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Gas Metal Arc Welding

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Answer 50 questions in 15 minutes.
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1. What current and polarity is generally used with GMAW?
85%
Flux cored wires
DCEP (Direct Current Electrode Positive) Reverse Polarity
Gas metal arc welding

2. What type of power source is used with a constant speed wire feeder?
Constant voltage (CV)
V groove or U groove
To limit the short circuiting current so that spatter is reduced
Wire feed speed

3. What is the maximum distance that hard wire can be successfully pushed?
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
To limit the short circuiting current so that spatter is reduced
15 feet (4.5 meters)
V groove or U groove

4. Why must CO2 cylinders be used in the vertical position?
To prevent drawing of liquid CO2 (Carbon Dioxide)
SMAW - GTAW
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
Welding process that joins metals by heating them with an electric arc

5. What controls the wire speed on a voltage sensing wire feeder?
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
Pressure - The rate of flow of a shielding gas
These terms are quite restrictive and often technically incorrect

6. List the basic equipment requirements for the GMAW process
Constant current (CC)
Guns
To prevent drawing of liquid CO2 (Carbon Dioxide)
Power source - wire feeder - welding gun - Spooled filler wire - Shielding gas - and a ground

7. What is the purpose of the pick- up lead on a voltage sensing wire feeder?
Controls the rate of flow of a shielding gas to the gun nozzle
20 to 200 times per second
V groove or U groove
Gives arc voltage values to the control system of the feeder

8. What processes are constant current (CC) power sources designed to be used with?
To prevent drawing of liquid CO2 (Carbon Dioxide)
SMAW - GTAW
By there current carrying capacity
Speed of the feed motor and - starting / stopping electrode feed

9. List 3 wire drive systems and give a short description of each
Spatter problems and poor weld appearance
V groove or U groove
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 - The rate of flow of a shielding gas

10. What output on the welding machine is used to rate the duty cycle?
To prevent drawing of liquid CO2 (Carbon Dioxide)
Duty cycle
Wire feed speed
Minutes of elapsed time continually run (out of 10 minutes)

11. What is the purpose of a regulator and what does it indicate on its gauges?
3
Aluminum wire
Reducing the gas source pressure to a constant working pressure
Duty cycle

12. What does inductance control?
DCEP (Direct Current Electrode Positive) Reverse Polarity
Constant current (CC)
The time rate of response for the current rise and fall
85%

13. What is the preferred drive roll design for solid wires?
1/4 inch to 1/2 inch
V groove or U groove
Motor driven generators - Transformer rectifiers - and Inverter designs
Puddle fluidity

14. Draw a typical volt/amp curve that would be found with a power source designed for SMAW or GTAW
Speed of the feed motor and - starting / stopping electrode feed
If you dont know this check your phone
Shielding the molten weld metal from atmospheric contamination
Cause flaking - which can clog the liner and contact tube

15. Is the arc voltage for spray transfer higher or lower than that used for short circuit transfer?
Higher 26 to 35 arc volts
Aluminum wire
Puddle fluidity
If you dont know this check your phone

16. List several industries that would use GMAW
Puddle fluidity
3
Pressure vessels and the piping industry
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld

17. Why is a line heater required when using GMAW?
Motor driven generators - Transformer rectifiers - and Inverter designs
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
DCEP (Direct Current Electrode Positive) Reverse Polarity
Dry ice can form within the flow control openings and cause blockage of shielding gas

18. Give a description of 'pinch effect'
Constant- speed wire feeders and Voltage- sennsing wire feeders
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
Gives arc voltage values to the control system of the feeder

19. What would be an indication that the drive roll pressure is adjusted correctly?
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
The resistace to electrical current flow increases with it. Causing the electrode to heat
Wire feeds smoothly (yet will slip should a problem occur in the gun)
(DCEP) Direct Current Electrode Positive or Reverse polarity

20. What is the purpose of the shielding gas used in GMAW?
Puddle fluidity
Wire feed speed
DCEP (Direct Current Electrode Positive) Reverse Polarity
Shielding the molten weld metal from atmospheric contamination

21. List the factors that determine the mode of metal transfer
3
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
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

22. What is the key advantage of short circuiting transfer?
Voltage is the force that overcomes resistance to allow amperage flow
Minimum distortion due to low heat input
By there current carrying capacity
AWS and CSA

23. Why is the term GMAW preferred over MIG or MAG?
Minutes of elapsed time continually run (out of 10 minutes)
Constant voltage (CV)
Constant current (CC)
These terms are quite restrictive and often technically incorrect

24. What does voltage do in an electrical circuit?
Constant voltage (CV)
12 to 22 arc volts
Voltage is the force that overcomes resistance to allow amperage flow
DCEP (Direct Current Electrode Positive) Reverse Polarity

25. What is the effect of too much slope?
To prevent leakage - Carbon Dioxide (CO2)
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
Insufficient current to melt the wire off cleanly
These terms are quite restrictive and often technically incorrect

26. What type of power source is commonly used with a voltage sensing wire feeder?
Constant current (CC)
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
By there current carrying capacity
...

27. List the three methods of metal transfer with GMAW
3
Spatter problems and poor weld appearance
Short- circuiting transfer - Globular transfer - Spray transfer
The time rate of response for the current rise and fall

28. What is the required arc voltage used for short circuit transfer?
Pressure vessels and the piping industry
SMAW - GTAW
By there current carrying capacity
12 to 22 arc volts

29. When is the metal transferred with short circuit transfer?
Welding Current - Filler wire diameter - arc length - type of shielding - position of the weld
Controls the rate of flow of a shielding gas to the gun nozzle
Short- circuiting transfer - Globular transfer - Spray transfer
When the filler wire is in direct contract with the base metal

30. What does the term GMAW identify?
Gas metal arc welding
12 to 22 arc volts
Short- circuiting transfer - Globular transfer - Spray transfer
The Arc voltage

31. What is a typical flow rate of CO2 for short circuit transfer?
Motor driven generators - Transformer rectifiers - and Inverter designs
20 to 200 times per second
5.8 to 12.5 L/min
(DCEP) Direct Current Electrode Positive or Reverse polarity

32. Give a brief description of the GMAW process
If you dont know this check your phone
Welding process that joins metals by heating them with an electric arc
Puddle fluidity
15 feet (4.5 meters)

33. What is the disadvantage of the gauge preset type of regulator/flowmeter?
Generally not as accurate
(DCEP) Direct Current Electrode Positive or Reverse polarity
The negative side of a welding unit
85%

34. What effect does increasing and decreasing the inductance have on the weld?
The resistace to electrical current flow increases with it. Causing the electrode to heat
15 feet (4.5 meters)
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

35. What does the abbreviation NEMA stand for?
National Electrical Manufactures Association
Compressed gas cylinder - Liquid filled cylinder - or a Liquid bulk system
Gas metal arc welding
The resistace to electrical current flow increases with it. Causing the electrode to heat

36. How are GMAW guns rated?
Gas metal arc welding
Constant current (CC)
By there current carrying capacity
The resistace to electrical current flow increases with it. Causing the electrode to heat

37. What 2 organizations designate specifications for GMAW wires?
Shielding the molten weld metal from atmospheric contamination
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
AWS and CSA

38. What is the main purpose of 'slope'?
Molten metal is separated from the end of the filler wire by a squeezing force created by a magnetic field
85%
To limit the short circuiting current so that spatter is reduced
20 to 200 times per second

39. In the GMAW process what does voltage control?
Reducing the gas source pressure to a constant working pressure
Puddle fluidity
The time rate of response for the current rise and fall
Wire feed speed

40. What is an advantage of pulsed arc transfer with GMAW?
National Electrical Manufactures Association
Cause flaking - which can clog the liner and contact tube
Heat input is less than spray transfer - resulting in less distortion - Used in all positions due to controlling the weld metal freeze
15 feet (4.5 meters)

41. What does the wire feeder control?
Speed of the feed motor and - starting / stopping electrode feed
When the filler wire is in direct contract with the base metal
Constant voltage (CV)
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

42. Draw a typical volt amp curve for a machine that is designed for GMAW
The negative side of a welding unit
If you dont know this check your phone
The Arc voltage
Aluminum wire

43. A 10 minute cycle of welding time vs cooling time a given machine can handle.
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
Penetration and burn - off rate of the electrode
Duty cycle

44. What is a solenoid valve and what actuates it?
If you dont know this check your phone
1/4 inch to 1/2 inch
Electricaly operated valves that control the flow of shielding gas to the weld zone. The control switch located on the gun
Guns

45. Regulators control_____________ flowmeters SHOW____________.
Constant- speed wire feeders and Voltage- sennsing wire feeders
Constant voltage (CV)
Pressure - The rate of flow of a shielding gas
Wire feed speed

46. What 2 controls are found on a GMAW set- up?
By there current carrying capacity
Wire feed speed - Voltage control
Minutes of elapsed time continually run (out of 10 minutes)
Generally not as accurate

47. What wire are knurled drive rolls most commonly used on?
Flux cored wires
Penetration and burn - off rate of the electrode
(DCEP) Direct Current Electrode Positive or Reverse polarity
The negative side of a welding unit

48. What power sources are used with the GMAW Process?
1/4 inch to 1/2 inch
...
Motor driven generators - Transformer rectifiers - and Inverter designs
Constant voltage (CV)

49. A machine with a 70% duty cycle can run at its max for 7 minutes with a cooling cycle of only _ minutes.
Constant voltage (CV)
3
Gives arc voltage values to the control system of the feeder
The negative side of a welding unit

50. What is the minimum % value of argon that must be present to use the spray transfer method of GMAW?
Short- circuiting transfer - Globular transfer - Spray transfer
85%
Dry ice can form within the flow control openings and cause blockage of shielding gas
Pressure vessels and the piping industry

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Gas Metal Arc Welding

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