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Gas Metal Arc Welding

Instructions:

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 controls the wire speed on a voltage sensing wire feeder?
The Arc voltage
The resistace to electrical current flow increases with it. Causing the electrode to heat
3
Reducing the gas source pressure to a constant working pressure

2. Why is the term GMAW preferred over MIG or MAG?
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The Arc voltage
These terms are quite restrictive and often technically incorrect
Puddle fluidity

3. Give a brief description of the GMAW process
V groove or U groove
Welding process that joins metals by heating them with an electric arc
Flux cored wires
Shielding the molten weld metal from atmospheric contamination

4. List the basic equipment requirements for the GMAW process
To prevent leakage - Carbon Dioxide (CO2)
By there current carrying capacity
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
85%

5. What does inductance control?
Constant voltage (CV)
Pressure vessels and the piping industry
The time rate of response for the current rise and fall
Minimum distortion due to low heat input

6. What is the preferred drive roll design for solid wires?
Voltage is the force that overcomes resistance to allow amperage flow
V groove or U groove
(DCEP) Direct Current Electrode Positive or Reverse polarity
Wire feed speed

7. 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
Dry ice can form within the flow control openings and cause blockage of 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

8. Draw a typical volt/amp curve that would be found with a power source designed for SMAW or GTAW
Aluminum wire
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Wire feed speed
Insufficient current to melt the wire off cleanly

9. What is the main purpose of 'slope'?
1/4 inch to 1/2 inch
To limit the short circuiting current so that spatter is reduced
Guns
Insufficient current to melt the wire off cleanly

10. Is the arc voltage for spray transfer higher or lower than that used for short circuit transfer?
Higher 26 to 35 arc volts
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Motor driven generators - Transformer rectifiers - and Inverter designs
Wire feeds smoothly (yet will slip should a problem occur in the gun)

11. 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
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Short- circuiting transfer - Globular transfer - Spray transfer
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground

12. What is the maximum distance that hard wire can be successfully pushed?
...
20 to 200 times per second
Puddle fluidity
15 feet (4.5 meters)

13. What is the purpose of the shielding gas used in GMAW?
Shielding the molten weld metal from atmospheric contamination
Constant voltage (CV)
(DCEP) Direct Current Electrode Positive or Reverse polarity
AWS and CSA

14. What is the required arc voltage used for short circuit transfer?
12 to 22 arc volts
When the filler wire is in direct contract with the base metal
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
V groove or U groove

15. What happens when the electrode extension is increased?
The resistace to electrical current flow increases with it. Causing the electrode to heat
Gives arc voltage values to the control system of the feeder
DCEP (Direct Current Electrode Positive) Reverse Polarity
V groove or U groove

16. What is a typical flow rate of CO2 for short circuit transfer?
Duty cycle
5.8 to 12.5 L/min
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
12 to 22 arc volts

17. What 2 controls are found on a GMAW set- up?
Generally not as accurate
85%
To prevent drawing of liquid CO2 (Carbon Dioxide)
Wire feed speed - Voltage control

18. What does the wire feeder control?
Reducing the gas source pressure to a constant working pressure
1/4 inch to 1/2 inch
Speed of the feed motor and - starting / stopping electrode feed
Constant current (CC)

19. List 3 forms compressed gases may be supplied for welding
Insufficient current to melt the wire off cleanly
Wire feed speed - Voltage control
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze

20. How are GMAW guns rated?
Penetration and burn - off rate of the electrode
3
Spatter problems and poor weld appearance
By there current carrying capacity

21. What does a flowmeter do and what does it measure?
Guns
Controls the rate of flow of a shielding gas to the gun nozzle
Constant voltage (CV)
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field

22. What is the minimum % value of argon that must be present to use the spray transfer method of GMAW?
85%
Wire feed speed
National Electrical Manufactures Association
Speed of the feed motor and - starting / stopping electrode feed

23. How many times per second does short circuiting take place?
Aluminum wire
20 to 200 times per second
Minimum distortion due to low heat input
By there current carrying capacity

24. What wire are knurled drive rolls most commonly used on?
Flux cored wires
The resistace to electrical current flow increases with it. Causing the electrode to heat
Minimum distortion due to low heat input
15 feet (4.5 meters)

25. 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
The negative side of a welding unit
Penetration and burn - off rate of the electrode
SMAW - GTAW

26. Why is a line heater required when using GMAW?
The negative side of a welding unit
Dry ice can form within the flow control openings and cause blockage of shielding gas
(DCEP) Direct Current Electrode Positive or Reverse polarity
The resistace to electrical current flow increases with it. Causing the electrode to heat

27. List several industries that would use GMAW
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
To limit the short circuiting current so that spatter is reduced
Pressure vessels and the piping industry
Duty cycle

28. What is the purpose of the pick- up lead on a voltage sensing wire feeder?
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
Speed of the feed motor and - starting / stopping electrode feed
Gives arc voltage values to the control system of the feeder
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system

29. What type of power source is commonly used with a voltage sensing wire feeder?
Flux cored wires
V groove or U groove
Controls the rate of flow of a shielding gas to the gun nozzle
Constant current (CC)

30. In the GMAW process what does amperage control?
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
AWS and CSA
Penetration and burn - off rate of the electrode
Insufficient current to melt the wire off cleanly

31. What would be an indication that the drive roll pressure is adjusted correctly?
Dry ice can form within the flow control openings and cause blockage of shielding gas
Insufficient current to melt the wire off cleanly
Wire feeds smoothly (yet will slip should a problem occur in the gun)
Puddle fluidity

32. What 2 organizations designate specifications for GMAW wires?
AWS and CSA
Puddle fluidity
To prevent leakage - Carbon Dioxide (CO2)
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground

33. What output on the welding machine is used to rate the duty cycle?
Minutes of elapsed time continually run (out of 10 minutes)
(DCEP) Direct Current Electrode Positive or Reverse polarity
V groove or U groove
The time rate of response for the current rise and fall

34. In the GMAW process what does voltage control?
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
Generally not as accurate
1/4 inch to 1/2 inch
Puddle fluidity

35. What is a solenoid valve and what actuates it?
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Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
National Electrical Manufactures Association
Guns

36. When is the metal transferred with short circuit transfer?
To prevent leakage - Carbon Dioxide (CO2)
If you dont know this check your phone
When the filler wire is in direct contract with the base metal
Voltage is the force that overcomes resistance to allow amperage flow

37. What are the 2 types of wire feeders available?
Shielding the molten weld metal from atmospheric contamination
Constant- speed wire feeders and Voltage- sennsing wire feeders
Voltage is the force that overcomes resistance to allow amperage flow
Wire feeds smoothly (yet will slip should a problem occur in the gun)

38. A machine with a 70% duty cycle can run at its max for 7 minutes with a cooling cycle of only _ minutes.
3
When the filler wire is in direct contract with the base metal
85%
Penetration and burn - off rate of the electrode

39. Why is a fiber washer required and what cylinder gas requires it?
To prevent leakage - Carbon Dioxide (CO2)
SMAW - GTAW
DCEP (Direct Current Electrode Positive) Reverse Polarity
Shielding the molten weld metal from atmospheric contamination

40. Why must CO2 cylinders be used in the vertical position?
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
To prevent drawing of liquid CO2 (Carbon Dioxide)
Cause flaking - which can clog the liner and contact tube

41. What does the term GMAW identify?
Wire feed speed
Wire feeds smoothly (yet will slip should a problem occur in the gun)
Gas metal arc welding
Guns

42. What controls amperage when using GMAW?
1/4 inch to 1/2 inch
V groove or U groove
Wire feed speed
Pressure vessels and the piping industry

43. List 3 wire drive systems and give a short description of each
Controls the rate of flow of a shielding gas to the gun nozzle
Spatter problems and poor weld appearance
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
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

44. What does the abbreviation NEMA stand for?
Cause flaking - which can clog the liner and contact tube
Controls the rate of flow of a shielding gas to the gun nozzle
National Electrical Manufactures Association
The resistace to electrical current flow increases with it. Causing the electrode to heat

45. List the factors that determine the mode of metal transfer
Dry ice can form within the flow control openings and cause blockage of shielding gas
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
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld

46. Regulators control_____________ flowmeters SHOW____________.
20 to 200 times per second
Pressure - The rate of flow of a shielding gas
Wire feeds smoothly (yet will slip should a problem occur in the gun)
(DCEP) Direct Current Electrode Positive or Reverse polarity

47. List the three methods of metal transfer with GMAW
Voltage is the force that overcomes resistance to allow amperage flow
Short- circuiting transfer - Globular transfer - Spray transfer
Pressure vessels and the piping industry
Gives arc voltage values to the control system of the feeder

48. With straight polarity where is 2/3 of the arc energy?
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
1/4 inch to 1/2 inch
Reducing the gas source pressure to a constant working pressure

49. A pull type drive system is usually used on what type of material?
Aluminum wire
Duty cycle
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
These terms are quite restrictive and often technically incorrect

50. What does voltage do in an electrical circuit?
Voltage is the force that overcomes resistance to allow amperage flow
To prevent leakage - Carbon Dioxide (CO2)
3
The time rate of response for the current rise and fall

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