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Gas Metal Arc Welding

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Answer 50 questions in 15 minutes.
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Match each statement with the correct term.
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1. What 2 organizations designate specifications for GMAW wires?
Flux cored wires
AWS and CSA
Constant current (CC)
Minimum distortion due to low heat input

2. Give a description of 'pinch effect'
DCEP (Direct Current Electrode Positive) Reverse Polarity
These terms are quite restrictive and often technically incorrect
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
Puddle fluidity

3. A 10 minute cycle of welding time vs cooling time a given machine can handle.
85%
When the filler wire is in direct contract with the base metal
Generally not as accurate
Duty cycle

4. What output on the welding machine is used to rate the duty cycle?
Generally not as accurate
Minutes of elapsed time continually run (out of 10 minutes)
20 to 200 times per second
Wire feed speed - Voltage control

5. When using flat drive rolls with too much pressure on copper coated solid wires what problem could take place?
Controls the rate of flow of a shielding gas to the gun nozzle
Cause flaking - which can clog the liner and contact tube
Wire feed speed
When the filler wire is in direct contract with the base metal

6. Give a brief description of the GMAW process
Welding process that joins metals by heating them with an electric arc
The resistace to electrical current flow increases with it. Causing the electrode to heat
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
15 feet (4.5 meters)

7. Why is globular transfer generally avoided with GMAW?
Insufficient current to melt the wire off cleanly
DCEP (Direct Current Electrode Positive) Reverse Polarity
Minutes of elapsed time continually run (out of 10 minutes)
Spatter problems and poor weld appearance

8. What current and polarity is generally used with GMAW?
SMAW - GTAW
Aluminum wire
DCEP (Direct Current Electrode Positive) Reverse Polarity
The time rate of response for the current rise and fall

9. Why is a line heater required when using GMAW?
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
Higher 26 to 35 arc volts
SMAW - GTAW
Dry ice can form within the flow control openings and cause blockage of shielding gas

10. What would be an indication that the drive roll pressure is adjusted correctly?
Gives arc voltage values to the control system of the feeder
Controls the rate of flow of a shielding gas to the gun nozzle
Wire feeds smoothly (yet will slip should a problem occur in the gun)
Wire feed speed

11. List 3 forms compressed gases may be supplied for welding
85%
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
1/4 inch to 1/2 inch
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts

12. What does the abbreviation NEMA stand for?
National Electrical Manufactures Association
When the filler wire is in direct contract with the base metal
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
Constant current (CC)

13. Draw a typical volt amp curve for a machine that is designed for GMAW
If you dont know this check your phone
To limit the short circuiting current so that spatter is reduced
Wire feed speed
85%

14. List the basic equipment requirements for the GMAW process
Pressure - The rate of flow of a shielding gas
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
The time rate of response for the current rise and fall
Puddle fluidity

15. What controls the wire speed on a voltage sensing wire feeder?
The Arc voltage
Wire feeds smoothly (yet will slip should a problem occur in the gun)
Constant- speed wire feeders and Voltage- sennsing wire feeders
The resistace to electrical current flow increases with it. Causing the electrode to heat

16. How many times per second does short circuiting take place?
20 to 200 times per second
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
Motor driven generators - Transformer rectifiers - and Inverter designs
Controls the rate of flow of a shielding gas to the gun nozzle

17. What type of power source is used with a constant speed wire feeder?
Constant voltage (CV)
Penetration and burn - off rate of the electrode
Wire feed speed
85%

18. What is the recommended electrode stick- out for .035 solid wire?
1/4 inch to 1/2 inch
Constant voltage (CV)
(DCEP) Direct Current Electrode Positive or Reverse polarity
Guns

19. What 2 controls are found on a GMAW set- up?
5.8 to 12.5 L/min
Wire feed speed - Voltage control
Spatter problems and poor weld appearance
Pressure vessels and the piping industry

20. What happens when the electrode extension is increased?
Pressure vessels and the piping industry
V groove or U groove
Pressure - The rate of flow of a shielding gas
The resistace to electrical current flow increases with it. Causing the electrode to heat

21. What wire are knurled drive rolls most commonly used on?
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
Flux cored wires
Controls the rate of flow of a shielding gas to the gun nozzle
These terms are quite restrictive and often technically incorrect

22. What does voltage do in an electrical circuit?
Wire feeds smoothly (yet will slip should a problem occur in the gun)
Voltage is the force that overcomes resistance to allow amperage flow
By there current carrying capacity
Puddle fluidity

23. How are GMAW guns rated?
(DCEP) Direct Current Electrode Positive or Reverse polarity
85%
Constant current (CC)
By there current carrying capacity

24. What is the effect of too much slope?
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
If you dont know this check your phone
Insufficient current to melt the wire off cleanly
Controls the rate of flow of a shielding gas to the gun nozzle

25. What is the key advantage of short circuiting transfer?
The Arc voltage
Minimum distortion due to low heat input
Spatter problems and poor weld appearance
15 feet (4.5 meters)

26. What is the purpose of the pick- up lead on a voltage sensing wire feeder?
85%
Gives arc voltage values to the control system of the feeder
Cause flaking - which can clog the liner and contact tube
The time rate of response for the current rise and fall

27. What is the purpose of a regulator and what does it indicate on its gauges?
If you dont know this check your phone
Gas metal arc welding
Higher 26 to 35 arc volts
Reducing the gas source pressure to a constant working pressure

28. In the GMAW process what does amperage control?
5.8 to 12.5 L/min
Voltage is the force that overcomes resistance to allow amperage flow
Penetration and burn - off rate of the electrode
Guns

29. List the three methods of metal transfer with GMAW
Short- circuiting transfer - Globular transfer - Spray transfer
3
Penetration and burn - off rate of the electrode
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze

30. With straight polarity where is 2/3 of the arc energy?
Constant- speed wire feeders and Voltage- sennsing wire feeders
The negative side of a welding unit
Wire feed speed
1/4 inch to 1/2 inch

31. What is the main purpose of 'slope'?
If you dont know this check your phone
The resistace to electrical current flow increases with it. Causing the electrode to heat
The Arc voltage
To limit the short circuiting current so that spatter is reduced

32. What effect does increasing and decreasing the inductance have on the weld?
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
Short- circuiting transfer - Globular transfer - Spray transfer
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field

33. What is the minimum % value of argon that must be present to use the spray transfer method of GMAW?
The time rate of response for the current rise and fall
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
85%

34. What does inductance control?
1/4 inch to 1/2 inch
If you dont know this check your phone
The time rate of response for the current rise and fall
Constant voltage (CV)

35. Regulators control_____________ flowmeters SHOW____________.
V groove or U groove
Guns
Pressure - The rate of flow of a shielding gas
Duty cycle

36. What type of power source is commonly used with a voltage sensing wire feeder?
V groove or U groove
Constant current (CC)
15 feet (4.5 meters)
Gives arc voltage values to the control system of the feeder

37. Why is a fiber washer required and what cylinder gas requires it?
To limit the short circuiting current so that spatter is reduced
Constant current (CC)
These terms are quite restrictive and often technically incorrect
To prevent leakage - Carbon Dioxide (CO2)

38. List 3 wire drive systems and give a short description of each
To prevent leakage - Carbon Dioxide (CO2)
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
Gas metal arc welding
85%

39. What is the disadvantage of the gauge preset type of regulator/flowmeter?
Generally not as accurate
National Electrical Manufactures Association
Pressure - The rate of flow of a shielding gas
Wire feed speed - Voltage control

40. In the GMAW process what does voltage control?
When the filler wire is in direct contract with the base metal
Puddle fluidity
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
The time rate of response for the current rise and fall

41. What is the purpose of the shielding gas used in GMAW?
Shielding the molten weld metal from atmospheric contamination
To prevent leakage - Carbon Dioxide (CO2)
SMAW - GTAW
12 to 22 arc volts

42. What does a flowmeter do and what does it measure?
Gas metal arc welding
Aluminum wire
Controls the rate of flow of a shielding gas to the gun nozzle
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts

43. What is the preferred drive roll design for solid wires?
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
SMAW - GTAW
The Arc voltage
V groove or U groove

44. List several industries that would use GMAW
Pressure vessels and the piping industry
Insufficient current to melt the wire off cleanly
1/4 inch to 1/2 inch
Constant current (CC)

45. What is a typical flow rate of CO2 for short circuit transfer?
Gas metal arc welding
Higher 26 to 35 arc volts
5.8 to 12.5 L/min
To prevent drawing of liquid CO2 (Carbon Dioxide)

46. What controls amperage when using GMAW?
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
Flux cored wires
1/4 inch to 1/2 inch
Wire feed speed

47. What is a solenoid valve and what actuates it?
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
Constant current (CC)
Constant voltage (CV)
Generally not as accurate

48. What is the required arc voltage used for short circuit transfer?
Gives arc voltage values to the control system of the feeder
12 to 22 arc volts
The negative side of a welding unit
By there current carrying capacity

49. A pull type drive system is usually used on what type of material?
To prevent leakage - Carbon Dioxide (CO2)
Pressure - The rate of flow of a shielding gas
Pressure vessels and the piping industry
Aluminum wire

50. What processes are constant current (CC) power sources designed to be used with?
Flux cored wires
SMAW - GTAW
Higher 26 to 35 arc volts
3

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Gas Metal Arc Welding

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