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Third Year > Shop > Flashcards

Shop Flashcards

1
Q

How close do you put your tungsten to material ?

A

Same diameter as tungsten

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2
Q

What tungsten is used for aluminum ?

A

Zirconium oxide (zirconia )

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3
Q

How are tungsten’s identified ?

A

Colour

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4
Q

What happens if Argon gas displaces your air supply ?

A

You could be asphyxiated

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5
Q

What percent is argon helium?

A

80% argon 20% helium

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6
Q

For most sheet metal projects a gas flow setting of _____ is a good starting point ?

A

20 cubic feet per hour

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7
Q

What’s the first thing u enter into the plasma table ?

A

Duct dimension

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8
Q

What is the most common satey feature on the plasma table ?

A

Nozzle in place saftey sensor

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9
Q

What type of metals can be cut using plasma arc ?

A

Almost all metals

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10
Q

What is the main advantage of using computerized layout ?

A

Speed (productivity)

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11
Q

What is the main advantage of using computerized layout ?

A

Speed (productivity)

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12
Q

Describe the plasma cutting process

A

Uses a high velocity jet of ionized gas , electricity is conducted through the plasma and melts the material

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13
Q

What can be done if it’s not possible to pattern into a template directory ?

A

Use a hand held plasma

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14
Q

Other than plasma cutters list 4 types of cutting equipment that is used in the sheet metal trade ?

A

Oxy fuel
Laser punch
Water jet
Router

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15
Q

Why is it important to nest fittings into the material being used for plasma cutting ?

A

Optimize material usage

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16
Q

What does nesting mean

A

The parts are laid side by side and rotated to match interlocking angles and contours

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17
Q

What are some process parameters that can be modified to obtain desired results ?

A

Kerf
Lead in
Lead out
Feed rate

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18
Q

What are some advantages of using customized labels ?

A

Extra critical data for estimating
Production
Shipping
Inventory
Management
Purchasing

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19
Q

List some ppe that should be worn for using computer cutting equipment

A

Long sleeve
Gloves
Eye protection
Follow all safety tops and guide lines

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20
Q

Why is it important to find a machine that uses a “ nozzel in place safety sensor “

A

The plasma cutter will not start an arc unless the nozzel is in place

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21
Q

How was plasma cutting discovered ?

A

Accidentally trying to develope a better welding process

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22
Q

What is the function of an electrode ?

A

Carry the negative charge from the power supply

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23
Q

What is the function of the gas distributior

A

To spin the plasma gas into a stable vortex of swirling gas

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24
Q

What is the function of a nozzel

A

Constrict and focus the plasma jet

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25
Q

What is the function of a shield ?

A

Protect the nozzel from spatter and focus the shield gas jet

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26
Q

What parts of the plasma need frequent replacement?

A

Nozzle and electrode

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27
Q

What changes on a plasma machine as we start to cut thicker materials

A

Amperage

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28
Q

How are cutting speeds measured ?

A

Inches per minute

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29
Q

How are consumables rated ?

A

Some rate consumables by number of cuts while others use number of starts

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30
Q

What is the advantage to use ing a smaller torch ?

A

Better see where you are cutting

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31
Q

Why do we need to filter the compressed air when useing a plasma cutter?

A

They ensure oil is removed from the compressed air

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32
Q

What can be the result of having oil in the compressed air when plasma cutting ?

A

Oil can cause arcing and reduce cutting performance and it will also reduce the life of consumables

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33
Q

What two dimensions are affected by the plasma cutter on a part being cut ?

A

Kerf width
Bevel angle

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34
Q

What is kerf ?

A

A void created by the plasma cutting processes or the amount of metal removed by the plasma arc

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35
Q

What four things can affect the plasma arc kerf ?

A

Amperage
Voltage
Gas flow
Velocity of moving torch

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36
Q

How are nozzles sized ?

A

According to amperage rating

The bigger the hole the more power it can handle

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37
Q

What problems can happen if the kerf is to wide ?

A

Worm nozzle
High torch standoff
Excessive amperage
Inadequate gas flow
Low speed

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38
Q

What is the problem if the kerf is to narrow

A

Low torch standoff
inadequate amperage
Excessive gas flow
High speed

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39
Q

What is bevel angle ?

A

The angle of the cut edge

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40
Q

When is a bevel angle starting to show problems with the machine parameters ?

A

When the angle is greater than 5 degrees may indicate a problem with the pac machine parameters

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41
Q

Whay can cause a positive bevel ?

A

Part top is smaller than the bottom

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42
Q

What can cause a negative bevel ?

A

Smaller bottom and bigger top

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43
Q

What can cause an irregular bevel ?

A

The presence of both positive and negative bevel on the same peice

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44
Q

What is dross ?

A

Re -solidified oxidized molten metal that is not fully ejected from the kerf during cutting

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45
Q

How can we eliminate “ low speed dross “

A

Increase cut speed 5ipm increments
Increase standoff in 5 volt increments
Decrease the amperage in 10amp increments
If none of these improve the cut consider another nozzel

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46
Q

How can we eliminate high speed dross ?

A

CHeck nozzles for sighns of wear
Decrease cutting speed 5ipm increments
Decrease the stand off in 5 volt increments
Increase ether amperage ( do not exceed 95% of the nozzle office rateing )

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47
Q

How can we eliminate top splatter dross ?

A

Check the nozzel for sighns of wear
Decrease the cutting sped in 5ipm increments
Decrease the standoff in 5 volt increments

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48
Q

What can be done to machines and equitment that are being used to form sheet metal fittings ?

A

Heat treat and harden the machine parts that come in contact with these edges

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49
Q

What can be done to the actual fitting pieces prior to using convention sheet metal equitment to prevent damage ?

A

Dross should be mechanically removed by grinding or filling to minimize wearing out ewuitment rollers and guides

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50
Q

What is some information that can be put on a label that will be attached to a fitting part ?

A

Job name
Address
Floor
Location
Fitting number
Which truck it should be loaded

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51
Q

What name is most commonly given to gas tungsten welding ?

A

Tig

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52
Q

Describe the welding process for gas tungsten arc welding ?

A

Fusion welding is accomplished by the heat of an electric arc drawn between a non consumable tungsten electrode and the work

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53
Q

Is gtwa more hazardous than any other welding process?

A

No

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54
Q

What four main safety precautions should be taken in respect to prior and during gtaw welding process?

A

Electrical hazards
Eye protection
Protective clothing
Ventilation

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55
Q

What should be checked prior to welding to prevent electrical shock ?

A

Check all electrical connections to ensure that they are properly made to avoid the possibility of electric shocks

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56
Q

How often should we check all current carrying components required for gtaw ?

A

Regularly

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57
Q

What must be in place prior to welding ?

A

All protective covers must be in place

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58
Q

Does the welding machine need to be properly grounded ?

A

Yes

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59
Q

How do we know what size torch needs to be used ?

A

Must be large enough to handle the amount of current used without overheating

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60
Q

What should be checked for on water cooled torch heads ?

A

All connections for leaks

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61
Q

List three things that are required of the work leads prior to using them for the welding process

A

Work leads should be in good conditions
Work leads should be large enough to handle the current used

The work lead should be firmly connected to the work to prevent accidental arcing

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62
Q

List three safety items that must be considered in regards to the hose or cables in the work space

A

Must be protected from hot materials or falling objects

Should be hung up out of the way when not in use

Leave the work area clear of obstacles and possible tripping hazards

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63
Q

Why should you turn the power off to the welder when not in use?

A

To prevent accidental arcing

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64
Q

Why is it important to have dry gloves and footwear and footwear when welding ?

A

Perspiration can cause gloves to become conductors. Ensure that gloves and footwear are dry and in good conditions

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65
Q

What needs to be done if u are welding in wet weather conditions or are standing on a wet surface ?

A

Take the necessary precautions to protect

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66
Q

In what scenario is the most intense ultraviolet radiant energy produced ?

A

When Argon shielding gas is used and when aluminum or stainless steel is being welded

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67
Q

What shade of welding lens is required for welding ?

A

Use the darkest shade that is comfortable, but not lighter than recommended

68
Q

What can happen to exposed skin that is not covered during the welding process?

A

Shinny surfaces can cause a sunburn effect to exposed skin

69
Q

When working inside a tank or confined space what should we be careful to also protect from bright light ?

A

Back of kneck and ears

70
Q

Who outlines acceptable noises levels in a working environment?

A

Provincial occupational health and safety standards

71
Q

What type and color of clothing is preferd when welding ?

A

Dark coloured tightly woven clothing

72
Q

What can be the results of wearing a light colour of clothing that can reflect light ?

A

More reflective and may cause burns to your eyes even when a helmet is worn

73
Q

Why should synthetic clothing be avoided when welding ?

A

They tend to flash (burn rapidly)

74
Q

List two considerations that must be met when selecting clothing used for welding ?

A

Relatively flame resistant

Free of any oil or grease

75
Q

Why is it important to keep collar buttoned and yiur pockets and cuffs covered when welding ?

A

To prevent the entry of sparks

76
Q

What should never be in your pockets when welding

A

Matches or lighters

77
Q

What type of glove is required for gtaw welding

A

Gauntlet gloves of an approved type to protect your wrist and lower arms

78
Q

What must a welder have readily available for fire prevention

A

Suitable fire extinguisher

79
Q

Why is it important to have the exhaust ventilation several inches away from the welding area ?

A

So the ventilation does not disturb the gas shield

80
Q

What is the maximum feet per minute that should be maintained over the surface of the welding area ?

A

50fpm

81
Q

Why do certain cylinders and regulators have diffrent sizes and types of connections?

A

To eliminate the possibility of interchanging regulators to cylinders

82
Q

Why is it important on how we store liquid and gas cylinders

A

To prevent the incorrect uses of gases

83
Q

What two important pieces of information must be attached to every cylinder containing liquids or gasses used for welding ?

A

To identify the gas
Must have who is symbols attached

84
Q

Where are two locations that we can store gas and liquid cylinders ?

A

Outdoors or in a well ventilated area

85
Q

How should gas and liquid cylinders be secured when storing transporting or being used for welding ?

A

Vertical upright position

86
Q

What 3 things need to be done to gas and liquid cylinders prior to returning them ?

A

Ensure valves are closed
Protective caps are in place
Outlet cap or plus replaced

87
Q

What four things are protected from atmospheric contamination by the gaseous shield when tig welding ?

A

Electrode
Arc
Weld puddle
Adjacent heated area of the work place

88
Q

Do we always need to use filler rod when tig welding ?

A

No

89
Q

Why was tig welding originally developed ?

A

Towels corrosion resistant and hard to weld metals such as aluminum and magnesium

90
Q

What delivers the heat between the electrode and the work prove ?

A

The arc

91
Q

How is filler rod inserted into the welding puddle when heated ?

A

It is added separately either manually or automatically

92
Q

When would tig welding be the preferred welding process ?

A

When highest possible quality welds are required for the more critical weld applications

93
Q

List four types of gtaw power sources ?

A

Transformers
Transformers/rectifers
Generators
Inverter type

94
Q

Which gtwa power source are best suited and most commonly used in our industry ?

A

Transformers/rectifers designed for gtaw

95
Q

Which type of current is generally used for welding aluminum and magnesium

A

Alternating current

96
Q

Which type of current is generally used for welding ferrous metal and some non ferrous metals ?

A

Direct current straight polarity

97
Q

What can be used on specific gtaw workstations to control gas flow cooling media and current ?

A

Remote control units

98
Q

When using a remote foot control on a gtaw workstation what restricts the maximum amount of current that will be delivered to the workpiece ?

A

Amperage adjustment control

99
Q

What are three things that are controlled by the remote control unit attached to the torch handle ?

A

The main contractor
Shielding gas flow
Amperage

100
Q

What are two methods of cooling the torch on a gtaw unit ?

A

Air cooled
Water cooled

101
Q

What is the difference between the power cable thickness on an air cooled torch assembly compared to a water cooled torch assembly

A

The power cable of an air cooled torch is heavier than that used in a water cooled torch assembly

102
Q

Why is one torches power cables thicker than other ?

A

Water cooled torch assembly can maintain cooler temperature

103
Q

What is the maximum amount of amperage that is recommended to be ran through the power cables of an air cooled torch head assembly?

A

200amps

104
Q

In regrades to the electrode what is the advantage of useing a water cooled torch head assembly opposed to an air cooled torch head assembly ?

A

Lower electrode Tempature and less electrode erosion

105
Q

Can the water cooled torch head assembly carry more or less amperage in comparison to the air cooled torch assembly?

A

More

106
Q

What are the advantages of having a flexiabke torch head assembly ?

A

Allow you to adjust the head angle for your comfort and better joint access

107
Q

What is the most common torch head angle used in gtaw?

A

120

108
Q

What are three functions of the torch cap ?

A

Prevents accidental arcing of the tungsten electrode at the back of the torch
Used to tighten. The collet onto the electrode

Give a positive shielding gas seal between the torch cap and body

109
Q

What are five components that make up an air cooled and / or water cooled torch body ?

A

Handle
A means of conveying shield gas
Collet body connection
A metal body to transfer power from the cable to the collet body
Cooling lines

110
Q

What three things are normally included in the torch body ?

A

Cables
Hoses
Machine connectors

111
Q

List three functions of the collet body

A

Holds electrode collet to position the electrode in the torch

Establish electrical contact between torch body and electrode collet

Directs shielding gas to the gas nozzel

112
Q

In regards to the electrode what are two functions of the collet ?

A

Positioning electrode
Makeing positive electrode contact

113
Q

What transfers the electrical current from the collet body to the electrode ?

A

The collet

114
Q

How is the tapered end of the collet pushed into the collet body resulting in tighting around the electrode ?

A

Tighting the back end cap

115
Q

What are most collets made from ?

A

Copper alloy

116
Q

What is the result of using mismatched collet bodies and collets ?

A

Damage to the collet occours and the electrode cannot be held in position

117
Q

What is the function of a gas nozzle

A

To direct shielding gas into the weld zone

118
Q

What type of nozzle is the most common and why ?

A

Ceramic type which is also the least costly

119
Q

What is a major disadvantage of using a ceramic type nozel ?

A

They become brittle after repeated use and cause chipping and uneven gas flow ?

120
Q

What are two considerations that must be taken into account when selecting a gas nozzle ?

A

Size of electrode
Size of puddle

121
Q

What are four advantages of using a smaller nozzle ?

A

Maintain a more stable arc
Give the welder better vision
Give a compression effect to the arc
Permit welding in restricted areas

122
Q

What is the main advantage of using a larger nozzel ?

A

Give a better shielding action at lower gas flows rates

123
Q

What metal are normally welding useing a larger nozzle ?

A

Metals that oxide readily at elevated temps

124
Q

List three other types of nozzels available but ware not commonly used in the sheet metal industry ?

A

Alumina gas nozzles
Fused quartz nozzles
Sleeve type metal nozzles of the slip on style

125
Q

What can result in not keeping the nozzle clean ?

A

Building of foreign matter results in turbulence in the gas flow and contamination of the weld puddle if this foreign matter falls into weld pool

126
Q

What is the result of using a gas lens inside a nozzle

A

Produce a longer undisturbed plume of gas

127
Q

What is meant by gas flowing in a laminar fashion ?

A

Arranged in thin layers

128
Q

By useing a gas lens will the distance between the work and nozzel increase or decrease ?

A

Greater nozel to work distances

129
Q

What can cause a gas lens to disrupt gas flow ?

A

Fine spatter or other contaminants

130
Q

What is imperative of the use of a work lead ?

A

Must have clean contact surfaces and must make good electrical contact with the work peice

131
Q

What defines an electrode ?

A

Picks up or emits electrons in an electrical circuit

132
Q

What type of electrode is used in a gtaw process ?

A

A non consumable tungsten electrode ?

133
Q

What is the purpose of an electrode when used in the GTAW process ?

A

Transfer electrical current across the arc between the elctrode and the work

134
Q

Why is tungsten used as an electrode ?

A

It is a highly refractory ( heat resistant) metal with a melting point of 3410 degrees delicious which is the highest melting point of all metals

135
Q

How are the sizes of tungsten expressed ?

A

Diameter and length

136
Q

How has the American welding society developed a system to quickly identify the diffrent alloyed tungsten used for GTAW?

A

Numbering and colour code system to identify each electrode

137
Q

What two types of finishes are electrodes manufactured in ?

A

Ground
Chemically cleaned

138
Q

What are two factors that can affect current ranges ?

A

Material type
Thickness

139
Q

What is the main purpose of a shielding gas ?

A

Exclude the atmosphere from the weld puddle

140
Q

What is the result of atmospheric air entering the molten metal ?

A

Porosity hardening and embrittlement in the weld

141
Q

List three gases that are normally used in the GTAW process ?

A

Argon
Helium
Argon helium

142
Q

Is argon heavier or lighter than air ?

A

Argon is 1.4 times as heavy as air

143
Q

What could be the result of argon replacing oxygen in the work area ?

A

You could be asphyxiated

144
Q

List 3 applications where helium would be the gas used for GTAW process ?

A

Heavier sections
Higher thermal conductive metals
Automatic high production welding

145
Q

What is the percentage of argon and helium in a mixed gas used for GTAW ?

A

80% argon and 20%helium

146
Q

Where would an argon helium mixture be a good choice for shielding gas used?

A

Stainless steel and non ferrous metals Automatic high

147
Q

What is the main disadvantage of using argon helium mixture ?

A

Cost

148
Q

What are two ways that shielding gases are stored?

A

High pressure cylinder
Bulk liquid system

149
Q

What type of label must be on gas cuylinder ?

A

WHMIS symbol indicating gas type

150
Q

In what position should a gas cylinder be used ?

A

Vertical position

151
Q

In what position should gas cylinder valves be opened to ?

A

Opened fully

152
Q

What two ranges are regulators designed to work within ?

A

Pressures
Volume

153
Q

What do regulators control ?

A

Control pressure
Not flow rates

154
Q

What regulates the flow rate of a shielding gas?

A

Flow meters

155
Q

How are flow meters calibrated to indicate ?

A

Litres per minute or in cubic feet per hour

156
Q

What is the difference between a regulator and flow meter in terms of what they indicate ?

A

Flow meters indicate volume flow while regulators indicate pressure

157
Q

Why are flow meters designed and calibrated for specific gases ?

A

Because of Thier diffrent density’s

158
Q

Why are gauges on a gauge style combination regulator /flowmeter not as accurate as a flow tube style flow meter ?

A

They operate on pressure converted to volume

159
Q

Why are plastic hoses used for helium shielding gas opposed to rubber hoses ?

A

Rubber will allow helium pressurized to above 138kpa (20psi) to penetrate through the hose and cause gas loss

160
Q

What does the solenoid valve control ?

A

Shielding gas and coolant flow

161
Q

List four ways that filler materials can be avalliable for gtaw ?

A

Straight rods
Flattened rods
Spooled wire
Consumable inserts

162
Q

What is the range of diameters that filler rod used for tig can be ordered ?

A

1.6mm to 6.4mm (1/16to 1/4 inch)

163
Q

How are diffrent types of filler rods identified ?

A

Attached tags or stamped impressions

164
Q

What just the filler rod match in relation to the base metal being welded ?

A

Match or exceed the base metal properties

165
Q

Under normal circumstances die’s filler rod require any specific preparation prior to welding ?

A

No

166
Q

Where should the hot end of the filler rod be located during welding ?

A

Protected by the inert shielding gas during welding to reduce atmospheric contamination

167
Q

Where should filler rod be stored when not being used ?

A

Remain in Thier containers until required for service

Third Year (10 decks)

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