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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. List the factors that determine the mode of metal transfer
The Arc voltage
Cause flaking - which can clog the liner and contact tube
When the filler wire is in direct contract with the base metal
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld

2. What is the maximum distance that hard wire can be successfully pushed?
12 to 22 arc volts
Shielding the molten weld metal from atmospheric contamination
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
15 feet (4.5 meters)

3. What output on the welding machine is used to rate the duty cycle?
Gives arc voltage values to the control system of the feeder
Minutes of elapsed time continually run (out of 10 minutes)
When the filler wire is in direct contract with the base metal
Pressure - The rate of flow of a shielding gas

4. Give a description of 'pinch effect'
5.8 to 12.5 L/min
The negative side of a welding unit
Constant voltage (CV)
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field

5. What term is used to describe when the workpiece is hooked to the negative pole on the power source?
(DCEP) Direct Current Electrode Positive or Reverse polarity
...
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
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

6. What does the wire feeder control?
Aluminum wire
85%
To prevent drawing of liquid CO2 (Carbon Dioxide)
Speed of the feed motor and - starting / stopping electrode feed

7. What controls amperage when using GMAW?
...
Pressure vessels and the piping industry
Wire feed speed
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground

8. What does a flowmeter do and what does it measure?
Voltage is the force that overcomes resistance to allow amperage flow
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts
Pressure vessels and the piping industry
Controls the rate of flow of a shielding gas to the gun nozzle

9. What is the purpose of the pick- up lead on a voltage sensing wire feeder?
Wire feeds smoothly (yet will slip should a problem occur in the gun)
Gives arc voltage values to the control system of the feeder
AWS and CSA
If you dont know this check your phone

10. A 10 minute cycle of welding time vs cooling time a given machine can handle.
DCEP (Direct Current Electrode Positive) Reverse Polarity
Duty cycle
When the filler wire is in direct contract with the base metal
The time rate of response for the current rise and fall

11. Why is globular transfer generally avoided with GMAW?
By there current carrying capacity
Spatter problems and poor weld appearance
Reducing the gas source pressure to a constant working pressure
Welding process that joins metals by heating them with an electric arc

12. How are GMAW guns rated?
By there current carrying capacity
Wire feeds smoothly (yet will slip should a problem occur in the gun)
Gas metal arc welding
Generally not as accurate

13. What is the required arc voltage used for short circuit transfer?
12 to 22 arc volts
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
...
To prevent drawing of liquid CO2 (Carbon Dioxide)

14. What does the term GMAW identify?
DCEP (Direct Current Electrode Positive) Reverse Polarity
20 to 200 times per second
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
Gas metal arc welding

15. What 2 controls are found on a GMAW set- up?
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
Motor driven generators - Transformer rectifiers - and Inverter designs
If you dont know this check your phone
Wire feed speed - Voltage control

16. Draw a typical volt/amp curve that would be found with a power source designed for SMAW or GTAW
AWS and CSA
If you dont know this check your phone
Minutes of elapsed time continually run (out of 10 minutes)
Pressure - The rate of flow of a shielding gas

17. What is the reason glass 'tube' type flowmeters must have the tube mounted truly vertical?
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
...
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
SMAW - GTAW

18. What wire are knurled drive rolls most commonly used on?
Welding process that joins metals by heating them with an electric arc
SMAW - GTAW
Dry ice can form within the flow control openings and cause blockage of shielding gas
Flux cored wires

19. What effect does increasing and decreasing the inductance have on the weld?
Generally not as accurate
The time rate of response for the current rise and fall
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

20. What does the abbreviation NEMA stand for?
Pressure - The rate of flow of a shielding gas
Short- circuiting transfer - Globular transfer - Spray transfer
Constant current (CC)
National Electrical Manufactures Association

21. What controls the wire speed on a voltage sensing wire feeder?
The Arc voltage
Guns
Generally not as accurate
By there current carrying capacity

22. List several industries that would use GMAW
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
Pressure vessels and the piping industry
Gives arc voltage values to the control system of the feeder
The resistace to electrical current flow increases with it. Causing the electrode to heat

23. What is the purpose of the shielding gas used in GMAW?
...
Shielding the molten weld metal from atmospheric contamination
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

24. List the basic equipment requirements for the GMAW process
Duty cycle
85%
Spatter problems and poor weld appearance
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground

25. What would be an indication that the drive roll pressure is adjusted correctly?
Insufficient current to melt the wire off cleanly
Wire feeds smoothly (yet will slip should a problem occur in the gun)
To limit the short circuiting current so that spatter is reduced
Welding process that joins metals by heating them with an electric arc

26. What is a typical flow rate of CO2 for short circuit transfer?
5.8 to 12.5 L/min
15 feet (4.5 meters)
Minimum distortion due to low heat input
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze

27. Why is a line heater required when using GMAW?
Dry ice can form within the flow control openings and cause blockage of shielding gas
Aluminum wire
These terms are quite restrictive and often technically incorrect
3

28. Draw a typical volt amp curve for a machine that is designed for GMAW
Penetration and burn - off rate of the electrode
If you dont know this check your phone
Gas metal arc welding
Gives arc voltage values to the control system of the feeder

29. A machine with a 70% duty cycle can run at its max for 7 minutes with a cooling cycle of only _ minutes.
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
Short- circuiting transfer - Globular transfer - Spray transfer
By there current carrying capacity
3

30. What happens when the electrode extension is increased?
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
To prevent drawing of liquid CO2 (Carbon Dioxide)
The resistace to electrical current flow increases with it. Causing the electrode to heat
Insufficient current to melt the wire off cleanly

31. Is the arc voltage for spray transfer higher or lower than that used for 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
DCEP (Direct Current Electrode Positive) Reverse Polarity
Higher 26 to 35 arc volts
Welding process that joins metals by heating them with an electric arc

32. When using flat drive rolls with too much pressure on copper coated solid wires what problem could take place?
These terms are quite restrictive and often technically incorrect
Cause flaking - which can clog the liner and contact tube
Welding process that joins metals by heating them with an electric arc
If you dont know this check your phone

33. What current and polarity is generally used with GMAW?
Penetration and burn - off rate of the electrode
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
Pressure - The rate of flow of a shielding gas

34. What is the disadvantage of the gauge preset type of regulator/flowmeter?
Constant current (CC)
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
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts

35. Why must CO2 cylinders be used in the vertical position?
Flux cored wires
Gives arc voltage values to the control system of the feeder
Wire feed speed - Voltage control
To prevent drawing of liquid CO2 (Carbon Dioxide)

36. 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
Pressure - The rate of flow of a shielding gas
Dry ice can form within the flow control openings and cause blockage of shielding gas
Constant current (CC)

37. What are the 2 types of wire feeders available?
Gas metal arc welding
DCEP (Direct Current Electrode Positive) Reverse Polarity
Minutes of elapsed time continually run (out of 10 minutes)
Constant- speed wire feeders and Voltage- sennsing wire feeders

38. A pull type drive system is usually used on what type of material?
(DCEP) Direct Current Electrode Positive or Reverse polarity
Wire feed speed - Voltage control
Aluminum wire
20 to 200 times per second

39. What is the recommended electrode stick- out for .035 solid wire?
Duty cycle
1/4 inch to 1/2 inch
85%
Minimum distortion due to low heat input

40. When is the metal transferred with short circuit transfer?
Puddle fluidity
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
When the filler wire is in direct contract with the base metal
Aluminum wire

41. List the three methods of metal transfer with GMAW
Wire feeds smoothly (yet will slip should a problem occur in the gun)
Short- circuiting transfer - Globular transfer - Spray transfer
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
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun

42. 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
SMAW - GTAW
Minutes of elapsed time continually run (out of 10 minutes)
If you dont know this check your phone

43. What type of power source is used with a constant speed wire feeder?
Minimum distortion due to low heat input
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
Flux cored wires
Constant voltage (CV)

44. What is the preferred drive roll design for solid wires?
Spatter problems and poor weld appearance
The negative side of a welding unit
V groove or U groove
To prevent leakage - Carbon Dioxide (CO2)

45. What is the main purpose of 'slope'?
Flux cored wires
Minutes of elapsed time continually run (out of 10 minutes)
If you dont know this check your phone
To limit the short circuiting current so that spatter is reduced

46. How many times per second does short circuiting take place?
20 to 200 times per second
12 to 22 arc volts
To limit the short circuiting current so that spatter is reduced
Constant voltage (CV)

47. In the GMAW process what does amperage control?
1/4 inch to 1/2 inch
Short- circuiting transfer - Globular transfer - Spray transfer
By there current carrying capacity
Penetration and burn - off rate of the electrode

48. List 3 forms compressed gases may be supplied for welding
Wire feed speed
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
5.8 to 12.5 L/min
Reducing the gas source pressure to a constant working pressure

49. List 3 wire drive systems and give a short description of each
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
Shielding the molten weld metal from atmospheric contamination
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

50. Give a brief description of the GMAW process
V groove or U groove
Wire feeds smoothly (yet will slip should a problem occur in the gun)
Welding process that joins metals by heating them with an electric arc
Cause flaking - which can clog the liner and contact tube

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Gas Metal Arc Welding

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