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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. Why is globular transfer generally avoided with GMAW?
Duty cycle
Spatter problems and poor weld appearance
When the filler wire is in direct contract with the base metal
Constant voltage (CV)

2. What is the purpose of a regulator and what does it indicate on its gauges?
Reducing the gas source pressure to a constant working pressure
1/4 inch to 1/2 inch
Constant current (CC)
Guns

3. A 10 minute cycle of welding time vs cooling time a given machine can handle.
Spatter problems and poor weld appearance
12 to 22 arc volts
To prevent leakage - Carbon Dioxide (CO2)
Duty cycle

4. What are the 2 types of wire feeders available?
Constant voltage (CV)
Penetration and burn - off rate of the electrode
Duty cycle
Constant- speed wire feeders and Voltage- sennsing wire feeders

5. What is the required arc voltage used for short circuit transfer?
Pressure - The rate of flow of a shielding gas
12 to 22 arc volts
To limit the short circuiting current so that spatter is reduced
DCEP (Direct Current Electrode Positive) Reverse Polarity

6. With straight polarity where is 2/3 of the arc energy?
The resistace to electrical current flow increases with it. Causing the electrode to heat
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
The negative side of a welding unit
To prevent leakage - Carbon Dioxide (CO2)

7. What effect does increasing and decreasing the inductance have on the weld?
Puddle fluidity
85%
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts
SMAW - GTAW

8. Why is a line heater required when using GMAW?
Flux cored wires
Dry ice can form within the flow control openings and cause blockage of shielding gas
Short- circuiting transfer - Globular transfer - Spray transfer
...

9. What is the reason glass 'tube' type flowmeters must have the tube mounted truly vertical?
...
The negative side of a welding unit
Aluminum wire
Constant- speed wire feeders and Voltage- sennsing wire feeders

10. Regulators control_____________ flowmeters SHOW____________.
Pressure - The rate of flow of a shielding gas
The negative side of a welding unit
If you dont know this check your phone
By there current carrying capacity

11. When is the metal transferred with short circuit transfer?
AWS and CSA
Higher 26 to 35 arc volts
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
When the filler wire is in direct contract with the base metal

12. What is another term for electrode holders for GMAW?
Minimum distortion due to low heat input
5.8 to 12.5 L/min
Guns
20 to 200 times per second

13. What is the recommended electrode stick- out for .035 solid wire?
To prevent drawing of liquid CO2 (Carbon Dioxide)
Pressure - The rate of flow of a shielding gas
DCEP (Direct Current Electrode Positive) Reverse Polarity
1/4 inch to 1/2 inch

14. What term is used to describe when the workpiece is hooked to the negative pole on the power source?
Pressure - The rate of flow of a shielding gas
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
Voltage is the force that overcomes resistance to allow amperage flow
(DCEP) Direct Current Electrode Positive or Reverse polarity

15. What is the main purpose of 'slope'?
Spatter problems and poor weld appearance
To limit the short circuiting current so that spatter is reduced
Minimum distortion due to low heat input
The negative side of a welding unit

16. List several industries that would use GMAW
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
Voltage is the force that overcomes resistance to allow amperage flow
Aluminum wire
Pressure vessels and the piping industry

17. What type of power source is used with a constant speed wire feeder?
15 feet (4.5 meters)
Constant voltage (CV)
Spatter problems and poor weld appearance
The negative side of a welding unit

18. What is the disadvantage of the gauge preset type of regulator/flowmeter?
The Arc voltage
Duty cycle
5.8 to 12.5 L/min
Generally not as accurate

19. What does inductance control?
Wire feeds smoothly (yet will slip should a problem occur in the gun)
The time rate of response for the current rise and fall
Insufficient current to melt the wire off cleanly
Dry ice can form within the flow control openings and cause blockage of shielding gas

20. Give a brief description of the GMAW process
To prevent leakage - Carbon Dioxide (CO2)
Guns
Welding process that joins metals by heating them with an electric arc
Wire feed speed

21. A pull type drive system is usually used on what type of material?
AWS and CSA
Aluminum wire
The resistace to electrical current flow increases with it. Causing the electrode to heat
Duty cycle

22. What is the maximum distance that hard wire can be successfully pushed?
Generally not as accurate
5.8 to 12.5 L/min
15 feet (4.5 meters)
Wire feed speed

23. What power sources are used with the GMAW Process?
V groove or U groove
Motor driven generators - Transformer rectifiers - and Inverter designs
1/4 inch to 1/2 inch
85%

24. What output on the welding machine is used to rate the duty cycle?
Minutes of elapsed time continually run (out of 10 minutes)
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts
DCEP (Direct Current Electrode Positive) Reverse Polarity
Generally not as accurate

25. What does voltage do in an electrical circuit?
Voltage is the force that overcomes resistance to allow amperage flow
These terms are quite restrictive and often technically incorrect
Motor driven generators - Transformer rectifiers - and Inverter designs
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system

26. What is the effect of too much slope?
Insufficient current to melt the wire off cleanly
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
Welding process that joins metals by heating them with an electric arc
Controls the rate of flow of a shielding gas to the gun nozzle

27. What does a flowmeter do and what does it measure?
Controls the rate of flow of a shielding gas to the gun nozzle
Wire feeds smoothly (yet will slip should a problem occur in the gun)
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

28. List 3 forms compressed gases may be supplied for welding
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
Wire feeds smoothly (yet will slip should a problem occur in the gun)
AWS and CSA
Duty cycle

29. Give a description of 'pinch effect'
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
AWS and CSA
The Arc voltage
5.8 to 12.5 L/min

30. What is the minimum % value of argon that must be present to use the spray transfer method of GMAW?
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
Cause flaking - which can clog the liner and contact tube
85%

31. What does the abbreviation NEMA stand for?
Guns
By there current carrying capacity
National Electrical Manufactures Association
If you dont know this check your phone

32. What 2 controls are found on a GMAW set- up?
Welding process that joins metals by heating them with an electric arc
Wire feed speed - Voltage control
Constant current (CC)
Voltage is the force that overcomes resistance to allow amperage flow

33. How are GMAW guns rated?
20 to 200 times per second
Constant current (CC)
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
By there current carrying capacity

34. How many times per second does short circuiting take place?
12 to 22 arc volts
20 to 200 times per second
Wire feed speed
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system

35. Draw a typical volt amp curve for a machine that is designed for GMAW
The negative side of a welding unit
If you dont know this check your phone
To limit the short circuiting current so that spatter is reduced
Controls the rate of flow of a shielding gas to the gun nozzle

36. What is the purpose of the pick- up lead on a voltage sensing wire feeder?
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
Insufficient current to melt the wire off cleanly
When the filler wire is in direct contract with the base metal
Gives arc voltage values to the control system of the feeder

37. Why is a fiber washer required and what cylinder gas requires it?
Welding process that joins metals by heating them with an electric arc
To prevent leakage - Carbon Dioxide (CO2)
12 to 22 arc volts
Penetration and burn - off rate of the electrode

38. Why is the term GMAW preferred over MIG or MAG?
These terms are quite restrictive and often technically incorrect
The negative side of a welding unit
Constant- speed wire feeders and Voltage- sennsing wire feeders
Dry ice can form within the flow control openings and cause blockage of shielding gas

39. What is the preferred drive roll design for solid wires?
Voltage is the force that overcomes resistance to allow amperage flow
Duty cycle
V groove or U groove
If you dont know this check your phone

40. What wire are knurled drive rolls most commonly used on?
Constant current (CC)
Spatter problems and poor weld appearance
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
Flux cored wires

41. In the GMAW process what does amperage control?
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
85%
Penetration and burn - off rate of the electrode
Insufficient current to melt the wire off cleanly

42. What would be an indication that the drive roll pressure is adjusted correctly?
Duty cycle
Reducing the gas source pressure to a constant working pressure
Wire feeds smoothly (yet will slip should a problem occur in the gun)
5.8 to 12.5 L/min

43. What controls the wire speed on a voltage sensing wire feeder?
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
The Arc voltage
AWS and CSA
The resistace to electrical current flow increases with it. Causing the electrode to heat

44. What does the wire feeder control?
Insufficient current to melt the wire off cleanly
Speed of the feed motor and - starting / stopping electrode feed
Gives arc voltage values to the control system of the feeder
National Electrical Manufactures Association

45. Why must CO2 cylinders be used in the vertical position?
Minimum distortion due to low heat input
Gives arc voltage values to the control system of the feeder
These terms are quite restrictive and often technically incorrect
To prevent drawing of liquid CO2 (Carbon Dioxide)

46. What current and polarity is generally used with GMAW?
When the filler wire is in direct contract with the base metal
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
DCEP (Direct Current Electrode Positive) Reverse Polarity

47. Draw a typical volt/amp curve that would be found with a power source designed for SMAW or GTAW
Higher 26 to 35 arc volts
To prevent leakage - Carbon Dioxide (CO2)
Speed of the feed motor and - starting / stopping electrode feed
If you dont know this check your phone

48. What controls amperage when using GMAW?
Wire feed speed
DCEP (Direct Current Electrode Positive) Reverse Polarity
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
These terms are quite restrictive and often technically incorrect

49. What is an advantage of pulsed arc transfer with GMAW?
Short- circuiting transfer - Globular transfer - Spray transfer
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
...
Puddle fluidity

50. What is the purpose of the shielding gas used in GMAW?
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
Shielding the molten weld metal from atmospheric contamination
Wire feed speed - Voltage control
By there current carrying capacity

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Gas Metal Arc Welding

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