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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 effect of too much slope?
Penetration and burn - off rate of the electrode
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
Insufficient current to melt the wire off cleanly

2. What is the minimum % value of argon that must be present to use the spray transfer method of GMAW?
Constant- speed wire feeders and Voltage- sennsing wire feeders
85%
Penetration and burn - off rate of the electrode
Minimum distortion due to low heat input

3. What output on the welding machine is used to rate the duty cycle?
Constant voltage (CV)
The Arc voltage
These terms are quite restrictive and often technically incorrect
Minutes of elapsed time continually run (out of 10 minutes)

4. What does a flowmeter do and what does it measure?
Shielding the molten weld metal from atmospheric contamination
The time rate of response for the current rise and fall
Controls the rate of flow of a shielding gas to the gun nozzle
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system

5. What type of power source is commonly used with a voltage sensing wire feeder?
Constant current (CC)
To limit the short circuiting current so that spatter is reduced
Gives arc voltage values to the control system of the feeder
Cause flaking - which can clog the liner and contact tube

6. What is the key advantage of short circuiting transfer?
Wire feed speed
Minimum distortion due to low heat input
To prevent leakage - Carbon Dioxide (CO2)
Generally not as accurate

7. What is the recommended electrode stick- out for .035 solid wire?
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
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
1/4 inch to 1/2 inch
The time rate of response for the current rise and fall

8. A machine with a 70% duty cycle can run at its max for 7 minutes with a cooling cycle of only _ minutes.
1/4 inch to 1/2 inch
When the filler wire is in direct contract with the base metal
15 feet (4.5 meters)
3

9. Give a description of 'pinch effect'
Generally not as accurate
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
Minutes of elapsed time continually run (out of 10 minutes)
If you dont know this check your phone

10. What current and polarity is generally used with GMAW?
The time rate of response for the current rise and fall
DCEP (Direct Current Electrode Positive) Reverse Polarity
If you dont know this check your phone
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld

11. What controls the wire speed on a voltage sensing wire feeder?
Spatter problems and poor weld appearance
Cause flaking - which can clog the liner and contact tube
The negative side of a welding unit
The Arc voltage

12. What is the purpose of the shielding gas used in GMAW?
DCEP (Direct Current Electrode Positive) Reverse Polarity
To prevent leakage - Carbon Dioxide (CO2)
To limit the short circuiting current so that spatter is reduced
Shielding the molten weld metal from atmospheric contamination

13. What does inductance control?
AWS and CSA
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
The time rate of response for the current rise and fall

14. List 3 wire drive systems and give a short description of each
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
Constant current (CC)
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
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. What wire are knurled drive rolls most commonly used on?
Controls the rate of flow of a shielding gas to the gun nozzle
Flux cored wires
85%
To prevent leakage - Carbon Dioxide (CO2)

16. Give a brief description of the GMAW process
Speed of the feed motor and - starting / stopping electrode feed
...
Welding process that joins metals by heating them with an electric arc
AWS and CSA

17. What term is used to describe when the workpiece is hooked to the negative pole on the power source?
Pressure vessels and the piping industry
(DCEP) Direct Current Electrode Positive or Reverse polarity
Wire feed speed - 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

18. List several industries that would use GMAW
Pressure vessels and the piping industry
Duty cycle
If you dont know this check your phone
Minutes of elapsed time continually run (out of 10 minutes)

19. What is the main purpose of 'slope'?
The resistace to electrical current flow increases with it. Causing the electrode to heat
Constant voltage (CV)
To limit the short circuiting current so that spatter is reduced
V groove or U groove

20. Regulators control_____________ flowmeters SHOW____________.
Welding process that joins metals by heating them with an electric arc
Penetration and burn - off rate of the electrode
Short- circuiting transfer - Globular transfer - Spray transfer
Pressure - The rate of flow of a shielding gas

21. What is the maximum distance that hard wire can be successfully pushed?
Minimum distortion due to low heat input
Gas metal arc welding
Speed of the feed motor and - starting / stopping electrode feed
15 feet (4.5 meters)

22. What is the preferred drive roll design for solid wires?
V groove or U groove
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
These terms are quite restrictive and often technically incorrect
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts

23. What are the 2 types of wire feeders available?
Wire feeds smoothly (yet will slip should a problem occur in the gun)
Constant- speed wire feeders and Voltage- sennsing wire feeders
Spatter problems and poor weld appearance
If you dont know this check your phone

24. Why is the term GMAW preferred over MIG or MAG?
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
The negative side of a welding unit
These terms are quite restrictive and often technically incorrect

25. How many times per second does short circuiting take place?
Penetration and burn - off rate of the electrode
20 to 200 times per second
V groove or U groove
Increasing inductance increases puddle fluidity - improves penatration - makes the bead flatter and smoother - and reduces spatter. To much inductance though will create erratic starts

26. What is a typical flow rate of CO2 for short circuit transfer?
These terms are quite restrictive and often technically incorrect
5.8 to 12.5 L/min
Generally not as accurate
Wire feed speed - Voltage control

27. With straight polarity where is 2/3 of the arc energy?
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
If you dont know this check your phone
The negative side of a welding unit
Duty cycle

28. Why is globular transfer generally avoided with GMAW?
Gas metal arc welding
Constant- speed wire feeders and Voltage- sennsing wire feeders
Spatter problems and poor weld appearance
85%

29. How are GMAW guns rated?
Dry ice can form within the flow control openings and cause blockage of shielding gas
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground
By there current carrying capacity
Gas metal arc welding

30. What is the required arc voltage used for short circuit transfer?
12 to 22 arc volts
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
Flux cored wires
By there current carrying capacity

31. What is the purpose of the pick- up lead on a voltage sensing wire feeder?
Cause flaking - which can clog the liner and contact tube
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
Shielding the molten weld metal from atmospheric contamination
Gives arc voltage values to the control system of the feeder

32. What does the abbreviation NEMA stand for?
Constant voltage (CV)
National Electrical Manufactures Association
Controls the rate of flow of a shielding gas to the gun nozzle
85%

33. What happens when the electrode extension is increased?
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
Pressure - The rate of flow of a shielding gas
The negative side of a welding unit
The resistace to electrical current flow increases with it. Causing the electrode to heat

34. What 2 controls are found on a GMAW set- up?
Wire feed speed - Voltage control
To limit the short circuiting current so that spatter is reduced
Minutes of elapsed time continually run (out of 10 minutes)
Insufficient current to melt the wire off cleanly

35. What is the disadvantage of the gauge preset type of regulator/flowmeter?
Constant- speed wire feeders and Voltage- sennsing wire feeders
12 to 22 arc volts
Generally not as accurate
85%

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
The Arc voltage
DCEP (Direct Current Electrode Positive) Reverse Polarity
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun

37. Why must CO2 cylinders be used in the vertical position?
Minutes of elapsed time continually run (out of 10 minutes)
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
To prevent drawing of liquid CO2 (Carbon Dioxide)

38. What is a solenoid valve and what actuates it?
DCEP (Direct Current Electrode Positive) Reverse Polarity
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
The time rate of response for the current rise and fall
The negative side of a welding unit

39. 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
Minutes of elapsed time continually run (out of 10 minutes)
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
20 to 200 times per second

40. List the three methods of metal transfer with GMAW
The time rate of response for the current rise and fall
Short- circuiting transfer - Globular transfer - Spray transfer
Wire feed speed - Voltage control
Wire feeds smoothly (yet will slip should a problem occur in the gun)

41. Why is a line heater required when using GMAW?
To prevent drawing of liquid CO2 (Carbon Dioxide)
Constant current (CC)
Dry ice can form within the flow control openings and cause blockage of shielding gas
3

42. Why is a fiber washer required and what cylinder gas requires it?
15 feet (4.5 meters)
To prevent leakage - Carbon Dioxide (CO2)
When the filler wire is in direct contract with the base metal
Short- circuiting transfer - Globular transfer - Spray transfer

43. Draw a typical volt/amp curve that would be found with a power source designed for SMAW or GTAW
Welding process that joins metals by heating them with an electric arc
Aluminum wire
If you dont know this check your phone
Constant voltage (CV)

44. In the GMAW process what does amperage control?
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
Penetration and burn - off rate of the electrode
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
Dry ice can form within the flow control openings and cause blockage of shielding gas

45. What is the reason glass 'tube' type flowmeters must have the tube mounted truly vertical?
The negative side of a welding unit
Generally not as accurate
...
When the filler wire is in direct contract with the base metal

46. Is the arc voltage for spray transfer higher or lower than that used for short circuit transfer?
Higher 26 to 35 arc volts
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
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld

47. What is another term for electrode holders for GMAW?
AWS and CSA
Guns
Wire feed speed
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze

48. What does voltage do in an electrical circuit?
Voltage is the force that overcomes resistance to allow amperage flow
The Arc voltage
To prevent drawing of liquid CO2 (Carbon Dioxide)
12 to 22 arc volts

49. What processes are constant current (CC) power sources designed to be used with?
SMAW - GTAW
85%
12 to 22 arc volts
Pressure vessels and the piping industry

50. 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
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
Constant voltage (CV)

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Gas Metal Arc Welding

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