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Gas Metal Arc Welding

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Answer 50 questions in 15 minutes.
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1. Draw a typical volt amp curve for a machine that is designed for GMAW
The Arc voltage
When the filler wire is in direct contract with the base metal
Voltage is the force that overcomes resistance to allow amperage flow
If you dont know this check your phone

2. Why is a fiber washer required and what cylinder gas requires it?
V groove or U groove
Wire feed speed - Voltage control
To prevent leakage - Carbon Dioxide (CO2)
85%

3. List the basic equipment requirements for the GMAW process
To prevent leakage - Carbon Dioxide (CO2)
Gas metal arc welding
Minutes of elapsed time continually run (out of 10 minutes)
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground

4. Draw a typical volt/amp curve that would be found with a power source designed for SMAW or GTAW
SMAW - GTAW
If you dont know this check your phone
The Arc voltage
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

5. A machine with a 70% duty cycle can run at its max for 7 minutes with a cooling cycle of only _ minutes.
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
Generally not as accurate
3

6. What processes are constant current (CC) power sources designed to be used with?
To limit the short circuiting current so that spatter is reduced
If you dont know this check your phone
The time rate of response for the current rise and fall
SMAW - GTAW

7. When is the metal transferred with short circuit transfer?
The time rate of response for the current rise and fall
12 to 22 arc volts
20 to 200 times per second
When the filler wire is in direct contract with the base metal

8. 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
Dry ice can form within the flow control openings and cause blockage of shielding gas
15 feet (4.5 meters)
By there current carrying capacity

9. What effect does increasing and decreasing the inductance have on the weld?
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
Dry ice can form within the flow control openings and cause blockage of shielding gas
National Electrical Manufactures Association

10. What is a solenoid valve and what actuates it?
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
1/4 inch to 1/2 inch
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
Speed of the feed motor and - starting / stopping electrode feed

11. Give a description of 'pinch effect'
The negative side of a welding unit
Constant- speed wire feeders and Voltage- sennsing wire feeders
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field

12. With straight polarity where is 2/3 of the arc energy?
The negative side of a welding unit
3
Reducing the gas source pressure to a constant working pressure
Guns

13. Is the arc voltage for spray transfer higher or lower than that used for short circuit transfer?
Minutes of elapsed time continually run (out of 10 minutes)
1/4 inch to 1/2 inch
The time rate of response for the current rise and fall
Higher 26 to 35 arc volts

14. What is the maximum distance that hard wire can be successfully pushed?
DCEP (Direct Current Electrode Positive) Reverse Polarity
Gas metal arc welding
If you dont know this check your phone
15 feet (4.5 meters)

15. What does voltage do in an electrical circuit?
Gas metal arc welding
Voltage is the force that overcomes resistance to allow amperage flow
If you dont know this check your phone
National Electrical Manufactures Association

16. What is the purpose of the shielding gas used in GMAW?
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
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
Shielding the molten weld metal from atmospheric contamination

17. In the GMAW process what does voltage control?
Gas metal arc welding
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
Puddle fluidity
Higher 26 to 35 arc volts

18. What current and polarity is generally used with GMAW?
Welding process that joins metals by heating them with an electric arc
Penetration and burn - off rate of the electrode
DCEP (Direct Current Electrode Positive) Reverse Polarity
To prevent leakage - Carbon Dioxide (CO2)

19. What controls the wire speed on a voltage sensing wire feeder?
AWS and CSA
1/4 inch to 1/2 inch
The Arc voltage
20 to 200 times per second

20. What is the required arc voltage used for short circuit transfer?
Puddle fluidity
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
12 to 22 arc volts
Wire feeds smoothly (yet will slip should a problem occur in the gun)

21. List the three methods of metal transfer with GMAW
DCEP (Direct Current Electrode Positive) Reverse Polarity
Short- circuiting transfer - Globular transfer - Spray transfer
5.8 to 12.5 L/min
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze

22. What are the 2 types of wire feeders available?
Constant- speed wire feeders and Voltage- sennsing wire feeders
Welding process that joins metals by heating them with an electric arc
Speed of the feed motor and - starting / stopping electrode feed
...

23. What is the main purpose of 'slope'?
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
Minimum distortion due to low heat input
SMAW - GTAW
To limit the short circuiting current so that spatter is reduced

24. Regulators control_____________ flowmeters SHOW____________.
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts
Pressure - The rate of flow of a shielding gas
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
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

25. What controls amperage when using GMAW?
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
Higher 26 to 35 arc volts
Wire feed speed
When the filler wire is in direct contract with the base metal

26. What is the recommended electrode stick- out for .035 solid wire?
Spatter problems and poor weld appearance
1/4 inch to 1/2 inch
Shielding the molten weld metal from atmospheric contamination
The Arc voltage

27. List the factors that determine the mode of metal transfer
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
20 to 200 times per second
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze

28. What output on the welding machine is used to rate the duty cycle?
Guns
Gives arc voltage values to the control system of the feeder
Minutes of elapsed time continually run (out of 10 minutes)
...

29. What does the term GMAW identify?
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
V groove or U groove
Higher 26 to 35 arc volts
Gas metal arc welding

30. Why is the term GMAW preferred over MIG or MAG?
Short- circuiting transfer - Globular transfer - Spray transfer
Gas metal arc welding
These terms are quite restrictive and often technically incorrect
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts

31. What does inductance control?
Higher 26 to 35 arc volts
Wire feeds smoothly (yet will slip should a problem occur in the gun)
The time rate of response for the current rise and fall
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld

32. In the GMAW process what does amperage control?
Minutes of elapsed time continually run (out of 10 minutes)
3
Voltage is the force that overcomes resistance to allow amperage flow
Penetration and burn - off rate of the electrode

33. What is a typical flow rate of CO2 for short circuit transfer?
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
Short- circuiting transfer - Globular transfer - Spray transfer
5.8 to 12.5 L/min
These terms are quite restrictive and often technically incorrect

34. What type of power source is commonly used with a voltage sensing wire feeder?
The resistace to electrical current flow increases with it. Causing the electrode to heat
Constant current (CC)
Duty cycle
85%

35. What is another term for electrode holders for GMAW?
20 to 200 times per second
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
Flux cored wires
Guns

36. What is the key advantage of short circuiting transfer?
Minimum distortion due to low heat input
20 to 200 times per second
Spatter problems and poor weld appearance
Constant voltage (CV)

37. List several industries that would use GMAW
5.8 to 12.5 L/min
Motor driven generators - Transformer rectifiers - and Inverter designs
V groove or U groove
Pressure vessels and the piping industry

38. How are GMAW guns rated?
Reducing the gas source pressure to a constant working pressure
Pressure vessels and the piping industry
The Arc voltage
By there current carrying capacity

39. How many times per second does short circuiting take place?
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
20 to 200 times per second
Reducing the gas source pressure to a constant working pressure

40. What does the abbreviation NEMA stand for?
National Electrical Manufactures Association
Pressure vessels and the piping industry
Generally not as accurate
The negative side of a welding unit

41. What happens when the electrode extension is increased?
Dry ice can form within the flow control openings and cause blockage of shielding gas
Minutes of elapsed time continually run (out of 10 minutes)
Guns
The resistace to electrical current flow increases with it. Causing the electrode to heat

42. What wire are knurled drive rolls most commonly used on?
Flux cored wires
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
Wire feed speed

43. What is the disadvantage of the gauge preset type of regulator/flowmeter?
Generally not as accurate
20 to 200 times per second
Motor driven generators - Transformer rectifiers - and Inverter designs
Reducing the gas source pressure to a constant working pressure

44. What power sources are used with the GMAW Process?
Generally not as accurate
Motor driven generators - Transformer rectifiers - and Inverter designs
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
Wire feed speed - Voltage control

45. What is an advantage of pulsed arc transfer with GMAW?
Constant voltage (CV)
Shielding the molten weld metal from atmospheric contamination
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

46. A pull type drive system is usually used on what type of material?
Constant voltage (CV)
National Electrical Manufactures Association
Aluminum wire
To prevent leakage - Carbon Dioxide (CO2)

47. What is the preferred drive roll design for solid wires?
V groove or U groove
Speed of the feed motor and - starting / stopping electrode feed
Minutes of elapsed time continually run (out of 10 minutes)
Puddle fluidity

48. What is the purpose of the pick- up lead on a voltage sensing wire feeder?
Minimum distortion due to low heat input
Constant current (CC)
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
Gives arc voltage values to the control system of the feeder

49. What term is used to describe when the workpiece is hooked to the negative pole on the power source?
85%
(DCEP) Direct Current Electrode Positive or Reverse polarity
Pressure - The rate of flow of a shielding gas
To prevent leakage - Carbon Dioxide (CO2)

50. What is the effect of too much slope?
Pressure vessels and the piping industry
To prevent drawing of liquid CO2 (Carbon Dioxide)
Welding process that joins metals by heating them with an electric arc
Insufficient current to melt the wire off cleanly

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Gas Metal Arc Welding

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