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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. A 10 minute cycle of welding time vs cooling time a given machine can handle.
Duty cycle
Penetration and burn - off rate of the electrode
When the filler wire is in direct contract with the base metal
Shielding the molten weld metal from atmospheric contamination

2. What power sources are used with the GMAW Process?
1/4 inch to 1/2 inch
To prevent drawing of liquid CO2 (Carbon Dioxide)
Motor driven generators - Transformer rectifiers - and Inverter designs
Puddle fluidity

3. What does the wire feeder control?
Speed of the feed motor and - starting / stopping electrode feed
Wire feed speed
Voltage is the force that overcomes resistance to allow amperage flow
(DCEP) Direct Current Electrode Positive or Reverse polarity

4. What type of power source is used with a constant speed wire feeder?
85%
Insufficient current to melt the wire off cleanly
Pressure - The rate of flow of a shielding gas
Constant voltage (CV)

5. What is the preferred drive roll design for solid wires?
Duty cycle
5.8 to 12.5 L/min
The time rate of response for the current rise and fall
V groove or U groove

6. What effect does increasing and decreasing the inductance have on the weld?
To prevent drawing of liquid CO2 (Carbon Dioxide)
Wire feed speed - Voltage control
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts
1/4 inch to 1/2 inch

7. What is the reason glass 'tube' type flowmeters must have the tube mounted truly vertical?
Penetration and burn - off rate of the electrode
12 to 22 arc volts
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
...

8. What processes are constant current (CC) power sources designed to be used with?
SMAW - GTAW
The resistace to electrical current flow increases with it. Causing the electrode to heat
Welding process that joins metals by heating them with an electric arc
12 to 22 arc volts

9. List 3 forms compressed gases may be supplied for welding
Aluminum wire
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
Minimum distortion due to low heat input
Speed of the feed motor and - starting / stopping electrode feed

10. List the factors that determine the mode of metal transfer
The negative side of a welding unit
To prevent leakage - Carbon Dioxide (CO2)
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
The resistace to electrical current flow increases with it. Causing the electrode to heat

11. Why is globular transfer generally avoided with GMAW?
If you dont know this check your phone
The time rate of response for the current rise and fall
Spatter problems and poor weld appearance
Constant voltage (CV)

12. When is the metal transferred with short circuit transfer?
When the filler wire is in direct contract with the base metal
Higher 26 to 35 arc volts
15 feet (4.5 meters)
These terms are quite restrictive and often technically incorrect

13. What is the purpose of the pick- up lead on a voltage sensing wire feeder?
These terms are quite restrictive and often technically incorrect
Wire feeds smoothly (yet will slip should a problem occur in the gun)
Reducing the gas source pressure to a constant working pressure
Gives arc voltage values to the control system of the feeder

14. What is another term for electrode holders for GMAW?
Motor driven generators - Transformer rectifiers - and Inverter designs
Guns
The Arc voltage
Constant current (CC)

15. List several industries that would use GMAW
Pressure vessels and the piping industry
Spatter problems and poor weld appearance
The negative side of a welding unit
Flux cored wires

16. What output on the welding machine is used to rate the duty cycle?
Minutes of elapsed time continually run (out of 10 minutes)
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
Flux cored wires
Insufficient current to melt the wire off cleanly

17. What is the main purpose of 'slope'?
To limit the short circuiting current so that spatter is reduced
Reducing the gas source pressure to a constant working pressure
1/4 inch to 1/2 inch
Constant current (CC)

18. What is the recommended electrode stick- out for .035 solid wire?
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
1/4 inch to 1/2 inch
The Arc voltage
85%

19. A machine with a 70% duty cycle can run at its max for 7 minutes with a cooling cycle of only _ minutes.
Penetration and burn - off rate of the electrode
85%
3
5.8 to 12.5 L/min

20. Why is a fiber washer required and what cylinder gas requires it?
To prevent leakage - Carbon Dioxide (CO2)
Constant current (CC)
Penetration and burn - off rate of the electrode
If you dont know this check your phone

21. What current and polarity is generally used with GMAW?
Constant current (CC)
DCEP (Direct Current Electrode Positive) Reverse Polarity
Minimum distortion due to low heat input
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground

22. What happens when the electrode extension is increased?
(DCEP) Direct Current Electrode Positive or Reverse polarity
The resistace to electrical current flow increases with it. Causing the electrode to heat
V groove or U groove
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system

23. What type of power source is commonly used with a voltage sensing wire feeder?
When the filler wire is in direct contract with the base metal
Minimum distortion due to low heat input
Guns
Constant current (CC)

24. What 2 organizations designate specifications for GMAW wires?
Generally not as accurate
AWS and CSA
Guns
When the filler wire is in direct contract with the base metal

25. What is a solenoid valve and what actuates it?
Higher 26 to 35 arc volts
Wire feed speed - Voltage control
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun

26. What is the effect of too much slope?
These terms are quite restrictive and often technically incorrect
Insufficient current to melt the wire off cleanly
(DCEP) Direct Current Electrode Positive or Reverse polarity
85%

27. With straight polarity where is 2/3 of the arc energy?
Shielding the molten weld metal from atmospheric contamination
The time rate of response for the current rise and fall
The negative side of a welding unit
Constant- speed wire feeders and Voltage- sennsing wire feeders

28. What does inductance control?
Pressure - The rate of flow of a shielding gas
If you dont know this check your phone
The time rate of response for the current rise and fall
Wire feeds smoothly (yet will slip should a problem occur in the gun)

29. A pull type drive system is usually used on what type of material?
Constant voltage (CV)
20 to 200 times per second
Aluminum wire
Welding process that joins metals by heating them with an electric arc

30. How are GMAW guns rated?
Pressure vessels and the piping industry
When the filler wire is in direct contract with the base metal
The negative side of a welding unit
By there current carrying capacity

31. What is the disadvantage of the gauge preset type of regulator/flowmeter?
If you dont know this check your phone
Generally not as accurate
Shielding the molten weld metal from atmospheric contamination
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system

32. What controls amperage when using GMAW?
12 to 22 arc volts
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) Reverse Polarity
Wire feed speed

33. What is a typical flow rate of CO2 for short circuit transfer?
Duty cycle
SMAW - GTAW
5.8 to 12.5 L/min
Shielding the molten weld metal from atmospheric contamination

34. Regulators control_____________ flowmeters SHOW____________.
Pressure - The rate of flow of a shielding gas
Speed of the feed motor and - starting / stopping electrode feed
Constant voltage (CV)
Insufficient current to melt the wire off cleanly

35. What 2 controls are found on a GMAW set- up?
SMAW - GTAW
Wire feed speed - Voltage control
National Electrical Manufactures Association
3

36. Why is the term GMAW preferred over MIG or MAG?
Duty cycle
The resistace to electrical current flow increases with it. Causing the electrode to heat
Short- circuiting transfer - Globular transfer - Spray transfer
These terms are quite restrictive and often technically incorrect

37. What is the required arc voltage used for short circuit transfer?
12 to 22 arc volts
Aluminum wire
Shielding the molten weld metal from atmospheric contamination
National Electrical Manufactures Association

38. Why is a line heater required when using GMAW?
Constant current (CC)
Dry ice can form within the flow control openings and cause blockage of shielding gas
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

39. How many times per second does short circuiting take place?
Short- circuiting transfer - Globular transfer - Spray transfer
20 to 200 times per second
Voltage is the force that overcomes resistance to allow amperage flow
Guns

40. What does the abbreviation NEMA stand for?
Pressure vessels and the piping industry
1/4 inch to 1/2 inch
The resistace to electrical current flow increases with it. Causing the electrode to heat
National Electrical Manufactures Association

41. When using flat drive rolls with too much pressure on copper coated solid wires what problem could take place?
Insufficient current to melt the wire off cleanly
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
Spatter problems and poor weld appearance
Cause flaking - which can clog the liner and contact tube

42. What does a flowmeter do and what does it measure?
Controls the rate of flow of a shielding gas to the gun nozzle
To prevent drawing of liquid CO2 (Carbon Dioxide)
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

43. What term is used to describe when the workpiece is hooked to the negative pole on the power source?
15 feet (4.5 meters)
Penetration and burn - off rate of the electrode
(DCEP) Direct Current Electrode Positive or Reverse polarity
The Arc voltage

44. What does the term GMAW identify?
Guns
20 to 200 times per second
Gas metal arc welding
Cause flaking - which can clog the liner and contact tube

45. List the basic equipment requirements for the GMAW process
Gas metal arc welding
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
3
Pressure vessels and the piping industry

46. Why must CO2 cylinders be used in the vertical position?
(DCEP) Direct Current Electrode Positive or Reverse polarity
To prevent drawing of liquid CO2 (Carbon Dioxide)
Generally not as accurate
Speed of the feed motor and - starting / stopping electrode feed

47. What is the key advantage of short circuiting transfer?
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
Minimum distortion due to low heat input
Pressure - The rate of flow of a shielding gas
SMAW - GTAW

48. What is the purpose of a regulator and what does it indicate on its gauges?
If you dont know this check your phone
Welding process that joins metals by heating them with an electric arc
Wire feed speed - Voltage control
Reducing the gas source pressure to a constant working pressure

49. List the three methods of metal transfer with GMAW
Higher 26 to 35 arc volts
Pressure - The rate of flow of a shielding gas
Short- circuiting transfer - Globular transfer - Spray transfer
DCEP (Direct Current Electrode Positive) Reverse Polarity

50. Draw a typical volt/amp curve that would be found with a power source designed for SMAW or GTAW
By there current carrying capacity
To limit the short circuiting current so that spatter is reduced
If you dont know this check your phone
Penetration and burn - off rate of the electrode

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Gas Metal Arc Welding

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