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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?
Wire feed speed
V groove or U groove
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
Minutes of elapsed time continually run (out of 10 minutes)

2. Draw a typical volt/amp curve that would be found with a power source designed for SMAW or GTAW
Welding process that joins metals by heating them with an electric arc
If you dont know this check your phone
Puddle fluidity
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun

3. What does voltage do in an electrical circuit?
Pressure - The rate of flow of a shielding gas
Voltage is the force that overcomes resistance to allow amperage flow
15 feet (4.5 meters)
Wire feed speed - Voltage control

4. What does a flowmeter do and what does it measure?
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
20 to 200 times per second
Penetration and burn - off rate of the electrode
Controls the rate of flow of a shielding gas to the gun nozzle

5. What is the disadvantage of the gauge preset type of regulator/flowmeter?
5.8 to 12.5 L/min
Cause flaking - which can clog the liner and contact tube
Generally not as accurate
Insufficient current to melt the wire off cleanly

6. Why is a fiber washer required and what cylinder gas requires it?
Constant- speed wire feeders and Voltage- sennsing wire feeders
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
3
To prevent leakage - Carbon Dioxide (CO2)

7. Give a brief description of the GMAW process
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
20 to 200 times per second
Wire feed speed
Welding process that joins metals by heating them with an electric arc

8. What 2 controls are found on a GMAW set- up?
85%
Wire feeds smoothly (yet will slip should a problem occur in the gun)
Generally not as accurate
Wire feed speed - Voltage control

9. What wire are knurled drive rolls most commonly used on?
Puddle fluidity
Flux cored wires
Speed of the feed motor and - starting / stopping electrode feed
Motor driven generators - Transformer rectifiers - and Inverter designs

10. List several industries that would use GMAW
Flux cored wires
Pressure vessels and the piping industry
Wire feeds smoothly (yet will slip should a problem occur in the gun)
Short- circuiting transfer - Globular transfer - Spray transfer

11. What is a typical flow rate of CO2 for short circuit transfer?
Flux cored wires
5.8 to 12.5 L/min
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
(DCEP) Direct Current Electrode Positive or Reverse polarity

12. Is the arc voltage for spray transfer higher or lower than that 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
The negative side of a welding unit
Gas metal arc welding
Higher 26 to 35 arc volts

13. What is the purpose of a regulator and what does it indicate on its gauges?
Higher 26 to 35 arc volts
12 to 22 arc volts
85%
Reducing the gas source pressure to a constant working pressure

14. What is a solenoid valve and what actuates it?
Constant- speed wire feeders and Voltage- sennsing wire feeders
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
Guns
Gives arc voltage values to the control system of the feeder

15. What is the key advantage of short circuiting transfer?
Reducing the gas source pressure to a constant working pressure
Minimum distortion due to low heat input
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 limit the short circuiting current so that spatter is reduced

16. What is the purpose of the shielding gas used in GMAW?
Shielding the molten weld metal from atmospheric contamination
To prevent drawing of liquid CO2 (Carbon Dioxide)
The negative side of a welding unit
Spatter problems and poor weld appearance

17. What is the required arc voltage used for short circuit transfer?
Dry ice can form within the flow control openings and cause blockage of shielding gas
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
12 to 22 arc volts
85%

18. A 10 minute cycle of welding time vs cooling time a given machine can handle.
Duty cycle
DCEP (Direct Current Electrode Positive) Reverse Polarity
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
The time rate of response for the current rise and fall

19. When using flat drive rolls with too much pressure on copper coated solid wires what problem could take place?
Minutes of elapsed time continually run (out of 10 minutes)
20 to 200 times per second
Spatter problems and poor weld appearance
Cause flaking - which can clog the liner and contact tube

20. What processes are constant current (CC) power sources designed to be used with?
By there current carrying capacity
SMAW - GTAW
85%
Dry ice can form within the flow control openings and cause blockage of shielding gas

21. What controls the wire speed on a voltage sensing wire feeder?
The Arc voltage
Wire feeds smoothly (yet will slip should a problem occur in the gun)
Motor driven generators - Transformer rectifiers - and Inverter designs
1/4 inch to 1/2 inch

22. What term is used to describe when the workpiece is hooked to the negative pole on the power source?
20 to 200 times per second
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
(DCEP) Direct Current Electrode Positive or Reverse polarity
3

23. With straight polarity where is 2/3 of the arc energy?
Speed of the feed motor and - starting / stopping electrode feed
The negative side of a welding unit
To prevent leakage - Carbon Dioxide (CO2)
Duty cycle

24. What 2 organizations designate specifications for GMAW wires?
If you dont know this check your phone
Speed of the feed motor and - starting / stopping electrode feed
Insufficient current to melt the wire off cleanly
AWS and CSA

25. Regulators control_____________ flowmeters SHOW____________.
...
Pressure vessels and the piping industry
20 to 200 times per second
Pressure - The rate of flow of a shielding gas

26. What is the effect of too much slope?
Motor driven generators - Transformer rectifiers - and Inverter designs
Insufficient current to melt the wire off cleanly
Guns
Controls the rate of flow of a shielding gas to the gun nozzle

27. What does the term GMAW identify?
Welding process that joins metals by heating them with an electric arc
Short- circuiting transfer - Globular transfer - Spray transfer
Gas metal arc welding
V groove or U groove

28. How many times per second does short circuiting take place?
The negative side of a welding unit
Minimum distortion due to low heat input
The time rate of response for the current rise and fall
20 to 200 times per second

29. What controls amperage when using GMAW?
Controls the rate of flow of a shielding gas to the gun nozzle
DCEP (Direct Current Electrode Positive) Reverse Polarity
(DCEP) Direct Current Electrode Positive or Reverse polarity
Wire feed speed

30. What output on the welding machine is used to rate the duty cycle?
National Electrical Manufactures Association
SMAW - GTAW
Minutes of elapsed time continually run (out of 10 minutes)
Dry ice can form within the flow control openings and cause blockage of shielding gas

31. What is the reason glass 'tube' type flowmeters must have the tube mounted truly vertical?
15 feet (4.5 meters)
Higher 26 to 35 arc volts
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
...

32. Draw a typical volt amp curve for a machine that is designed for GMAW
If you dont know this check your phone
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
When the filler wire is in direct contract with the base metal
3

33. Why is the term GMAW preferred over MIG or MAG?
The negative side of a welding unit
Pressure vessels and the piping industry
These terms are quite restrictive and often technically incorrect
Motor driven generators - Transformer rectifiers - and Inverter designs

34. 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
Wire feed speed
By there current carrying capacity
12 to 22 arc volts

35. List 3 forms compressed gases may be supplied for welding
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
V groove or U groove
...
Welding process that joins metals by heating them with an electric arc

36. What does the wire feeder control?
National Electrical Manufactures Association
Speed of the feed motor and - starting / stopping electrode feed
1/4 inch to 1/2 inch
Shielding the molten weld metal from atmospheric contamination

37. What is the maximum distance that hard wire can be successfully pushed?
Insufficient current to melt the wire off cleanly
Aluminum wire
15 feet (4.5 meters)
Shielding the molten weld metal from atmospheric contamination

38. When is the metal transferred with short circuit transfer?
The negative side of a welding unit
These terms are quite restrictive and often technically incorrect
When the filler wire is in direct contract with the base metal
The Arc voltage

39. A machine with a 70% duty cycle can run at its max for 7 minutes with a cooling cycle of only _ minutes.
Constant voltage (CV)
Wire feed speed
Insufficient current to melt the wire off cleanly
3

40. What are the 2 types of wire feeders available?
12 to 22 arc volts
Constant- speed wire feeders and Voltage- sennsing wire feeders
When the filler wire is in direct contract with the base metal
Aluminum wire

41. List the basic equipment requirements for the GMAW process
Welding process that joins metals by heating them with an electric arc
15 feet (4.5 meters)
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
Duty cycle

42. What is an advantage of pulsed arc transfer with GMAW?
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
Duty cycle
85%
The time rate of response for the current rise and fall

43. What power sources are used with the GMAW Process?
Spatter problems and poor weld appearance
Puddle fluidity
Motor driven generators - Transformer rectifiers - and Inverter designs
Minutes of elapsed time continually run (out of 10 minutes)

44. In the GMAW process what does amperage control?
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
Shielding the molten weld metal from atmospheric contamination
Penetration and burn - off rate of the electrode
5.8 to 12.5 L/min

45. What effect does increasing and decreasing the inductance have on the weld?
Constant current (CC)
Cause flaking - which can clog the liner and contact tube
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts
Welding process that joins metals by heating them with an electric arc

46. Why is a line heater required when using GMAW?
Dry ice can form within the flow control openings and cause blockage of shielding gas
Shielding the molten weld metal from atmospheric contamination
15 feet (4.5 meters)
AWS and CSA

47. Why must CO2 cylinders be used in the vertical position?
Reducing the gas source pressure to a constant working pressure
Higher 26 to 35 arc volts
To prevent drawing of liquid CO2 (Carbon Dioxide)
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system

48. A pull type drive system is usually used on what type of material?
Penetration and burn - off rate of the electrode
12 to 22 arc volts
Aluminum wire
Wire feed speed - Voltage control

49. 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
The time rate of response for the current rise and fall
Gas metal arc welding
Guns

50. What happens when the electrode extension is increased?
When the filler wire is in direct contract with the base metal
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
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
The resistace to electrical current flow increases with it. Causing the electrode to heat

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Gas Metal Arc Welding

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