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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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1. When is the metal transferred with short circuit transfer?
Flux cored wires
When the filler wire is in direct contract with the base metal
1/4 inch to 1/2 inch
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld

2. What is the purpose of the shielding gas used in GMAW?
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
5.8 to 12.5 L/min
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
Shielding the molten weld metal from atmospheric contamination

3. What 2 controls are found on a GMAW set- up?
Wire feed speed - Voltage control
National Electrical Manufactures Association
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
To prevent drawing of liquid CO2 (Carbon Dioxide)

4. What does voltage do in an electrical circuit?
Voltage is the force that overcomes resistance to allow amperage flow
Minutes of elapsed time continually run (out of 10 minutes)
V groove or U groove
The resistace to electrical current flow increases with it. Causing the electrode to heat

5. Draw a typical volt/amp curve that would be found with a power source designed for SMAW or GTAW
Penetration and burn - off rate of the electrode
Dry ice can form within the flow control openings and cause blockage of shielding gas
If you dont know this check your phone
Shielding the molten weld metal from atmospheric contamination

6. What does the term GMAW identify?
Wire feeds smoothly (yet will slip should a problem occur in the gun)
If you dont know this check your phone
Gas metal arc welding
Penetration and burn - off rate of the electrode

7. What is a typical flow rate of CO2 for short circuit transfer?
V groove or U groove
Wire feed speed - Voltage control
5.8 to 12.5 L/min
Short- circuiting transfer - Globular transfer - Spray transfer

8. List 3 wire drive systems and give a short description of each
DCEP (Direct Current Electrode Positive) Reverse Polarity
...
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
15 feet (4.5 meters)

9. 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
To prevent leakage - Carbon Dioxide (CO2)
Flux cored wires
The time rate of response for the current rise and fall

10. What is the main purpose of 'slope'?
5.8 to 12.5 L/min
To limit the short circuiting current so that spatter is reduced
The time rate of response for the current rise and fall
Higher 26 to 35 arc volts

11. What term is used to describe when the workpiece is hooked to the negative pole on the power source?
Gas metal arc welding
Motor driven generators - Transformer rectifiers - and Inverter designs
(DCEP) Direct Current Electrode Positive or Reverse polarity
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field

12. List the basic equipment requirements for the GMAW process
20 to 200 times per second
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
...
By there current carrying capacity

13. List several industries that would use GMAW
Pressure vessels and the piping industry
Gives arc voltage values to the control system of the feeder
Minutes of elapsed time continually run (out of 10 minutes)
Spatter problems and poor weld appearance

14. What is the recommended electrode stick- out for .035 solid wire?
1/4 inch to 1/2 inch
Constant voltage (CV)
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts
SMAW - GTAW

15. What is the minimum % value of argon that must be present to use the spray transfer method of GMAW?
National Electrical Manufactures Association
85%
Constant- speed wire feeders and Voltage- sennsing wire feeders
Insufficient current to melt the wire off cleanly

16. How are GMAW guns rated?
Constant- speed wire feeders and Voltage- sennsing wire feeders
Constant current (CC)
By there current carrying capacity
Motor driven generators - Transformer rectifiers - and Inverter designs

17. What is the effect of too much slope?
When the filler wire is in direct contract with the base metal
Wire feed speed - Voltage control
Insufficient current to melt the wire off cleanly
12 to 22 arc volts

18. Why is the term GMAW preferred over MIG or MAG?
These terms are quite restrictive and often technically incorrect
Constant voltage (CV)
5.8 to 12.5 L/min
Higher 26 to 35 arc volts

19. What current and polarity is generally used with GMAW?
Shielding the molten weld metal from atmospheric contamination
DCEP (Direct Current Electrode Positive) Reverse Polarity
Short- circuiting transfer - Globular transfer - Spray transfer
Gas metal arc welding

20. What is the reason glass 'tube' type flowmeters must have the tube mounted truly vertical?
...
To prevent drawing of liquid CO2 (Carbon Dioxide)
Short- circuiting transfer - Globular transfer - Spray transfer
Gives arc voltage values to the control system of the feeder

21. What is the preferred drive roll design for solid wires?
V groove or U groove
Guns
To limit the short circuiting current so that spatter is reduced
Insufficient current to melt the wire off cleanly

22. What type of power source is commonly used with a voltage sensing wire feeder?
Duty cycle
Constant current (CC)
Minimum distortion due to low heat input
The negative side of a welding unit

23. What does a flowmeter do and what does it measure?
Controls the rate of flow of a shielding gas to the gun nozzle
Pressure vessels and the piping industry
12 to 22 arc volts
SMAW - GTAW

24. What power sources are used with the GMAW Process?
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
Cause flaking - which can clog the liner and contact tube
Motor driven generators - Transformer rectifiers - and Inverter designs
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

25. Why is a fiber washer required and what cylinder gas requires it?
Constant current (CC)
Minutes of elapsed time continually run (out of 10 minutes)
To prevent leakage - Carbon Dioxide (CO2)
To prevent drawing of liquid CO2 (Carbon Dioxide)

26. How many times per second does short circuiting take place?
Generally not as accurate
AWS and CSA
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
20 to 200 times per second

27. What is an advantage of pulsed arc transfer with GMAW?
Flux cored wires
AWS and CSA
Aluminum wire
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze

28. What output on the welding machine is used to rate the duty cycle?
Minutes of elapsed time continually run (out of 10 minutes)
Higher 26 to 35 arc volts
Insufficient current to melt the wire off cleanly
Flux cored wires

29. List 3 forms compressed gases may be supplied for welding
Minutes of elapsed time continually run (out of 10 minutes)
(DCEP) Direct Current Electrode Positive or Reverse polarity
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
By there current carrying capacity

30. With straight polarity where is 2/3 of the arc energy?
National Electrical Manufactures Association
The time rate of response for the current rise and fall
The negative side of a welding unit
Spatter problems and poor weld appearance

31. What would be an indication that the drive roll pressure is adjusted correctly?
Shielding the molten weld metal from atmospheric contamination
Higher 26 to 35 arc volts
Constant- speed wire feeders and Voltage- sennsing wire feeders
Wire feeds smoothly (yet will slip should a problem occur in the gun)

32. A pull type drive system is usually used on what type of material?
12 to 22 arc volts
Aluminum wire
15 feet (4.5 meters)
AWS and CSA

33. What wire are knurled drive rolls most commonly used on?
Flux cored wires
If you dont know this check your phone
Dry ice can form within the flow control openings and cause blockage of shielding gas
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun

34. List the three methods of metal transfer with GMAW
Short- circuiting transfer - Globular transfer - Spray transfer
20 to 200 times per second
To prevent drawing of liquid CO2 (Carbon Dioxide)
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system

35. Why is a line heater required when using GMAW?
Insufficient current to melt the wire off cleanly
Pressure vessels and the piping industry
Dry ice can form within the flow control openings and cause blockage of shielding gas
Reducing the gas source pressure to a constant working pressure

36. What controls amperage when using GMAW?
85%
Wire feed speed
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld

37. In the GMAW process what does voltage control?
Cause flaking - which can clog the liner and contact tube
Puddle fluidity
Duty cycle
1/4 inch to 1/2 inch

38. What is the required arc voltage used for short circuit transfer?
Short- circuiting transfer - Globular transfer - Spray transfer
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
Reducing the gas source pressure to a constant working pressure
12 to 22 arc volts

39. What is the key advantage of short circuiting transfer?
Minimum distortion due to low heat input
To prevent leakage - Carbon Dioxide (CO2)
Short- circuiting transfer - Globular transfer - Spray transfer
Gives arc voltage values to the control system of the feeder

40. Give a description of 'pinch effect'
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
Duty cycle
To limit the short circuiting current so that spatter is reduced
If you dont know this check your phone

41. What effect does increasing and decreasing the inductance have on the weld?
(DCEP) Direct Current Electrode Positive or Reverse polarity
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts
When the filler wire is in direct contract with the base metal
The Arc voltage

42. What does inductance control?
The time rate of response for the current rise and fall
Pressure vessels and the piping industry
5.8 to 12.5 L/min
Minimum distortion due to low heat input

43. Why must CO2 cylinders be used in the vertical position?
By there current carrying capacity
The negative side of a welding unit
To prevent drawing of liquid CO2 (Carbon Dioxide)
Wire feeds smoothly (yet will slip should a problem occur in the gun)

44. What controls the wire speed on a voltage sensing wire feeder?
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
Puddle fluidity
The Arc voltage
Controls the rate of flow of a shielding gas to the gun nozzle

45. What are the 2 types of wire feeders available?
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
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
Constant- speed wire feeders and Voltage- sennsing wire feeders

46. What is another term for electrode holders for GMAW?
Guns
Generally not as accurate
(DCEP) Direct Current Electrode Positive or Reverse polarity
Constant- speed wire feeders and Voltage- sennsing wire feeders

47. What is the purpose of the pick- up lead on a voltage sensing wire feeder?
Penetration and burn - off rate of the electrode
Gives arc voltage values to the control system of the feeder
Cause flaking - which can clog the liner and contact tube
Speed of the feed motor and - starting / stopping electrode feed

48. In the GMAW process what does amperage control?
Penetration and burn - off rate of the electrode
Insufficient current to melt the wire off cleanly
Short- circuiting transfer - Globular transfer - Spray transfer
To limit the short circuiting current so that spatter is reduced

49. What is the maximum distance that hard wire can be successfully pushed?
(DCEP) Direct Current Electrode Positive or Reverse polarity
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
To prevent drawing of liquid CO2 (Carbon Dioxide)
15 feet (4.5 meters)

50. What is the disadvantage of the gauge preset type of regulator/flowmeter?
Aluminum wire
15 feet (4.5 meters)
Constant voltage (CV)
Generally not as accurate

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Gas Metal Arc Welding

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