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Gas Metal Arc Welding

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Answer 50 questions in 15 minutes.
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Match each statement with the correct term.
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1. What is a typical flow rate of CO2 for short circuit transfer?
12 to 22 arc volts
1/4 inch to 1/2 inch
Short- circuiting transfer - Globular transfer - Spray transfer
5.8 to 12.5 L/min

2. When using flat drive rolls with too much pressure on copper coated solid wires what problem could take place?
Cause flaking - which can clog the liner and contact tube
To prevent leakage - Carbon Dioxide (CO2)
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
Duty cycle

3. Draw a typical volt amp curve for a machine that is designed for GMAW
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
Penetration and burn - off rate of the electrode
(DCEP) Direct Current Electrode Positive or Reverse polarity

4. What is the key advantage of short circuiting transfer?
Controls the rate of flow of a shielding gas to the gun nozzle
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
Minimum distortion due to low heat input
The time rate of response for the current rise and fall

5. What type of power source is commonly used with a voltage sensing wire feeder?
The Arc voltage
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
Constant current (CC)
SMAW - GTAW

6. What is the purpose of the shielding gas used in GMAW?
Shielding the molten weld metal from atmospheric contamination
Controls the rate of flow of a shielding gas to the gun nozzle
Generally not as accurate
Motor driven generators - Transformer rectifiers - and Inverter designs

7. List the basic equipment requirements for the GMAW process
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
1/4 inch to 1/2 inch
3
Voltage is the force that overcomes resistance to allow amperage flow

8. Is the arc voltage for spray transfer higher or lower than that used for short circuit transfer?
By there current carrying capacity
Higher 26 to 35 arc volts
Aluminum wire
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field

9. Why is globular transfer generally avoided with GMAW?
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
Spatter problems and poor weld appearance
Duty cycle
Puddle fluidity

10. List 3 wire drive systems and give a short description of each
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
15 feet (4.5 meters)
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

11. Regulators control_____________ flowmeters SHOW____________.
Duty cycle
Speed of the feed motor and - starting / stopping electrode feed
Pressure - The rate of flow of a shielding gas
Insufficient current to melt the wire off cleanly

12. Why must CO2 cylinders be used in the vertical position?
To prevent drawing of liquid CO2 (Carbon Dioxide)
Guns
85%
AWS and CSA

13. What is the purpose of the pick- up lead on a voltage sensing wire feeder?
Aluminum wire
20 to 200 times per second
Gives arc voltage values to the control system of the feeder
Wire feed speed

14. What are the 2 types of wire feeders available?
1/4 inch to 1/2 inch
Spatter problems and poor weld appearance
Constant- speed wire feeders and Voltage- sennsing wire feeders
To limit the short circuiting current so that spatter is reduced

15. When is the metal transferred with short circuit transfer?
Voltage is the force that overcomes resistance to allow amperage flow
The resistace to electrical current flow increases with it. Causing the electrode to heat
When the filler wire is in direct contract with the base metal
National Electrical Manufactures Association

16. What term is used to describe when the workpiece is hooked to the negative pole on the power source?
Wire feed speed - Voltage control
(DCEP) Direct Current Electrode Positive or Reverse polarity
5.8 to 12.5 L/min
85%

17. What controls the wire speed on a voltage sensing wire feeder?
The Arc voltage
Dry ice can form within the flow control openings and cause blockage of shielding gas
Aluminum wire
Gives arc voltage values to the control system of the feeder

18. What would be an indication that the drive roll pressure is adjusted correctly?
The time rate of response for the current rise and fall
Wire feed speed
Generally not as accurate
Wire feeds smoothly (yet will slip should a problem occur in the gun)

19. Give a description of 'pinch effect'
Short- circuiting transfer - Globular transfer - Spray transfer
Guns
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
The negative side of a welding unit

20. Why is a fiber washer required and what cylinder gas requires it?
To prevent leakage - Carbon Dioxide (CO2)
When the filler wire is in direct contract with the base metal
(DCEP) Direct Current Electrode Positive or Reverse polarity
85%

21. 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
Pressure vessels and the piping industry
If you dont know this check your phone

22. A 10 minute cycle of welding time vs cooling time a given machine can handle.
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
Duty cycle
Wire feed speed - Voltage control
Reducing the gas source pressure to a constant working pressure

23. What is the disadvantage of the gauge preset type of regulator/flowmeter?
To prevent leakage - Carbon Dioxide (CO2)
Dry ice can form within the flow control openings and cause blockage of shielding gas
3
Generally not as accurate

24. What type of power source is used with a constant speed wire feeder?
Constant voltage (CV)
15 feet (4.5 meters)
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
...

25. How many times per second does short circuiting take place?
Speed of the feed motor and - starting / stopping electrode feed
20 to 200 times per second
Spatter problems and poor weld appearance
Motor driven generators - Transformer rectifiers - and Inverter designs

26. What happens when the electrode extension is increased?
Shielding the molten weld metal from atmospheric contamination
The resistace to electrical current flow increases with it. Causing the electrode to heat
Pressure - The rate of flow of a shielding gas
Puddle fluidity

27. What power sources are used with the GMAW Process?
Constant current (CC)
Motor driven generators - Transformer rectifiers - and Inverter designs
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
These terms are quite restrictive and often technically incorrect

28. Draw a typical volt/amp curve that would be found with a power source designed for SMAW or GTAW
Pressure - The rate of flow of a shielding gas
Shielding the molten weld metal from atmospheric contamination
1/4 inch to 1/2 inch
If you dont know this check your phone

29. What is an advantage of pulsed arc transfer with GMAW?
Spatter problems and poor weld appearance
DCEP (Direct Current Electrode Positive) Reverse Polarity
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze

30. What is another term for electrode holders for GMAW?
Guns
Higher 26 to 35 arc volts
V groove or U groove
Wire feed speed

31. Why is a line heater required when using GMAW?
Puddle fluidity
Flux cored wires
(DCEP) Direct Current Electrode Positive or Reverse polarity
Dry ice can form within the flow control openings and cause blockage of shielding gas

32. How are GMAW guns rated?
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
The negative side of a welding unit
Gas metal arc welding

33. What is the purpose of a regulator and what does it indicate on its gauges?
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
If you dont know this check your phone
3
Reducing the gas source pressure to a constant working pressure

34. A machine with a 70% duty cycle can run at its max for 7 minutes with a cooling cycle of only _ minutes.
Pressure vessels and the piping industry
Puddle fluidity
3
The resistace to electrical current flow increases with it. Causing the electrode to heat

35. What does inductance control?
Guns
Dry ice can form within the flow control openings and cause blockage of shielding gas
The time rate of response for the current rise and fall
Speed of the feed motor and - starting / stopping electrode feed

36. Why is the term GMAW preferred over MIG or MAG?
5.8 to 12.5 L/min
Higher 26 to 35 arc volts
These terms are quite restrictive and often technically incorrect
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun

37. Give a brief description of the GMAW process
3
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
15 feet (4.5 meters)
Welding process that joins metals by heating them with an electric arc

38. What does voltage do in an electrical circuit?
V groove or U groove
Flux cored wires
Voltage is the force that overcomes resistance to allow amperage flow
If you dont know this check your phone

39. What controls amperage when using GMAW?
DCEP (Direct Current Electrode Positive) Reverse Polarity
Flux cored wires
Wire feed speed
Welding process that joins metals by heating them with an electric arc

40. List the factors that determine the mode of metal transfer
If you dont know this check your phone
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld

41. With straight polarity where is 2/3 of the arc energy?
Reducing the gas source pressure to a constant working pressure
The negative side of a welding unit
SMAW - GTAW
Insufficient current to melt the wire off cleanly

42. What is the required arc voltage used for short circuit transfer?
15 feet (4.5 meters)
The Arc voltage
To limit the short circuiting current so that spatter is reduced
12 to 22 arc volts

43. What is the maximum distance that hard wire can be successfully pushed?
15 feet (4.5 meters)
Short- circuiting transfer - Globular transfer - Spray transfer
Speed of the feed motor and - starting / stopping electrode feed
Reducing the gas source pressure to a constant working pressure

44. What output on the welding machine is used to rate the duty cycle?
Minutes of elapsed time continually run (out of 10 minutes)
The time rate of response for the current rise and fall
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
Duty cycle

45. What processes are constant current (CC) power sources designed to be used with?
85%
Generally not as accurate
SMAW - GTAW
3

46. A pull type drive system is usually used on what type of material?
National Electrical Manufactures Association
Constant- speed wire feeders and Voltage- sennsing wire feeders
These terms are quite restrictive and often technically incorrect
Aluminum wire

47. List several industries that would use GMAW
3
Pressure vessels and the piping industry
If you dont know this check your phone
Generally not as accurate

48. What does a flowmeter do and what does it measure?
The negative side of a welding unit
Controls the rate of flow of a shielding gas to the gun nozzle
Spatter problems and poor weld appearance
85%

49. What does the abbreviation NEMA stand for?
Welding process that joins metals by heating them with an electric arc
National Electrical Manufactures Association
Guns
15 feet (4.5 meters)

50. What does the term GMAW identify?
The negative side of a welding unit
By there current carrying capacity
The resistace to electrical current flow increases with it. Causing the electrode to heat
Gas metal arc welding

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Gas Metal Arc Welding

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