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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. What is the required arc voltage used for short circuit transfer?
12 to 22 arc volts
Dry ice can form within the flow control openings and cause blockage of shielding gas
20 to 200 times per second
SMAW - GTAW

2. What is the purpose of the pick- up lead on a voltage sensing wire feeder?
If you dont know this check your phone
Controls the rate of flow of a shielding gas to the gun nozzle
Gives arc voltage values to the control system of the feeder
Welding process that joins metals by heating them with an electric arc

3. What 2 controls are found on a GMAW set- up?
Pressure vessels and the piping industry
Wire feed speed - Voltage control
Higher 26 to 35 arc volts
Aluminum wire

4. What is the maximum distance that hard wire can be successfully pushed?
15 feet (4.5 meters)
Cause flaking - which can clog the liner and contact tube
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
Spatter problems and poor weld appearance

5. A machine with a 70% duty cycle can run at its max for 7 minutes with a cooling cycle of only _ minutes.
Cause flaking - which can clog the liner and contact tube
Constant current (CC)
Pressure - The rate of flow of a shielding gas
3

6. Give a brief description of the GMAW process
Guns
SMAW - GTAW
Welding process that joins metals by heating them with an electric arc
(DCEP) Direct Current Electrode Positive or Reverse polarity

7. List 3 wire drive systems and give a short description of each
Reducing the gas source pressure to a constant working pressure
Gives arc voltage values to the control system of the feeder
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
Speed of the feed motor and - starting / stopping electrode feed

8. What is the main purpose of 'slope'?
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
To limit the short circuiting current so that spatter is reduced
Wire feeds smoothly (yet will slip should a problem occur in the gun)

9. What does the abbreviation NEMA stand for?
Wire feed speed - Voltage control
National Electrical Manufactures Association
5.8 to 12.5 L/min
12 to 22 arc volts

10. How many times per second does short circuiting take place?
When the filler wire is in direct contract with the base metal
Shielding the molten weld metal from atmospheric contamination
20 to 200 times per second
The resistace to electrical current flow increases with it. Causing the electrode to heat

11. What happens when the electrode extension is increased?
(DCEP) Direct Current Electrode Positive or Reverse polarity
The resistace to electrical current flow increases with it. Causing the electrode to heat
To prevent drawing of liquid CO2 (Carbon Dioxide)
12 to 22 arc volts

12. With straight polarity where is 2/3 of the arc energy?
The negative side of a welding unit
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)
Generally not as accurate

13. When using flat drive rolls with too much pressure on copper coated solid wires what problem could take place?
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
Cause flaking - which can clog the liner and contact tube
Controls the rate of flow of a shielding gas to the gun nozzle
Gas metal arc welding

14. Is the arc voltage for spray transfer higher or lower than that used for short circuit transfer?
To prevent leakage - Carbon Dioxide (CO2)
Insufficient current to melt the wire off cleanly
Higher 26 to 35 arc volts
Wire feeds smoothly (yet will slip should a problem occur in the gun)

15. What effect does increasing and decreasing the inductance have on the weld?
1/4 inch to 1/2 inch
Cause flaking - which can clog the liner and contact tube
Puddle fluidity
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts

16. What is the purpose of a regulator and what does it indicate on its gauges?
Voltage is the force that overcomes resistance to allow amperage flow
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
Guns
Reducing the gas source pressure to a constant working pressure

17. What does voltage do in an electrical circuit?
Constant current (CC)
Voltage is the force that overcomes resistance to allow amperage flow
If you dont know this check your phone
The negative side of a welding unit

18. Why is the term GMAW preferred over MIG or MAG?
These terms are quite restrictive and often technically incorrect
If you dont know this check your phone
The negative side of a welding unit
SMAW - GTAW

19. Draw a typical volt/amp curve that would be found with a power source designed for SMAW or GTAW
Minimum distortion due to low heat input
1/4 inch to 1/2 inch
If you dont know this check your phone
Duty cycle

20. 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
5.8 to 12.5 L/min
Short- circuiting transfer - Globular transfer - Spray transfer
Pressure vessels and the piping industry

21. What is the key advantage of short circuiting transfer?
15 feet (4.5 meters)
Minimum distortion due to low heat input
To prevent drawing of liquid CO2 (Carbon Dioxide)
The Arc voltage

22. What does inductance control?
Speed of the feed motor and - starting / stopping electrode feed
The time rate of response for the current rise and fall
Reducing the gas source pressure to a constant working pressure
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system

23. Why is a line heater required when using GMAW?
Dry ice can form within the flow control openings and cause blockage of shielding gas
85%
Aluminum wire
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun

24. What is the reason glass 'tube' type flowmeters must have the tube mounted truly vertical?
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
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
...

25. Regulators control_____________ flowmeters SHOW____________.
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
Wire feed speed
Gives arc voltage values to the control system of the feeder
Pressure - The rate of flow of a shielding gas

26. What is the recommended electrode stick- out for .035 solid wire?
1/4 inch to 1/2 inch
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
Duty cycle

27. What is the minimum % value of argon that must be present to use the spray transfer method of GMAW?
To prevent leakage - Carbon Dioxide (CO2)
Constant current (CC)
By there current carrying capacity
85%

28. What type of power source is used with a constant speed wire feeder?
Constant voltage (CV)
SMAW - GTAW
To prevent leakage - Carbon Dioxide (CO2)
The time rate of response for the current rise and fall

29. List the three methods of metal transfer with GMAW
Shielding the molten weld metal from atmospheric contamination
If you dont know this check your phone
Short- circuiting transfer - Globular transfer - Spray transfer
The resistace to electrical current flow increases with it. Causing the electrode to heat

30. Why must CO2 cylinders be used in the vertical position?
Pressure vessels and the piping industry
Wire feeds smoothly (yet will slip should a problem occur in the gun)
AWS and CSA
To prevent drawing of liquid CO2 (Carbon Dioxide)

31. Give a description of 'pinch effect'
Pressure - The rate of flow of a shielding gas
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
Constant current (CC)
Gives arc voltage values to the control system of the feeder

32. What controls amperage when using GMAW?
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
Cause flaking - which can clog the liner and contact tube
20 to 200 times per second
Wire feed speed

33. In the GMAW process what does voltage control?
Wire feed speed - Voltage control
20 to 200 times per second
Puddle fluidity
By there current carrying capacity

34. What current and polarity is generally used with GMAW?
Flux cored wires
Controls the rate of flow of a shielding gas to the gun nozzle
15 feet (4.5 meters)
DCEP (Direct Current Electrode Positive) Reverse Polarity

35. In the GMAW process what does amperage control?
Penetration and burn - off rate of the electrode
The Arc voltage
Aluminum wire
Voltage is the force that overcomes resistance to allow amperage flow

36. Why is a fiber washer required and what cylinder gas requires it?
The Arc voltage
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
To prevent leakage - Carbon Dioxide (CO2)
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

37. What is the disadvantage of the gauge preset type of regulator/flowmeter?
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
Generally not as accurate
SMAW - GTAW
To prevent leakage - Carbon Dioxide (CO2)

38. What wire are knurled drive rolls most commonly used on?
Minutes of elapsed time continually run (out of 10 minutes)
(DCEP) Direct Current Electrode Positive or Reverse polarity
Constant- speed wire feeders and Voltage- sennsing wire feeders
Flux cored wires

39. What controls the wire speed on a voltage sensing wire feeder?
The Arc voltage
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
AWS and CSA

40. What would be an indication that the drive roll pressure is adjusted correctly?
5.8 to 12.5 L/min
Short- circuiting transfer - Globular transfer - Spray transfer
Pressure vessels and the piping industry
Wire feeds smoothly (yet will slip should a problem occur in the gun)

41. What does the term GMAW identify?
Gas metal arc welding
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts
Wire feeds smoothly (yet will slip should a problem occur in the gun)
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground

42. What is a typical flow rate of CO2 for short circuit transfer?
5.8 to 12.5 L/min
Controls the rate of flow of a shielding gas to the gun nozzle
Speed of the feed motor and - starting / stopping electrode feed
Pressure vessels and the piping industry

43. What does the wire feeder control?
Speed of the feed motor and - starting / stopping electrode feed
These terms are quite restrictive and often technically incorrect
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
Spatter problems and poor weld appearance

44. List the factors that determine the mode of metal transfer
Higher 26 to 35 arc volts
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
Wire feed speed
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field

45. What 2 organizations designate specifications for GMAW wires?
15 feet (4.5 meters)
AWS and CSA
5.8 to 12.5 L/min
By there current carrying capacity

46. List 3 forms compressed gases may be supplied for welding
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
Voltage is the force that overcomes resistance to allow amperage flow
Constant current (CC)

47. What processes are constant current (CC) power sources designed to be used with?
Gas metal arc welding
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts
The resistace to electrical current flow increases with it. Causing the electrode to heat
SMAW - GTAW

48. How are GMAW guns rated?
Motor driven generators - Transformer rectifiers - and Inverter designs
V groove or U groove
By there current carrying capacity
Welding process that joins metals by heating them with an electric arc

49. What is the effect of too much slope?
12 to 22 arc volts
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
Insufficient current to melt the wire off cleanly
Minutes of elapsed time continually run (out of 10 minutes)

50. What is another term for electrode holders for GMAW?
Dry ice can form within the flow control openings and cause blockage of shielding gas
Minimum distortion due to low heat input
Spatter problems and poor weld appearance
Guns

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Gas Metal Arc Welding

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