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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 processes are constant current (CC) power sources designed to be used with?
Higher 26 to 35 arc volts
SMAW - GTAW
Pressure vessels and the piping industry
Welding process that joins metals by heating them with an electric arc

2. What is the disadvantage of the gauge preset type of regulator/flowmeter?
Aluminum wire
Generally not as accurate
Controls the rate of flow of a shielding gas to the gun nozzle
To limit the short circuiting current so that spatter is reduced

3. When using flat drive rolls with too much pressure on copper coated solid wires what problem could take place?
Generally not as accurate
Higher 26 to 35 arc volts
The time rate of response for the current rise and fall
Cause flaking - which can clog the liner and contact tube

4. How are GMAW guns rated?
The Arc voltage
By there current carrying capacity
SMAW - GTAW
AWS and CSA

5. List 3 forms compressed gases may be supplied for welding
Higher 26 to 35 arc volts
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
1/4 inch to 1/2 inch

6. What 2 controls are found on a GMAW set- up?
Voltage is the force that overcomes resistance to allow amperage flow
If you dont know this check your phone
Wire feed speed - Voltage control
The time rate of response for the current rise and fall

7. What output on the welding machine is used to rate the duty cycle?
85%
To prevent drawing of liquid CO2 (Carbon Dioxide)
Reducing the gas source pressure to a constant working pressure
Minutes of elapsed time continually run (out of 10 minutes)

8. What does the abbreviation NEMA stand for?
Higher 26 to 35 arc volts
To prevent drawing of liquid CO2 (Carbon Dioxide)
The time rate of response for the current rise and fall
National Electrical Manufactures Association

9. What term is used to describe when the workpiece is hooked to the negative pole on the power source?
Insufficient current to melt the wire off cleanly
Pressure - The rate of flow of a shielding gas
(DCEP) Direct Current Electrode Positive or Reverse polarity
To limit the short circuiting current so that spatter is reduced

10. Why is a line heater required when using GMAW?
Aluminum wire
Dry ice can form within the flow control openings and cause blockage of shielding gas
Guns
Wire feed speed - Voltage control

11. When is the metal transferred with short circuit transfer?
To prevent drawing of liquid CO2 (Carbon Dioxide)
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
5.8 to 12.5 L/min
When the filler wire is in direct contract with the base metal

12. Why is the term GMAW preferred over MIG or MAG?
Pressure vessels and the piping industry
To prevent drawing of liquid CO2 (Carbon Dioxide)
These terms are quite restrictive and often technically incorrect
To prevent leakage - Carbon Dioxide (CO2)

13. A machine with a 70% duty cycle can run at its max for 7 minutes with a cooling cycle of only _ minutes.
Welding process that joins metals by heating them with an electric arc
3
Constant voltage (CV)
5.8 to 12.5 L/min

14. What current and polarity is generally used with GMAW?
The Arc voltage
Duty cycle
DCEP (Direct Current Electrode Positive) Reverse Polarity
Constant- speed wire feeders and Voltage- sennsing wire feeders

15. List 3 wire drive systems and give a short description of each
85%
Duty cycle
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
Puddle fluidity

16. What type of power source is used with a constant speed wire feeder?
Higher 26 to 35 arc volts
Generally not as accurate
Constant voltage (CV)
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts

17. What does a flowmeter do and what does it measure?
To limit the short circuiting current so that spatter is reduced
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
Controls the rate of flow of a shielding gas to the gun nozzle

18. Regulators control_____________ flowmeters SHOW____________.
Pressure - The rate of flow of a shielding gas
Guns
Constant current (CC)
Minutes of elapsed time continually run (out of 10 minutes)

19. What does voltage do in an electrical circuit?
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
3
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
Voltage is the force that overcomes resistance to allow amperage flow

20. Why must CO2 cylinders be used in the vertical position?
To prevent drawing of liquid CO2 (Carbon Dioxide)
Flux cored wires
By there current carrying capacity
Spatter problems and poor weld appearance

21. What is the minimum % value of argon that must be present to use the spray transfer method of GMAW?
Wire feeds smoothly (yet will slip should a problem occur in the gun)
Short- circuiting transfer - Globular transfer - Spray transfer
Minimum distortion due to low heat input
85%

22. List the three methods of metal transfer with GMAW
Higher 26 to 35 arc volts
The time rate of response for the current rise and fall
Constant current (CC)
Short- circuiting transfer - Globular transfer - Spray transfer

23. What is the key advantage of short circuiting transfer?
Minimum distortion due to low heat input
Guns
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
Insufficient current to melt the wire off cleanly

24. What is a solenoid valve and what actuates it?
5.8 to 12.5 L/min
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
DCEP (Direct Current Electrode Positive) Reverse Polarity

25. What effect does increasing and decreasing the inductance have on the weld?
Voltage is the force that overcomes resistance to allow amperage flow
Puddle fluidity
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

26. What is the required arc voltage used for short circuit transfer?
Constant current (CC)
12 to 22 arc volts
Voltage is the force that overcomes resistance to allow amperage flow
Gives arc voltage values to the control system of the feeder

27. What controls the wire speed on a voltage sensing wire feeder?
Short- circuiting transfer - Globular transfer - Spray transfer
When the filler wire is in direct contract with the base metal
The Arc voltage
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze

28. What is the purpose of the shielding gas used in GMAW?
Shielding the molten weld metal from atmospheric contamination
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
5.8 to 12.5 L/min
National Electrical Manufactures Association

29. What is the effect of too much slope?
Constant current (CC)
Insufficient current to melt the wire off cleanly
By there current carrying capacity
Flux cored wires

30. What is the recommended electrode stick- out for .035 solid wire?
1/4 inch to 1/2 inch
If you dont know this check your phone
The time rate of response for the current rise and fall
Motor driven generators - Transformer rectifiers - and Inverter designs

31. In the GMAW process what does voltage control?
5.8 to 12.5 L/min
Short- circuiting transfer - Globular transfer - Spray transfer
Aluminum wire
Puddle fluidity

32. What does inductance control?
The Arc voltage
5.8 to 12.5 L/min
If you dont know this check your phone
The time rate of response for the current rise and fall

33. How many times per second does short circuiting take place?
20 to 200 times per second
Insufficient current to melt the wire off cleanly
The time rate of response for the current rise and fall
SMAW - GTAW

34. 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
Speed of the feed motor and - starting / stopping electrode feed
Gives arc voltage values to the control system of the feeder
Wire feed speed

35. What is the main purpose of 'slope'?
To limit the short circuiting current so that spatter is reduced
To prevent leakage - Carbon Dioxide (CO2)
Spatter problems and poor weld appearance
Voltage is the force that overcomes resistance to allow amperage flow

36. What happens when the electrode extension is increased?
Aluminum wire
Higher 26 to 35 arc volts
The resistace to electrical current flow increases with it. Causing the electrode to heat
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground

37. What does the term GMAW identify?
Generally not as accurate
Reducing the gas source pressure to a constant working pressure
Gas metal arc welding
The time rate of response for the current rise and fall

38. What power sources are used with the GMAW Process?
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
Motor driven generators - Transformer rectifiers - and Inverter designs
Voltage is the force that overcomes resistance to allow amperage flow
The negative side of a welding unit

39. What is the purpose of the pick- up lead on a voltage sensing wire feeder?
Spatter problems and poor weld appearance
Gives arc voltage values to the control system of the feeder
V groove or U groove
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld

40. List several industries that would use GMAW
Spatter problems and poor weld appearance
DCEP (Direct Current Electrode Positive) Reverse Polarity
Pressure vessels and the piping industry
Shielding the molten weld metal from atmospheric contamination

41. What is another term for electrode holders for GMAW?
Guns
15 feet (4.5 meters)
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
Constant voltage (CV)

42. List the basic equipment requirements for the GMAW process
If you dont know this check your phone
SMAW - GTAW
If you dont know this check your phone
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground

43. What are the 2 types of wire feeders available?
Constant- speed wire feeders and Voltage- sennsing wire feeders
Spatter problems and poor weld appearance
The time rate of response for the current rise and fall
3

44. Why is a fiber washer required and what cylinder gas requires it?
20 to 200 times per second
To prevent leakage - Carbon Dioxide (CO2)
To prevent drawing of liquid CO2 (Carbon Dioxide)
Higher 26 to 35 arc volts

45. A pull type drive system is usually used on what type of material?
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
Aluminum wire
Gives arc voltage values to the control system of the feeder

46. List the factors that determine the mode of metal transfer
Generally not as accurate
The negative side of a welding unit
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
Dry ice can form within the flow control openings and cause blockage of shielding gas

47. What is the preferred drive roll design for solid wires?
V groove or U groove
85%
Speed of the feed motor and - starting / stopping electrode feed
Constant voltage (CV)

48. With straight polarity where is 2/3 of the arc energy?
SMAW - GTAW
Motor driven generators - Transformer rectifiers - and Inverter designs
Constant- speed wire feeders and Voltage- sennsing wire feeders
The negative side of a welding unit

49. Draw a typical volt/amp curve that would be found with a power source designed for SMAW or GTAW
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts
If you dont know this check your phone
Voltage is the force that overcomes resistance to allow amperage flow
To prevent drawing of liquid CO2 (Carbon Dioxide)

50. What type of power source is commonly used with a voltage sensing wire feeder?
Constant current (CC)
Dry ice can form within the flow control openings and cause blockage of shielding gas
Flux cored wires
The resistace to electrical current flow increases with it. Causing the electrode to heat

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