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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. In the GMAW process what does voltage control?
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
V groove or U groove
3
Puddle fluidity

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

3. Why is the term GMAW preferred over MIG or MAG?
Speed of the feed motor and - starting / stopping electrode feed
National Electrical Manufactures Association
If you dont know this check your phone
These terms are quite restrictive and often technically incorrect

4. What does inductance control?
Reducing the gas source pressure to a constant working pressure
SMAW - GTAW
Wire feed speed - Voltage control
The time rate of response for the current rise and fall

5. A pull type drive system is usually used on what type of material?
Aluminum wire
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
By there current carrying capacity
15 feet (4.5 meters)

6. 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
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
Pressure - The rate of flow of a shielding gas
Welding process that joins metals by heating them with an electric arc

7. What is the purpose of the shielding gas used in GMAW?
If you dont know this check your phone
Shielding the molten weld metal from atmospheric contamination
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
Pressure - The rate of flow of a shielding gas

8. What is the required arc voltage used for short circuit 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
Wire feed speed
12 to 22 arc volts
Short- circuiting transfer - Globular transfer - Spray transfer

9. What does the term GMAW identify?
Motor driven generators - Transformer rectifiers - and Inverter designs
Flux cored wires
Aluminum wire
Gas metal arc welding

10. What is a typical flow rate of CO2 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
By there current carrying capacity
Pressure - The rate of flow of a shielding gas
5.8 to 12.5 L/min

11. A machine with a 70% duty cycle can run at its max for 7 minutes with a cooling cycle of only _ minutes.
Constant current (CC)
3
Dry ice can form within the flow control openings and cause blockage of shielding gas
1/4 inch to 1/2 inch

12. What is the preferred drive roll design for solid wires?
V groove or U groove
Controls the rate of flow of a shielding gas to the gun nozzle
Wire feed speed
3

13. How many times per second does short circuiting take place?
20 to 200 times per second
When the filler wire is in direct contract with the base metal
If you dont know this check your phone
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

14. Draw a typical volt/amp curve that would be found with a power source designed for SMAW or GTAW
If you dont know this check your phone
These terms are quite restrictive and often technically incorrect
20 to 200 times per second
Gas metal arc welding

15. What controls amperage when using GMAW?
Wire feed speed
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts
Aluminum wire
3

16. Why is a fiber washer required and what cylinder gas requires it?
Higher 26 to 35 arc volts
To prevent leakage - Carbon Dioxide (CO2)
Pressure vessels and the piping industry
5.8 to 12.5 L/min

17. Why is globular transfer generally avoided with GMAW?
Speed of the feed motor and - starting / stopping electrode feed
Spatter problems and poor weld appearance
Shielding the molten weld metal from atmospheric contamination
If you dont know this check your phone

18. What is the minimum % value of argon that must be present to use the spray transfer method of GMAW?
Gas metal arc welding
85%
To limit the short circuiting current so that spatter is reduced
SMAW - GTAW

19. What type of power source is commonly used with a voltage sensing wire feeder?
Reducing the gas source pressure to a constant working pressure
Guns
Gas metal arc welding
Constant current (CC)

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
20 to 200 times per second
Short- circuiting transfer - Globular transfer - Spray transfer
If you dont know this check your phone

21. What is the key advantage of short circuiting transfer?
Minimum distortion due to low heat input
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts
Dry ice can form within the flow control openings and cause blockage of shielding gas
Gas metal arc welding

22. List 3 forms compressed gases may be supplied for welding
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
(DCEP) Direct Current Electrode Positive or Reverse polarity
Wire feeds smoothly (yet will slip should a problem occur in the gun)
To limit the short circuiting current so that spatter is reduced

23. What is the main purpose of 'slope'?
AWS and CSA
To limit the short circuiting current so that spatter is reduced
National Electrical Manufactures Association
Short- circuiting transfer - Globular transfer - Spray transfer

24. List the basic equipment requirements for the GMAW process
Pressure - The rate of flow of a shielding gas
Penetration and burn - off rate of the electrode
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
To limit the short circuiting current so that spatter is reduced

25. Draw a typical volt amp curve for a machine that is designed for GMAW
If you dont know this check your phone
To prevent drawing of liquid CO2 (Carbon Dioxide)
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

26. What 2 organizations designate specifications for GMAW wires?
Aluminum wire
Speed of the feed motor and - starting / stopping electrode feed
AWS and CSA
Pressure - The rate of flow of a shielding gas

27. When using flat drive rolls with too much pressure on copper coated solid wires what problem could take place?
Voltage is the force that overcomes resistance to allow amperage flow
Reducing the gas source pressure to a constant working pressure
Cause flaking - which can clog the liner and contact tube
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld

28. What is a solenoid valve and what actuates it?
Controls the rate of flow of a shielding gas to the gun nozzle
Short- circuiting transfer - Globular transfer - Spray transfer
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
Minutes of elapsed time continually run (out of 10 minutes)

29. What does voltage do in an electrical circuit?
Wire feeds smoothly (yet will slip should a problem occur in the gun)
Voltage is the force that overcomes resistance to allow amperage flow
If you dont know this check your phone
Speed of the feed motor and - starting / stopping electrode feed

30. What is the maximum distance that hard wire can be successfully pushed?
Constant- speed wire feeders and Voltage- sennsing wire feeders
15 feet (4.5 meters)
12 to 22 arc volts
Shielding the molten weld metal from atmospheric contamination

31. What 2 controls are found on a GMAW set- up?
Wire feed speed - Voltage control
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze

32. Regulators control_____________ flowmeters SHOW____________.
Higher 26 to 35 arc volts
Gas metal arc welding
...
Pressure - The rate of flow of a shielding gas

33. When is the metal transferred with short circuit transfer?
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
By there current carrying capacity
Flux cored wires

34. What are the 2 types of wire feeders available?
Constant- speed wire feeders and Voltage- sennsing wire feeders
Wire feeds smoothly (yet will slip should a problem occur in the gun)
SMAW - GTAW
The time rate of response for the current rise and fall

35. What does the wire feeder control?
If you dont know this check your phone
When the filler wire is in direct contract with the base metal
Speed of the feed motor and - starting / stopping electrode feed
SMAW - GTAW

36. Why is a line heater required when using GMAW?
Dry ice can form within the flow control openings and cause blockage of shielding gas
Cause flaking - which can clog the liner and contact tube
1/4 inch to 1/2 inch
Pressure vessels and the piping industry

37. What happens when the electrode extension is increased?
The resistace to electrical current flow increases with it. Causing the electrode to heat
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
The time rate of response for the current rise and fall
Wire feed speed

38. List the three methods of metal transfer with GMAW
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
Short- circuiting transfer - Globular transfer - Spray transfer
Constant voltage (CV)
Insufficient current to melt the wire off cleanly

39. What is the disadvantage of the gauge preset type of regulator/flowmeter?
The time rate of response for the current rise and fall
Generally not as accurate
Gas metal arc welding
Motor driven generators - Transformer rectifiers - and Inverter designs

40. What does a flowmeter do and what does it measure?
Controls the rate of flow of a shielding gas to the gun nozzle
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
Pressure vessels and the piping industry

41. What is the purpose of the pick- up lead on a voltage sensing wire feeder?
Constant current (CC)
85%
V groove or U groove
Gives arc voltage values to the control system of the feeder

42. What term is used to describe when the workpiece is hooked to the negative pole on the power source?
Puddle fluidity
Constant- speed wire feeders and Voltage- sennsing wire feeders
Aluminum wire
(DCEP) Direct Current Electrode Positive or Reverse polarity

43. What output on the welding machine is used to rate the duty cycle?
Shielding the molten weld metal from atmospheric contamination
The time rate of response for the current rise and fall
The negative side of a welding unit
Minutes of elapsed time continually run (out of 10 minutes)

44. Is the arc voltage for spray transfer higher or lower than that used for short circuit transfer?
The resistace to electrical current flow increases with it. Causing the electrode to heat
To prevent leakage - Carbon Dioxide (CO2)
Speed of the feed motor and - starting / stopping electrode feed
Higher 26 to 35 arc volts

45. 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
85%
(DCEP) Direct Current Electrode Positive or Reverse polarity
Minimum distortion due to low heat input

46. A 10 minute cycle of welding time vs cooling time a given machine can handle.
Motor driven generators - Transformer rectifiers - and Inverter designs
Duty cycle
The time rate of response for the current rise and fall
3

47. What controls the wire speed on a voltage sensing wire feeder?
The Arc voltage
Short- circuiting transfer - Globular transfer - Spray transfer
If you dont know this check your phone
Puddle fluidity

48. What does the abbreviation NEMA stand for?
Constant current (CC)
Shielding the molten weld metal from atmospheric contamination
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

49. In the GMAW process what does amperage control?
Gas metal arc welding
3
Minutes of elapsed time continually run (out of 10 minutes)
Penetration and burn - off rate of the electrode

50. What wire are knurled drive rolls most commonly used on?
DCEP (Direct Current Electrode Positive) Reverse Polarity
Penetration and burn - off rate of the electrode
12 to 22 arc volts
Flux cored wires

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