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WELDER SECOND PERIOD AIT EXAM MATERIAL v2 > SMAW Equipment > Flashcards

SMAW Equipment Flashcards

Identify SMAW equipment

1
Q

1

Q: What is arc blow?

Objective 1: Define SMAW related terms

A

A: Arc blow occurs when the welding arc flares uncontrollably during DC welding, caused by magnetic fields forming around the work.

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2
Q

2

Q: What is amperage in welding?

Objective 1: Define SMAW related terms

A

A: Amperage, or the heat setting, refers to the strength of the electrical current, measured in amperes, and determines the metal deposition rate and penetration.

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3
Q

3

Q: What is alternating current (AC)?

Objective 1: Define SMAW related terms

A

A: AC is a type of electrical current that flows in one direction during a half cycle and then reverses direction during the next half cycle. It is measured in cycles per second (Hertz), with 60 Hz AC being common in North America.

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4
Q

4

Q: What is metal deposition rate?

Objective 1: Define SMAW related terms

A

A: Metal deposition rate, also known as burn-off rate, refers to how fast the electrode melts and deposits metal. It increases with higher amperage.

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5
Q

5

Q: What is an arc in welding?

Objective 1: Define SMAW related terms

A

A: An arc is formed when sufficient amperage and voltage are available at the electrode tip to overcome the resistance in the air gap between the electrode and the workpiece.

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6
Q

6

Q: What is penetration in welding?

Objective 1: Define SMAW related terms

A

A: Penetration refers to the depth to which the welding arc melts the base metal. Higher amperage increases penetration, while lower amperage decreases it.

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7
Q

7

Q: Define arc voltage.

Objective 1: Define SMAW related terms

A

A: Arc voltage is the voltage output of the welding machine during welding, responsible for maintaining the arc between the electrode and the workpiece.

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8
Q

8

Q: What is a buzz box?

Objective 1: Define SMAW related terms

A

A: A buzz box is an informal term for AC transformer welding machines, named for the buzzing sound they make during operation.

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9
Q

9

Q: What is a circuit in welding?

Objective 1: Define SMAW related terms

A

A: A circuit is a system of conductors designed to complete the path of an electric current, allowing current to flow when voltage is applied.

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10
Q

10

Q: What is the core in a welding transformer?

Objective 1: Define SMAW related terms

A

A: The core is the magnetic link between the primary and secondary coils of a welding transformer, used to control the welding current by adjusting its position.

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11
Q

11

Q: What is a coil in welding equipment?

Objective 1: Define SMAW related terms

A

A: A coil is made of insulated copper wire with several turns, used to control the welding current by its proximity to the core in a welding transformer.

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12
Q

12

Q: What is a conductor?

Objective 1: Define SMAW related terms

A

A: A conductor is a material, usually a metal, capable of transmitting electrical current due to its low resistance to current flow.

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13
Q

13

Q: What does constant current (CC) mean in welding?

Objective 1: Define SMAW related terms

A

A: Constant current refers to a welding machine that provides a stable current, typically used for SMAW and GTAW, with a steep volt-amp curve.

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14
Q

14

Q: What is constant voltage (CV)?

Objective 1: Define SMAW related terms

A

A: Constant voltage refers to a welding machine designed to maintain a stable voltage regardless of amperage changes, commonly used for wire-feed welding processes.

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15
Q

15

Q: What is current flow in welding?

Objective 1: Define SMAW related terms

A

A: Current flow is the movement of electrons through a circuit, measured in amperes, and it determines the welding heat and metal deposition.

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16
Q

16

Q: What is a cycle in alternating current (AC)?

Objective 1: Define SMAW related terms

A

A: A cycle is a complete rotation of the AC sine wave, beginning at zero, peaking at maximum positive and negative values, and returning to zero. In 60 Hz AC, this happens 60 times per second.

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17
Q

17

Q: What is a diode in welding machines?

Objective 1: Define SMAW related terms

A

A: A diode is an electrical component that allows current to flow in one direction only, used in welding machines to convert AC to DC.

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18
Q

18

Q: What is direct current (DC)?

Objective 1: Define SMAW related terms

A

A: DC is an electric current that flows in one direction only, used in welding for consistent and stable arcs without the directional changes of AC.

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19
Q

19

Q: What is duty cycle in welding machines?

Objective 1: Define SMAW related terms

A

A: Duty cycle refers to the amount of time, expressed as a percentage, that a welding machine can operate at its maximum output before needing to cool down, based on a 10-minute period.

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20
Q

20

Q: What is an electron in electrical theory?

Objective 1: Define SMAW related terms

A

A: An electron is a negatively charged particle that moves through a conductor, creating electric current when a voltage is applied.

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21
Q

21

Q: What is frequency in welding?

Objective 1: Define SMAW related terms

A

A: Frequency refers to the number of times AC reverses direction per second, measured in Hertz (Hz). It is crucial in processes like high-frequency arc starting.

22
Q

22

Q: What is a generator in welding?

Objective 1: Define SMAW related terms

A

A: A generator is a device that produces electricity for welding, with some generators producing AC and others producing DC.

23
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23

Q: What is inductance in welding?

Objective 1: Define SMAW related terms

A

A: Inductance is the ability of a conductor to induce current in a neighboring body without direct contact, a principle used in transformer welding machines.

24
Q

24

Q: What is an insulator in welding?

Objective 1: Define SMAW related terms

A

A: An insulator is a material that prevents the flow of electricity, protecting against accidental electric shock.

25
Q

25

Q: What is an inverter in welding?

Objective 1: Define SMAW related terms

A

A: An inverter is a device that converts DC to AC and is also used to increase the frequency of AC for welding purposes.

26
Q

1

Q: What are welding cables, and what is their purpose in SMAW?

Objective 2: Identify welding cables and accessories

A

A: Welding cables are flexible cables made of many strands of fine copper wire, encased in rubber for insulation. They transmit welding current from the welding machine to the workpiece and back, helping reduce voltage loss.

27
Q

2

Q: What are the key sizes of welding cables, and how are they selected?

Objective 2: Identify welding cables and accessories

A

A: Welding cables come in sizes from #4 (smallest) to #4/0 (largest). The appropriate size is selected based on the amperage required and the total distance between the welding machine and the workpiece. Larger cables reduce resistance and prevent overheating.

28
Q

3

Q: How should welding cables be connected if cables of different sizes are used?

Objective 2: Identify welding cables and accessories

A

A: When using cables of different sizes, connect the larger cable to the power source and the smaller cable to the electrode holder. This setup reduces current flow restrictions and voltage drop.

29
Q

4

Q: What is a “whip” in welding, and why is it used?

Objective 2: Identify welding cables and accessories

A

A: A whip is a short length of small-diameter welding cable attached to the end of the main cable. It makes the electrode holder lighter and more flexible for easier welding, especially in SMAW. If the whip overheats, a larger cable should be used.

30
Q

5

Q: What are cable connectors, and how are they used?

Objective 2: Identify welding cables and accessories

A

A: Cable connectors are used to join lengths of welding cable. They are sized based on their amperage rating, ensuring proper electrical transfer. Connectors should be clean, snug, and wrapped with electrical tape to prevent accidental arcing.

31
Q

6

Q: What are quick-connect cable connectors?

Objective 2: Identify welding cables and accessories

A

A: Quick-connect cable connectors have male and female ends that twist and lock together, providing a secure electrical connection. These connectors are made of conductive materials like copper or brass and must be cleaned regularly to prevent overheating.

32
Q

7

Q: What are cable lugs, and where are they used?

Objective 2: Identify welding cables and accessories

A

A: Cable lugs are used to attach welding cables to machines, work clamps, or work tables. They are typically made of copper and provide good electrical contact. Lugs must be correctly sized and installed to prevent overheating and ensure a tight connection.

33
Q

8

Q: What are the two basic types of electrode holders?

Objective 2: Identify welding cables and accessories

A

A: The two basic types of electrode holders are:
Alligator jaw type: Uses spring-loaded jaws to hold the electrode.
Twist head type: Holds the electrode in place by tightening it with mechanical pressure using a twist head.

34
Q

9

Q: How are electrode holders rated, and why is proper sizing important?

Objective 2: Identify welding cables and accessories

A

A: Electrode holders are rated by their amperage-carrying capacity (e.g., 200A or 300A). The holder size must match the welding amperage and the welding cable size to prevent overheating and ensure a stable connection.

35
Q

10

Q: What is the twist head type electrode holder, and what advantage does it offer?

Objective 2: Identify welding cables and accessories

A

A: The twist head type electrode holder allows for tightening the electrode by twisting the head. It has a removable head that can be replaced without disconnecting the welding cable, making maintenance easier.

36
Q

11

Q: What safety features are included in electrode holders?

Objective 2: Identify welding cables and accessories

A

A: Electrode holders have insulated handles to protect welders from electric shock and prevent accidental arc strikes when the welding circuit is energized.

37
Q

12

Q: What are work lead clamps, and what is their role in SMAW?

Objective 2: Identify welding cables and accessories

A

A: Work lead clamps (also called ground clamps) complete the welding circuit by connecting the workpiece to the welding machine. They can be spring-loaded clamps, magnetic clamps, C-clamps, or lugs welded to the work.

38
Q

13

Q: What is the advantage of using a C-clamp type work lead clamp?

Objective 2: Identify welding cables and accessories

A

A: The C-clamp type has a deep throat, allowing for a more secure connection on thick or bulky workpieces, which may be difficult for spring-loaded clamps to attach to.

39
Q

14

Q: What are spring-loaded work lead clamps?

Objective 2: Identify welding cables and accessories

A

A: Spring-loaded work lead clamps use spring tension to secure a tight connection to the workpiece. They are easy to move and are commonly used for general-purpose SMAW applications.

Objective 3: Identify the effect of arc length on amperage and voltage

40
Q

15

Q: What is a magnetic work lead device?

Objective 2: Identify welding cables and accessories

A

A: A magnetic work lead device provides a quick, secure attachment to the workpiece using a magnetic connection. It can be easily moved and avoids damaging the surface of the workpiece but cannot be used on non-magnetic materials like aluminum.

41
Q

16

Q: Why is a secure work lead connection important in welding?

Objective 2: Identify welding cables and accessories

A

A: A poor connection can cause arcing at the work lead, resulting in hard, brittle spots on the workpiece, unstable arcs, and overheating in the welding cables.

42
Q

17

Q: What is the danger of attaching a work lead clamp near bearings or bushings?

Objective 2: Identify welding cables and accessories

A

A: If current passes through bearings or bushings, internal arcing can damage these components. It’s essential to place the work lead clamp where it won’t affect such parts, especially when welding on machinery.

43
Q

1

Q: What is arc length in welding?

Objective 3: Identify the effect of arc length on amperage and voltage

A

A: Arc length is the distance from the end of the electrode’s core wire to the surface of the molten weld pool. A normal arc length is typically equal to the diameter of the electrode’s core wire.

44
Q

2

Q: What happens if the arc length is too short?

Objective 3: Identify the effect of arc length on amperage and voltage

A

A: If the arc length is too short, voltage decreases and may drop below the minimum required to maintain the arc. This can cause the electrode to short-circuit and stick to the workpiece.

45
Q

3

Q: What are the effects of an excessively short arc length?

Objective 3: Identify the effect of arc length on amperage and voltage

A

A: An excessively short arc length can lead to insufficient voltage, causing the electrode to stick to the work and resulting in an unstable arc.

46
Q

4

Q: What happens if the arc length is too long?

Objective 3: Identify the effect of arc length on amperage and voltage

A

A: A long arc length increases voltage and decreases amperage, resulting in shallow penetration, excessive spatter, and reduced effectiveness of the flux in shielding the weld from atmospheric contamination.

47
Q

5

Q: How does a long arc length affect arc stability?

Objective 3: Identify the effect of arc length on amperage and voltage

A

A: If the arc length is too long, there may not be enough voltage to maintain the arc over the widening gap between the electrode and the workpiece, causing the arc to stop.

48
Q

6

Q: How can arc length be used to control weld bead characteristics?

Objective 3: Identify the effect of arc length on amperage and voltage

A

A: Shorter arc lengths result in deeper penetration, a narrow bead, and more build-up, while longer arc lengths produce wider beads with shallower penetration.

49
Q

7

Q: When is a shorter arc length preferable?

Objective 3: Identify the effect of arc length on amperage and voltage

A

A: A shorter arc length is preferable for root beads and fill passes, as it results in deeper penetration and a narrower bead.

50
Q

8

Q: When is a longer arc length preferable?

Objective 3: Identify the effect of arc length on amperage and voltage

A

A: A longer arc length is typically used for cover passes on multi-pass welds, as it results in a wider bead with shallower penetration.

51
Q

9

Q: How does changing the arc length affect amperage and voltage?

Objective 3: Identify the effect of arc length on amperage and voltage

A

A: When the arc length is shortened, amperage increases and voltage decreases. Conversely, when the arc length is lengthened, amperage decreases and voltage increases.

52
Q

10

Q: Why is it important to control arc length during welding?

Objective 3: Identify the effect of arc length on amperage and voltage

A

A: Proper control of arc length ensures sound welds by balancing penetration and bead characteristics, minimizing defects like spatter and ensuring effective shielding.

WELDER SECOND PERIOD AIT EXAM MATERIAL v2 (6 decks)

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