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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. A 10 minute cycle of welding time vs cooling time a given machine can handle.
Duty cycle
To prevent leakage - Carbon Dioxide (CO2)
Cause flaking - which can clog the liner and contact tube
When the filler wire is in direct contract with the base metal

2. What is the minimum % value of argon that must be present to use the spray transfer method of GMAW?
Gives arc voltage values to the control system of the feeder
85%
Gas metal arc welding
When the filler wire is in direct contract with the base metal

3. What would be an indication that the drive roll pressure is adjusted correctly?
Wire feed speed
5.8 to 12.5 L/min
Minimum distortion due to low heat input
Wire feeds smoothly (yet will slip should a problem occur in the gun)

4. What processes are constant current (CC) power sources designed to be used with?
SMAW - GTAW
Constant- speed wire feeders and Voltage- sennsing wire feeders
5.8 to 12.5 L/min
Aluminum wire

5. What is another term for electrode holders for GMAW?
If you dont know this check your phone
(DCEP) Direct Current Electrode Positive or Reverse polarity
Pressure - The rate of flow of a shielding gas
Guns

6. What is the maximum distance that hard wire can be successfully pushed?
Shielding the molten weld metal from atmospheric contamination
85%
15 feet (4.5 meters)
The negative side of a welding unit

7. List the basic equipment requirements for the GMAW process
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
Pressure - The rate of flow of a shielding gas
By there current carrying capacity
Minimum distortion due to low heat input

8. What is the purpose of the pick- up lead on a voltage sensing wire feeder?
Wire feed speed
Duty cycle
Gives arc voltage values to the control system of the feeder
Insufficient current to melt the wire off cleanly

9. Why must CO2 cylinders be used in the vertical position?
The negative side of a welding unit
Motor driven generators - Transformer rectifiers - and Inverter designs
To prevent drawing of liquid CO2 (Carbon Dioxide)
Reducing the gas source pressure to a constant working pressure

10. With straight polarity where is 2/3 of the arc energy?
Motor driven generators - Transformer rectifiers - and Inverter designs
The negative side of a welding unit
Aluminum wire
Minutes of elapsed time continually run (out of 10 minutes)

11. What term is used to describe when the workpiece is hooked to the negative pole on the power source?
The time rate of response for the current rise and fall
(DCEP) Direct Current Electrode Positive or Reverse polarity
Constant current (CC)
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 are the 2 types of wire feeders available?
Constant- speed wire feeders and Voltage- sennsing wire feeders
Flux cored wires
Voltage is the force that overcomes resistance to allow amperage flow
When the filler wire is in direct contract with the base metal

13. List 3 wire drive systems and give a short description of each
3
SMAW - GTAW
Dry ice can form within the flow control openings and cause blockage of shielding gas
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

14. Regulators control_____________ flowmeters SHOW____________.
Pressure - The rate of flow of a shielding gas
The resistace to electrical current flow increases with it. Causing the electrode to heat
...
To prevent drawing of liquid CO2 (Carbon Dioxide)

15. What happens when the electrode extension is increased?
5.8 to 12.5 L/min
The resistace to electrical current flow increases with it. Causing the electrode to heat
Short- circuiting transfer - Globular transfer - Spray transfer
By there current carrying capacity

16. What wire are knurled drive rolls most commonly used on?
Flux cored wires
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts
20 to 200 times per second
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground

17. What does the wire feeder control?
Minimum distortion due to low heat input
15 feet (4.5 meters)
Speed of the feed motor and - starting / stopping electrode feed
When the filler wire is in direct contract with the base metal

18. What does the term GMAW identify?
Speed of the feed motor and - starting / stopping electrode feed
Guns
Gas metal arc welding
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun

19. What is the purpose of the shielding gas used in GMAW?
Motor driven generators - Transformer rectifiers - and Inverter designs
Shielding the molten weld metal from atmospheric contamination
Insufficient current to melt the wire off cleanly
Pressure vessels and the piping industry

20. What is a solenoid valve and what actuates it?
Flux cored wires
Pressure vessels and the piping industry
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

21. List 3 forms compressed gases may be supplied for welding
If you dont know this check your phone
To prevent drawing of liquid CO2 (Carbon Dioxide)
Constant current (CC)
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system

22. What effect does increasing and decreasing the inductance have on the weld?
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
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts
To prevent drawing of liquid CO2 (Carbon Dioxide)
Pressure vessels and the piping industry

23. List several industries that would use GMAW
Short- circuiting transfer - Globular transfer - Spray transfer
V groove or U groove
20 to 200 times per second
Pressure vessels and the piping industry

24. Why is the term GMAW preferred over MIG or MAG?
These terms are quite restrictive and often technically incorrect
V groove or U groove
15 feet (4.5 meters)
Duty cycle

25. Draw a typical volt amp curve for a machine that is designed for GMAW
If you dont know this check your phone
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
3
The resistace to electrical current flow increases with it. Causing the electrode to heat

26. What is the required arc voltage used for short circuit transfer?
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
These terms are quite restrictive and often technically incorrect
12 to 22 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

27. Draw a typical volt/amp curve that would be found with a power source designed for SMAW or GTAW
If you dont know this check your phone
Cause flaking - which can clog the liner and contact tube
Dry ice can form within the flow control openings and cause blockage of shielding gas
To limit the short circuiting current so that spatter is reduced

28. What is the main purpose of 'slope'?
To limit the short circuiting current so that spatter is reduced
Constant current (CC)
If you dont know this check your phone
Minutes of elapsed time continually run (out of 10 minutes)

29. What does inductance control?
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
To prevent drawing of liquid CO2 (Carbon Dioxide)
The time rate of response for the current rise and fall
Spatter problems and poor weld appearance

30. When using flat drive rolls with too much pressure on copper coated solid wires what problem could take place?
Cause flaking - which can clog the liner and contact tube
V groove or U groove
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
Spatter problems and poor weld appearance

31. What is an advantage of pulsed arc transfer with GMAW?
The time rate of response for the current rise and fall
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
Reducing the gas source pressure to a constant working pressure

32. What current and polarity is generally used with GMAW?
Duty cycle
Generally not as accurate
DCEP (Direct Current Electrode Positive) Reverse Polarity
The Arc voltage

33. What does the abbreviation NEMA stand for?
Shielding the molten weld metal from atmospheric contamination
National Electrical Manufactures Association
Wire feed speed
5.8 to 12.5 L/min

34. What type of power source is commonly used with a voltage sensing wire feeder?
Minutes of elapsed time continually run (out of 10 minutes)
When the filler wire is in direct contract with the base metal
12 to 22 arc volts
Constant current (CC)

35. What controls the wire speed on a voltage sensing wire feeder?
Reducing the gas source pressure to a constant working pressure
These terms are quite restrictive and often technically incorrect
The Arc voltage
Speed of the feed motor and - starting / stopping electrode feed

36. Is the arc voltage for spray transfer higher or lower than that used for short circuit transfer?
Higher 26 to 35 arc volts
Speed of the feed motor and - starting / stopping electrode feed
AWS and CSA
Guns

37. When is the metal transferred with short circuit transfer?
Duty cycle
Higher 26 to 35 arc volts
When the filler wire is in direct contract with the base metal
Wire feed speed - Voltage control

38. What 2 controls are found on a GMAW set- up?
To prevent leakage - Carbon Dioxide (CO2)
Minimum distortion due to low heat input
Wire feed speed
Wire feed speed - Voltage control

39. What does a flowmeter do and what does it measure?
Aluminum wire
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
5.8 to 12.5 L/min
Controls the rate of flow of a shielding gas to the gun nozzle

40. In the GMAW process what does amperage control?
Penetration and burn - off rate of the electrode
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
SMAW - GTAW

41. What 2 organizations designate specifications for GMAW wires?
V groove or U groove
Higher 26 to 35 arc volts
AWS and CSA
Gas metal arc welding

42. Why is globular transfer generally avoided with GMAW?
To prevent drawing of liquid CO2 (Carbon Dioxide)
85%
Spatter problems and poor weld appearance
Puddle fluidity

43. What is the recommended electrode stick- out for .035 solid wire?
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
To prevent leakage - Carbon Dioxide (CO2)
If you dont know this check your phone
1/4 inch to 1/2 inch

44. What type of power source is used with a constant speed wire feeder?
Gas metal arc welding
If you dont know this check your phone
Constant voltage (CV)
Higher 26 to 35 arc volts

45. Give a brief description of the GMAW process
85%
Welding process that joins metals by heating them with an electric arc
The negative side of a welding unit
When the filler wire is in direct contract with the base metal

46. Give a description of 'pinch effect'
Wire feed speed
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
Wire feeds smoothly (yet will slip should a problem occur in the gun)

47. What is the purpose of a regulator and what does it indicate on its gauges?
To prevent leakage - Carbon Dioxide (CO2)
AWS and CSA
Reducing the gas source pressure to a constant working pressure
15 feet (4.5 meters)

48. What output on the welding machine is used to rate the duty cycle?
Insufficient current to melt the wire off cleanly
Voltage is the force that overcomes resistance to allow amperage flow
Minutes of elapsed time continually run (out of 10 minutes)
20 to 200 times per second

49. How many times per second does short circuiting take place?
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
Speed of the feed motor and - starting / stopping electrode feed
20 to 200 times per second
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

50. What power sources are used with the GMAW Process?
To prevent drawing of liquid CO2 (Carbon Dioxide)
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
Short- circuiting transfer - Globular transfer - Spray transfer
Motor driven generators - Transformer rectifiers - and Inverter designs

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Gas Metal Arc Welding

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