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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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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. What is the minimum % value of argon that must be present to use the spray transfer method of GMAW?
Gives arc voltage values to the control system of the feeder
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
85%

2. When is the metal transferred with short circuit transfer?
Pressure - The rate of flow of a shielding gas
Aluminum wire
DCEP (Direct Current Electrode Positive) Reverse Polarity
When the filler wire is in direct contract with the base metal

3. Why must CO2 cylinders be used in the vertical position?
To prevent drawing of liquid CO2 (Carbon Dioxide)
Reducing the gas source pressure to a constant working pressure
Shielding the molten weld metal from atmospheric contamination
Generally not as accurate

4. Why is a fiber washer required and what cylinder gas requires it?
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
If you dont know this check your phone
To prevent leakage - Carbon Dioxide (CO2)
Motor driven generators - Transformer rectifiers - and Inverter designs

5. What output on the welding machine is used to rate the duty cycle?
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
Minutes of elapsed time continually run (out of 10 minutes)
(DCEP) Direct Current Electrode Positive or Reverse polarity
Aluminum wire

6. What is a solenoid valve and what actuates it?
15 feet (4.5 meters)
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
5.8 to 12.5 L/min
Higher 26 to 35 arc volts

7. What is a typical flow rate of CO2 for short circuit transfer?
Wire feed speed - Voltage control
By there current carrying capacity
Minutes of elapsed time continually run (out of 10 minutes)
5.8 to 12.5 L/min

8. What term is used to describe when the workpiece is hooked to the negative pole on the power source?
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 or Reverse polarity
Constant- speed wire feeders and Voltage- sennsing wire feeders
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts

9. What 2 controls are found on a GMAW set- up?
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
Wire feeds smoothly (yet will slip should a problem occur in the gun)
Wire feed speed - Voltage control

10. What does a flowmeter do and what does it measure?
Flux cored wires
(DCEP) Direct Current Electrode Positive or Reverse polarity
Wire feed speed - Voltage control
Controls the rate of flow of a shielding gas to the gun nozzle

11. What controls amperage when using GMAW?
Voltage is the force that overcomes resistance to allow amperage flow
Minimum distortion due to low heat input
Wire feed speed
AWS and CSA

12. With straight polarity where is 2/3 of the arc energy?
Generally not as accurate
The negative side of a welding unit
Spatter problems and poor weld appearance
...

13. What is the effect of too much slope?
Insufficient current to melt the wire off cleanly
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts
V groove or U groove
5.8 to 12.5 L/min

14. What does voltage do in an electrical circuit?
3
AWS and CSA
Voltage is the force that overcomes resistance to allow amperage flow
Higher 26 to 35 arc volts

15. What wire are knurled drive rolls most commonly used on?
Constant- speed wire feeders and Voltage- sennsing wire feeders
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
Guns
Flux cored wires

16. How are GMAW guns rated?
1/4 inch to 1/2 inch
Pressure - The rate of flow of a shielding gas
Pressure vessels and the piping industry
By there current carrying capacity

17. A pull type drive system is usually used on what type of material?
By there current carrying capacity
The resistace to electrical current flow increases with it. Causing the electrode to heat
Duty cycle
Aluminum wire

18. 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
Welding process that joins metals by heating them with an electric arc
Generally not as accurate
Cause flaking - which can clog the liner and contact tube

19. A machine with a 70% duty cycle can run at its max for 7 minutes with a cooling cycle of only _ minutes.
3
1/4 inch to 1/2 inch
The Arc voltage
Higher 26 to 35 arc volts

20. List the factors that determine the mode of metal transfer
Constant current (CC)
By there current carrying capacity
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld

21. What does the abbreviation NEMA stand for?
These terms are quite restrictive and often technically incorrect
When the filler wire is in direct contract with the base metal
National Electrical Manufactures Association
Wire feed speed - Voltage control

22. Give a description of 'pinch effect'
Constant current (CC)
Higher 26 to 35 arc volts
The time rate of response for the current rise and fall
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field

23. What current and polarity is generally used with GMAW?
Gives arc voltage values to the control system of the feeder
DCEP (Direct Current Electrode Positive) Reverse Polarity
AWS and CSA
SMAW - GTAW

24. What does inductance control?
1/4 inch to 1/2 inch
Gives arc voltage values to the control system of the feeder
The time rate of response for the current rise and fall
15 feet (4.5 meters)

25. List 3 forms compressed gases may be supplied for welding
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
Penetration and burn - off rate of the electrode
To prevent drawing of liquid CO2 (Carbon Dioxide)
Welding process that joins metals by heating them with an electric arc

26. Is the arc voltage for spray transfer higher or lower than that used for short circuit transfer?
V groove or U groove
Higher 26 to 35 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
Gives arc voltage values to the control system of the feeder

27. What is the maximum distance that hard wire can be successfully pushed?
Flux cored wires
15 feet (4.5 meters)
Dry ice can form within the flow control openings and cause blockage of shielding gas
Minimum distortion due to low heat input

28. What type of power source is commonly used with a voltage sensing wire feeder?
Constant current (CC)
Guns
When the filler wire is in direct contract with the base metal
12 to 22 arc volts

29. List the three methods of metal transfer with GMAW
Short- circuiting transfer - Globular transfer - Spray transfer
Shielding the molten weld metal from atmospheric contamination
Cause flaking - which can clog the liner and contact tube
Gas metal arc welding

30. What 2 organizations designate specifications for GMAW wires?
If you dont know this check your phone
DCEP (Direct Current Electrode Positive) Reverse Polarity
Short- circuiting transfer - Globular transfer - Spray transfer
AWS and CSA

31. How many times per second does short circuiting take place?
SMAW - GTAW
20 to 200 times per second
Guns
V groove or U groove

32. What is the reason glass 'tube' type flowmeters must have the tube mounted truly vertical?
...
If you dont know this check your phone
V groove or U groove
Guns

33. A 10 minute cycle of welding time vs cooling time a given machine can handle.
Duty cycle
To prevent leakage - Carbon Dioxide (CO2)
Controls the rate of flow of a shielding gas to the gun nozzle
National Electrical Manufactures Association

34. What power sources are used with the GMAW Process?
5.8 to 12.5 L/min
Voltage is the force that overcomes resistance to allow amperage flow
Motor driven generators - Transformer rectifiers - and Inverter designs
Wire feeds smoothly (yet will slip should a problem occur in the gun)

35. In the GMAW process what does voltage control?
Dry ice can form within the flow control openings and cause blockage of shielding gas
15 feet (4.5 meters)
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
Puddle fluidity

36. What are the 2 types of wire feeders available?
Constant- speed wire feeders and Voltage- sennsing wire feeders
Aluminum wire
SMAW - GTAW
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts

37. Why is a line heater required when using GMAW?
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
Dry ice can form within the flow control openings and cause blockage of shielding gas
The negative side of a welding unit
Wire feed speed - Voltage control

38. In the GMAW process what does amperage control?
Dry ice can form within the flow control openings and cause blockage of shielding gas
Penetration and burn - off rate of the electrode
...
Insufficient current to melt the wire off cleanly

39. What controls the wire speed on a voltage sensing wire feeder?
The Arc voltage
Generally not as accurate
Flux cored wires
Voltage is the force that overcomes resistance to allow amperage flow

40. Draw a typical volt amp curve for a machine that is designed for GMAW
Constant voltage (CV)
Controls the rate of flow of a shielding gas to the gun nozzle
If you dont know this check your phone
85%

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

42. Why is globular transfer generally avoided with GMAW?
Generally not as accurate
Spatter problems and poor weld appearance
Pressure - The rate of flow of a shielding gas
These terms are quite restrictive and often technically incorrect

43. Why is the term GMAW preferred over MIG or MAG?
Generally not as accurate
DCEP (Direct Current Electrode Positive) Reverse Polarity
These terms are quite restrictive and often technically incorrect
Shielding the molten weld metal from atmospheric contamination

44. What processes are constant current (CC) power sources designed to be used with?
Welding process that joins metals by heating them with an electric arc
Speed of the feed motor and - starting / stopping electrode feed
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
SMAW - GTAW

45. What is an advantage of pulsed arc transfer with GMAW?
3
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
Generally not as accurate

46. What is another term for electrode holders for GMAW?
V groove or U groove
Insufficient current to melt the wire off cleanly
Guns
To prevent leakage - Carbon Dioxide (CO2)

47. What happens when the electrode extension is increased?
Puddle fluidity
Controls the rate of flow of a shielding gas to the gun nozzle
Minimum distortion due to low heat input
The resistace to electrical current flow increases with it. Causing the electrode to heat

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
Controls the rate of flow of a shielding gas to the gun nozzle
Wire feed speed
Generally not as accurate

49. List the basic equipment requirements for the GMAW process
Duty cycle
SMAW - GTAW
The negative side of a welding unit
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground

50. List several industries that would use GMAW
Dry ice can form within the flow control openings and cause blockage of shielding gas
Pressure vessels and the piping industry
V groove or U groove
By there current carrying capacity

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Gas Metal Arc Welding

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