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Gas Metal Arc Welding

Instructions:

Answer 50 questions in 15 minutes.
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Match each statement with the correct term.
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This is a study tool. The 3 wrong answers for each question are randomly chosen from answers to other questions. So, you might find at times the answers obvious, but you will see it re-enforces your understanding as you take the test each time.

1. List the basic equipment requirements for the GMAW process
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
Puddle fluidity
The negative side of a welding unit
Reducing the gas source pressure to a constant working pressure

2. What is the purpose of a regulator and what does it indicate on its gauges?
5.8 to 12.5 L/min
Reducing the gas source pressure to a constant working pressure
Spatter problems and poor weld appearance
Gas metal arc welding

3. What is the purpose of the shielding gas used in GMAW?
Shielding the molten weld metal from atmospheric contamination
Wire feeds smoothly (yet will slip should a problem occur in the gun)
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
Duty cycle

4. Draw a typical volt amp curve for a machine that is designed for GMAW
AWS and CSA
To prevent leakage - Carbon Dioxide (CO2)
If you dont know this check your phone
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze

5. What effect does increasing and decreasing the inductance have on the weld?
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts
1/4 inch to 1/2 inch
(DCEP) Direct Current Electrode Positive or Reverse polarity
Guns

6. A machine with a 70% duty cycle can run at its max for 7 minutes with a cooling cycle of only _ minutes.
National Electrical Manufactures Association
3
1/4 inch to 1/2 inch
Penetration and burn - off rate of the electrode

7. What is another term for electrode holders for GMAW?
(DCEP) Direct Current Electrode Positive or Reverse polarity
Guns
Voltage is the force that overcomes resistance to allow amperage flow
These terms are quite restrictive and often technically incorrect

8. When using flat drive rolls with too much pressure on copper coated solid wires what problem could take place?
The time rate of response for the current rise and fall
If you dont know this check your phone
Dry ice can form within the flow control openings and cause blockage of shielding gas
Cause flaking - which can clog the liner and contact tube

9. What term is used to describe when the workpiece is hooked to the negative pole on the power source?
The Arc voltage
15 feet (4.5 meters)
By there current carrying capacity
(DCEP) Direct Current Electrode Positive or Reverse polarity

10. What is the minimum % value of argon that must be present to use the spray transfer method of GMAW?
Short- circuiting transfer - Globular transfer - Spray transfer
Insufficient current to melt the wire off cleanly
85%
SMAW - GTAW

11. What processes are constant current (CC) power sources designed to be used with?
Minutes of elapsed time continually run (out of 10 minutes)
Guns
SMAW - GTAW
12 to 22 arc volts

12. What are the 2 types of wire feeders available?
To limit the short circuiting current so that spatter is reduced
The resistace to electrical current flow increases with it. Causing the electrode to heat
15 feet (4.5 meters)
Constant- speed wire feeders and Voltage- sennsing wire feeders

13. Why is a line heater required when using GMAW?
15 feet (4.5 meters)
Dry ice can form within the flow control openings and cause blockage of shielding gas
National Electrical Manufactures Association
Puddle fluidity

14. What wire are knurled drive rolls most commonly used on?
Voltage is the force that overcomes resistance to allow amperage flow
Flux cored wires
Higher 26 to 35 arc volts
Spatter problems and poor weld appearance

15. What does the abbreviation NEMA stand for?
To prevent drawing of liquid CO2 (Carbon Dioxide)
National Electrical Manufactures Association
Aluminum wire
Penetration and burn - off rate of the electrode

16. What is the purpose of the pick- up lead on a voltage sensing wire feeder?
5.8 to 12.5 L/min
Gives arc voltage values to the control system of the feeder
National Electrical Manufactures Association
Constant- speed wire feeders and Voltage- sennsing wire feeders

17. What output on the welding machine is used to rate the duty cycle?
(DCEP) Direct Current Electrode Positive or Reverse polarity
Minutes of elapsed time continually run (out of 10 minutes)
20 to 200 times per second
Speed of the feed motor and - starting / stopping electrode feed

18. What is the required arc voltage used for short circuit transfer?
Short- circuiting transfer - Globular transfer - Spray transfer
12 to 22 arc volts
3
Voltage is the force that overcomes resistance to allow amperage flow

19. What is an advantage of pulsed arc transfer with GMAW?
1/4 inch to 1/2 inch
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
DCEP (Direct Current Electrode Positive) Reverse Polarity
12 to 22 arc volts

20. What does the term GMAW identify?
1/4 inch to 1/2 inch
Gas metal arc welding
Short- circuiting transfer - Globular transfer - Spray transfer
Wire feed speed - Voltage control

21. List 3 forms compressed gases may be supplied for welding
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
Higher 26 to 35 arc volts
The negative side of a welding unit
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts

22. What controls amperage when using GMAW?
Wire feed speed
Guns
Dry ice can form within the flow control openings and cause blockage of shielding gas
20 to 200 times per second

23. What type of power source is commonly used with a voltage sensing wire feeder?
The Arc voltage
Constant- speed wire feeders and Voltage- sennsing wire feeders
Guns
Constant current (CC)

24. A 10 minute cycle of welding time vs cooling time a given machine can handle.
Dry ice can form within the flow control openings and cause blockage of shielding gas
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
Higher 26 to 35 arc volts
Duty cycle

25. What is the main purpose of 'slope'?
Pressure - The rate of flow of a shielding gas
Aluminum wire
To limit the short circuiting current so that spatter is reduced
Flux cored wires

26. What happens when the electrode extension is increased?
Puddle fluidity
Speed of the feed motor and - starting / stopping electrode feed
The resistace to electrical current flow increases with it. Causing the electrode to heat
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze

27. What does inductance control?
Puddle fluidity
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
To limit the short circuiting current so that spatter is reduced
The time rate of response for the current rise and fall

28. What controls the wire speed on a voltage sensing wire feeder?
The Arc voltage
1/4 inch to 1/2 inch
Gas metal arc welding
Aluminum wire

29. Give a description of 'pinch effect'
To limit the short circuiting current so that spatter is reduced
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
These terms are quite restrictive and often technically incorrect

30. What 2 controls are found on a GMAW set- up?
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
Constant voltage (CV)
Wire feed speed - Voltage control
Wire feed speed

31. What is the maximum distance that hard wire can be successfully pushed?
To prevent drawing of liquid CO2 (Carbon Dioxide)
Speed of the feed motor and - starting / stopping electrode feed
Wire feed speed - Voltage control
15 feet (4.5 meters)

32. What is the disadvantage of the gauge preset type of regulator/flowmeter?
Wire feeds smoothly (yet will slip should a problem occur in the gun)
Controls the rate of flow of a shielding gas to the gun nozzle
Duty cycle
Generally not as accurate

33. What is a solenoid valve and what actuates it?
Gives arc voltage values to the control system of the feeder
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
Pressure vessels and the piping industry
Pressure - The rate of flow of a shielding gas

34. What power sources are used with the GMAW Process?
Motor driven generators - Transformer rectifiers - and Inverter designs
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
1/4 inch to 1/2 inch
Voltage is the force that overcomes resistance to allow amperage flow

35. List several industries that would use GMAW
Pressure vessels and the piping industry
Aluminum wire
Push type: Wire is fed by a set of drive rolls located in the wire feed unit - Pull type: Drive rolls mounted in the gun itself - Push- pull type: Combination of the two
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld

36. What current and polarity is generally used with GMAW?
...
Reducing the gas source pressure to a constant working pressure
DCEP (Direct Current Electrode Positive) Reverse Polarity
Higher 26 to 35 arc volts

37. What does the wire feeder control?
Speed of the feed motor and - starting / stopping electrode feed
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
Generally not as accurate
Minimum distortion due to low heat input

38. Give a brief description of the GMAW process
These terms are quite restrictive and often technically incorrect
Insufficient current to melt the wire off cleanly
Welding process that joins metals by heating them with an electric arc
Speed of the feed motor and - starting / stopping electrode feed

39. What does a flowmeter do and what does it measure?
Wire feeds smoothly (yet will slip should a problem occur in the gun)
Welding process that joins metals by heating them with an electric arc
Controls the rate of flow of a shielding gas to the gun nozzle
Constant current (CC)

40. In the GMAW process what does amperage control?
Generally not as accurate
(DCEP) Direct Current Electrode Positive or Reverse polarity
These terms are quite restrictive and often technically incorrect
Penetration and burn - off rate of the electrode

41. Why is globular transfer generally avoided with GMAW?
Pressure vessels and the piping industry
AWS and CSA
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
Spatter problems and poor weld appearance

42. In the GMAW process what does voltage control?
Minimum distortion due to low heat input
Puddle fluidity
Duty cycle
To prevent leakage - Carbon Dioxide (CO2)

43. What is the key advantage of short circuiting transfer?
Pressure vessels and the piping industry
Minimum distortion due to low heat input
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
Wire feed speed - Voltage control

44. A pull type drive system is usually used on what type of material?
1/4 inch to 1/2 inch
Speed of the feed motor and - starting / stopping electrode feed
Aluminum wire
Insufficient current to melt the wire off cleanly

45. List the three methods of metal transfer with GMAW
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
Short- circuiting transfer - Globular transfer - Spray transfer
Duty cycle
3

46. List the factors that determine the mode of metal transfer
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
AWS and CSA
Constant current (CC)
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld

47. Why is a fiber washer required and what cylinder gas requires it?
To prevent leakage - Carbon Dioxide (CO2)
Shielding the molten weld metal from atmospheric contamination
DCEP (Direct Current Electrode Positive) Reverse Polarity
Cause flaking - which can clog the liner and contact tube

48. What is the effect of too much slope?
These terms are quite restrictive and often technically incorrect
DCEP (Direct Current Electrode Positive) Reverse Polarity
Insufficient current to melt the wire off cleanly
AWS and CSA

49. What is the recommended electrode stick- out for .035 solid wire?
Pressure vessels and the piping industry
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
Aluminum wire
1/4 inch to 1/2 inch

50. Is the arc voltage for spray transfer higher or lower than that used for short circuit transfer?
To prevent leakage - Carbon Dioxide (CO2)
Higher 26 to 35 arc volts
Voltage is the force that overcomes resistance to allow amperage flow
By there current carrying capacity

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