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Submerged Arc Welding (SAW) > GMAW, FCAW & SAW > Flashcards

GMAW, FCAW & SAW Flashcards

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0
Q

What position(s) can SAW be used in?

A) flat position only
B) flat and horizontal positions
C) flat, horizontal and vertical positions
D) all positions

A

B) flat and horizontal positions

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1
Q

Describe and explain the principles of operation of SAW.

A

Submerged arc welding is defined as an arc welding process by which metals are joined using electric arc established between a continuously fed bare metal consumable electrode or electrodes & the work. Sheilding is provided by a granular, fusible flux material usually brought to the work area using a flux feed system.

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2
Q

Name four (4) types of materials that SAW can be used on.

1) ___________
2) ___________
3) ___________
4) ___________

A

1) Carbon
2) Carbon & alloy steels
3) Stainless steels
4) Nickel alloys

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3
Q

List the basic equipment components required for a SAW set-up and briefly explain their function.

A

Welding power source - provides welding current
Welding head assembly - includes wire feeder, torch assembly, travel carriage (machine and automatic operation), fixtures and positioners - positions the work piece for welding
Spooled filler wire - provides filler metal for the weld
Supply feed and recovery equipment - provides shielding, shapes the bead, alloy additions
Flux feed and recovery equipment - conveys flux to the weld zone; collects unused flux
Work lead connection - completes the welding current circuit to the work piece

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4
Q

What is the advantage of using a screw-type work clamp with SAW?

A

A screw type work lead connection provides a strong and positive contact to the work. The screw type connection also minimizes heat build-up.

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5
Q

What type(s) of output slope do SAW power sources use?

A) CC
B) CV
C) Variable potential
D) CC and CV

A

D) CC and CV

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6
Q

What duty cycle rating is recommended for most SAW power sources?

A) 40%
B) 60%
C) 80%
D) 100%

A

D) 100%

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7
Q

SAW May be used in the semi-automatic or automatic operations.

A) True
B) False

A

A) True

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8
Q

What is the advantage of using an AC power source of SAW?

A) uses less power than DC equipment
B) the arc is more stable than DC current
C) minimizes arc blow with multiple wire set-ups
D) AC power sources have higher duty cycle ratings than DC machines

A

C) minimizes arc blow with multiple wire set-ups

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9
Q

What type(s) of drive rolls are normally used with SAW?

A) angled
B) U-groove
C) flat & smooth-faced
D) knurled or V-groove

A

D) knurled or V-groove

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10
Q

What type of wires feed set-up is used with CV power source?

A) constant speed
B) voltage-sensing
C) amperage-sensing
D) arc force-controlled

A

A) constant speed

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11
Q

List the main SAW operating variables and explain their effects.

A

Amperage - controls penetration & rate of deposit
Voltage - arc length
Travel speed - effects the penetration & bead profile
Electrode diameter - direct effect on weld bead shape, depth penetration & deposition rates
Electrode extension - affects rate of metal deposition, depth of flux layer, influence on arc action, bead appearance and weld metal soundness

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12
Q

To increase arc length when you are welding with SAW, you would:

A) use a longer contact tip
B) increase wire feed speed
C) increase arc voltage
D) use a shorter contact tip

A

C) increase arc voltage

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13
Q

When using SAW, an increase in arc voltage produces a:

A) wider arc stream and shallower penetration
B) wider arc stream and deeper penetration
C) narrower arc stream and shallower penetration
D) narrower arc stream and deeper penetration

A

A) wider arc stream and shallower penetration

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14
Q

When is DCEN used with SAW?

A) when deeper penetration is required
B) when welding on non-ferrous materials
C) when shallower penetration is required
D) for applications requiring more than 1500 amperes

A

C) when shallower penetration is required

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15
Q

Why are wire cast and helix requirements placed in CSA and AWS SAW filler metals specifications?

A

To ensure that the electrode wire will feed smoothly to the weld zone.

16
Q

What diameters are SAW electrode wires available in?

A) 1.6mm to 6.4mm (1/16” to 1/4”)
B) 2.5mm to 9.6mm (3/32”to 3/8”)
C) 3.2mm to 12.7mm (1/8” to 1/2”)
D) 4.0mm to 19mm (5/32” to 3/4”)

A

A) 1.6mm to 6.4mm (1/16” to 1/4”)

17
Q

What is the main difference between the CSA and AWS classification systems for SAW wires?

A) CSA uses the imperial system to measure tensile strength values
B) AWS uses the metric system to measure tensile strength values
C) CSA uses the metric system to measure tensile strength values
D) AWS uses yield strength values while CSA uses tensile strength values in their classification system

A

C) CSA uses the metric system to measure tensile strength values

18
Q 
Interpret the AWS classification for the F7AZ-EL12K flux/wire designation.
A) F \_\_\_\_\_\_\_\_\_\_\_
B) 7 \_\_\_\_\_\_\_\_\_\_
C) A \_\_\_\_\_\_\_\_\_\_
D) Z \_\_\_\_\_\_\_\_\_\_
E) E \_\_\_\_\_\_\_\_\_\_
F) L \_\_\_\_\_\_\_\_\_\_
G) 12 \_\_\_\_\_\_\_\_\_\_\_
H)  K \_\_\_\_\_\_\_\_\_\_
A 
A) F - designates flux
B) 7 - minimum tensile strength x 10,000 in psi
C) A - as welded condition
D) Z - no impact properties are specified
E) E - denotes electrode
F) L - low manganese content
G) 12 - nominal carbon content (0.12%)
H)  K - mad from fully killed steel
19
Q

Interpret the CSA classification for the F49AZ-EM14K flux/wire designation.

A) F\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_
B) 49 \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_
C) A \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_
D) Z \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_
E) E \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_
F) M \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_
G) 14 \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_
H) K \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_
A 
A) F= designates the flux
B) 49 = minimum tensile strength in Megapascals x 10
C) A = as welded condition
D) Z = no impact properties specified
E) E = denotes electrode
F) M = medium manganese content
G) 14 = nominal carbon content (0.14%)
H) K = made from fully killed steel
20
Q

Which type of flux can be re-used?

A) bonded
B) agglomerated
C) fused
D) rutile-based

A

C) fused

21
Q

Which type of SAW flux is generally used for addition of alloying elements?

A) active flux
B) fused flux
C) recycled flux
D) neutral flux

A

A) active flux

22
Q

What should be done with SAW fluxes after they have become exposed to moisture?

A) they should be discarded
B) they should be dried and re-baked according to manufacturer specifications
C) they should only be used for non-critical welds
D) they should be used at 35 arc volts or higher to allow moisture and gases to escape the weld before solidification

A

B) they should be dried and re-baked according to manufacturer specifications

23
Q

Name (4) process-related causes of an unstable arc.

1) __________
2) __________
3) __________
4) __________

A

1) joint dirty with scale, rust, ect…
2) incorrect electrical stick out
3) incorrect drive rolls
4) too much wire cast or helix causing poor wire feed

24
Q

Name (3) things you should check for when the wire feed motor operates but the wire fails to feed.

1) __________
2) __________
3) __________

A

1) insufficient drive roll pressure
2) incorrect drive rolls
3) excessive pressure on spool brake

25
Q

List (3) advantages & disadvantages of SAW.

Advantages

1) __________
2) __________
3) __________

Disadvantages

1) __________
2) __________
3) __________

A

Advantages

1) high weld metal deposition
2) high quality weld metal
3) arc operates under a flux, eliminating spatter & arc flash

Disadvantages

1) restricted to flat & horizontal positions
2) specified training
3) specialized equipment for fixturing & positioning the work piece

Submerged Arc Welding (SAW) (1 decks)

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