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Module 7 > WELDING, BRAZING, SOLDERING AND BONDING > Flashcards

WELDING, BRAZING, SOLDERING AND BONDING Flashcards

1
Q

The definition of joining two pieces of metal by brazing typically meant using ______ as the filler metal which adhered to both pieces.

A

brass or bronze

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2
Q

any metal joining process in which the bonding material is a nonferrous metal or alloy with a melting point higher than 800°F, but lower than that of the metals being joined.

A

BRAZING

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3
Q

A brazing rod can be purchased with a flux coating already applied, or any one of the numerous fluxes available on the market for specific application may be used. Most fluxes contain a mixture of _____.

A

borax and boric acid

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4
Q

Torch brazing of aluminum is done using similar methods as brazing of other materials. The brazing material itself is an _________ having a slightly lower melting temperature than the base material.

A

aluminum/silicon alloy

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5
Q

Soft soldering is generally performed only in _____.

A

minor repair jobs

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6
Q

_______ produces joints of higher strength than those produced by other brazing processes.

A

Silver soldering

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7
Q

The three recommended types of joint for silver soldering are _______.

A

lap, flanged, and edge

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8
Q

The oxy-acetylene flame for silver soldering should be a ___________.

A

soft neutral or slightly reducing flame

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9
Q

_______ is accomplished by heating the ends or edges of metal parts to a molten state with a high temperature flame.

A

Gas welding

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10
Q

The oxy-acetylene flame, with a temperature of approximately _______, is produced with a torch burning acetylene and mixing it with pure oxygen.

A

6 300°Fahrenheit (F)

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11
Q

Hydrogen may be used in place of acetylene for aluminum welding, but the heat output is reduced to about ________.

A

4 000°F

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12
Q

________ is used extensively by the aircraft industry in both the manufacture and repair of aircraft.
It can be used satisfactorily to join all weldable metals, provided that the proper processes and materials are used

A

Electric arc welding

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13
Q

_______ is the most common type of welding and is usually referred to as “stick” welding.

A

Shielded metal arc welding (SMAW)

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14
Q

_______ was formerly called Metal Inert Gas (MIG) welding

A

Gas metal arc welding (GMAW)

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15
Q

an uncoated wire electrode is fed into and through the torch and an inert gas, such as argon, helium, or carbon dioxide, flows out around the wire to protect the puddle from oxygen.

A

Gas metal arc welding (GMAW)

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16
Q

______ is a method of electric arc welding that fills most of the needs in aircraft maintenance and repair when proper procedures and materials are used. It is the preferred method to use on stainless steel, magnesium, and most forms of thick aluminum.

A

Gas tungsten arc welding (GTAW)

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17
Q

It is more commonly known as _______ welding and by the trade names of Heliarc or Heliweld.

A

Tungsten Inert Gas (TIG)

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18
Q

In ____, the electrode is a tungsten rod that forms the path for the high amperage arc between it and the work to melt the metal at over 5 400°F. The electrode is not consumed and used as filler so a filler rod is manually fed into the molten puddle in almost the same manner as when using an oxy-acetylene torch.

A

TIG welding

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19
Q

Two copper electrodes are held in the jaws of the _____ machine, and the material to be welded is clamped between them.

A

spot welding

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20
Q

_______ was developed in 1964 as a method of bringing better control to the arc welding process. ______ provides an advanced level of control and accuracy using automated equipment to produce high quality welds in miniature and precision applications

A

Plasma arc welding (PAW)

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21
Q

In the ______, a non-consumable tungsten electrode is located within a fine-bore copper nozzle. A pilot arc is initiated between the torch electrode and
nozzle tip. This arc is then transferred to the metal being welded By forcing the plasma gas and arc through a constricted orifice, the torch delivers a high concentration of heat to a small area. The plasma process produces exceptionally high quality welds.

A

plasma welding torch

22
Q

________ systems can cut all electrically conductive metals, including aluminum and stainless steel. These two metals cannot be cut by oxy-fuel cutting systems because they have an oxide layer that prevents oxidation from occurring

A

Plasma arc

23
Q

Plasma arc systems can cut all electrically conductive metals, including ______.

A

aluminum and stainless steel

24
Q

The______ machine works by constricting an electrical arc in a nozzle and forcing the ionized gas through it. This heats the gas that melts the metal which is blown away by the air pressure.
By increasing air pressure and intensifying the arc with higher voltages, the cutter is capable of blasting through thicker metals and blowing away the dross with minimal cleanup.

A

plasma cutting

25
Q

This is the primary fuel for oxy-fuel welding and cutting.

A

ACETYLENE

26
Q

The acetylene pressure gauge should never be set higher than ____ for welding or cutting

A

15 psi

27
Q

______ is a colorless, odorless, tasteless, and nontoxic inert gas. Inert gas cannot combine with other elements. It has a very low chemical reactivity and low thermal conductivity. It is used as a gas shield for the electrode in MIG, TIG, and plasma welding equipment.

A

ARGON

28
Q

_________ is a colorless, odorless, tasteless, and nontoxic inert gas. Its boiling and melting points are the lowest of the elements and it normally exists only in gas form. It is used as a protective gas shield for many industrial uses including electric arc welding.

A

HELIUM

29
Q

_______ is a colorless, odorless, tasteless, and highly flammable gas. It can be used at a higher pressure than acetylene and is used for underwater welding and cutting. It also can be used for aluminum welding using the oxy-hydrogen process

A

Hydrogen

30
Q

______ is a colorless, odorless, and nonflammable gas. It is used in the welding process to increase the combustion rate which increases the flame temperature of flammable gas.

A

Oxygen

31
Q

A _______ is attached to a gas cylinder and is used to lower the cylinder pressure to the desired working pressure.

A

pressure regulator

32
Q

A ______ installed on each hose prevents a high pressure flame or oxygen-fuel mixture from being pushed back into either cylinder causing an explosion.

A

flashback arrestor

33
Q

The ______ stops the reverse flow of the gas and can be installed either between the regulator and the hose or the hose and the torch.

A

check valve

34
Q

The _______ burns at approximately 5 850°F at the tip of the inner luminous cone and is produced by a balanced mixture of acetylene and oxygen supplied by the torch. The _______ is used for most welding because it does not alter the composition of the base Metal. When using this flame on steel, the molten metal puddle is quiet and clear, and the metal flows to give a thoroughly fused weld without burning or sparking.

A

neutral flame

35
Q

The ________ burns at approximately 5 700°F at the tip of the inner core. It is also referred to as a reducing flame because it tends to reduce the amount of oxygen in the iron oxides. The flame burns with a coarse rushing sound, and has a bluish-white inner cone, a white center cone, and a light blue outer cone

A

carburizing flame

36
Q

The _______ burns at approximately 6 300°F and is produced by burning an excess of oxygen. It takes about two parts of oxygen to one part acetylene to produce this flame. It can be identified by the shorter outer flame and the small, white, inner cone.

A

oxidizing flame

37
Q

A ______ is used for fusion welding of brass and bronze.

A

stronger oxidizing flame

38
Q

A _______ is used for bronze welding (brazing) of steel and cast iron.

A

slightly oxidizing flame

39
Q

There are two essentially similar methods of striking the arc. One is the ______ method. When using this method, the electrode should be held in a vertical position and lowered until it is an inch or so above the point where the arc is to be struck. Then, the electrode is lightly tapped on the work piece and immediately lifted to form an arc approximately 1/4 inch in length

A

tough or tapping

40
Q

The second (and usually easier to master) is a ______ method. To strike the arc by the scratch method, the electrode is held just above the plate at an angle of 20°-25°. The arc should be struck by sweeping the electrode with a wrist motion and lightly scratching the plate. The electrode is then lifted immediately to form an arc

A

scratch or sweeping

41
Q

Either method takes some practice, but with time and experience, it becomes easy. The key is to raise the electrode quickly, but only about ______ from the base or the arc is lost. If it is raised too slowly, the electrode sticks to the plate.

A

1/4 inch

42
Q

The _____ utilizes the same technique that is used when depositing a bead on a flat metal surface. The only difference is that the deposited bead is at the butt joint of two steel plates, fusing them together. Square butt joints may be welded in one or multiple passes. If the thickness of the metal is such that complete fusion cannot be obtained by welding from one side, the joint must be welded from both sides. Most joints should first be tack-welded to ensure alignment and reduce warping

A

bead weld

43
Q

______ may be performed on a butt joint or an outside corner joint. _______ are made on butt joints where the metal to be welded is 1/4-inch or more in thickness. The butt joint can be prepared using either a single or double groove depending on the thickness of the plate. The number of passes required to complete a weld is determined by the thickness of the metal being welded and the size of the electrode being used. Any groove weld made in more than one pass must have the slag, spatter, and oxide carefully removed from all previous weld deposits before welding over them.

A

Groove welding

44
Q

______ are used to make tee and lap joints. The electrode should be held at an angle of 45° to the plate surface. The electrode should be tilted at an angle of about 15° in the direction of welding. Thin plates should be welded with little or no weaving motion of the electrode and the weld is made in one pass. _____welding of thicker plates may require two or more passes using a semicircular weaving motion of the electrode.

A

Fillet welds

45
Q

The procedure for making fillet weld in a _____is similar to that used in the tee joint. The electrode is held at about a 30° angle to the vertical and tilted to an angle of about 15° in the direction of welding when joining plates of the same thickness

A

Lap Joint Weld

46
Q

The _______ of a metal is the amount in inches that a one inch piece of metal expands when its temperature is raised 1°F.

A

coefficient of linear expansion

47
Q

A ______ is made by placing two pieces of material edge to edge, without overlap, and then welding. This type of joint is usually made without the use of a filler rod. If the metal is thicker than 1/8 inch, it may be necessary to bevel the edges so that the heat from the torch can completely penetrate the metal

A

butt joint

48
Q

A ______ is formed when the edge or end of one piece is welded to the surface of another.
The plain _______ is suitable for most thicknesses of metal used in aircraft, but heavier thicknesses require the vertical member to be either single or double beveled to permit the heat to penetrate deeply enough.

A

tee joint

49
Q

An _______ is used when two pieces of sheet metal must be fastened together and load stresses are not important. Edge joints are usually made by bending the edges of one or both parts upward, placing the two ends parallel to each other, and welding along the outside of the seam formed by the two joined edges

A

edge joint

50
Q

The ______ is seldom used in aircraft structures when welding with oxy-acetylene, but is commonly used and joined by spot welding.

A

lap joint

51
Q

Cracks in parts and materials can vary from tiny ______, that are visible only with magnification, to those easily identified by unaided eyes. _____ are the worst type of defect for two reasons; they are often hard to detect, and they produce the worst form of notch effect/stress concentration

A

Micro-fissures

Module 7 (22 decks)

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