Weld Theory > WT3 Midterm > Flashcards

WT3 Midterm Flashcards

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1
Q

What is the difference between the words “shall,” “should,” and “may” in the context of a standard?

A

Shall: mandatory use of materials/methods/procedures
Should: advised, but not required
May: opinion w/in standard’s limits

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2
Q

What is the difference between a specification and a code/standard?

A

Specifications: requirements for products
Codes/standards: requirements for processes

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3
Q

What do the CSA designations W, B, G, N, and S stand for?

A

W: welding
B: pressure retaining
G: materials
N: nuclear
S: design of structures w fab references

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4
Q

What does CSA W59 cover?

A

Welding requirements for carbon and low alloy welded steel construction.

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5
Q

What does CSA W47.1 cover?

A

Certification of companies to weld steel.

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6
Q

What does CSA W178 cover?

A

Certification of inspection personnel.

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7
Q

What does CSA W48 cover?

A

Filler metals for arc welding

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8
Q

What is CSA S16?

A

Code for structural steel construction.

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9
Q

What does WPS stand for?

A

Welding Procedure Specifications

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10
Q

What does WPDS stand for?

A

Welding Procedure Data Sheets

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11
Q

W47.1 provides certification of companies in three divisions. What are they?

A

Division 1: requires employment of a welding engineer on a full time basis
Division 2: requires company to retain welding engineer on a part time basis
Division 3: does not require employment or retention of welding engineer

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12
Q

What are the 2 requirements for a welding engineer?

A
  1. Member of a provincial/territorial engineering association
  2. Minimum of 5 years of welding-related exp in a company producing steel weldments
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13
Q

What does PQR stand for?

A

Procedure Qualification Record

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14
Q

What is soundness testing?

A

Verification that material is free from defects e.g. bend test, break test, NDE

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15
Q

What is mechanical testing?

A

Determination of materials’ physical or chemical properties, e.g. tensile, impact, hardness testing

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16
Q

What does CSA W47.2 deal with?

A

Certification of aluminum welding

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17
Q

What are filler metals classified according to? (6 options)

A
  1. Chemical composition
  2. Usability characteristics
  3. Type of coating
  4. Hydrogen controlled
  5. Mechanical properties of weld metal
  6. Weld position
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18
Q

What three levels of inspection personnel does CSA W178.1 cover?

A
  1. Welding inspection supervisor
  2. Welding inspectors (3 levels)
  3. Mechanical and non-destructive testing operators
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19
Q

What does CSA W178.2 cover?

A

Certification of welding inspectors

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20
Q

How many years as a level one inspector do level 2 inspectors need? How many years as a level 2 inspector do level 3 inspectors need?

A

Level 2 inspectors need two years of experience as a certified level one inspector. Level 3 inspectors need four years of experience as a level 2 inspector.

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21
Q

What do ASME codes B31.[1,3,5,9] refer to?

A

Pressure piping and fitting (power, process, refrigeration, and building services piping)

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22
Q

What are the benefits of using Ar-CO2 with rutile wires?

A
  1. Less spatter
  2. Smoother beads
  3. Better wetting action
  4. Puddle control for OOP welding
  5. Less fumes than 100% CO2
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23
Q

Since argon is an inert gas, it is easily _______ by the arc.

A

ionized

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24
Q

Ionization results in smaller droplet size associated with____ ______.

A

spray transfer

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25
Ar-CO2 shielding gases cause less oxidation of ___________ and ___________ present in the wire, leading to higher contents in the weld metal.
Manganese (Mn), Silicon (Si)
26
As the percentage of CO2 increases, the weld penetration ____________.
increases
27
As the percentage of CO2 increases, the arc stability __________.
decreases
28
Shielding gas selection affects deposition rate. (T/F)
False
29
What is the maximum groove weld thickness before edge preparation is required?
13mm
30
Self shielded electrodes don't penetrate as deeply as gas shielded wires. (T/F)
True
31
When welding in the vertical position, electrode diameter is typically less than how many mm?
1.6
32
What are the principal welding parameters?
1. WFS/Current 2. Voltage 3. CTWD
33
What are the 3 main welder controlled parameters?
1. Travel speed 2. Work angles 3. Electrode position wrt joint
34
Travel angle with rutile and basic gas shielded flux cored electrodes is usually 20-30 degrees, dragging. (T/F)
True
35
Metal cored wires use a 10-20 degree _________ technique.
push/forehand
36
How do you fix incomplete fusion?
1. Ensuring settings are high enough 2. Reducing CTWD
37
What causes worm tracks/holes?
Trapped hydrogen between slag and weld metal -- caused by poor wire storage conditions or high humidity during welding.
38
How do you prevent cold cracking?
1. Maintain clean weld joint 2. Follow pre and post heating procedures 3. Ensure correct electrode selection and storage
39
What are the two main types of gas shielded carbon steel/low alloy steel flux cored wires?
Rutile and basic.
40
What are the three modes of metal transfer?
1. Short circuit transfer 2. Globular transfer 3. Spray transfer
41
Which metal transfer mode is most common when welding with metal cored wires?
Spray transfer
42
What are rutile (acidic) fluxes sometimes called, and why?
Fast freeze, because they solidify at a higher temp than the weld metal.
43
Rutile fluxes produce a smooth, stable arc and are good for OOP welding. They create a fine drop transfer, low fumes, and easily removable slag. (T/F)
True
44
Lime (basic) fluxes are good at removing impurities from weld metal, have low melting temps, and are not suitable for OOP welding due to liquid slag. They produce more globular transfer, spatter, and fumes than rutile fluxes. (T/F)
True
45
What is CAC-A?
Carbon Arc Cutting - Air
46
Carbon arc gouging is performed using constant __________ power sources with a high open circuit voltage of at least _______.
Current, 60V
47
When carbon arc gouging, what is the polarity used for steel and stainless steel applications?
DCEP
48
Carbon arc gouging affects metallurgical properties. (T/F)
False
49
What materials can CAC-A be used on?
1. Carbon steels 2. Stainless steels 3. Copper 4. Cast irons 5. Aluminum
50
CAC-A relies on oxidization to melt the material. (T/F)
False. It uses the intense heat of the arc.
51
Can CAC-A be used on non-ferrous metals?
Yes, because it doesn't rely on oxidization.
52
What materials require AC carbon arc gouging?
1. Copper alloys 2. Cast iron 3. Nickel alloys
53
DCEP carbon arc gouging is recommended for which metals.
1. Carbon steels 2. Low alloy steels 3. Stainless steels 4. Magnesium alloys 5. Aluminum alloys 6. Cast iron
54
AC copper coated electrodes are used on _________ and ___________ alloys and ________ ________.
Copper, nickel, cast iron
55
(CAC-A) the arc voltage should be _____ or higher.
28V
56
Single phase power sources ________ recommended for CAC-A.
Are not
57
What are the three basic types of carbon-graphite cutting rods?
1. DC copper-coated 2. DC uncoated 3. AC copper-coated
58
How long are DC copper coated electrodes?
12-18" (300-450 mm)
59
What range of diameters are DC copper coated electrodes available in?
5/32-1" (4-25 mm)
60
The copper coating on DC electrodes improves heat dissipation, prevents overheating, and maintains cutting tip shape. (T/F)
True
61
How does copper coating improve electrode life?
By reducing oxidation rate.
62
DC uncoated electrodes are mainly used in what kind of work? Why?
Demolition work, because they are less expensive, but burn off very quickly and struggle to keep groove size consistent.
63
What diameter are DC uncoated electrodes?
3/8" (10 mm)
64
AC copper coated electrodes use which rare earth element to increase arc stability?
Yttrium
65
AC electrodes can be used with a DC power source BUT DC eletrodes cannot be used with an AC power source. (T/F)
True
66
AC copper coated electrode diameters range from _____ to _____.
3/16-1/2" (5-13 mm)
67
What are the four CAC-A electrode shapes?
1. Pointed 2. Jointed 3. Flat 4. Half round
68
Which electrode shape is most common?
Pointed. Used for most grooves and removing weld defects.
69
Why do jointed electrodes have tapered joints at their ends?
So they can be fitted together. This allows for longer continuous cutting.
70
What groove shape are flat electrodes used for?
Wide, rectangular, shallow grooves with close tolerances.
71
What are the benefits of half-round electrodes?
They can be used like both round and flat electrodes. They can create rectangular grooves and remove weld reinforcements.
72
What are the four factors that affect travel speed? (CAC-A)
1. Carbon electrode size 2. Current setting 3. Compressed air supply 4. Base metal
73
What should electrode stick out be? Why?
4-6" Longer stick out will consume electrode at a much higher rate due to resistance heating. The air jet will also not be able to blow the material away.
74
What is the max stick-out for carbon steel? Aluminum?
Carbon steel: 7" (180 mm) Aluminum: 4" (102 mm)
75
What are the parts of a plasma torch assembly?
1. Heatshield 2. Nozzle 3. Swirl baffle 4. Electrode 5. Head
76
Why are plasma cuts less susceptible to distortion?
High travel speed, less HAZ
77
Non-conductive materials can be coated with conductive material so they can be plasma cut. (T/F)
True
78
Plasma jets can reach temperatures higher than 30,000 degrees Celsius, around 10 times hotter than an oxy-acetylene flame. (T/F)
True
79
Plasma is formed when a gas becomes __________.
Ionized
80
PAC machines are built with OCV ranging from _______ to ________ volts.
120 to 400
81
List the typical PAC torch consumables.
1. Swirl ring 2. Electrode 3. Nozzle 4. Retaining cap 5. Shielding cap
82
What is double arcing?
Double arcing happens when the arc jumps from the electrode to the gas nozzle, then to the workpiece.
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