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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. What is the preferred drive roll design for solid wires?
Speed of the feed motor and - starting / stopping electrode feed
Flux cored wires
V groove or U groove
Constant- speed wire feeders and Voltage- sennsing wire feeders

2. What is the purpose of the shielding gas used in GMAW?
Shielding the molten weld metal from atmospheric contamination
The negative side of a welding unit
The time rate of response for the current rise and fall
Short- circuiting transfer - Globular transfer - Spray transfer

3. Regulators control_____________ flowmeters SHOW____________.
When the filler wire is in direct contract with the base metal
Pressure - The rate of flow of a shielding gas
Wire feeds smoothly (yet will slip should a problem occur in the gun)
Constant current (CC)

4. List several industries that would use GMAW
If you dont know this check your phone
Pressure vessels and the piping industry
The Arc voltage
Duty cycle

5. How are GMAW guns rated?
Short- circuiting transfer - Globular transfer - Spray transfer
1/4 inch to 1/2 inch
Guns
By there current carrying capacity

6. What does voltage do in an electrical circuit?
Spatter problems and poor weld appearance
Short- circuiting transfer - Globular transfer - Spray transfer
Voltage is the force that overcomes resistance to allow amperage flow
Welding process that joins metals by heating them with an electric arc

7. What is a typical flow rate of CO2 for short circuit transfer?
1/4 inch to 1/2 inch
Duty cycle
5.8 to 12.5 L/min
(DCEP) Direct Current Electrode Positive or Reverse polarity

8. What happens when the electrode extension is increased?
85%
...
Flux cored wires
The resistace to electrical current flow increases with it. Causing the electrode to heat

9. What is the recommended electrode stick- out for .035 solid wire?
1/4 inch to 1/2 inch
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
Wire feed speed

10. What type of power source is commonly used with a voltage sensing wire feeder?
(DCEP) Direct Current Electrode Positive or Reverse polarity
Constant current (CC)
The time rate of response for the current rise and fall
If you dont know this check your phone

11. What controls amperage when using 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
The negative side of a welding unit
3
Wire feed speed

12. How many times per second does short circuiting take place?
1/4 inch to 1/2 inch
...
DCEP (Direct Current Electrode Positive) Reverse Polarity
20 to 200 times per second

13. What would be an indication that the drive roll pressure is adjusted correctly?
Wire feeds smoothly (yet will slip should a problem occur in the gun)
Higher 26 to 35 arc volts
If you dont know this check your phone
5.8 to 12.5 L/min

14. What 2 organizations designate specifications for GMAW wires?
AWS and CSA
Gas metal arc welding
...
Guns

15. With straight polarity where is 2/3 of the arc energy?
To prevent drawing of liquid CO2 (Carbon Dioxide)
The Arc voltage
The negative side of a welding unit
Pressure - The rate of flow of a shielding gas

16. Why is a line heater required when using GMAW?
Dry ice can form within the flow control openings and cause blockage of shielding gas
Aluminum wire
Constant current (CC)
If you dont know this check your phone

17. What is the reason glass 'tube' type flowmeters must have the tube mounted truly vertical?
5.8 to 12.5 L/min
...
V groove or U groove
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts

18. What power sources are used with the GMAW Process?
Motor driven generators - Transformer rectifiers - and Inverter designs
Wire feed speed
Voltage is the force that overcomes resistance to allow amperage flow
3

19. List 3 wire drive systems and give a short description of each
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
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)
When the filler wire is in direct contract with the base metal

20. When using flat drive rolls with too much pressure on copper coated solid wires what problem could take place?
Dry ice can form within the flow control openings and cause blockage of shielding gas
Flux cored wires
Wire feeds smoothly (yet will slip should a problem occur in the gun)
Cause flaking - which can clog the liner and contact tube

21. Draw a typical volt/amp curve that would be found with a power source designed for SMAW or GTAW
V groove or U groove
Higher 26 to 35 arc volts
3
If you dont know this check your phone

22. What is the disadvantage of the gauge preset type of regulator/flowmeter?
Puddle fluidity
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
Generally not as accurate

23. Give a description of 'pinch effect'
Dry ice can form within the flow control openings and cause blockage of shielding gas
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
Wire feed speed
Voltage is the force that overcomes resistance to allow amperage flow

24. In the GMAW process what does amperage control?
Minutes of elapsed time continually run (out of 10 minutes)
By there current carrying capacity
3
Penetration and burn - off rate of the electrode

25. What is the minimum % value of argon that must be present to use the spray transfer method of GMAW?
Generally not as accurate
To limit the short circuiting current so that spatter is reduced
85%
V groove or U groove

26. What is the main purpose of 'slope'?
Minutes of elapsed time continually run (out of 10 minutes)
Reducing the gas source pressure to a constant working pressure
To limit the short circuiting current so that spatter is reduced
If you dont know this check your phone

27. Give a brief description of the GMAW process
(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
Dry ice can form within the flow control openings and cause blockage of shielding gas
Welding process that joins metals by heating them with an electric arc

28. What 2 controls are found on a GMAW set- up?
Minutes of elapsed time continually run (out of 10 minutes)
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
Wire feed speed - Voltage control
Pressure vessels and the piping industry

29. List the three methods of metal transfer with GMAW
Gas metal arc welding
Short- circuiting transfer - Globular transfer - Spray transfer
Wire feed speed
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system

30. Why is globular transfer generally avoided with GMAW?
Spatter problems and poor weld appearance
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
Constant- speed wire feeders and Voltage- sennsing wire feeders

31. What controls the wire speed on a voltage sensing wire feeder?
Controls the rate of flow of a shielding gas to the gun nozzle
If you dont know this check your phone
The Arc voltage
Spatter problems and poor weld appearance

32. What is the purpose of a regulator and what does it indicate on its gauges?
The Arc voltage
The resistace to electrical current flow increases with it. Causing the electrode to heat
Reducing the gas source pressure to a constant working pressure
National Electrical Manufactures Association

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

34. What wire are knurled drive rolls most commonly used on?
20 to 200 times per second
To prevent leakage - Carbon Dioxide (CO2)
Flux cored wires
Cause flaking - which can clog the liner and contact tube

35. What is the key advantage of short circuiting transfer?
Constant voltage (CV)
National Electrical Manufactures Association
Insufficient current to melt the wire off cleanly
Minimum distortion due to low heat input

36. List 3 forms compressed gases may be supplied for welding
Flux cored wires
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
V groove or U groove
Insufficient current to melt the wire off cleanly

37. A pull type drive system is usually used on what type of material?
Guns
To prevent drawing of liquid CO2 (Carbon Dioxide)
When the filler wire is in direct contract with the base metal
Aluminum wire

38. What is the effect of too much slope?
By there current carrying capacity
20 to 200 times per second
Insufficient current to melt the wire off cleanly
To prevent drawing of liquid CO2 (Carbon Dioxide)

39. What output on the welding machine is used to rate the duty cycle?
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 to 22 arc volts
Voltage is the force that overcomes resistance to allow amperage flow
Minutes of elapsed time continually run (out of 10 minutes)

40. What processes are constant current (CC) power sources designed to be used with?
SMAW - GTAW
National Electrical Manufactures Association
Puddle fluidity
Voltage is the force that overcomes resistance to allow amperage flow

41. What term is used to describe when the workpiece is hooked to the negative pole on the power source?
(DCEP) Direct Current Electrode Positive or Reverse polarity
Pressure - The rate of flow of a shielding gas
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld

42. Draw a typical volt amp curve for a machine that is designed for GMAW
If you dont know this check your phone
Dry ice can form within the flow control openings and cause blockage of shielding gas
Wire feed speed - Voltage control
By there current carrying capacity

43. What are the 2 types of wire feeders available?
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
(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
Constant- speed wire feeders and Voltage- sennsing wire feeders

44. What is the maximum distance that hard wire can be successfully pushed?
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
85%
Welding process that joins metals by heating them with an electric arc
15 feet (4.5 meters)

45. What is the purpose of the pick- up lead on a voltage sensing wire feeder?
Gas metal arc welding
Gives arc voltage values to the control system of the feeder
Generally not as accurate
5.8 to 12.5 L/min

46. Why is the term GMAW preferred over MIG or MAG?
National Electrical Manufactures Association
These terms are quite restrictive and often technically incorrect
Motor driven generators - Transformer rectifiers - and Inverter designs
Flux cored wires

47. In the GMAW process what does voltage control?
Gives arc voltage values to the control system of the feeder
Dry ice can form within the flow control openings and cause blockage of shielding gas
Puddle fluidity
DCEP (Direct Current Electrode Positive) Reverse Polarity

48. What does the term GMAW identify?
Gas metal arc welding
Controls the rate of flow of a shielding gas to the gun nozzle
Generally not as accurate
Dry ice can form within the flow control openings and cause blockage of shielding gas

49. What does the wire feeder control?
Pressure vessels and the piping industry
Speed of the feed motor and - starting / stopping electrode feed
Wire feed speed
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld

50. What does a flowmeter do and what does it measure?
When the filler wire is in direct contract with the base metal
The Arc voltage
Controls the rate of flow of a shielding gas to the gun nozzle
Guns

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Gas Metal Arc Welding

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