WireFed Processes

Question 1

What is the most commonly used, general use GMAW wire used in industry?

1.) ER70S-6
2.) ER70S-3
3.) ER70S-G
4.) ER70S-2

Answer 1

1.) ER70S-6

Question 2

Match each type of wire to the corresponding drive roller.

1.) FCAW wire
2.) MCAW wire
3.) .035 solid wire
4.) Soft wires (aluminum)

a.) v-groove
b.) knurled
c.) u groove
d.) knurled

Answer 2

1.) (b) Knurled
2.) (d) Knurled
3.) (a) V-groove
4.) (c) U-groove

Question 3

The system of classification for carbon steel FCAW electrodes, W48, is based on whether the electrode is self-shielded or gas-shielded.

True
or
False

Answer 3

True

Question 4

Which shielding gas or shielding gas mix is used to weld non-ferrous metals (aluminum)

1.) Argon
2.) CO2
3.) Argon/CO2
4.) Oxygen/CO2

Answer 4

1.) Argon

Question 5

The number “2” in the CSA Standard W48, FCAW classification E492T-9 indicates that the electrode can be used for:

1.) Vertical down fillets and groove welds only
2.) All position welding
3.) Overhead fillets and groove welds only
4.) Flat groove welds and flat and horizontal fillet welds only.

Answer 5

4.) Flat groove welds and flat and horizontal fillet welds only.

Question 6

Which shield gas or gas mix is used to increase the wetting action at the edge of the weld.

1.) Argon/oxygen
2.) CO2
3.) Helium/CO2/Argon
4.) Helium
5.) CO2/argon

Answer 6

1.) Argon/oxygen

Question 7

MCAW electrodes contain no flux and are filled with metal powders and arc stabilizers.

True
OR
False

Answer 7

True

Question 8

Which of the following are functions of the shielding gas?

1.) Increase the cooling rate of the weld puddle and reduce the wetting action
2.) Add alloying elements to the weld puddle and increase weld metal deposition
3.) Add nitrogen and oxygen to the weld zone
4.) Influence the mode of metal transfer and aid in arc initiation and stability

Answer 8

4.) Influence the mode of metal transfer and aid in arc initiation and stability

Question 9

What mode of metal transfer combines the best properties of both spray and short circuit transfer while welding?

1.) Pulsed spray transfer
2.) Spray Transfer
3.) Globular transfer
4.) Short-circuit transfer

Answer 9

1.) Pulsed spray transfer

Question 9

What mode of metal transfer use low voltage and most common defect is lack of fusion?

1.) Spray
2.) Pulsed spray
3.) Globular
4.) Short-circuit

Answer 9

4.) Short-circuit

Question 10

The most likely cause of weld failures with the FCAW process is the use of excessive voltage.

True
OR
False

Answer 10

True

Question 11

Which primary variable affects the bead profile and width while welding with wire fed processes?

1.) Travel speed
2.) Wire feed speed
3.) Work and travel angles
4.) Arc voltage

Answer 11

4.) Arc voltage

Question 12

Aside from influencing the mode of metal transfer, which weld characteristic is most directly affected by changes in wire-feed speed (amperage) during the GMAW process?

1.) Ease of arc initiation
2.) Weld puddle fluidity
3.) Overall weld bead shape and profile
4.) Reduction of spatter during welding

Answer 12

3.) Overall weld bead shape and profile

Question 13

What does the “C” mean in electrode designation E 49 C - 6M H4?

1.) Chemical composition
2.) Chemical Deoxidizers added to wire
3.) Cored wire
4.) Tensile strength

Answer 13

3.) Cored wire

Question 14

What has to happen in order for the gas solenoid to open, for the drive rolls to engage and for the current to be sent to the gun?

1.) The polarity must be set to DCEN.
2.) The gun trigger must be depressed.
3.) The polarity must set to DCEP.
4.) The feeder must be connected to the power source.

Answer 14

2.) The gun trigger must be depressed.

Question 15

Which of the following is a limitation of the FCAW process?

1.) Electrodes are only available for welding a few steels
2.) Can only be applied in the flat and horizontal positions
3.) Prone to incomplete fusion defects
4.) Amount of fume generation

Answer 15

4.) Amount of fume generation

Question 16

What are considered advantages of GMAW-G welding? Select all that apply.

1.) High productivity of continuous welding
2.) Draft sensitive
3.) Good access to narrow joint preparations because there is no need for a gas nozzle
4.) Arc stability is significantly improved using CO₂ shielding gas
5.) Ability to handle surface contaminants on the parent material

Answer 16

1.) High productivity of continuous welding
4.) Arc stability is significantly improved using CO₂ shielding gas
5.) Ability to handle surface contaminants on the parent material

Question 17

What does a contact tip do when using wire fed processes?

1.) None of these answers.
2.) Directs shield gas to the weld zone.
3.) Transfer the current from the welding gun to the wire electrode.
4.) Supplies shielding gas evenly to the contact tip.

Answer 17

3.) Transfer the current from the welding gun to the wire electrode.

Question 18

Link the power source settings on the left with their corresponding functionality on the right.

1.) Wire speed (amperage)
2.) Jog
3.) Inductance/Slope
4.) Purge

A.) Used to adjust the shielding gas flow rate
B.) Allows fine-tuning of the current (short-circuit mode of transfer)
C.) Affects depth of penetration and metal deposition rate
D.) Feeds the electrode through the drive mechanism

Answer 18

1.) (C) Affects depth of penetration and metal deposition rate
2.) (D) Feeds the electrode through the drive mechanism
3.) (B) Allows fine-tuning of the current (short-circuit mode of transfer)
4.) (A) Used to adjust the shielding gas flow rate

Question 19

Self-shielded electrodes must provide all the protection from the atmosphere since no shielding gas is used.

True
OR
False

Answer 19

True

Question 20

Match the shield gas equipment with its corresponding function

1.) Gas Regulator
2.) Flowmeter
3.) Gas Mixer
4.) Manifold

a.)Provides shielding gas in liters per minute / cubic feet per hour
b.) May provide cost savings and provide a precise blend of gas
c.) Reduces the surface pressure to a working pressure
d.) Several bottles are connected together in a parallel feed

Answer 20

1.) (c) Reduces the surface pressure to a working pressure
2.) (a.)Provides shielding gas in liters per minute / cubic feet per hour
3.) (b.) May provide cost savings and provide a precise blend of gas
4.) (d.) Several bottles are connected together in a parallel feed

Question 21

What type of power source is most commonly needed for GMAW welding?

1.) AC (alternating current)
2.) DC (direct current)
3.) CV (constant voltage)
4.) CC (constant current)

Answer 21

3.) CV (constant voltage)

Question 22

What gas mixture is required to achieve spray transfer?

1.) A minimum of 85% Argon
2.) A minimum of 85% Carbon Dioxide
3.) 75% Argon 25% Carbon Dioxide
4.) 75% Carbon Dioxide, 25% Argon

Answer 22

1.) A minimum of 85% Argon

Question 23

Select all that are considered modes of metal transfer when using a standard welding machine:

1.) Short-circuit
2.) Spray
3.) Globular
4.)Pulsed

Answer 23

1.) Short-circuit
2.) Spray
3.) Globular

Question 24

If the shielding gas flow meter is adjusted significantly higher than the recommended setting, which welding defect is most likely to occur as a result of excessive turbulence? 1.) Porosity 2.) Lack of penetration 3.) Burnback 4.) Excessive penetration

Answer 24

1.) Porosity

Question 25

Which shielding gas or mix gas is commonly used for welding high performance steels? 1.) CO2 2.) Argon/oxygen mix 3.) Argon 4.) Argon/CO2 mix 5.) CO2/Argon/helium mix

Answer 25

4.) Argon/CO2 mix

Question 26

Select all gases that are considered INERT 1.) Oxygen 2.) Argon 3.) CO2 4.) Helium

Answer 26

2.) Argon 4.) Helium

Question 27

The wire feed equipment required to properly feed aluminum filler metal into the weld are specially designed because the wire is so: 1.) Soft 2.) Smooth 3.) Brittle 4.) Hard

Answer 27

1.) Soft

Question 28

The transition current is the point at which: 1.) None of the answers 2.) The mode of transfer changes from globular to spray 3.) The weld will provide full penetration 4.) The weld no longer requires shielding gas

Answer 28

The mode of transfer changes from globular to spray

Question 29

The most common gas mixture used for the FCAW welding process is (trade names) 1.) C15 2.) CO2 3.) MIG Mix Gold (92/8) 4.) A10

Answer 29

CO2

Question 30

Shielding gas cylinders should always be stored: 1.) At a 45* angle 2.) Upright or laying down 3.) Laying down 4.) Upright

Answer 30

Upright

Question 31

Select all gases that are considered ACTIVE 1.) Oxygen 2.) Argon 3.) CO2 4.) Helium

Answer 31

Oxygen CO2

Question 32

To avoid contaminants, welding wire should be stored: 1.) In a storage area such as a storage closet. 2.) Unwrapped and stored away from contaminants. 3.) Wrapped and stored away from contaminants. 4.) None of these answers.

Answer 32

Wrapped and stored away from contaminants.