Q

Which type of joint involves two parts lying in the same plane and joined at their edges?
a) Lap joint
b) Butt joint
c) Corner joint
d) Tee joint

A

b) Butt joint

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14
Q

What is a key characteristic of solid-state welding?
a) Filler material is required for all operations
b) Coalescence occurs through the melting of the base metal
c) Welding occurs at temperatures below the melting point of the metals
d) It uses combustible gases to generate heat

A

c) Welding occurs at temperatures below the melting point of the metals

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15
Q

Which welding process uses resistance to electric current to generate heat for joining parts?
a) Friction welding
b) Resistance welding
c) Arc welding
d) Oxyfuel gas welding

A

b) Resistance welding

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16
Q

What is the main purpose of surfacing welds?
a) To join two parts together
b) To fill the gap between two plates
c) To deposit filler material onto the surface for increased thickness or protection
d) To reduce the heat-affected zone (HAZ)

A

c) To deposit filler material onto the surface for increased thickness or protection

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17
Q

What type of joint forms a right angle and is joined at the corner?
a) Lap joint
b) Tee joint
c) Butt joint
d) Corner joint

A

d) Corner joint

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18
Q

What is the role of a “fitter” in welding operations?
a) To inspect the quality of the welds
b) To assist the welder by arranging and positioning parts before welding
c) To perform automated welding tasks
d) To supervise the use of gases in gas welding

A

b) To assist the welder by arranging and positioning parts before welding

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19
Q

Which factor can affect melting efficiency during welding?
a) Color of the base metal
b) Thermal conductivity of the metal
c) Thickness of the welding gloves
d) Type of mechanical fastener used

A

b) Thermal conductivity of the metal

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20
Q

What is the main drawback of high-power density in welding?
a) Inadequate melting of the metals
b) Excessive energy loss to the environment
c) Localized vaporization of the metal
d) Increased assembly time

A

c) Localized vaporization of the metal

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21
Q

Which of the following joints involves two overlapping parts?
a) Corner joint
b) Lap joint
c) Butt joint
d) Tee joint

A

b) Lap joint

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22
Q

What is the difference between a spot weld and a seam weld?
a) Spot weld uses filler material, while seam weld does not
b) Spot weld is localized, while seam weld is continuous along a joint
c) Spot weld is stronger than seam weld
d) Seam weld requires a higher temperature than spot weld

A

b) Spot weld is localized, while seam weld is continuous along a joint

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23
Q

What is the typical temperature range produced by arc welding processes?
a) 1,500 – 2,000℃
b) 3,500 – 4,000℃
c) 5,500 – 6,600℃
d) 7,000 – 8,500℃

A

c) 5,500 – 6,600℃

24
Q

What is the function of a heat-affected zone (HAZ) in welding?
a) It provides additional filler material for reinforcement
b) It represents the area where the metal melts completely
c) It shows where the material experienced structural changes from heat exposure
d) It prevents the welded joint from corroding

A

c) It shows where the material experienced structural changes from heat exposure

25
Q

Which of the following processes requires no filler material?
a) Arc welding
b) Groove welding
c) Ultrasonic welding
d) Oxyfuel gas welding

A

c) Ultrasonic welding

26
Q

What is power density in the context of welding?
a) The amount of energy needed to ignite the arc
b) The power transferred to the work surface per unit area
c) The energy lost during the welding process
d) The total heat generated during welding

A

b) The power transferred to the work surface per unit area

27
Q

What is the main purpose of flange welds?
a) To seal the edges of overlapping plates
b) To join parts along their surfaces
c) To join the edges of sheet metals or thin plates
d) To create decorative patterns on metal surfaces

A

c) To join the edges of sheet metals or thin plates

28
Q

Which factor influences heat transfer efficiency in welding?
a) The color of the metal
b) The type of welding process used
c) The humidity of the environment
d) The shape of the welding electrode

A

b) The type of welding process used

29
Q

Which of the following best describes an autogenous weld?
a) A weld that requires no external heat
b) A weld made without adding any filler material
c) A weld that requires only pressure
d) A weld performed with minimal edge preparation

A

b) A weld made without adding any filler material

30
Q

What is a common drawback of high-conductivity metals like aluminum in welding?
a) They corrode easily at high temperatures
b) They require specialized gases for welding
c) They dissipate heat quickly, making welding more difficult
d) They are incompatible with solid-state welding

A

c) They dissipate heat quickly, making welding more difficult

31
Q

Which of the following welding processes uses an oxyfuel gas like acetylene?
a) Resistance welding
b) Arc welding
c) Oxyfuel gas welding (OFW)
d) Ultrasonic welding

A

c) Oxyfuel gas welding (OFW)

32
Q

Which metal property can negatively affect welding due to rapid heat dissipation?
a) Low density
b) High thermal conductivity
c) High melting point
d) Low specific heat

A

b) High thermal conductivity

33
Q

What does the term “melting efficiency” refer to in welding?
a) The proportion of heat used for melting compared to the total heat applied
b) The speed at which the filler material melts
c) The ability of the metal to absorb heat without damage
d) The percentage of a joint’s surface area that melts during welding

A

a) The proportion of heat used for melting compared to the total heat applied

34
Q

Which type of joint has one part perpendicular to the other, forming a “T” shape?
a) Tee joint
b) Corner joint
c) Lap joint
d) Butt joint

A

a) Tee joint

35
Q

What is the main advantage of robotic welding?
a) It requires less initial setup time
b) It eliminates the need for filler materials
c) It reduces labor costs and increases safety
d) It can be performed without electricity

A

c) It reduces labor costs and increases safety

36
Q

What is the role of unit energy for melting (Um) in welding calculations?
a) It determines how fast the welding process can be completed
b) It indicates the amount of heat required to melt a unit volume of metal
c) It measures the cooling time of a welded joint
d) It specifies the amount of pressure needed for solid-state welding

A

b) It indicates the amount of heat required to melt a unit volume of metal

37
Q

Which of the following is true about a plug weld?
a) It requires both heat and gas pressure
b) It involves filling a hole with filler material to join two parts
c) It is typically used for high-pressure pipelines
d) It uses no additional material to complete the weld

A

b) It involves filling a hole with filler material to join two parts

38
Q

What is the key hazard associated with gas welding?
a) Electric shock
b) UV radiation
c) Fuel gases create a fire risk
d) Rapid metal vaporization

A

c) Fuel gases create a fire risk

39
Q

What type of weld involves creating overlapping parallel passes to increase thickness or provide protection?
a) Fillet weld
b) Groove weld
c) Surfacing weld
d) Spot weld

A

c) Surfacing weld

40
Q

Why are filler metals sometimes used in fusion welding?
a) To conduct heat between two parts
b) To minimize arc length during welding
c) To provide additional strength to the joint
d) To prevent oxidation of the metals being joined

A

c) To provide additional strength to the joint

41
Q

Which of the following best describes friction welding (FRW)?
a) Joining metals by applying ultrasonic waves
b) Coalescence achieved through mechanical friction under pressure
c) Fusion welding using molten filler material
d) A process that uses gases to generate high heat

A

b) Coalescence achieved through mechanical friction under pressure

42
Q

What is the purpose of edge preparation in groove welds?
a) To improve joint flexibility
b) To enhance weld penetration and strength
c) To reduce the need for filler material
d) To allow faster cooling after welding

A

b) To enhance weld penetration and strength

43
Q

In what environment can welding typically be performed?
a) Only in temperature-controlled factories
b) Only in laboratories with specialized equipment
c) Both in the field and in factories
d) Only in low-humidity environments

A

c) Both in the field and in factories

44
Q

Which type of joint is formed when two parallel parts share a common edge?
a) Tee joint
b) Lap joint
c) Butt joint
d) Edge joint

A

d) Edge joint

45
Q

What safety equipment is essential for arc welding to protect the welder’s vision?
a) Fireproof clothing
b) Safety gloves
c) Helmet with a dark viewing window
d) Respirator mask

A

c) Helmet with a dark viewing window

46
Q

What is the main reason that aluminum and copper present challenges during welding?
a) They have a high melting point
b) They require expensive filler materials
c) They conduct heat away from the weld area too quickly
d) They are incompatible with robotic welding processes

A

c) They conduct heat away from the weld area too quickly

47
Q

Which type of welding involves creating a small, localized fused area between two overlapping plates?
a) Groove weld
b) Fillet weld
c) Spot weld
d) Surfacing weld

A

c) Spot weld

48
Q

Which efficiency factor measures the percentage of total heat used to melt the metal?
a) Heat transfer efficiency
b) Cooling efficiency
c) Arc efficiency
d) Melting efficiency

A

d) Melting efficiency

49
Q

What does “robotic welding” refer to?
a) Welding performed in zero-gravity environments
b) A fully automated welding process controlled by industrial robots
c) Welding where operators manually assist with robotic arms
d) Portable welding systems used in construction

A

b) A fully automated welding process controlled by industrial robots

50
Q

Which hazard is specific to welding processes that use gas fuels like acetylene?
a) Electrical shock
b) Chemical poisoning
c) Fire and explosion risk
d) UV radiation exposure

A

c) Fire and explosion risk

51
Q

What is power density in welding?
a) The rate at which filler material melts during welding
b) The amount of power transferred to the workpiece per unit area
c) The total power used by the welding machine
d) The thickness of the weld bead

A

b) The amount of power transferred to the workpiece per unit area

52
Q

What happens if the power density during welding is too low?
a) The metal will vaporize
b) The metal will not melt, and fusion will not occur
c) The weld will cool too quickly
d) The joint will become brittle

A

b) The metal will not melt, and fusion will not occur

53
Q

Which factor determines the melting efficiency (f₂) in welding?
a) The type of shielding gas used
b) The thermal properties of the base metal
c) The ambient temperature of the workspace
d) The color of the metal

A

b) The thermal properties of the base metal

54
Q

What is the heat-affected zone (HAZ) in welding?
a) The region where metal is vaporized during the welding process
b) The area adjacent to the weld where the metal experiences elevated temperatures but does not melt
c) The part of the workpiece that cools the fastest
d) The area where the shielding gas is applied

A

b) The area adjacent to the weld where the metal experiences elevated temperatures but does not melt

55
Q

How does high thermal conductivity of a metal, like aluminum, affect welding?
a) It makes the welding process faster
b) It helps to achieve better fusion
c) It dissipates heat quickly, making welding more difficult
d) It allows for higher power densities

A

c) It dissipates heat quickly, making welding more difficult