S1: SMAW One _ SMAW Equipment Flashcards
Arc Blow
Objective 1: Define SMAW Related Terms
Occurs during DC welding when the arc flares uncontrollably due to magnetic fields set up around the work. To minimize arc blow:
Change the position of the ground clamp.
Use a different electrode angle or inclination.
Weld toward a heavy tack or existing weld.
Use a lower current setting.
Amperage
Objective 1: Define SMAW Related Terms
Also known as the heat setting, it measures the strength of the current in amperes, which causes the electrode and/or parent metal to melt. It affects the metal deposition rate and penetration in arc welding.
Alternating Current (AC)
Objective 1: Define SMAW Related Terms
Current that flows in one direction during any half cycle, then reverses and flows in the opposite direction during the next half cycle. Commonly measured as 60 cycles per second in North America.
Arc
Objective 1: Define SMAW Related Terms
Created when enough amperage and voltage overcome the natural resistance between the electrode tip and the workpiece, resulting in an electrical discharge.
Arc Voltage
Objective 1: Define SMAW Related Terms
The voltage output of the welding machine during welding, which maintains the arc between the electrode and the workpiece.
Buzz Box
Objective 1: Define SMAW Related Terms
A term for AC transformer welding machines due to their buzzing sound during operation. These machines typically have coarse settings.
Direct Current (DC)
Objective 1: Define SMAW Related Terms
Electric current that flows in one direction only, with no change of direction as with AC. Electrons flow from negative to positive.
Duty Cycle
Objective 1: Define SMAW Related Terms
Rated by the National Electrical Manufacturers Association (NEMA), it is the maximum output duration of a machine over a 10-minute period. Expressed as a percentage, it indicates how long the machine can run at maximum output before cooling is needed.
Electron
Objective 1: Define SMAW Related Terms
Negatively charged particles that move through a conductor when current is flowing. They flow from negative to positive due to their negative charge.
Frequency
Objective 1: Define SMAW Related Terms
Relates to the speed at which AC changes direction. High-frequency current is used in some welding processes for non-touch arc starting.
Generator
Objective 1: Define SMAW Related Terms
A machine that creates electricity for welding. It can produce either AC or DC depending on its internal configuration.
Inverter
Objective 1: Define SMAW Related Terms
A device that changes DC to AC and increases the frequency of AC in welding machines.
Voltage
Objective 1: Define SMAW Related Terms
The electrical pressure or force that causes current to flow in a conductor or across an arc gap. Responsible for starting and maintaining the arc, puddle fluidity, and puddle flow.
Welding Cables
Objective 2: Identify Welding Cables and Accessories for Welding Power Sources
Flexible cables consisting of many strands of fine copper wire in a rubber covering. They transmit welding current from the welding machine to the workpiece and back. Available in eight standard sizes to reduce voltage loss.
Cable Connectors and Lugs
Objective 2: Identify Welding Cables and Accessories for Welding Power Sources
Used to join lengths of welding cable. Connectors have amperage ratings and must be wrapped with electrical tape to prevent accidental arcing. Quick-connect types are also available, using male and female ends that twist and lock together.
Electrode Holders
Objective 2: Identify Welding Cables and Accessories for Welding Power Sources
Devices to hold the electrode during welding. Two main types:
Alligator jaw type: Clamps the bare end of the electrode in a spring-loaded jaw.
Twist head type: The electrode is inserted into the head and tightened mechanically. Handles are insulated to protect from electric shock and heat.
Work Lead Clamps
Objective 2: Identify Welding Cables and Accessories for Welding Power Sources
Used to complete the welding circuit. Types include spring-loaded clamps, magnetic clamps, and C-clamps. A clean, tight connection is crucial to avoid arcing and overheating.
Arc Length
Objective 3: Identify the Effect of Arc Length on Amperage and Voltage
The distance from the end of the electrode core wire to the surface of the molten weld pool. Normal arc length is approximately equal to the diameter of the core wire of the electrode.
Short Arc
Objective 3: Identify the Effect of Arc Length on Amperage and Voltage
Decreases voltage, which may cause the electrode to stick to the workpiece due to insufficient voltage to maintain the arc.
Long Arc
Objective 3: Identify the Effect of Arc Length on Amperage and Voltage
Increases voltage, leading to excessive spatter and shallow penetration due to decreased amperage.
Optimal Arc Length
Objective 3: Identify the Effect of Arc Length on Amperage and Voltage
Maintains a stable arc with appropriate penetration and bead width. Adjusting arc length can control welding outcomes, such as using a shorter arc for deeper penetration and a longer arc for wider beads.
Q: What is arc blow?
Q&A: Obj 1
A: A condition during DC welding where the arc flares uncontrollably from side to side due to magnetic fields set up around the work.
Q: What is amperage in welding?
Q&A: Obj 1
A: Amperage, also known as the heat setting, measures the strength of the current in amperes and is responsible for the metal deposition rate and penetration.
Q: What is alternating current (AC) in welding?
Q&A: Obj 1
A: AC is a current that flows in one direction during any half cycle, then reverses and flows in the opposite direction during the next half cycle. It is measured as cycles per second.
Q: What is an arc in welding?
Q&A: Obj 1
A: An arc is created when enough amperage and voltage overcome the natural resistance between the electrode tip and the workpiece, resulting in an electrical discharge.
Q: What is arc voltage?
Q&A: Obj 1
A: Arc voltage is the voltage output of the welding machine during welding, which maintains the arc between the electrode and the workpiece.
Q: What is a buzz box?
Q&A: Obj 1
A: A term for AC transformer welding machines due to their buzzing sound during operation. These machines typically have coarse settings.
Q: What is direct current (DC) in welding?
Q&A: Obj 1
A: DC is electric current that flows in one direction only, with no change of direction as with AC. Electrons flow from negative to positive.
Q: What is duty cycle in welding?
Q&A: Obj 1
A: The duty cycle is the maximum output duration of a machine over a 10-minute period before cooling is needed, expressed as a percentage.
Q: What is an electron in the context of welding?
Q&A: Obj 1
A: Electrons are negatively charged particles that move through a conductor when current is flowing, flowing from negative to positive due to their charge.
Q: What is frequency in welding?
Q&A: Obj 1
A: Frequency relates to the speed at which AC changes direction, used in some welding processes for non-touch arc starting.
Q: What is a generator in welding?
Q&A: Obj 1
A: A generator is a machine that creates electricity for welding, capable of producing either AC or DC depending on its internal configuration.
Q: What is an inverter in welding?
Q&A: Obj 1
A: An inverter is a device that changes DC to AC and increases the frequency of AC in welding machines.
Q: What is voltage in welding?
Q&A: Obj 1
A: Voltage is the electrical pressure or force that causes current to flow in a conductor or across an arc gap, responsible for starting and maintaining the arc, puddle fluidity, and puddle flow.
Q: What are welding cables?
Q&A: Obj 2
A: Welding cables are flexible cables consisting of many strands of fine copper wire in a rubber covering, transmitting welding current from the welding machine to the workpiece and back.
Q: What are cable connectors and lugs used for?
Q&A: Obj 2
A: Cable connectors and lugs are used to join lengths of welding cable, ensuring a clean and tight connection to avoid overheating.
Q: What are the two main types of electrode holders?
Q&A: Obj 2
A: The two main types of electrode holders are the alligator jaw type, which clamps the bare end of the electrode in a spring-loaded jaw, and the twist head type, where the electrode is inserted into the head and tightened mechanically.
Q: What are work lead clamps used for?
Q&A: Obj 2
A: Work lead clamps are used to complete the welding circuit, with types including spring-loaded clamps, magnetic clamps, and C-clamps, ensuring a clean, tight connection to avoid arcing and overheating.
Q: What is arc length in welding?
Q&A: Obj 3
A: Arc length is the distance from the end of the electrode core wire to the surface of the molten weld pool, typically equal to the diameter of the core wire.
Q: What happens if the arc length is too short?
Q&A: Obj 3
A: If the arc length is too short, it decreases voltage, which may cause the electrode to stick to the workpiece due to insufficient voltage to maintain the arc.
Q: What happens if the arc length is too long?
Q&A: Obj 3
A: If the arc length is too long, it increases voltage, leading to excessive spatter and shallow penetration due to decreased amperage.
Q: What is the optimal arc length in welding?
Q&A: Obj 3
A: The optimal arc length maintains a stable arc with appropriate penetration and bead width, with adjustments for different welding outcomes.
