Welding Workbook

Question 1

What is an electrode?

Answer 1

A rod that is used in arc welding to carry a current through a workpiece to fuse two pieces together. (May also act as a filler metal.)

Question 2

What is a filler metal?

Answer 2

Metal deposited into the weld to add strength and mass to the weld joint.

Question 3

What is a flux?

Answer 3

A chemical cleaning agent that is applied to a joint just prior to the welding process to clean and protect the metal surface from surface oxides that form as a result of heating.

Question 4

What is porosity?

Answer 4

The appearance of tiny bubbles on a weld bead as a result of gas entrapment; excessive porosity can weaken a weld.

Question 5

What is a root opening?

Answer 5

The separation at the Joint root between the base metals.

Question 6

What is shielding gas?

Answer 6

An inert or semi-inert gas that is used to protect the weld puddle and Arc from reacting negatively with the atmosphere.

Question 7

What is a cooled flux that forms over the top of the weld?

Answer 7

Slag, it protects the cooling metal and is then chipped off.

Question 8

What is the liquid metal droplets expelled from the welding process called?

Answer 8

Splatter

Question 9

The ability of a material to be welded under prescribed conditions and to perform as intended is what term?

Answer 9

Weldability

Question 10

What is the Method of capturing welding fumes and moving them somewhere else? Should provide 100 ft per minute of air flow and capture fumes by fixtures, fans, fixed hoods, etc.

Answer 10

Mechanical Ventilation

Question 11

This outlines the specific potential health effects which relate to a product. Includes threshold limit values (TLV) and permissible exposure limits (PEL) for substances in welding fumes.

Answer 11

Manufacture Safety Data Sheets

Question 12

Produced by base metals, coatings, and from the burning of the welding consumable.

Answer 12

Fumes

Question 13

What is required to reduce exposure to the harmful metal oxides produced in welding operations?

Answer 13

Ventilation

Question 14

What is PPE?

Answer 14

Personal Protective Equipment

Question 15

What is Oxyfuel Cutting (OFC)

Answer 15

Flame from mixing fuel, gas, and oxygen. Cannot be use on stainless steel and aluminum. Fuel gases include acetylene, propane, chemtane, and natural gas.

Question 16

What is AKA Resistance Spot Welding (RSW), Electricity is passed through base metals - resistance uses localized heating. Commonly used on sheet metal?

Answer 16

Electric Resistance Welding (ERW)

Question 17

What is the coalescence of materials (fusion). Permanent joining of metal parts/pieces by heat, and the use of pressure or filler material?

Answer 17

Welding

Question 18

What is the most common welding processes?

Answer 18

Shielded Metal Arc Welding (SMAW), Flux cored arc welding (FCAW), and Submerged arc welding.

Question 19

What is the ability of a material to be welded under prescribed conditions and to perform as intended?

Answer 19

Weldability

Question 20

What is cooled flux that forms over the top of the weld?

Answer 20

Slag

Question 21

Inert or semi-inert gas that is used to protect the weld puddle and arc from reacting negatively with the atmosphere. What am I?

Answer 21

Shielding Gas

Question 22

What is the separation at the joint root between the base metals?

Answer 22

Root Opening

Question 23

What is sufficient for welding and brazing operations if the present work area is 10,000 ft 2 per welder, ceiling height more than 16 ft, and welding area clear of restrictions to air flow.

Answer 23

Natural Ventilation

Question 24

What is OSHA?

Answer 24

Occupational Safety and Health Administration

Question 25

How does a welder get an electric shock?

Answer 25

Happens when welders insert themselves into the electrical circuit, currents from the primary voltage to secondary voltage.

Question 26

Cutting with air, also known as gouging or scarfing. Uses a carbon electrode and a large power source. Opposite of welding. What am I?

Answer 26

Carbon Arc Cutting (CAC-A)

Question 27

Uses compressed air, coupled with electric arc to rapidly melt and blow away metal. Can be used on steel, stainless steel, aluminum, etc. What am I?

Answer 27

Plasma Arc Cutting (PAC)

Question 28

Weld attachments to the surface. What am I?

Answer 28

Stud Welding (SW)

Question 29

Welding is shield by granular flux, and has a high deposition and penetration. What am I?

Answer 29

Submerged Arc Welding (SAW)

Question 30

Also known as TIG or Heliarc. Is a manual process when guided by welder, shielding gas required and has a non-consumable tungsten electrode. What am I?

Answer 30

Gas Tungsten Arc Welding (GTAW)

Question 31

What are the two flux cored arc welding (FCAW) processes?

Answer 31

Has two categories: Gas Shield (FCAW-G/ called Dualshield) and Self Shield (FCAW-S/ called Innershield).

Question 32

What are the 4 modes of transfer in Gas Metal Arc Welding (GMAW)?

Answer 32

Has 4 modes of transfer: Short-circuit (GMAW-S), Spray, Pulsed Spray (GMAW-P), Globular.

Question 33

Also known as a MIG, MAG, Solid Wire welding. Uses a solid wire electrode, and shielding gas required. Is a semi automatic process when guided by welder. What am I?

Answer 33

Gas Metal Arc Welding (GMAW)

Question 34

Stick welding, uses heat created by the arc (solid rod) and produces a shield and forms slag created from burning flux. Considered manual welding. What am I?

Answer 34

Shielded Metal Arc Welding (SMAW)

Question 35

Gas welding using high temperature flame from mixing acetylene and oxygen. (Also used for heating, brazing, and cutting with proper attachments) What am I?

Answer 35

Oxyacetylene Welding (OAW)

Question 36

What are welding alternatives?

Answer 36

Riveting, bolting, adhesives.

Question 37

Appearance of tiny bubbles on a weld bead as a result of gas entrapment (Excessive ________, can weaken a weld).

Answer 37

Porosity