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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 processes are constant current (CC) power sources designed to be used with?
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
If you dont know this check your phone
The Arc voltage
SMAW - GTAW

2. What current and polarity is generally used with GMAW?
20 to 200 times per second
DCEP (Direct Current Electrode Positive) Reverse Polarity
The Arc voltage
Aluminum wire

3. What is the purpose of the pick- up lead on a voltage sensing wire feeder?
20 to 200 times per second
Motor driven generators - Transformer rectifiers - and Inverter designs
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
Gives arc voltage values to the control system of the feeder

4. What 2 controls are found on a GMAW set- up?
3
Wire feed speed - Voltage control
Shielding the molten weld metal from atmospheric contamination
Cause flaking - which can clog the liner and contact tube

5. What controls amperage when using GMAW?
Wire feed speed
To prevent drawing of liquid CO2 (Carbon Dioxide)
Dry ice can form within the flow control openings and cause blockage of shielding gas
Gas metal arc welding

6. What is the reason glass 'tube' type flowmeters must have the tube mounted truly vertical?
When the filler wire is in direct contract with the base metal
By there current carrying capacity
...
If you dont know this check your phone

7. A 10 minute cycle of welding time vs cooling time a given machine can handle.
Duty cycle
Wire feeds smoothly (yet will slip should a problem occur in the gun)
To prevent leakage - Carbon Dioxide (CO2)
Cause flaking - which can clog the liner and contact tube

8. What does the abbreviation NEMA stand for?
Speed of the feed motor and - starting / stopping electrode feed
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
National Electrical Manufactures Association

9. What does the term GMAW identify?
Pressure vessels and the piping industry
V groove or U groove
Gas metal arc welding
When the filler wire is in direct contract with the base metal

10. How many times per second does short circuiting take place?
Spatter problems and poor weld appearance
Duty cycle
To prevent drawing of liquid CO2 (Carbon Dioxide)
20 to 200 times per second

11. What is a typical flow rate of CO2 for short circuit transfer?
1/4 inch to 1/2 inch
5.8 to 12.5 L/min
These terms are quite restrictive and often technically incorrect
Penetration and burn - off rate of the electrode

12. List the three methods of metal transfer with GMAW
If you dont know this check your phone
When the filler wire is in direct contract with the base metal
Short- circuiting transfer - Globular transfer - Spray transfer
Controls the rate of flow of a shielding gas to the gun nozzle

13. What are the 2 types of wire feeders available?
(DCEP) Direct Current Electrode Positive or Reverse polarity
Gas metal arc welding
To limit the short circuiting current so that spatter is reduced
Constant- speed wire feeders and Voltage- sennsing wire feeders

14. A machine with a 70% duty cycle can run at its max for 7 minutes with a cooling cycle of only _ minutes.
3
Guns
These terms are quite restrictive and often technically incorrect
Generally not as accurate

15. What is the recommended electrode stick- out for .035 solid wire?
Voltage is the force that overcomes resistance to allow amperage flow
Minutes of elapsed time continually run (out of 10 minutes)
1/4 inch to 1/2 inch
The Arc voltage

16. What wire are knurled drive rolls most commonly used on?
Gives arc voltage values to the control system of the feeder
Flux cored wires
If you dont know this check your phone
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun

17. What does voltage do in an electrical circuit?
12 to 22 arc volts
Voltage is the force that overcomes resistance to allow amperage flow
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
Cause flaking - which can clog the liner and contact tube

18. What does inductance control?
Controls the rate of flow of a shielding gas to the gun nozzle
When the filler wire is in direct contract with the base metal
SMAW - GTAW
The time rate of response for the current rise and fall

19. What type of power source is commonly used with a voltage sensing wire feeder?
Penetration and burn - off rate of the electrode
Wire feed speed
Constant current (CC)
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground

20. What term is used to describe when the workpiece is hooked to the negative pole on the power source?
5.8 to 12.5 L/min
To limit the short circuiting current so that spatter is reduced
(DCEP) Direct Current Electrode Positive or Reverse polarity
These terms are quite restrictive and often technically incorrect

21. List the basic equipment requirements for the GMAW process
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
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
Minutes of elapsed time continually run (out of 10 minutes)
12 to 22 arc volts

22. Give a brief description of the GMAW process
Welding process that joins metals by heating them with an electric arc
Shielding the molten weld metal from atmospheric contamination
If you dont know this check your phone
The Arc voltage

23. Why is a fiber washer required and what cylinder gas requires it?
5.8 to 12.5 L/min
Motor driven generators - Transformer rectifiers - and Inverter designs
To prevent leakage - Carbon Dioxide (CO2)
Shielding the molten weld metal from atmospheric contamination

24. What is the purpose of the shielding gas used in GMAW?
If you dont know this check your phone
Spatter problems and poor weld appearance
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
Shielding the molten weld metal from atmospheric contamination

25. What is the disadvantage of the gauge preset type of regulator/flowmeter?
Constant current (CC)
Reducing the gas source pressure to a constant working pressure
Generally not as accurate
15 feet (4.5 meters)

26. What output on the welding machine is used to rate the duty cycle?
(DCEP) Direct Current Electrode Positive or Reverse polarity
Cause flaking - which can clog the liner and contact tube
Minutes of elapsed time continually run (out of 10 minutes)
Welding process that joins metals by heating them with an electric arc

27. With straight polarity where is 2/3 of the arc energy?
Pressure vessels and the piping industry
The negative side of a welding unit
Cause flaking - which can clog the liner and contact tube
Motor driven generators - Transformer rectifiers - and Inverter designs

28. In the GMAW process what does voltage control?
Puddle fluidity
Constant current (CC)
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
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field

29. What type of power source is used with a constant speed wire feeder?
To prevent leakage - Carbon Dioxide (CO2)
Guns
Constant voltage (CV)
Generally not as accurate

30. Draw a typical volt/amp curve that would be found with a power source designed for SMAW or GTAW
Pressure - The rate of flow of a shielding gas
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
15 feet (4.5 meters)
If you dont know this check your phone

31. When is the metal transferred with short circuit transfer?
5.8 to 12.5 L/min
Motor driven generators - Transformer rectifiers - and Inverter designs
Wire feed speed
When the filler wire is in direct contract with the base metal

32. What is another term for electrode holders for GMAW?
Wire feed speed
Guns
If you dont know this check your phone
Gives arc voltage values to the control system of the feeder

33. List 3 wire drive systems and give a short description of each
Reducing the gas source pressure to a constant working pressure
Constant voltage (CV)
Cause flaking - which can clog the liner and contact tube
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

34. What does a flowmeter do and what does it measure?
5.8 to 12.5 L/min
Controls the rate of flow of a shielding gas to the gun nozzle
Higher 26 to 35 arc volts
Wire feed speed - Voltage control

35. 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
Voltage is the force that overcomes resistance to allow amperage flow
To prevent drawing of liquid CO2 (Carbon Dioxide)

36. What is the purpose of a regulator and what does it indicate on its gauges?
Welding process that joins metals by heating them with an electric arc
National Electrical Manufactures Association
Reducing the gas source pressure to a constant working pressure
These terms are quite restrictive and often technically incorrect

37. What does the wire feeder control?
DCEP (Direct Current Electrode Positive) Reverse Polarity
Generally not as accurate
Speed of the feed motor and - starting / stopping electrode feed
1/4 inch to 1/2 inch

38. 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
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
Higher 26 to 35 arc volts

39. 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
If you dont know this check your phone
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
Higher 26 to 35 arc volts

40. 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
Dry ice can form within the flow control openings and cause blockage of shielding gas
Spatter problems and poor weld appearance
1/4 inch to 1/2 inch

41. A pull type drive system is usually used on what type of material?
5.8 to 12.5 L/min
Aluminum wire
DCEP (Direct Current Electrode Positive) 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

42. 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
Generally not as accurate
To limit the short circuiting current so that spatter is reduced
Voltage is the force that overcomes resistance to allow amperage flow

43. Why is the term GMAW preferred over MIG or MAG?
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
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
These terms are quite restrictive and often technically incorrect

44. Why is a line heater required when using GMAW?
Dry ice can form within the flow control openings and cause blockage of shielding gas
Higher 26 to 35 arc volts
Constant current (CC)
Constant- speed wire feeders and Voltage- sennsing wire feeders

45. Draw a typical volt amp curve for a machine that is designed for GMAW
Penetration and burn - off rate of the electrode
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
1/4 inch to 1/2 inch

46. What happens when the electrode extension is increased?
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
1/4 inch to 1/2 inch

47. What controls the wire speed on a voltage sensing wire feeder?
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
To prevent drawing of liquid CO2 (Carbon Dioxide)
The Arc voltage
1/4 inch to 1/2 inch

48. How are GMAW guns rated?
Constant- speed wire feeders and Voltage- sennsing wire feeders
Higher 26 to 35 arc volts
Wire feeds smoothly (yet will slip should a problem occur in the gun)
By there current carrying capacity

49. 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)
The Arc voltage
Constant current (CC)
Puddle fluidity

50. What is an advantage of pulsed arc transfer with GMAW?
Flux cored wires
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
Guns
Puddle fluidity

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Gas Metal Arc Welding

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