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E - 1ST > gmaw modules questions > Flashcards

gmaw modules questions Flashcards

1
Q

What color should your protective clothing be when welding with GMAW and why?

A

Clothing should be dark to reduce reflected light radiation.

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2
Q

Is it advisable to weld with any arc welding process under wet weather conditions? Explain.

A

When you are exposed to wet weather conditions or standing on wet surfaces protect yourself from electrical shock hazards by wearing rubber boots with dry socks and rubber gloves.

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3
Q

The use of shielding gases when using wire feed processes increases the need for good:

A

ventilation.

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4
Q

Name two (2) toxic gases that can be created from the ultraviolet light produced from welding.

A

ozone, phosgene gas (from chlorinated hydrocarbon degreasers)

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5
Q

How can air quality be affected when welding with a process that uses a shielding gas?

A

Shielding gases in sufficient quantities displace enough air to render the work area oxygen deficient. Dizziness or euphoria is usually the first sign of oxygen deficiency. Precautions must always be taken to ensure adequate breathing air is supplied.

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6
Q

High ultraviolet radiation emissions from an open arc can cause atmospheric oxygen in the vicinity of the arc to convert to:

A

ozone.

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7
Q

A potential source of poisonous chemical fumes when welding is:

A

chlorinated degreasing solvents.

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8
Q

Define and describe the GMAW process in detail.

A

GMAW is an arc welding process that uses an arc between a continuous filler metal electrode and the weld pool. The process uses shielding gas from an externally supplied source.

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9
Q

The gas metal arc welding process is also known as:

A

MIG welding.

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10
Q

GMAW is recommended for use on which of the following metals?

A

all of the above

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11
Q

Describe the operating principles of FCAW.

A

FCAW uses an arc established between a continuously fed consumable electrode and the workpiece. Appropriate settings made by the operator maintain a constant burn-off rate of the wire electrode. Depending upon the power source and wire drive system used the arc length is maintained automatically. Shielding gas can be externally applied and/or obtained from a flux contained within the hollow electrode core (depending upon the type of flux cored wire used).

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12
Q

Self-shielded FCAW uses shielding gas generated from:

A

the flux.

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13
Q

What is the electrode extension range for self-shielded FCAW?

A

For self-shielded electrodes extensions range from 19 mm to 95 mm,.

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14
Q

The MCAW process uses the same equipment as which process?

A

FCAW

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15
Q

List the basic equipment components always required for the set-up of a wire feed outfit.

A

power source, wire feeder, gun and cable assembly, spooled filler wire, shielding gas, gas control equipment

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16
Q

How are wire feed guns rated?

A

by current-carrying capacity

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17
Q

The major factor in choosing between an air-cooled or a water-cooled gun is the required:

A

current/voltage.

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18
Q

Welding power sources designed only for wire feed welding can be used for shielded metal arc welding (SMAW).

A

false

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19
Q

GMAW may be used in the semi-automatic or automatic operation modes.

A

true

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20
Q

What type of welding power source is most often used for GMAW?

A

constant voltage

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21
Q

Constant voltage (CV) machines produce a:

A

relatively flat volt-amp curve.

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22
Q

The power source best suited for the short-circuit mode of metal transfer is a:

A

constant voltage power source.

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23
Q

What type of volt-amp curve does a constant current machine produce?

A

drooping

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24
Q

A welding machine that produces an almost horizontal output slope is a:

A

constant voltage machine

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25
Q

List three (3) advantages and three (3) disadvantage of GMAW.

A

Advantages: Any three of the following: lower skill requirements than SMAW, excellent for light gauge metals, good arc control when working with poor fit-ups, less heat input means less distortion than SMAW, high production rates, no slag to remove little or no post weld clean-up. Disadvantages: Any three of the following: special equipment required resulting in higher initial cost, equipment requires more maintenance and down time, lack of fusion can be a problem, cannot be used outdoors or in drafty locations, high radiant energy requires protection for the welder and others in the vicinity, wire feeder must be in close proximity to welding.

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26
Q

One of the main advantages of metal core wires is:

A

high deposition rates.

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27
Q

The powder in a MCAW wire consists mostly of:

A

metal

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28
Q

What is the primary purpose of wire feed welding?

A

Increasing production efficiency and quality in welding.

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29
Q

What are the safety measures to consider before starting wire feed welding?

A

Read operator’s manuals and comply with safety recommendations.

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30
Q

What type of clothing should be worn during wire feed welding?

A

Dark, tight-knit, 100% cotton clothing.

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31
Q

Which shade of filter plate is recommended for GMAW welding at 60-160 amperes?

A

Shade #11.

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32
Q

What is the recommended gas for GMAW on aluminum?

A

Argon or helium.

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33
Q

What is the advantage of using a longer contact tip to work distance (CTTWD) in wire feed welding?

A

It provides better visibility and accessibility in tight spaces.

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34
Q

What is the main purpose of a drive roll in a wire feed welding system?

A

To feed the welding wire from the spool through the gun.

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35
Q

In GMAW, what does a ‘push’ gun angle typically do?

A

Directs the shielding gas ahead of the weld puddle.

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36
Q

What is the primary function of shielding gas in wire feed welding?

A

To protect the weld area from atmospheric contamination.

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37
Q

What is the effect of increasing wire feed speed in GMAW?

A

Increases the deposition rate and size of the weld bead.

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38
Q

What is the effect of electrode extension on voltage in wire feed welding?

A

Longer electrode extension increases the voltage.

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39
Q

In MIG welding, what is the function of the contact tip?

A

To transfer current to the wire and direct it into the weld pool.

40
Q

Why is it important to properly maintain welding equipment?

A

To ensure safety, efficiency, and quality of welds.

41
Q

What is a common cause of porosity in welds?

A

Contamination in the weld area or shielding gas problems.

42
Q

What type of power source is typically used in wire feed welding?

A

Constant voltage (CV) power source.

43
Q

What is the primary advantage of using flux-cored wire in welding?

A

It allows for higher deposition rates and better penetration.

44
Q

How does wire diameter affect welding?

A

Larger diameters allow for higher current and increased deposition rate.

45
Q

What is the purpose of a gas diffuser in a MIG welding torch?

A

To distribute shielding gas evenly around the welding arc.

46
Q

What is the primary cause of spatter in MIG welding?

A

Incorrect voltage or wire feed speed settings.

47
Q

In wire feed welding, what is the function of the drive roll tension?

A

To ensure consistent feeding of the welding wire.

48
Q

What is the effect of using too high a wire feed speed in MIG welding?

A

It can lead to excessive spatter and poor penetration.

49
Q

What is the recommended angle for holding a MIG welding gun for most applications?

A

10 to 15 degrees from vertical.

50
Q

What is the primary function of a liner in a MIG welding gun?

A

To guide the welding wire from the feed unit to the contact tip.

51
Q

In wire feed welding, what is the purpose of the polarity setting?

A

To control the direction of current flow, affecting heat input and bead shape.

52
Q

How does stick-out length affect MIG welding?

A

Longer stick-out reduces heat input and narrows the weld bead.

53
Q

What is a key advantage of using a synergic MIG welding machine?

A

It automatically adjusts wire feed speed to match the set voltage.

54
Q

What is the primary purpose of a nozzle in MIG welding?

A

To direct the flow of shielding gas over the weld pool.

55
Q

In MIG welding, what is typically used as a shielding gas for welding steel?

A

A mixture of argon and carbon dioxide.

56
Q

What is the consequence of using an incorrect shielding gas mixture in MIG welding?

A

Poor weld quality and possible contamination.

57
Q

How does outdoor welding affect the choice of welding process in wire feed welding?

A

Flux-cored welding is preferred due to its resistance to wind.

58
Q

What is a typical symptom of having too low a voltage setting in MIG welding?

A

Lack of penetration and a narrow, rope-like bead appearance.

59
Q

Why is wire cleanliness important in wire feed welding?

A

To prevent contamination of the weld and ensure smooth wire feeding.

60
Q

What is the effect of a high electrode stick-out in MIG welding?

A

Decreased current density and a cooler weld puddle.

61
Q

In MIG welding, what does the term ‘duty cycle’ refer to?

A

The amount of time a welder can operate at a given output without overheating.

62
Q

What is the impact of using a smaller diameter wire in MIG welding?

A

Suitable for lower current welding and thinner materials.

63
Q

What role does the tension setting on a wire feeder play in MIG welding?

A

It ensures stable wire feeding without slippage or wire crush.

64
Q

Why is it important to have the correct torch angle in MIG welding?

A

To ensure proper gas coverage and weld bead formation.

65
Q

What is the primary purpose of inter-pass temperature control in welding?

A

To control the microstructure and mechanical properties of the weld.

66
Q

What is the consequence of improper shielding gas flow rate in MIG welding?

A

It can lead to porosity and lack of shielding from atmospheric gases.

67
Q

What is a common effect of welding with an excessively long arc in MIG welding?

A

Increased spatter and a lack of control over the weld pool.

68
Q

Why was gas metal arc welding (GMAW) developed?

A

To eliminate the use of fluxes when welding aluminum and magnesium alloys.

69
Q

What is an advantage of using the flux cored arc welding (FCAW) process?

A

High weld metal deposition rates.

70
Q

Which type of power source is recommended for wire feed welding processes?

A

Constant voltage (CV) power source.

71
Q

What is a key characteristic of metal-cored arc welding (MCAW)?

A

Uses a tubular wire electrode with a metal outer sheath and a core of powdered materials.

72
Q

What is the primary function of the shielding gas in wire feed welding processes?

A

To protect the molten weld metal from atmospheric contamination.

73
Q

What is the main hazard associated with electrical equipment in wire feed welding?

A

Electrical shock due to improper grounding.

74
Q

What type of protective clothing is recommended for wire feed welding?

A

Dark, tight-knit, 100% cotton clothing.

75
Q

What shade of filter plate is suggested for welding in the range of 60-160 amperes in GMAW?

A

Shade #11.

76
Q

What is the main function of flux in self-shielded FCAW?

A

Generating shielding gases to protect the weld.

77
Q

What are the primary characteristics of a CV power source in wire feed welding?

A

Maintains arc voltage during current surges and adjusts current flow automatically.

78
Q

How does wire feed speed affect the welding process in CV welding?

A

Controls amperage; higher feed speed increases amperage.

79
Q

What is a disadvantage of GMAW compared to other welding processes?

A

Special equipment that is more complex and costly to purchase.

80
Q

Why is FCAW favored for high weld metal deposition rates?

A

It provides high quality weld metal at lower costs and less effort than SMAW.

81
Q

What is a key advantage of MCAW over other welding processes?

A

High quality weld metal deposits and no slag or interpass cleaning.

82
Q

What type of cooling system is commonly required in high current applications of wire feed welding?

A

Water cooling system.

83
Q

What is the recommended amperage range for welding power sources in wire feed processes for light duty work?

A

Less than 100 amperes.

84
Q

What does a duty cycle rating of 60% at 300 amps mean for a welding power source?

A

The machine can operate at 300 amps for 6 minutes out of 10 minutes of elapsed time.

85
Q

What hazard is associated with the intense ultraviolet light radiation produced by the electric arc in wire feed welding?

A

Ozone and other harmful fumes may become toxic.

86
Q

What are the essential components of the basic equipment required for wire feed welding?

A

Welding power source, wire feeder, electrode holder (welding gun), spooled filler wire, shielding gas, regulator/flowmeter, and cooling system (if required).

87
Q

What is the function of the drive roll system in wire feed welding?

A

To push the wire electrode forward through the cable assembly and gun to the weld zone.

88
Q

What is the primary reason for using hearing protection during wire feed welding?

A

To avoid hearing loss in high noise level environments.

89
Q

How is the electrode for GMAW commonly supplied?

A

Continuously fed from a spool.

90
Q

What is the primary role of deoxidizers in gas-shielded FCAW?

A

To combine with any small amounts of oxygen produced during welding.

91
Q

What is an advantage of self-shielded FCAW in field fabrications?

A

Better tolerance of windy conditions.

92
Q

What is the difference in the shielding method between gas-shielded and self-shielded FCAW?

A

Gas-shielded uses external gas, while self-shielded generates its own shielding from the flux.

93
Q

What is the effect of increasing electrode extension in self-shielded FCAW?

A

Results in a narrow bead with shallow penetration.

94
Q

What is a typical application of spray transfer in MCAW?

A

Welding in the flat or horizontal position.

95
Q

What is the primary advantage of using a CV power source in wire feed welding?

A

It maintains arc voltage during current surges and smoothens short-circuit transitions.

96
Q

What type of welding operation is MCAW particularly suitable for?

A

High-production automatic welding.

97
Q

What is a disadvantage of using MCAW for outdoor welding?

A

Requires protection from strong drafts that can blow the shielding gas away from the weld zone.

E - 1ST (11 decks)

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