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CWB1 > Welding Processes and Equipment > Flashcards

Welding Processes and Equipment Flashcards

1
Q

The type of cored wire most suitable for open air field work is: (Multiple choice)

A) Self-shielded flux-cored wire.

B) Gas-shielded flux-cored wire.

C) Metal-cored wire.

D) Basic cored wire.

A

A) Self-shielded flux-cored wire.

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1
Q

In FCAW, wire feed speed is directly proportional to: (Multiple choice)

A) the length and diameter of the welding cable.

B) contact tip-to-work (CTTW) distance.

C) the welding current.

D) amperage.

A

C) the welding current.

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1
Q

Welding equipment for gas shielded flux-cored arc welding is essentially the same as for gas metal arc welding. T/F

A

true

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1
Q

What could cause porosity when using the flux-cored welding process? (Multiple choice)
Question 3 options:

A) A loose ground cable.

B) Too long a tip-to-work distance.

C) Too slow a travel speed.

D) Too fast a travel speed.

A

B) Too long a tip-to-work distance.

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1
Q

Which of the following is a CSA flux-cored wire classification? (Multiple choice)

A) E4310.

B) B-G 49A 3 C1 S6.

C) E4918-1-H8.

D) E491T-6M-H8.

A

D) E491T-6M-H8.

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1
Q

Flux-cored arc welding is a process usually used in the semi-automatic mode, consisting of a: (Multiple choice)
Question 6 options:

A) constant current power supply, a continuous speed wire feeder, a welding gun, and a continuous solid filler metal electrode.

B) constant voltage power supply, a continuous speed wire feeder, a welding gun, and a continuous filler metal electrode with a hollow core containing flux and other ingredients.

C) constant current power supply, a variable speed wire feeder, a welding gun, and a continuous filler metal electrode with a hollow core containing flux and other ingredients.

D) constant voltage power supply, a continuous speed wire feeder, a welding gun, and a continuous filler metal electrode with a hollow core containing primarily metal powder.

A

B) constant voltage power supply, a continuous speed wire feeder, a welding gun, and a continuous filler metal electrode with a hollow core containing flux and other ingredients.

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2
Q

MCAW is primarily used for production welding of low-carbon steel. (True/False)
Question 7 options:
True
False

A

True

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3
Q

The drawback of MCAW when used in production is its: (Multiple choice)
Question 8 options:

A) high heat input.

B) higher associated costs.

C) difficult post-weld cleanup.

D) low deposition rates.

A

A) high heat input.

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4
Q

In MCAW, the burning of the wire is______________due to the deoxidizers and arc stabilizers added to the flux. (Multiple choice)
Question 9 options:

A) faster and higher in deposition rates.

B) unstable and undesirable.

C) hotter and unpredictable.

D) cleaner and more stable.

A

D) cleaner and more stable.

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5
Q

What is the recommended cable size for SMAW with equipment running at 400 amperes with a cable length of 20 metres? (Multiple choice)
Question 12 options:

A) #1/0

B) #2/0

C) #3/0

D) #4/0

A

B) #2/0

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5
Q

Wet low-hydrogen electrodes should be: (Multiple choice)
Question 10 options:

A) rebaked 2 hours at 230 to 260 degrees Celcius.

B) rebaked 24 hours at 120 degrees Celcius.

C) discarded.

D) rebaked for 1 hour at 430 degrees Celcius.

A

C) discarded.

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6
Q

The components of the SMAW system are: (Multiple choice)
Question 11 options:

A) CV power supply, welding gun, ground cable, and external shielding gas.

B) CV power supply, welding gun, and ground cable.

C) CC power supply, electrode holder, and ground cable.

D) CC power supply, electrode holder, ground cable, and external shielding gas.

A

C) CC power supply, electrode holder, and ground cable.

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7
Q

It is important to keep low-hydrogen SMAW electrodes: (Multiple choice)
Question 13 options:

A) stored at room temperature.

B) at a moisture content between 3 and 7%.

C) in an oven with a temperature between 370 and 430 °C (700 and 800 °F).

D) in a holding oven at no less than 120 °C (250 °F).

A

D) in a holding oven at no less than 120 °C (250 °F).

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8
Q

How many times may low-hydrogen SMAW electrodes be rebaked? (Multiple choice)
Question 14 options:

A) One time.

B) Two times.

C) Three times.

D) Four times.

A

A) One time.

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9
Q

Constant voltage power sources are preferred for SMAW. (True/False)
Question 15 options:
True
False

A

False

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10
Q

Some advantages of using robotic GMAW include: (Multiple choice)
Question 16 options:

A) High cost, high productivity, deep penetration, and works well on all material thickness ranges.

B) High productivity, comparatively easy to feed the wire, and works for sheet metal and thicker materials.

C) Low cost, easy initial set-up, high productivity, and capable of welding a wide range of materials.

D) Fast travel speed, complex initial set-up, no operators required, and capable of welding unlimited material thicknesses.

A

B) High productivity, comparatively easy to feed the wire, and works for sheet metal and thicker materials.

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11
Q

What are the four modes of transfer used in gas metal arc welding? (Multiple choice)
Question 17 options:

A) Short circuit, dip, spray, and arc.

B) Short circuit, puddle, spray, and dip.

C) Short circuit, globular, spray, and pulsed.

D) Short circuit, intermittent, continuous, and pulsed.

A

C) Short circuit, globular, spray, and pulsed.

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12
Q

When comparing the GMAW process to SMAW, GMAW’s higher productivity is partially due to: (Multiple choice)
Question 18 options:

A) a larger diameter electrode.

B) a thinner coating of flux on the deposited metal.

C) a travel speed and deposition rates that are higher.

D) a lower utilization of filler metal.

A

C) a travel speed and deposition rates that are higher.

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13
Q

Which physical properties of shielding gases used for GMAW influence the arc? (Multiple choice)
Question 19 options:

A) Flow rate, temperature range, and density.

B) Radiation potential, thermal expansion, and weight.

C) Dew point, cylinder size, hose diameter.

D) Ionizing potential, thermal conductivity, and specific gravity.

A

D) Ionizing potential, thermal conductivity, and specific gravity.

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14
Q

Which of the following applies to the GMAW process? (Multiple choice)
Question 20 options:

A) It is always completely automatic.

B) It is always semi-automatic.

C) It may be either automatic or semi-automatic.

D) It is a manual process.

A

C) It may be either automatic or semi-automatic.

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15
Q

The GMAW process generally uses: (Multiple choice)
Question 21 options:

A) a constant current power source with a constant speed wire feeder.

B) a constant current power source with a variable speed wire feeder.

C) a constant voltage power source with a constant speed wire feeder.

D) a constant voltage power source with a variable speed wire feeder.

A

C) a constant voltage power source with a constant speed wire feeder.

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16
Q

The SAW fluxes are: (Multiple choice)
Question 22 options:

A) classified on their own. They have their own separate designation.

B) not classified. Only the wire is classified.

C) classified in conjunction with the welding wire forming an electrode/flux designation.

D) all classified with EM12K wire. The use of other wires would require companies to perform testing to verify desired properties.

A

C) classified in conjunction with the welding wire forming an electrode/flux designation.

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17
Q

There are two types of fluxes used for submerged arc welding. These are: (Multiple choice)
Question 25 options:

A) Coarse and fine.

B) Active and neutral.

C) Fused and bonded.

D) Wet and dry.

A

C) Fused and bonded.

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18
Q

Fluxes for submerged arc welding: (Multiple choice)
Question 23 options:

A) can be substituted as needed.

B) when molten, provide a current path to sustain the arc.

C) must be mixed with water and pressed prior to use.

D) should be stored in a dry environment after opening.

A

D) should be stored in a dry environment after opening.

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18
Q

What is considered a limitation when using the SAW process? (Multiple choice)
Question 24 options:

A) Welds have deep penetration.

B) The deposition rates are high.

C) This process is not applicable for vertical and overhead welding.

D) No manual skill is required.

A

C) This process is not applicable for vertical and overhead welding.

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19
Q

Which welding process has an arc efficiency of 90 to 95%? (Multiple choice)
Question 26 options:

A) SMAW

B) FCAW

C) GTAW

D) SAW

A

D) SAW

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20
Q

In welding, the arc is intensely hot with temperatures exceeding: (Multiple choice)
Question 28 options:

A) 20,000 °C (36,000 °F)

B) 30,000 °C (54,000 °F)

C) 33,000 °C (60,000 °F)

D) 40,000 °C (72,000 °F)

A

B) 30,000 °C (54,000 °F)

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21
Q

A welding arc consists of: (Multiple choice)
Question 27 options:

A) A low current and a high voltage.

B) A high current and a low voltage.

C) A high current and a high voltage.

D) A low current and a low voltage.

A

B) A high current and a low voltage.

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22
Q

A consumable electrode is designed to melt and add filler material to the weld joint in the following processes: (Multiple choice)
Question 29 options:

A) SMAW, SAW, GTAW, and OFW.

B) GTAW, FCAW, SAW, and MCAW.

C) SMAW, GTAW, MCAW, and RSW

D) SMAW, GMAW, FCAW, and SAW.

A

D) SMAW, GMAW, FCAW, and SAW.

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23
Q

The GTAW process was developed to weld more difficult materials, such as corrosion-resistant alloys. (True/False)
Question 30 options:
True
False

A

True

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24
Q

A CC power source helps to maintain a nearly constant welding current even if the voltage (or arc length) changes during the manual application of the process. (True/False)
Question 31 options:
True
False

A

True

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25
Q

In GTAW, AC combines the advantages of both DCEN and DCEP, where DCEN provides increased penetration and DCEP provides: (Multiple choice)
Question 32 options:

A) the cleaning action.

B) high deposition rates.

C) the ability to weld in various positions.

D) sound welds with low heat input.

A

A) the cleaning action.

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26
Q

When grinding a GTAW electrode, the grinding marks should be parallel to the length of the electrode. If the electrode is ground with the marks going circumferentially around the diameter, the arc will be: (Multiple choice)
Question 33 options:

A) Inefficient.

B) Excessively hot.

C) Unstable.

D) Unaffected.

A

C) Unstable.

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27
Q

What colour code are 2% thoriated tungsten electrodes? (Multiple choice)
Question 34 options:

A) Green

B) Black

C) Red

D) Brown

A

C) Red

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28
Q

The main advantage of using the GTAW process is: (Multiple choice)
Question 35 options:

A) The ability to weld virtually all weldable metals.

B) High productivity welding with no post-weld cleaning required.

C) The ability to weld cast and wrought iron.

D) Tolerance to rust and mill scale.

A

A) The ability to weld virtually all weldable metals.

29
Q

An example of solid state welding (SSW) is: (Multiple choice)
Question 1 options:

A) Gas tungsten arc welding (GTAW)

B) Explosion welding (EXW)

C) Arc braze welding (ABW)

D) Oxyacetylene welding (OAW)

A

B) Explosion welding (EXW)

30
Q

What process typically contains the highest level of weld metal hydrogen? (Multiple choice)
Question 3 options:

A) SAW

B) FCAW

C) GMAW

D) GTAW

A

B) FCAW

30
Q

The two main methods of arc shielding are: (Multiple choice)
Question 2 options:

A) Gas shielding and atmospheric controls.

B) Flux shielding and gas shielding.

C) Active flux and bonded flux.

D) Gas shielding and welding curtains.

A

B) Flux shielding and gas shielding.

31
Q

When an arc is formed between two electrodes: (Multiple choice)
Question 4 options:

A) electricity flows from the negative cathode to the positive anode.

B) electricity flows from the positive cathode to the negative anode.

C) electricity flows at random between the anode and the cathode.

D) electricity stops flowing once the arc is established.

A

A) electricity flows from the negative cathode to the positive anode.

32
Q

Electrodes for flux-cored arc welding: (Multiple choice)
Question 5 options:

A) can be self-shielded or gas-shielded.

B) can only be self-shielded.

C) can only be gas-shielded.

D) can only be a solid electrode.

A

A) can be self-shielded or gas-shielded.

33
Q

FCAW electrodes are solid wires that have an oxide/flux coating. (Ture/False)
Question 6 options:
True
False

A

False

34
Q

A common application of the FCAW process is: (Multiple choice)
Question 7 options:

A) welding aluminum.

B) welding gauge materials less than 2 mm thick.

C) where weld metal strength is not a consideration.

D) medium and heavy fabrication.

A

D) medium and heavy fabrication.

35
Q

Flux-cored wire electrodes are more expensive than gas metal arc electrodes. (True/False)
Question 8 options:
True
False

A

True

36
Q

A wire designated by CSA standard W48 as an E491T-9MJ-H8: (Multiple choice)
Question 9 options:

A) results in a weld deposit with a maximum of 8 ml of diffusible hydrogen per 100 g of weld metal.

B) has a yield strength of 550 MPa.

C) is limited to welding in the flat and horizontal positions.

D) does not meet the requirements for improved toughness at 27 J at -40 °C.

A

A) results in a weld deposit with a maximum of 8 ml of diffusible hydrogen per 100 g of weld metal.

37
Q

Self-shielded flux-cored wires are: (Multiple choice)
Question 10 options:

A) better able to tolerate air currents.

B) limited to use on sheet steel.

C) less productive than other flux-cored electrodes.

D) limited to less than 1.6 mm electrode diameters.

A

A) better able to tolerate air currents.

38
Q

In MCAW, a mixture of 80% Ar or more is needed to achieve spray transfer. (True/False)
Question 11 options:
True
False

A

True

39
Q

MCAW uses a ________ push (forehand) technique for optimal bead shape and appearance. (Multiple choice)
Question 12 options:

A) 10° to 20°

B) 20° to 30°

C) 5° to 15°

D) 15° to 30°

A

A) 10° to 20°

40
Q

The CSA W48 standard classes metal-cored wires along with: (Multiple choice)
Question 13 options:

A) GMAW wires.

B) GTAW filler wires.

C) SAW wires.

D) FCAW wires.

A

D) FCAW wires.

41
Q

Gas tungsten arc welding can be used with: (Multiple choice)
Question 14 options:

A) Alternating current only.

B) Direct current electrode positive only.

C) Both AC and DC current of either polarity.

D) Direct current electrode negative only.

A

C) Both AC and DC current of either polarity.

42
Q

Balled or rounded ends are often used for welding on materials that require a cleaning action to remove a surface oxide layer (aluminum or magnesium). (True/False)
Question 16 options:
True
False

A

True

42
Q

What is a weld called when no filler is added while using the gas tungsten arc welding process? (Multiple choice)
Question 15 options:

A) A surface weld.

B) An automatic weld.

C) A braze weld

D) An autogenous weld.

A

D) An autogenous weld.

43
Q

Which of the following processes uses a non-consumable electrode? (Multiple choice)
Question 17 options:

A) SAW

B) SMAW

C) GTAW

D) GMAW

A

C) GTAW

44
Q

When welding using the gas tungsten arc welding process using direct current electrode negative (DCEN), the penetration is: (Multiple choice)
Question 18 options:

A) Shallow and wide.

B) Deep and narrow.

C) Shallow and narrow.

D) Deep and wide.

A

B) Deep and narrow.

45
Q

Welding using the GTAW process with direct current electrode positive (DCEP) results in: (Multiple choice)
Question 19 options:

A) 40% arc heat at the electrode and 60% arc heat at the work.

B) 60% arc heat at the electrode and 40% arc heat at the work.

C) 70% arc heat at the electrode and 30% arc heat at the work.

D) 30% arc heat at the electrode and 70% arc heat at the work.

A

C) 70% arc heat at the electrode and 30% arc heat at the work.

46
Q

When using the gas metal arc welding process, what is an advantage of the short circuit transfer mode? (Multiple choice)
Question 20 options:

A) Higher deposition rate.

B) Lower overall cost.

C) Low heat input, reducing distortion.

D) Minimal spatter.

A

C) Low heat input, reducing distortion.

47
Q

The GMAW process uses __________ to shield the molten weld metal from the atmosphere. (Multiple choice)
Question 21 options:

A) a slag system.

B) a blanket of flux.

C) a vacuum chamber.

D) an external shielding gas.

A

D) an external shielding gas.

48
Q

GMAW is more forgiving than SMAW and FCAW. (True/False)
Question 24 options:
True
False

A

False

48
Q

Which of the following statements applies to the GMAW process? (Multiple choice)
Question 22 options:

A) Pressure and heat are applied to the components, but there is no welding arc.

B) A continuously-fed electrode is used.

C) No shielding is required.

D) Filler wire may or may not be present.

A

B) A continuously-fed electrode is used.

49
Q

Why are four drive roll systems more reliable than two drive roll systems? (Multiple choice)
Question 23 options:

A) They provide more tension.

B) They are more adjustable.

C) They have fewer moving parts.

D) They allow less wire slippage.

A

D) They allow less wire slippage.

50
Q

The specific gravity of a gas refers to: (Multiple choice)
Question 25 options:

A) its density relative to oxygen.

B) its density relative to air.

C) its chemical composition.

D) its volume.

A

B) its density relative to air.

51
Q

The submerged arc welding process: (Multiple choice)
Question 26 options:

A) can only be used with a constant voltage power supply.

B) can only be used with a constant current power supply.

C) can only be used with a constant current power supply with high frequency.

D) can be used with either a constant voltage or a constant current power supply.

A

D) can be used with either a constant voltage or a constant current power supply.

52
Q

How is the arc shielded when using the submerged arc welding process? (Multiple choice)
Question 27 options:

A) By the flux in the electrode.

B) By externally applied shielding gas.

C) By the protective oxide layer on the electrode.

D) By a blanket of granular flux.

A

D) By a blanket of granular flux.

53
Q

The primary concern with excessive penetration in submerged arc welding is: (Multiple choice)
Question 29 options:

A) Distortion.

B) Solidification cracking.

C) Strength.

D) Underbead cracking.

A

B) Solidification cracking.

54
Q

Which of the following would avoid resulting in an increase in deposition rate with the SAW process? (Multiple choice)
Question 28 options:

A) An increased contact tip-to-work distance.

B) The use of tandem arc.

C) The use of twin wire with smaller diameter wires.

D) The use of DCEP.

A

D) The use of DCEP.

55
Q

Which of the following does the welder manipulate when using the SMAW processes? (Multiple choice)
Question 30 options:

A) The temperature of the arc, the gas mixture, and the size of flux granules.

B) The current setting, the speed of travel, the arc length, and the electrode angle.

C) The current setting, the temperature of the arc, the arc length, and the electrode angle

D) The voltage setting, the speed of travel, the arc length, and the electrode angle.

A

D) The voltage setting, the speed of travel, the arc length, and the electrode angle.

56
Q

What are examples of an F3 fast-freeze SMAW electrode? (Multiple choice)
Question 31 options:

A) EXX15, EXX16, EXX18.

B) EXX10, EXX11.

C) EXX12, EXX13, EXX14.

D) EXX22, EXX24, EXX27, EXX28.

A

B) EXX10, EXX11.

57
Q

What do the first two digits of a shielded metal arc welding electrode classification indicate? (Multiple choice)
Question 32 options:

A) The weld deposit strength.

B) The deposition rate of the electrode.

C) The yield strength of the electrode.

D) The type of electrode coating.

A

A) The weld deposit strength.

58
Q

E7018 electrodes should only be exposed to the atmosphere for up to: (Multiple choice)
Question 33 options:

A) 1 hour.

B) 2 hours.

C) 4 hours.

D) 8 hours.

A

C) 4 hours.

59
Q

Each electrode for SMAW must be imprinted with its classification. (True/False)
Question 34 options:
True
False

A

True

60
Q

The power source used for SMAW is: (Multiple choice)
Question 35 options:

A) Constant current.

B) Constant voltage.

C) Variable current.

D) Pulsed voltage.

A

A) Constant current.

61
Q

What does the third number in an SMAW electrode classification represent? (Multiple choice)
Question 1 options:

A) The welding position.

B) The preheat number.

C) The chemical composition.

D) The tensile strength.

A

A) The welding position.

62
Q

Carbon steel low-hydrogen electrodes in hermetically-sealed containers can be used: (Multiple choice)
Question 2 options:

A) After rebaking.

B) Immediately up to a period of 4 hours.

C) Immediately up to a period of 2 hours.

D) Immediately up to a period of 5 hours.

A

B) Immediately up to a period of 4 hours.

63
Q

When using the SMAW process, what are some of the functions of the flux? (Multiple choice)
Question 3 options:

A) Shield the arc and molten metal, stabilize the arc, control the weld metal chemistry, and provide a slag coating.

B) Shield the arc and molten metal, provide identification for the electrode, and increase the size of the electrode.

C) Shield the arc, control the arc form, add elements to the molten weld, and allow for welding in other positions.

D) Shield the arc, decrease the burnoff rate, stabilize the voltage, and allow a change in polarity.

A

A) Shield the arc and molten metal, stabilize the arc, control the weld metal chemistry, and provide a slag coating.

64
Q

The primary control on a SMAW power source is: (Multiple choice)
Question 4 options:

A) Current.

B) Voltage.

C) Wire feed speed.

D) AC balance.

A

A) Current.

65
Q

What temperature should electrode holding ovens be held at? (Multiple choice)
Question 5 options:

A) 115 degrees Celcius.

B) 120 degrees Celcius.

C) 250 degrees Celcius.

D) 100 degrees Celcius.

A

B) 120 degrees Celcius.

66
Q

The function of the ingredients in the electrode coating of SMAW electrodes is to: (Multiple choice)
Question 6 options:

A) provide a gas shield, slag covering, arc stabilization, and add additional alloying elements.

B) react with the base metal to assist in the weld fusion.

C) remove rust, mill scale, and other contaminants from the surface of the joint.

D) counteract the effects of arc blow.

A

A) provide a gas shield, slag covering, arc stabilization, and add additional alloying elements.

67
Q

The heat of the welding arc is used to: (Multiple choice)
Question 7 options:

A) locally melt the base material and filler material to create fusion upon solidification.

B) heat the base material and melt the filler material to form a surface bond between two materials.

C) heat the materials to be joined before the application of pressure.

D) promote a metallurgical reaction resulting in the bonding of the adjoining materials.

A

A) locally melt the base material and filler material to create fusion upon solidification.

68
Q

Welding power sources are broadly classified as: (Multiple choice)
Question 8 options:

A) Constant current and variable voltage.

B) Variable current and constant voltage.

C) Variable current and variable voltage.

D) Constant current and constant voltage

A

D) Constant current and constant voltage

69
Q

When using the submerged arc process with direct current, which polarity gives better control over bead shape and deeper penetration? (Multiple choice)
Question 11 options:

A) Direct current electrode positive (DCEP).

B) Direct current electrode negative (DCEN).

C) Alternating current (AC).

D) Pulsed alternating current (PAC).

A

A) Direct current electrode positive (DCEP).

69
Q

If the flux bed is too deep with submerged arc welding, you may experience: (Multiple choice)
Question 12 options:

A) Flash through.

B) Increased penetration

C) Higher deposition rates.

D) A ropey weld.

A

D) A ropey weld.

70
Q

The SAW fluxes that significantly influence the composition of the weld metal through slag/metal reactions are called: (Multiple choice)
Question 13 options:

A) Fused.

B) Bonded.

C) Active.

D) Neutral.

A

C) Active.

71
Q

Argon is an inert gas. (True/False)
Question 31 options:
True
False

A

True

72
Q

An advantage of GMAW pulse transfer is reduced heat input. (True/False)
Question 30 options:
True
False

A

True

73
Q

The gas metal arc welding process uses: (Multiple choice)
Question 32 options:

A) only inert gasses for shielding.

B) both inert gasses and active gas mixtures.

C) only active gas mixtures.

D) active fluxes for shielding.

A

B) both inert gasses and active gas mixtures.

74
Q

The deposition rate for GMAW compared to SMAW is: (Multiple choice)
Question 33 options:

A) The same.

B) Higher.

C) Lower.

D) Not applicable.

A

B) Higher.

CWB1 (10 decks)

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