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Gas Metal Arc Welding

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Answer 50 questions in 15 minutes.
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1. What is the recommended electrode stick- out for .035 solid wire?
Puddle fluidity
To prevent drawing of liquid CO2 (Carbon Dioxide)
1/4 inch to 1/2 inch
Constant voltage (CV)

2. What is the effect of too much slope?
Insufficient current to melt the wire off cleanly
Flux cored wires
To limit the short circuiting current so that spatter is reduced
National Electrical Manufactures Association

3. What is the key advantage of short circuiting transfer?
By there current carrying capacity
Pressure vessels and the piping industry
Dry ice can form within the flow control openings and cause blockage of shielding gas
Minimum distortion due to low heat input

4. What does a flowmeter do and what does it measure?
Controls the rate of flow of a shielding gas to the gun nozzle
The resistace to electrical current flow increases with it. Causing the electrode to heat
20 to 200 times per second
Puddle fluidity

5. What wire are knurled drive rolls most commonly used on?
3
Flux cored wires
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
V groove or U groove

6. Why must CO2 cylinders be used in the vertical position?
To prevent drawing of liquid CO2 (Carbon Dioxide)
Minutes of elapsed time continually run (out of 10 minutes)
National Electrical Manufactures Association
The time rate of response for the current rise and fall

7. What type of power source is used with a constant speed wire feeder?
Wire feeds smoothly (yet will slip should a problem occur in the gun)
To prevent drawing of liquid CO2 (Carbon Dioxide)
Constant voltage (CV)
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

8. List the factors that determine the mode of metal transfer
Short- circuiting transfer - Globular transfer - Spray transfer
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
DCEP (Direct Current Electrode Positive) Reverse Polarity
Aluminum wire

9. What is the reason glass 'tube' type flowmeters must have the tube mounted truly vertical?
Wire feed speed
5.8 to 12.5 L/min
To prevent drawing of liquid CO2 (Carbon Dioxide)
...

10. With straight polarity where is 2/3 of the arc energy?
20 to 200 times per second
Constant voltage (CV)
Pressure vessels and the piping industry
The negative side of a welding unit

11. What is the minimum % value of argon that must be present to use the spray transfer method of GMAW?
Penetration and burn - off rate of the electrode
85%
To prevent leakage - Carbon Dioxide (CO2)
The resistace to electrical current flow increases with it. Causing the electrode to heat

12. List the three methods of metal transfer with GMAW
(DCEP) Direct Current Electrode Positive or Reverse polarity
Short- circuiting transfer - Globular transfer - Spray transfer
20 to 200 times per second
Puddle fluidity

13. Why is globular transfer generally avoided with GMAW?
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
Spatter problems and poor weld appearance
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 Arc voltage

14. What is the preferred drive roll design for solid wires?
Speed of the feed motor and - starting / stopping electrode feed
Constant current (CC)
V groove or U groove
Shielding the molten weld metal from atmospheric contamination

15. What is a solenoid valve and what actuates it?
The Arc voltage
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 or Reverse polarity

16. Draw a typical volt amp curve for a machine that is designed for GMAW
Shielding the molten weld metal from atmospheric contamination
If you dont know this check your phone
The Arc voltage
By there current carrying capacity

17. What output on the welding machine is used to rate the duty cycle?
V groove or U groove
Minutes of elapsed time continually run (out of 10 minutes)
National Electrical Manufactures Association
Duty cycle

18. In the GMAW process what does voltage control?
Flux cored wires
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts
12 to 22 arc volts
Puddle fluidity

19. What is the purpose of a regulator and what does it indicate on its gauges?
Insufficient current to melt the wire off cleanly
Reducing the gas source pressure to a constant working pressure
15 feet (4.5 meters)
Short- circuiting transfer - Globular transfer - Spray transfer

20. 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
By there current carrying capacity
If you dont know this check your phone
Controls the rate of flow of a shielding gas to the gun nozzle

21. Why is a fiber washer required and what cylinder gas requires it?
Guns
Flux cored wires
To prevent leakage - Carbon Dioxide (CO2)
The time rate of response for the current rise and fall

22. What is the disadvantage of the gauge preset type of regulator/flowmeter?
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
Reducing the gas source pressure to a constant working pressure
20 to 200 times per second
Generally not as accurate

23. What processes are constant current (CC) power sources designed to be used with?
Pressure vessels and the piping industry
Minutes of elapsed time continually run (out of 10 minutes)
12 to 22 arc volts
SMAW - GTAW

24. When is the metal transferred with short circuit transfer?
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
When the filler wire is in direct contract with the base metal
Cause flaking - which can clog the liner and contact tube

25. Is the arc voltage for spray transfer higher or lower than that used for short circuit transfer?
Higher 26 to 35 arc volts
National Electrical Manufactures Association
Penetration and burn - off rate of the electrode
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground

26. A machine with a 70% duty cycle can run at its max for 7 minutes with a cooling cycle of only _ minutes.
15 feet (4.5 meters)
The Arc voltage
To prevent leakage - Carbon Dioxide (CO2)
3

27. List several industries that would use GMAW
The Arc voltage
15 feet (4.5 meters)
Short- circuiting transfer - Globular transfer - Spray transfer
Pressure vessels and the piping industry

28. 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
Pressure vessels and the piping industry
These terms are quite restrictive and often technically incorrect
When the filler wire is in direct contract with the base metal

29. What is the required arc voltage used for short circuit transfer?
15 feet (4.5 meters)
12 to 22 arc volts
Puddle fluidity
Pressure - The rate of flow of a shielding gas

30. List 3 forms compressed gases may be supplied for welding
Constant voltage (CV)
Dry ice can form within the flow control openings and cause blockage of shielding gas
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
Reducing the gas source pressure to a constant working pressure

31. What is the purpose of the shielding gas used in GMAW?
Gas metal arc welding
Shielding the molten weld metal from atmospheric contamination
Controls the rate of flow of a shielding gas to the gun nozzle
To limit the short circuiting current so that spatter is reduced

32. What does the abbreviation NEMA stand for?
The negative side of a welding unit
Speed of the feed motor and - starting / stopping electrode feed
National Electrical Manufactures Association
If you dont know this check your phone

33. What are the 2 types of wire feeders available?
Higher 26 to 35 arc volts
Constant- speed wire feeders and Voltage- sennsing wire feeders
If you dont know this check your phone
To prevent leakage - Carbon Dioxide (CO2)

34. A 10 minute cycle of welding time vs cooling time a given machine can handle.
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts
Gives arc voltage values to the control system of the feeder
Duty cycle

35. List 3 wire drive systems and give a short description of each
Gas metal arc welding
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
5.8 to 12.5 L/min

36. How many times per second does short circuiting take place?
Controls the rate of flow of a shielding gas to the gun nozzle
When the filler wire is in direct contract with the base metal
Shielding the molten weld metal from atmospheric contamination
20 to 200 times per second

37. Why is a line heater required when using GMAW?
The resistace to electrical current flow increases with it. Causing the electrode to heat
Constant- speed wire feeders and Voltage- sennsing wire feeders
Dry ice can form within the flow control openings and cause blockage of shielding gas
Gives arc voltage values to the control system of the feeder

38. Why is the term GMAW preferred over MIG or MAG?
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
To prevent leakage - Carbon Dioxide (CO2)
These terms are quite restrictive and often technically incorrect
Speed of the feed motor and - starting / stopping electrode feed

39. What is another term for electrode holders for GMAW?
Guns
15 feet (4.5 meters)
By there current carrying capacity
Spatter problems and poor weld appearance

40. What is the maximum distance that hard wire can be successfully pushed?
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
15 feet (4.5 meters)
Insufficient current to melt the wire off cleanly

41. What happens when the electrode extension is increased?
The resistace to electrical current flow increases with it. Causing the electrode to heat
12 to 22 arc volts
V groove or U groove
15 feet (4.5 meters)

42. How are GMAW guns rated?
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts
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
Flux cored wires

43. What controls the wire speed on a voltage sensing wire feeder?
5.8 to 12.5 L/min
The Arc voltage
To prevent drawing of liquid CO2 (Carbon Dioxide)
Reducing the gas source pressure to a constant working pressure

44. What current and polarity is generally used with GMAW?
Pressure - The rate of flow of a shielding gas
The time rate of response for the current rise and fall
The Arc voltage
DCEP (Direct Current Electrode Positive) Reverse Polarity

45. What does inductance control?
...
Generally not as accurate
The time rate of response for the current rise and fall
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun

46. A pull type drive system is usually used on what type of material?
Aluminum wire
Gas metal arc welding
Insufficient current to melt the wire off cleanly
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system

47. What effect does increasing and decreasing the inductance have on the weld?
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
Voltage is the force that overcomes resistance to allow amperage flow
National Electrical Manufactures Association

48. When using flat drive rolls with too much pressure on copper coated solid wires what problem could take place?
Gives arc voltage values to the control system of the feeder
Cause flaking - which can clog the liner and contact tube
These terms are quite restrictive and often technically incorrect
To prevent leakage - Carbon Dioxide (CO2)

49. What type of power source is commonly used with a voltage sensing wire feeder?
Flux cored wires
Constant current (CC)
To prevent drawing of liquid CO2 (Carbon Dioxide)
Gas metal arc welding

50. What is the main purpose of 'slope'?
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
If you dont know this check your phone
To limit the short circuiting current so that spatter is reduced
Short- circuiting transfer - Globular transfer - Spray transfer

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Gas Metal Arc Welding

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