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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 is a typical flow rate of CO2 for short circuit transfer?
5.8 to 12.5 L/min
Constant current (CC)
Duty cycle
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field

2. What is the purpose of the shielding gas used in GMAW?
To limit the short circuiting current so that spatter is reduced
1/4 inch to 1/2 inch
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
Shielding the molten weld metal from atmospheric contamination

3. What are the 2 types of wire feeders available?
Constant- speed wire feeders and Voltage- sennsing wire feeders
Minutes of elapsed time continually run (out of 10 minutes)
The Arc voltage
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

4. In the GMAW process what does voltage control?
Dry ice can form within the flow control openings and cause blockage of shielding gas
3
Insufficient current to melt the wire off cleanly
Puddle fluidity

5. What is a solenoid valve and what actuates it?
...
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
5.8 to 12.5 L/min

6. What wire are knurled drive rolls most commonly used on?
Voltage is the force that overcomes resistance to allow amperage flow
Flux cored wires
The Arc voltage
Minutes of elapsed time continually run (out of 10 minutes)

7. What output on the welding machine is used to rate the duty cycle?
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
Minutes of elapsed time continually run (out of 10 minutes)
Puddle fluidity
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

8. A machine with a 70% duty cycle can run at its max for 7 minutes with a cooling cycle of only _ minutes.
These terms are quite restrictive and often technically incorrect
3
12 to 22 arc volts
SMAW - GTAW

9. What is the effect of too much slope?
Spatter problems and poor weld appearance
Insufficient current to melt the wire off cleanly
AWS and CSA
Speed of the feed motor and - starting / stopping electrode feed

10. What is the recommended electrode stick- out for .035 solid wire?
AWS and CSA
Wire feed speed
To prevent drawing of liquid CO2 (Carbon Dioxide)
1/4 inch to 1/2 inch

11. What controls the wire speed on a voltage sensing wire feeder?
Speed of the feed motor and - starting / stopping electrode feed
Gives arc voltage values to the control system of the feeder
The Arc voltage
Flux cored wires

12. What processes are constant current (CC) power sources designed to be used with?
15 feet (4.5 meters)
SMAW - GTAW
Cause flaking - which can clog the liner and contact tube
Minimum distortion due to low heat input

13. Is the arc voltage for spray transfer higher or lower than that used for short circuit transfer?
Constant- speed wire feeders and Voltage- sennsing wire feeders
Higher 26 to 35 arc volts
The time rate of response for the current rise and fall
Shielding the molten weld metal from atmospheric contamination

14. Why is globular transfer generally avoided with GMAW?
Generally not as accurate
Spatter problems and poor weld appearance
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts
Penetration and burn - off rate of the electrode

15. What is the key advantage of short circuiting transfer?
To prevent drawing of liquid CO2 (Carbon Dioxide)
Minimum distortion due to low heat input
These terms are quite restrictive and often technically incorrect
...

16. List 3 wire drive systems and give a short description of each
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
Controls the rate of flow of a shielding gas to the gun nozzle
85%
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground

17. What effect does increasing and decreasing the inductance have on the weld?
If you dont know this check your phone
Voltage is the force that overcomes resistance to allow amperage flow
15 feet (4.5 meters)
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 is the purpose of the pick- up lead on a voltage sensing wire feeder?
The Arc voltage
Gives arc voltage values to the control system of the feeder
15 feet (4.5 meters)
Controls the rate of flow of a shielding gas to the gun nozzle

19. How are GMAW guns rated?
By there current carrying capacity
Dry ice can form within the flow control openings and cause blockage of shielding gas
The negative side of a welding unit
Spatter problems and poor weld appearance

20. Give a brief description of the GMAW process
These terms are quite restrictive and often technically incorrect
Welding process that joins metals by heating them with an electric arc
Shielding the molten weld metal from atmospheric contamination
12 to 22 arc volts

21. What does the term GMAW identify?
The negative side of a welding unit
Gas metal arc welding
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
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze

22. What is the required arc voltage used for short circuit transfer?
V groove or U groove
12 to 22 arc volts
...
Shielding the molten weld metal from atmospheric contamination

23. A pull type drive system is usually used on what type of material?
Voltage is the force that overcomes resistance to allow amperage flow
Duty cycle
Aluminum wire
Insufficient current to melt the wire off cleanly

24. List 3 forms compressed gases may be supplied for welding
To prevent leakage - Carbon Dioxide (CO2)
Constant current (CC)
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
Controls the rate of flow of a shielding gas to the gun nozzle

25. What is the reason glass 'tube' type flowmeters must have the tube mounted truly vertical?
5.8 to 12.5 L/min
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
...
Welding process that joins metals by heating them with an electric arc

26. What is the minimum % value of argon that must be present to use the spray transfer method of GMAW?
85%
Puddle fluidity
Insufficient current to melt the wire off cleanly
Higher 26 to 35 arc volts

27. What does a flowmeter do and what does it measure?
Controls the rate of flow of a shielding gas to the gun nozzle
Flux cored wires
Gives arc voltage values to the control system of the feeder
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts

28. List the three methods of metal transfer with GMAW
Short- circuiting transfer - Globular transfer - Spray transfer
To prevent drawing of liquid CO2 (Carbon Dioxide)
If you dont know this check your phone
Shielding the molten weld metal from atmospheric contamination

29. What current and polarity is generally used with GMAW?
85%
DCEP (Direct Current Electrode Positive) Reverse Polarity
SMAW - GTAW
Pressure vessels and the piping industry

30. What is the maximum distance that hard wire can be successfully pushed?
...
15 feet (4.5 meters)
Spatter problems and poor weld appearance
Welding process that joins metals by heating them with an electric arc

31. What controls amperage when using GMAW?
85%
Higher 26 to 35 arc volts
Aluminum wire
Wire feed speed

32. 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
DCEP (Direct Current Electrode Positive) Reverse Polarity
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
Speed of the feed motor and - starting / stopping electrode feed

33. Why is the term GMAW preferred over MIG or MAG?
Gas metal arc welding
Minimum distortion due to low heat input
These terms are quite restrictive and often technically incorrect
The Arc voltage

34. List the basic equipment requirements for the GMAW process
Guns
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
Constant voltage (CV)
Short- circuiting transfer - Globular transfer - Spray transfer

35. What is the purpose of a regulator and what does it indicate on its gauges?
The negative side of a welding unit
Wire feeds smoothly (yet will slip should a problem occur in the gun)
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
Reducing the gas source pressure to a constant working pressure

36. What does voltage do in an electrical circuit?
Voltage is the force that overcomes resistance to allow amperage flow
Aluminum wire
Generally not as accurate
To prevent leakage - Carbon Dioxide (CO2)

37. Give a description of 'pinch effect'
12 to 22 arc volts
20 to 200 times per second
85%
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field

38. What is another term for electrode holders for GMAW?
If you dont know this check your phone
Guns
National Electrical Manufactures Association
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts

39. How many times per second does short circuiting take place?
20 to 200 times per second
The time rate of response for the current rise and fall
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
Duty cycle

40. Draw a typical volt amp curve for a machine that is designed for GMAW
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
Insufficient current to melt the wire off cleanly
Pressure vessels and the piping industry
If you dont know this check your phone

41. What happens when the electrode extension is increased?
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
The resistace to electrical current flow increases with it. Causing the electrode to heat
Gas metal arc welding

42. What is the preferred drive roll design for solid wires?
Wire feeds smoothly (yet will slip should a problem occur in the gun)
V groove or U groove
Cause flaking - which can clog the liner and contact tube
20 to 200 times per second

43. With straight polarity where is 2/3 of the arc energy?
The negative side of a welding unit
3
Duty cycle
Higher 26 to 35 arc volts

44. Why is a fiber washer required and what cylinder gas requires it?
Gives arc voltage values to the control system of the feeder
Duty cycle
Controls the rate of flow of a shielding gas to the gun nozzle
To prevent leakage - Carbon Dioxide (CO2)

45. What 2 controls are found on a GMAW set- up?
Gas metal arc welding
Wire feed speed - Voltage control
Guns
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze

46. What 2 organizations designate specifications for GMAW wires?
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
AWS and CSA
The time rate of response for the current rise and fall
20 to 200 times per second

47. 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)
AWS and CSA
Insufficient current to melt the wire off cleanly
V groove or U groove

48. What is an advantage of pulsed arc transfer with GMAW?
Pressure vessels and the piping industry
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
Gives arc voltage values to the control system of the feeder
Constant- speed wire feeders and Voltage- sennsing wire feeders

49. List several industries that would use 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
Gives arc voltage values to the control system of the feeder
Pressure vessels and the piping industry
The time rate of response for the current rise and fall

50. List the factors that determine the mode of metal transfer
By there current carrying capacity
Penetration and burn - off rate of the electrode
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
Gas metal arc welding

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Gas Metal Arc Welding

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