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Custom Metal Fabrication > Specialty Gas Metal Arc Welding > Flashcards

Specialty Gas Metal Arc Welding Flashcards

1
Q

What is the most common mode of metal transfer when welding base metal that is made of coated steel or stainless steel?

A

Short-circuit transfer

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2
Q

What does GMAW stand for?

A

Gas Metal Arc Welding

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3
Q

What GMAW process is used most for sheet metal work?

A

Short-circuit transfer

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4
Q

What effect does changing the wire speed have on the voltage or amperage of the welding process?

A

The current varies with the amount of wire feed and increases in proportion to the wire speed.

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5
Q

Which organizations have written specifications for GMAW filler metals?

A

AWS and CSA

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6
Q

When using GMAW on mild steel with carbon dioxide shielding, which type of filler wire should be selected?

A

Deoxidized wire

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7
Q

When wires are packaged in sealed containers, what are we protecting them from?

A

Moisture contamination

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8
Q

Improperly stored wires most often produce welds with which defects?

A

Porosity

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9
Q

When welding aluminum you ___ the gun towards the weld?

A

Push

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10
Q

When welding stainless you ___ the gun towards the weld?

A

Pull

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11
Q

Filler metals containing additional deoxidizers are intended for use on which metals?

A

Moderately rusty low-carbon steels

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12
Q

When adding small percentages of oxygen to inert gases like argon, the oxidizing nature of oxygen breaks down surface tension on the molten metal and allows the puddle to?

A

Wet out the edges of the weld bead and minimize undercut in the molten weld.

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13
Q

Which gas is the lightest?

A

Hydrogen

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14
Q

Argon and helium are what kind of gases?

A

Inert gases

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15
Q

Where would you use pure argon shielding gas with GMAW?

A

In the welding of non-ferrous metals such as aluminum, magnesium and their alloys.

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16
Q

What is carbon dioxide gas primarily used for?

A

The welding of mild steel and low alloy steels

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17
Q

What is a characteristic of helium used as a shielding gas when used with short-circuiting metal transfer?

A

A uniform penetration pattern and a broader weld bead result

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18
Q

All GMAW processes need shielding gas. True or False?

A

False

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19
Q

What is the recommended lens shade for a person welding aluminum or stainless steel?

A

They should use the darkest shade that is comfortable, but not lighter than the recommended one.

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20
Q

What is the best material to wear while welding?

A

Heavy denim

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21
Q

What is the best way to prevent sparks from entering your pockets and other entry’s?

A

Keep collars buttoned and pocket flaps and cuffs covered

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22
Q

What must be done to cylinders being stored or transported?

A

They must have their protective caps in place, valves closed, and be stored in the upright position..

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23
Q

What recommended pressure must remain in the depleted cylinder to avoid atmospheric contamination?

A

25 psi residual pressure

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24
Q

What GMAW process is used mostly for welding lighter gauges of sheet metal work?

A

Short-circuit transfer

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25
Q

What determines the type of metal transfer method?

A

The voltage used

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26
Q

What is the recommended flow settings for shielding gas in cfh?

A

25 cfh

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27
Q

What weld defect is not obvious, but very common to the GMAW process?

A

Cold lap

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28
Q

What mixture is best to eliminate the spatter on mild steel?

A

Carbon dioxide and argon

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29
Q

Which gas mixes tend to produce low crowned welds on stainless steels?

A

Argon - helium - carbon dioxide

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30
Q

When 1 percent to 5 percent oxygen is added to argon shielding gas, it is to?

A

Improve wetting action

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31
Q

Improperly stored stainless steel wire most often will produce welds with?

A

Porosity

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32
Q

When you are welding austenitic stainless steels, why must you maintain the moisture content at low levels?

A

Because moisture can cause porosity

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33
Q

What must you do because austenitic stainless steel has a very high coefficient of thermal expansion?

A

You must control distortion by balancing the heat input and minimize joint restraint.

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34
Q

What does MIG stand for?

A

Metallic Inert Gas

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35
Q

What is becoming the main welding process in the sheet metal industry?

A

GMAW

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36
Q

What does GMAW stand for?

A

Gas Metal Arc Welding

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37
Q

What does SMAW stand for?

A

Shielded Metal Arc Welding

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38
Q

Which welding process uses more radiation? GMAW or SMAW

A

GMAW

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39
Q

What is mandatory for all GMAW operations?

A

Adequate ventilation

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40
Q

You must use extreme caution when working with what type of metals that contain these?

A

Zinc, cadmium, lead, and beryllium

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41
Q

Fans or drafts of over ___ surface feet per minute may blow the protective gas envelope away from the weld zone, causing oxidation of the weld metal.

A

50 surface feet per minute

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42
Q

All cylinders must have what attached to it?

A

A WHMIS symbol attached

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43
Q

Which welding process uses a constant voltage (CV) power source that is used to supply a constant voltage no matter what the conditions are and has a wire feed mechanism that feeds wire at a constant rate to the weld zone?

A

GMAW

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44
Q

More voltage requires?

A

Thicker wire and material

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45
Q

More wire being supplied to the weld zone requires?

A

More heat to melt it

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46
Q

What are the 3 basic types of metal transfer methods?

A

Short-circuit transfer, globular transfer, and spray arc transfer

47
Q

Which type of metal transfer methods should be avoided?

A

Globular transfer

48
Q

The welding of steel sheet metal, whether it is coated steel or stainless steel is accomplished through?

A

The short-circuit transfer method

49
Q

Which transfer occurs when the weld metal passes through an open arc in the form of large globules that are often larger in diameter than the filler wire?

A

Globular transfer

50
Q

What transfer occurs when using a direct current electrode positive (DCEP) with a shielding gas containing at least 85 percent argon and by increasing the welding current above a critical value called the transition current?

A

Spray transfer

51
Q

What type of transfer is a stream of tiny metal droplets crossing the welding arc from the filler wire to the base metal?

A

Spray transfer

52
Q

What does DCEP stand for?

A

Direct current electrode positive

53
Q

What does DCEN stand for?

A

Direct current electrode negative

54
Q

Current goes from ____ to ____?

A

Negative to positive

55
Q

The spray transfer method must have no less than ___ percent argon when welding carbon steel?

A

85 percent

56
Q

Voltage set the?

A

Arc length

57
Q

Wire speed sets the?

58
Q

If the voltage is too low or the wire speed is too high, you will get what is referred to as?

59
Q

What does FCAW stand for?

A

Flux cored arc welding

60
Q

What is referred to as a semiautomatic welding process?

61
Q

Which type of welding produces a flux that must be removed, has good weld appearance, and creates smooth uniform welds?

62
Q

Wires must be identified by?

A

Classification, batch number, wire and spool size

63
Q

What is the purpose of a shielding gas?

A

To prevent the molten weld metal from absorbing elements such as oxygen and nitrogen from atmospheric air.

64
Q

The atmosphere is made up of approximately?

A

1 percent argon, 21 percent oxygen, and 78 percent nitrogen

65
Q

What is the thermal conductivity of a gas?

A

It is its ability to conduct heat

66
Q

Argon gas has a low or high thermal conductivity?

A

Low thermal conductivity

67
Q

Helium has a low or high thermal conductivity?

A

High thermal conductivity

68
Q

What is a chemically inert gas that does not combine with the products of the weld zone. It is also a colourless, odourless, non flammable gas that acts as an asphyxiant which can cause suffocation?

69
Q

Argon is approximately ____ times heavier than air.

70
Q

Which is better fir welding thin sections? Argon or Helium?

71
Q

What gas is colourless, odourless, non-flammable and is derived from the processing of natural gas?

72
Q

The density of helium is about ___ that of air.

A

0.14 times

73
Q

What gas is used primarily for the non-ferrous metals such as aluminum, magnesium, and copper?

74
Q

Argon gas flow rates are usually set to?

A

20 to 25 cubic ft per hour (cfh)

75
Q

What are referred to as reactive gases?

A

Carbon dioxide, oxygen, hydrogen, and nitrogen

76
Q

What is a compound gas that is reactive, colourless, odourless, non flammable, and acts as an asphyxiant. It’s elements are carbon and oxygen?

A

Carbon dioxide

77
Q

Carbon dioxide is ___ percent heavier than air.

A

53 percent

78
Q

What compound gas is often used for the short-circuiting and globular modes of metal transfer?

A

Carbon dioxide

79
Q

What is currently the cheapest shielding gas available?

A

Carbon dioxide

80
Q

What is a colourless, odourless, oxidizing gas that combines with with nearly all known elements?

81
Q

Added oxygen must be less then ___ percent.

A

10 percent

82
Q

What is a colourless, odourless, flammable gas that acts as an asphyxiant and is the lightest known element. It is also highly combustible in air or oxygen. It also burns with an almost invisible flame?

83
Q

What is generally used for special applications such as joining stainless steel?

84
Q

What gas is colourless, odourless, non-flammable, acts like an asphyxiant and is considered inert, but will react with some elements at high temperatures?

85
Q

A widely used ratio of argon to carbon dioxide is?

A

75 percent argon with 25 percent carbon dioxide known as C25

86
Q

Any mixed gas containing ___ is not recommended for non-ferrous metals, as these metals are generally reactive.

87
Q

Welders prefer to use backup plates for materials up to?

A

1/4 “ thick

88
Q

What wire diameters are commonly used for the spray process?

A

0.030” and 0.045”

89
Q

What transfer method must be used in order to minimize distortion when welding lighter gauge stainless steels?

A

The short circuit transfer weld mode is used

90
Q

What is of great importance for all types of stainless steel?

A

The need for cleaning prior to and after welding.

91
Q

What causes porosity?

92
Q

Stainless steel has high or low thermal conductivity?

A

Low thermal conductivity

93
Q

What type of metal has a high coefficient of thermal expansion?

A

Stainless steel

94
Q

What is the most important aspect of welding austenitic stainless steels?

A

The selection of a filler wire having the correct alloy compostition.

95
Q

What is the second most commonly used metal?

96
Q

What is the number one commonly used metal?

97
Q

Aluminum is obtained from an ore called?

98
Q

What is the thermal conductivity of aluminum?

A

About half that of copper and almost four times higher than that of steel

99
Q

Aluminum requires a heat input ___ times more rapid than mild steel to raise its temperature to the melting point.

A

4 times more

100
Q

What is the melting point of aluminum?

A

660 degrees C (1220 degress F)

101
Q

What type of metal is non-magnetic and is often used to shield electronic equipment. It also does not spark and is used in the fabrication of storage containers?

102
Q

What electro-chemical process is used almost exclusively on aluminum?

103
Q

Aluminum’s coefficient of expansion is almost ___ that of steel?

A

Twice that of steel

104
Q

To weld aluminum successfully, you must remove the?

A

Oxide layer

105
Q

For MIG welding alumiunum, you need to use a ___ to ___ push travel angle pointed in the direction of travel.

A

10 degress to 15 degrees

106
Q

GMAW is advantageous for welding aluminum material thicknesses greater than?

A

3.2 mm (1/8”)

107
Q

Argon helium mixes are not required until the metal is more than?

A

1” (25mm) thick

108
Q

What welding process is preferred when weld appearance is not a concern?

109
Q

What are the two types of power sources that can be used for GMAW on aluminum?

A

Constant voltage (CV) and constant current (CC)

110
Q

What power source is most often used for GMAW on aluminum?

A

Constant voltage (CV)

111
Q

Always use 100 percent of what shielding gas for best results on aluminum?

112
Q

What are the two most popular wires for welding aluminum?

A

ER4043 and ER5356

113
Q

What type of wire feeders are commonly used with aluminum?

A

Pull types, push types, or a combination of both

Custom Metal Fabrication (4 decks)

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