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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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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. How many times per second does short circuiting take place?
20 to 200 times per second
The negative side of a welding unit
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
Motor driven generators - Transformer rectifiers - and Inverter designs

2. What output on the welding machine is used to rate the duty cycle?
Constant- speed wire feeders and Voltage- sennsing wire feeders
DCEP (Direct Current Electrode Positive) Reverse Polarity
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
Minutes of elapsed time continually run (out of 10 minutes)

3. What is an advantage of pulsed arc transfer with GMAW?
Short- circuiting transfer - Globular transfer - Spray transfer
Minutes of elapsed time continually run (out of 10 minutes)
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

4. What is the reason glass 'tube' type flowmeters must have the tube mounted truly vertical?
(DCEP) Direct Current Electrode Positive or Reverse polarity
Spatter problems and poor weld appearance
3
...

5. Why is a fiber washer required and what cylinder gas requires it?
To prevent leakage - Carbon Dioxide (CO2)
3
Voltage is the force that overcomes resistance to allow amperage flow
Constant voltage (CV)

6. What current and polarity is generally used with GMAW?
Minutes of elapsed time continually run (out of 10 minutes)
DCEP (Direct Current Electrode Positive) Reverse Polarity
Guns
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system

7. What happens when the electrode extension is increased?
...
The resistace to electrical current flow increases with it. Causing the electrode to heat
Wire feeds smoothly (yet will slip should a problem occur in the gun)
5.8 to 12.5 L/min

8. List 3 wire drive systems and give a short description of each
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
...
Spatter problems and poor weld appearance

9. What is the preferred drive roll design for solid wires?
V groove or U groove
To limit the short circuiting current so that spatter is reduced
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
Gas metal arc welding

10. What is the key advantage of short circuiting transfer?
Minimum distortion due to low heat input
Constant- speed wire feeders and Voltage- sennsing wire feeders
3
Speed of the feed motor and - starting / stopping electrode feed

11. In the GMAW process what does voltage control?
Pressure vessels and the piping industry
Puddle fluidity
3
Constant voltage (CV)

12. What term is used to describe when the workpiece is hooked to the negative pole on the power source?
Minimum distortion due to low heat input
(DCEP) Direct Current Electrode Positive or Reverse polarity
Wire feed speed
15 feet (4.5 meters)

13. Is the arc voltage for spray transfer higher or lower than that used for short circuit transfer?
85%
Aluminum wire
Higher 26 to 35 arc volts
Generally not as accurate

14. List 3 forms compressed gases may be supplied for welding
The negative side of a welding unit
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
Insufficient current to melt the wire off cleanly
These terms are quite restrictive and often technically incorrect

15. What power sources are used with the GMAW Process?
Gives arc voltage values to the control system of the feeder
Wire feeds smoothly (yet will slip should a problem occur in the gun)
Motor driven generators - Transformer rectifiers - and Inverter designs
V groove or U groove

16. What is the maximum distance that hard wire can be successfully pushed?
Guns
Constant- speed wire feeders and Voltage- sennsing wire feeders
15 feet (4.5 meters)
The time rate of response for the current rise and fall

17. A pull type drive system is usually used on what type of material?
SMAW - GTAW
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
(DCEP) Direct Current Electrode Positive or Reverse polarity
Aluminum wire

18. What does the wire feeder control?
85%
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
Aluminum wire
Speed of the feed motor and - starting / stopping electrode feed

19. What is a solenoid valve and what actuates it?
Reducing the gas source pressure to a constant working pressure
To limit the short circuiting current so that spatter is reduced
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
5.8 to 12.5 L/min

20. What are the 2 types of wire feeders available?
AWS and CSA
Short- circuiting transfer - Globular transfer - Spray transfer
By there current carrying capacity
Constant- speed wire feeders and Voltage- sennsing wire feeders

21. What is the minimum % value of argon that must be present to use the spray transfer method of GMAW?
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
85%
12 to 22 arc volts
The negative side of a welding unit

22. What effect does increasing and decreasing the inductance have on the weld?
To prevent leakage - Carbon Dioxide (CO2)
Wire feeds smoothly (yet will slip should a problem occur in the gun)
Higher 26 to 35 arc volts
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts

23. What controls amperage when using GMAW?
To limit the short circuiting current so that spatter is reduced
Controls the rate of flow of a shielding gas to the gun nozzle
(DCEP) Direct Current Electrode Positive or Reverse polarity
Wire feed speed

24. Why is the term GMAW preferred over MIG or MAG?
Welding process that joins metals by heating them with an electric arc
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts
Motor driven generators - Transformer rectifiers - and Inverter designs
These terms are quite restrictive and often technically incorrect

25. What type of power source is commonly used with a voltage sensing wire feeder?
12 to 22 arc volts
Duty cycle
Constant current (CC)
Guns

26. What does a flowmeter do and what does it measure?
Puddle fluidity
Controls the rate of flow of a shielding gas to the gun nozzle
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

27. Regulators control_____________ flowmeters SHOW____________.
15 feet (4.5 meters)
Spatter problems and poor weld appearance
Pressure - The rate of flow of a shielding gas
Wire feeds smoothly (yet will slip should a problem occur in the gun)

28. What is the purpose of a regulator and what does it indicate on its gauges?
Gas metal arc welding
Higher 26 to 35 arc volts
Reducing the gas source pressure to a constant working pressure
National Electrical Manufactures Association

29. What wire are knurled drive rolls most commonly used on?
The Arc voltage
Shielding the molten weld metal from atmospheric contamination
Higher 26 to 35 arc volts
Flux cored wires

30. In the GMAW process what does amperage control?
Controls the rate of flow of a shielding gas to the gun nozzle
By there current carrying capacity
Speed of the feed motor and - starting / stopping electrode feed
Penetration and burn - off rate of the electrode

31. Give a brief description of the GMAW process
By there current carrying capacity
Welding process that joins metals by heating them with an electric arc
Constant voltage (CV)
5.8 to 12.5 L/min

32. What is the purpose of the shielding gas used in GMAW?
AWS and CSA
The negative side of a welding unit
Shielding the molten weld metal from atmospheric contamination
Gives arc voltage values to the control system of the feeder

33. Why is globular transfer generally avoided with GMAW?
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts
Aluminum wire
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
Spatter problems and poor weld appearance

34. With straight polarity where is 2/3 of the arc energy?
The negative side of a welding unit
Shielding the molten weld metal from atmospheric contamination
Motor driven generators - Transformer rectifiers - and Inverter designs
Cause flaking - which can clog the liner and contact tube

35. When using flat drive rolls with too much pressure on copper coated solid wires what problem could take place?
(DCEP) Direct Current Electrode Positive or Reverse polarity
The Arc voltage
Cause flaking - which can clog the liner and contact tube
Shielding the molten weld metal from atmospheric contamination

36. Why must CO2 cylinders be used in the vertical position?
V groove or U groove
1/4 inch to 1/2 inch
The Arc voltage
To prevent drawing of liquid CO2 (Carbon Dioxide)

37. What does the abbreviation NEMA stand for?
Pressure - The rate of flow of a shielding gas
1/4 inch to 1/2 inch
National Electrical Manufactures Association
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field

38. What processes are constant current (CC) power sources designed to be used with?
SMAW - GTAW
Welding process that joins metals by heating them with an electric arc
If you dont know this check your phone
By there current carrying capacity

39. What is the main purpose of 'slope'?
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
Aluminum wire
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts

40. How are GMAW guns rated?
By there current carrying capacity
3
Gives arc voltage values to the control system of the feeder
Cause flaking - which can clog the liner and contact tube

41. What would be an indication that the drive roll pressure is adjusted correctly?
12 to 22 arc volts
DCEP (Direct Current Electrode Positive) Reverse Polarity
Wire feeds smoothly (yet will slip should a problem occur in the gun)
To prevent drawing of liquid CO2 (Carbon Dioxide)

42. What type of power source is used with a constant speed wire feeder?
When the filler wire is in direct contract with the base metal
Aluminum wire
Constant voltage (CV)
3

43. A 10 minute cycle of welding time vs cooling time a given machine can handle.
The negative side of a welding unit
By there current carrying capacity
Minutes of elapsed time continually run (out of 10 minutes)
Duty cycle

44. What does voltage do in an electrical circuit?
These terms are quite restrictive and often technically incorrect
SMAW - GTAW
When the filler wire is in direct contract with the base metal
Voltage is the force that overcomes resistance to allow amperage flow

45. What is the purpose of the pick- up lead on a voltage sensing wire feeder?
To limit the short circuiting current so that spatter is reduced
Gives arc voltage values to the control system of the feeder
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
Welding process that joins metals by heating them with an electric arc

46. List the basic equipment requirements for the GMAW process
Speed of the feed motor and - starting / stopping electrode feed
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
Motor driven generators - Transformer rectifiers - and Inverter designs
Gas metal arc welding

47. What is the effect of too much slope?
Guns
Pressure - The rate of flow of a shielding gas
Insufficient current to melt the wire off cleanly
SMAW - GTAW

48. What is the recommended electrode stick- out for .035 solid wire?
1/4 inch to 1/2 inch
Gas metal arc welding
Puddle fluidity
20 to 200 times per second

49. What does the term GMAW identify?
Gas metal arc welding
If you dont know this check your phone
Duty cycle
When the filler wire is in direct contract with the base metal

50. List several industries that would use GMAW
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
Pressure vessels and the piping industry
Reducing the gas source pressure to a constant working pressure
Flux cored wires

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Gas Metal Arc Welding

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