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Millwright Year 2 > Welding > Flashcards

Welding Flashcards

1
Q

What is your first consideration when looking at the composition of the base metal?

A

Which filler material to use.

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2
Q

Which organizations have written specifications for wire feed filler metals?

A

AWS and CSA

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3
Q

When added to filler wire, silicon, aluminum and manganese are used as what?

A

Deoxidizers.

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4
Q

What does Cast refer to?

A

Diameter of one wrap of the wire.

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5
Q

What is the purpose of wire packaged in sealed containers?

A

Protect it from moisture and contamination.

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6
Q

What is most often produced in welds made by unclean wire?

A

Porosity.

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7
Q

What are filler metals containing additional deoxidizers intended for?

A

Moderately rusty low-carbon steels.

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8
Q

What does the G stand for in the electrode classification?

A

General classification for electrodes not covered under any other classification.

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9
Q

In the GMAW short circuiting transfer mode, how is the metal transferred?

A

When the electrode comes in contact with the weld pool.

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10
Q

Very fine droplets of metal transferred across the arc in an axial fashion describes what mode of metal transfer?

A

Spray arc transfer.

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11
Q

Which mode of metal transfer is best suited for welding thin metals?

A

Short circuiting arc transfer.

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12
Q

Which MCAW mode of metal transfer is best suited for welding thin metals?

A

Pulsed arc transfer.

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13
Q

A pull type welding gun is designed to be used with what type of wire?

A

Soft wires.

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14
Q

What type of wire drive system allows greater distance from the machine to the work?

A

Push-pull system.

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15
Q

When using GMAW on mild steel, what is the most popular type of wire feed system that is used?

A

Push system.

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16
Q

Besides comfort, what is the purpose of the curved neck on a welding gun?

A

Ensures proper electrical transfer to the wire electrode.

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17
Q

What is the purpose of the welding cable assembly?

A

To supply current, gas and wire to the welding gun.

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18
Q

What are the three most used conduit liners for soft wire?

A

Nylon, Teflon and plastic.

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19
Q

What is the main purpose of the contact tube?

A

It transfers the welding current to the filler wire.

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20
Q

What is the purpose of the gas nozzle?

A

To transfer shielding gas onto the weld zone to prevent atmospheric contamination.

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21
Q

What is the longest practical feed cable used with small diameter wire and a push feed system?

A

15 feet.

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22
Q

Where are the drive rolls located on a pull type drive system?

A

On the gun unit.

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23
Q

Ideally, where should a welding power source should be located?

A

In an uncluttered, well ventilated area.

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24
Q

What position should a flow meter be mounted to obtain an accurate reading?

A

Vertical.

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25
Q

What would be the proper way to adjust the wire spool hub?

A

It should feed freely, yet prevent backlash when the wire feeding has stopped.

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26
Q

How is penetration effected when stick out is increased?

A

Penetration decreases.

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27
Q

What changes with the gun inclination?

A

Penetration of the weld.

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28
Q

What is caused by excessive splatter buildup in the gun nozzle?

A

Inadequate gas coverage.

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29
Q

What is moisture and dirt on the surface of an electrode likely to cause?

A

Porosity.

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30
Q

What is excessive drag from a dirty liner likely to cause?

A

Slippage or bird nesting at the drive rolls.

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31
Q

What is most likely causing the problem when arc hunting occurs?

A

Dirty contact tip or conduit liner.

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32
Q

What causes excessive stubbing?

A

Wire feed speed.

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33
Q

What is the major cause of cold lap when using GMAW short circuit metal transfer?

A

Slow travel with a large bead.

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34
Q

How often should you clean the conduit liner of a wire drive setup?

A

Every time the wire spool is changed.

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35
Q

What should you do when the liner becomes kinked?

A

Replace it.

36
Q

What part of the GMAW system requires the most maintenance?

A

Gun and cable assembly.

37
Q

What can result from a poor work lead connection?

A

An unstable arc.

38
Q

What should be checked when adjusting from short circuiting to spray transfer with GMAW?

A

Make sure the gun is rated to handle higher currents.

39
Q

What should be a consideration when using shielding gas in the wire feed process?

A

Ventilation.

40
Q

High ultraviolet radiation emissions from an open arc can convert oxygen in the vicinity of the arc into what?

A

Ozone.

41
Q

When welding, what is a potential source of poisonous chemical fumes?

A

Chlorinated degreasing solvents.

42
Q

The process of gas metal arc welding is also known as what?

A

MIG welding.

43
Q

What is the shielding gas generated from in self shielded FCAW?

A

The flux.

44
Q

The MCAW process uses the same equipment as which process?

A

FCAW.

45
Q

How are wire feed guns rated?

A

By current carrying capacity.

46
Q

What is the major factor in choosing between an air cooled or water cooled gun?

A

Current and Voltage.

47
Q

Welding power sources designed for wire feed welding can be used for SMAW.

A

False.

48
Q

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

A

True.

49
Q

What type of power source is most often used in GMAW?

A

Constant voltage.

50
Q

What do constant volt machines produce?

A

A relatively flat volt-amp curve.

51
Q

What is the best power source suited for the short circuit mode of metal transfer?

A

Constant voltage power source.

52
Q

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

A

Drooping.

53
Q

What type of welding machine would produce an almost horizontal output slope?

A

Constant voltage machine.

54
Q

What is one of the main advantages of metal core wire?

A

High deposition rates.

55
Q

What does the powder in a MCAW wire mostly consist of?

A

Metal.

56
Q

Self shielded FCAW uses what type of shielding gas?

A

No Gas. Flux contained within the electrode provides the shielding gas.

57
Q

What is the most common duty cycle on welding machines?

A

60%.

58
Q

Constant speed wore fee uses what type of voltage?

A

Constant voltage.

59
Q

What type of drive roller is used wit flux core wire?

A

Knurled.

60
Q

What is the advantage of using a 75% Argon and 25% Carbon Dioxide shielding gas?

A

Provides a better arc transfer.

61
Q

What is the main advantage of using a metal core wire?

A

High deposition rates.

62
Q

Spray transfer occurs when using DCEP and what minimum percent of Argon gas?

A

85%

63
Q

What type of liner is recommended for GMAW or FCAW?

A

Steel.

64
Q

What type of current is used in spray transfer?

A

Direct current electrode positive. (DCEP)

65
Q

What is the most common type of gas used with constant voltage FCAW?

A

Carbon Dioxide and Argon.

66
Q

What is the purpose of the contact tube?

A

To transfer voltage to the filler wire.

67
Q

What is the arc length controlled by?

A

Voltage.

68
Q

What would be an advantage to using direct current electrode negative (DCEN)?

A

Welding thinner gauge metals.

69
Q

How are wire feed guns generally rated?

A

By current carrying capacity.

70
Q

What are the two main types of wire feed systems?

A

Constant speed and voltage sensing.

71
Q

Which mode of transfer used low current?

A

Short circuit.

72
Q

What is essential to prevent shock?

A

Make sure all work is grounded.

73
Q

Which mode of transfer is best for out of position?

A

Pulse.

74
Q

How would you correct under cutting?

A

Lower travel speed.

75
Q

Which polarity is used with gas metal arc welding?

A

Direct current electrode positive. (DCEP)

76
Q

What is the primary cause of poor penetration?

A

Insufficient current.

77
Q

The contact tip is made from what material?

A

Copper.

78
Q

What are the flow rates for spray transfer on mild steel?

A

35 to 45 cfh.

79
Q

Define electrode extension.

A

The distance between the end of the contact tube and the end of the filler wire.

80
Q

What is the recommended electrode extension?

A

3/8” to 3/4”

81
Q

What toxic gas is created when carbon dioxide is mixed with high heat?

A

Carbon Monoxide.

82
Q

What are the main disadvantages of push feed system?

A

Complexity and costliness.

83
Q

Which gas mix is most commonly used for spray transfer on mild steel?

A

85% Argon and 15% Carbon Dioxide.

84
Q

At what pressure is it recommended to change out your CO² cylinder?

A

150 psi.

85
Q

The inside diameter of your contact tip depends on what?

A

The diameter of your filler wire.

Millwright Year 2 (7 decks)

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