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Gas Metal Arc Welding

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Answer 50 questions in 15 minutes.
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1. When using flat drive rolls with too much pressure on copper coated solid wires what problem could take place?
3
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
Cause flaking - which can clog the liner and contact tube
12 to 22 arc volts

2. What controls amperage when using GMAW?
Motor driven generators - Transformer rectifiers - and Inverter designs
Wire feed speed
Gives arc voltage values to the control system of the feeder
Constant- speed wire feeders and Voltage- sennsing wire feeders

3. What wire are knurled drive rolls most commonly used on?
Flux cored wires
Insufficient current to melt the wire off cleanly
The negative side of a welding unit
Generally not as accurate

4. What effect does increasing and decreasing the inductance have on the weld?
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
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts

5. List 3 forms compressed gases may be supplied for welding
...
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
Minimum distortion due to low heat input
These terms are quite restrictive and often technically incorrect

6. How are GMAW guns rated?
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
By there current carrying capacity
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
Wire feeds smoothly (yet will slip should a problem occur in the gun)

7. What are the 2 types of wire feeders available?
When the filler wire is in direct contract with the base metal
Constant- speed wire feeders and Voltage- sennsing wire feeders
The resistace to electrical current flow increases with it. Causing the electrode to heat
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld

8. What does the abbreviation NEMA stand for?
National Electrical Manufactures Association
Generally not as accurate
...
Higher 26 to 35 arc volts

9. A pull type drive system is usually used on what type of material?
Short- circuiting transfer - Globular transfer - Spray transfer
Wire feeds smoothly (yet will slip should a problem occur in the gun)
Aluminum wire
(DCEP) Direct Current Electrode Positive or Reverse polarity

10. What happens when the electrode extension is increased?
The resistace to electrical current flow increases with it. Causing the electrode to heat
Generally not as accurate
Controls the rate of flow of a shielding gas to the gun nozzle
SMAW - GTAW

11. What type of power source is commonly used with a voltage sensing wire feeder?
Duty cycle
Constant current (CC)
V groove or U groove
Wire feeds smoothly (yet will slip should a problem occur in the gun)

12. What power sources are used with the GMAW Process?
Motor driven generators - Transformer rectifiers - and Inverter designs
Generally not as accurate
15 feet (4.5 meters)
85%

13. What does voltage do in an electrical circuit?
Constant current (CC)
Reducing the gas source pressure to a constant working pressure
The time rate of response for the current rise and fall
Voltage is the force that overcomes resistance to allow amperage flow

14. Is the arc voltage for spray transfer higher or lower than that used for short circuit transfer?
Controls the rate of flow of a shielding gas to the gun nozzle
Dry ice can form within the flow control openings and cause blockage of shielding gas
Higher 26 to 35 arc volts
Generally not as accurate

15. What is the main purpose of 'slope'?
Wire feeds smoothly (yet will slip should a problem occur in the gun)
(DCEP) Direct Current Electrode Positive or Reverse polarity
The Arc voltage
To limit the short circuiting current so that spatter is reduced

16. List 3 wire drive systems and give a short description of each
20 to 200 times per second
Flux cored wires
To prevent drawing of liquid CO2 (Carbon Dioxide)
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

17. Why must CO2 cylinders be used in the vertical position?
SMAW - GTAW
To prevent drawing of liquid CO2 (Carbon Dioxide)
Higher 26 to 35 arc volts
DCEP (Direct Current Electrode Positive) Reverse Polarity

18. What is another term for electrode holders for GMAW?
To prevent leakage - Carbon Dioxide (CO2)
12 to 22 arc volts
Shielding the molten weld metal from atmospheric contamination
Guns

19. What controls the wire speed on a voltage sensing wire feeder?
Duty cycle
Short- circuiting transfer - Globular transfer - Spray transfer
The Arc voltage
Guns

20. What is the effect of too much slope?
To prevent leakage - Carbon Dioxide (CO2)
...
Insufficient current to melt the wire off cleanly
Pressure - The rate of flow of a shielding gas

21. What 2 organizations designate specifications for GMAW wires?
Motor driven generators - Transformer rectifiers - and Inverter designs
AWS and CSA
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
Penetration and burn - off rate of the electrode

22. Why is a fiber washer required and what cylinder gas requires it?
If you dont know this check your phone
The time rate of response for the current rise and fall
15 feet (4.5 meters)
To prevent leakage - Carbon Dioxide (CO2)

23. When is the metal transferred with short circuit transfer?
Speed of the feed motor and - starting / stopping electrode feed
The Arc voltage
When the filler wire is in direct contract with the base metal
These terms are quite restrictive and often technically incorrect

24. What is the minimum % value of argon that must be present to use the spray transfer method of GMAW?
85%
Minutes of elapsed time continually run (out of 10 minutes)
To prevent drawing of liquid CO2 (Carbon Dioxide)
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld

25. What is the disadvantage of the gauge preset type of regulator/flowmeter?
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
The resistace to electrical current flow increases with it. Causing the electrode to heat
Generally not as accurate

26. What output on the welding machine is used to rate the duty cycle?
Constant- speed wire feeders and Voltage- sennsing wire feeders
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
Minutes of elapsed time continually run (out of 10 minutes)

27. List the factors that determine the mode of metal transfer
To prevent leakage - Carbon Dioxide (CO2)
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
Pressure - The rate of flow of a shielding gas
(DCEP) Direct Current Electrode Positive or Reverse polarity

28. What is the preferred drive roll design for solid wires?
Controls the rate of flow of a shielding gas to the gun nozzle
V groove or U groove
1/4 inch to 1/2 inch
Gives arc voltage values to the control system of the feeder

29. What 2 controls are found on a GMAW set- up?
Controls the rate of flow of a shielding gas to the gun nozzle
Welding process that joins metals by heating them with an electric arc
Wire feed speed - Voltage control
Insufficient current to melt the wire off cleanly

30. 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
Puddle fluidity
SMAW - GTAW
12 to 22 arc volts

31. With straight polarity where is 2/3 of the arc energy?
Cause flaking - which can clog the liner and contact tube
Gives arc voltage values to the control system of the feeder
By there current carrying capacity
The negative side of a welding unit

32. Why is globular transfer generally avoided with GMAW?
By there current carrying capacity
1/4 inch to 1/2 inch
Spatter problems and poor weld appearance
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground

33. Regulators control_____________ flowmeters SHOW____________.
12 to 22 arc volts
V groove or U groove
(DCEP) Direct Current Electrode Positive or Reverse polarity
Pressure - The rate of flow of a shielding gas

34. What type of power source is used with a constant speed wire feeder?
Insufficient current to melt the wire off cleanly
When the filler wire is in direct contract with the base metal
Constant voltage (CV)
Shielding the molten weld metal from atmospheric contamination

35. What does a flowmeter do and what does it measure?
Controls the rate of flow of a shielding gas to the gun nozzle
Motor driven generators - Transformer rectifiers - and Inverter designs
Cause flaking - which can clog the liner and contact tube
15 feet (4.5 meters)

36. What is the recommended electrode stick- out for .035 solid wire?
Pressure - The rate of flow of a shielding gas
1/4 inch to 1/2 inch
Minutes of elapsed time continually run (out of 10 minutes)
Constant current (CC)

37. List several industries that would use GMAW
Voltage is the force that overcomes resistance to allow amperage flow
AWS and CSA
By there current carrying capacity
Pressure vessels and the piping industry

38. What is the maximum distance that hard wire can be successfully pushed?
Penetration and burn - off rate of the electrode
DCEP (Direct Current Electrode Positive) Reverse Polarity
SMAW - GTAW
15 feet (4.5 meters)

39. What is the reason glass 'tube' type flowmeters must have the tube mounted truly vertical?
V groove or U groove
The Arc voltage
...
Controls the rate of flow of a shielding gas to the gun nozzle

40. List the three methods of metal transfer with GMAW
Puddle fluidity
Reducing the gas source pressure to a constant working pressure
85%
Short- circuiting transfer - Globular transfer - Spray transfer

41. What is the key advantage of short circuiting transfer?
Generally not as accurate
If you dont know this check your phone
Spatter problems and poor weld appearance
Minimum distortion due to low heat input

42. Why is a line heater required when using GMAW?
These terms are quite restrictive and often technically incorrect
By there current carrying capacity
Welding process that joins metals by heating them with an electric arc
Dry ice can form within the flow control openings and cause blockage of shielding gas

43. What is a typical flow rate of CO2 for short circuit transfer?
The negative side of a welding unit
Puddle fluidity
Controls the rate of flow of a shielding gas to the gun nozzle
5.8 to 12.5 L/min

44. In the GMAW process what does voltage control?
The Arc voltage
Puddle fluidity
Constant voltage (CV)
Constant current (CC)

45. Why is the term GMAW preferred over MIG or MAG?
V groove or U groove
Gas metal arc welding
These terms are quite restrictive and often technically incorrect
Speed of the feed motor and - starting / stopping electrode feed

46. What is the purpose of a regulator and what does it indicate on its gauges?
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
Reducing the gas source pressure to a constant working pressure
Puddle fluidity

47. What processes are constant current (CC) power sources designed to be used with?
Dry ice can form within the flow control openings and cause blockage of shielding gas
...
To prevent drawing of liquid CO2 (Carbon Dioxide)
SMAW - GTAW

48. What is the purpose of the pick- up lead on a voltage sensing wire feeder?
Gives arc voltage values to the control system of the feeder
To limit the short circuiting current so that spatter is reduced
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts
Aluminum wire

49. What does the term GMAW identify?
When the filler wire is in direct contract with the base metal
Gas metal arc welding
SMAW - GTAW
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground

50. What does inductance control?
Aluminum wire
The negative side of a welding unit
The time rate of response for the current rise and fall
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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