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Welding Study Guide #2 (101-184)

Total questions: 86

Worksheet time: 43mins

Name
Class
Date
1.

Which one of the following is NOT a consideration when a welding equipment set-up is being made?

a)

the type and size of electrode to be used

b)

the type and amount of welding current to be used

c)

the type and size of ground clamp to be used

d)

the type of parent metal to be welded

2.

A major limitation of flux-cored welding is that it

a)

is a low deposition process

b)

produces low quality welds

c)

is limited to thin gauge materials

d)

produces slag covering which must be removed.

3.

Flux-cored welding benefits include

a)

continuous wire welding

b)

metallurgical benefits from the flux

c)

slag that supports and shapes weld bead

d)

all of the above.

4.

For GMAW of aluminum and stainless steel, the recommended type welding current is

a)

alternating current high frequency

b)

direct current reverse polarity

c)

direct current straight polarity

d)

direct current straight polarity high frequency.

5.

For precise control of argon from a high pressure gas cylinder, which of the following should be used?

a)

flowmeter

b)

standard acetylene regulator

c)

combination argon regulator with built-in flow meter

d)

standard oxygen regulator with a flow meter attached

6.

The only type of metal transfer not compatible with GMAW is ______ transfer.

a)

spray

b)

reverse

c)

globular

d)

short circuiting

7.

The duty cycle for most industrial rated GMAW constant potential power sources greater than 300 amps is

a)

40%

b)

60%

c)

80%

d)

100%.

8.

To change from a short circuit to a spray arc metal transfer, the voltage must be at least ____ volts and the shielding gas should have at least 80% argon.

a)

10

b)

16

c)

18

d)

22

9.

Burn-thru encountered in GMAW can be eliminated by

a)

decreasing the gas flow

b)

reducing wire feed and voltage

c)

decreasing travel speed

d)

increasing the wire feed.

10.

The pinch effect force in GMAW, which helps transfer metal across the arc, is created by

a)

anode pole

b)

cathode pole

c)

welding position

d)

electromagnetic force.

11.

An advantage of CO2 over Argon/CO2 mixture when GMAW steel is

a)

a better bead appearance

b)

less spatter

c)

stronger welds

d)

depth of penetration.

12.

When GMAW, with a constant voltage power supply, adjustment of the slope DOES NOT affect

a)

the shape of the volt – amp curve

b)

the rate of wire feed speed

c)

the limit of available short circuit current

d)

the rate of response of the welding machine to changing arc conditions.

13.

The type(s) of metal transfer possible when employing the GMAW consumable electrode process is/are the ______ transfer.

a)

spray

b)

globular

c)

short circuiting

d)

all of the above modes

14.

What are two types of transfers used in GMAW?

a)

short circuit and spray transfer

b)

snap transfer and globular transfer

c)

sigma transfer and short circuit

d)

constant transfer and spray transfer

15.

What is the distance from the contactor tip to the work called?

a)

wire feed

b)

electrical stickout

c)

projection

d)

arc length

16.

The purpose of the insulator on a GMAW gun is to prevent electrical contact with the

a)

contact tip

b)

gas nozzle or gas cup

c)

wire

d)

gas diffuser.

17.

Because of the high deposition rate, spray transfer is usually done in which positions?

a)

flat and horizontal

b)

vertical and overhead

c)

vertical and horizontal

d)

all positions

18.

Which GMAW process is usually used on sheet material?

a)

globular transfer

b)

constant transfer

c)

short-circuit transfer

d)

spray arc transfer

19.

Spray-arc transfer requires which voltage and amperage relationship?

a)

high voltage/high amperage

b)

high voltage/low amperage

c)

low voltage/high amperage

d)

low voltage/low amperage

20.

What is the major difference in FCAW and GMAW?

a)

polarity

b)

power source

c)

filler wire

d)

wire feeder

21.

What amount of carbon dioxide is used with short-circuit transfer on 1/8" mild steel?

a)

20 to 25 CFH

b)

35 to 50 CFH

c)

20 to 30 PSI

d)

30 to 50 PSI

22.

In GMAW, inconsistent wire feeding can be caused by

a)

worn contact tip

b)

excessive shielding gas

c)

obstruction in liner

d)

excessive voltage

23.

An excessive flow of carbon dioxide gas may cause

a)

a leak in the line

b)

the flow meter to freeze

c)

a hole in the diaphragm

d)

the plastic tube to break

24.

In the gas metal arc welding of stainless steel, what percentage of oxygen is contained in the argon gas?

a)

1% to 5%

b)

5% to 10%

c)

10% to 20%

d)

20% to 30%

25.

Which of the following metals CANNOT be welded by the GMAW process?

a)

zinc alloys

b)

aluminum

c)

stainless steel

d)

brass

26.

When using the GMAW dip transfer process, the transfer of metal to the puddle is accomplished by

a)

the "pinch effect" caused by the momentary necking of the liquid drop that is conducting the current

b)

the absorption of gas at the electrode tip

c)

the electromagnetic action produced by a globular transfer

d)

all of the above

27.

In gas metal arc welding, the most important function of the shielding gas that is selected is

a)

the exclusion of undesirable gases by displacement and the provision of an ionizing medium for sustaining the arc

b)

the elimination of excessive splatter due to the containment of the metal globules, by the gases

c)

the prevention of contamination of the consumable electrode by the ionization of the oxides on the electrode surface

d)

an electrical cleaning action of the base metal prior to the deposition of the filler metal

28.

In GMAW, the use of CO2 will improve

a)

bead contour

b)

penetration

c)

wettability

d)

all of the above

29.

An excessively high flow rate of shielding gas for a given nozzle size will result in

a)

the absolute elimination of all atmospheric contamination

b)

air contamination

c)

a higher quality deposition of the consumable electrode

d)

increased deposition rates of the filler metal

30.

Arc stabilization is accomplished in the GMAW process by the

a)

use of a constant voltage power system and a matched wire feeder

b)

correct impedance characteristics and time response features which are electrically controlled

c)

addition of alloying elements, scavenging and deoxidizing elements compounded into the consumable electrode

d)

use of all of the above techniques

31.

Which type of metal transfer is NOT employed with the GMAW process?

a)

the spray transfer

b)

the globular transfer

c)

the short circuiting transfer

d)

the snap transfer

32.

Indication of the amperes per square inch of cross sectional area of an electrode is referred to as

a)

current capacity

b)

current flow

c)

current measure

d)

current density

33.

In most instances, changing alternating current to direct current for welding purposes requires

a)

inverters

b)

transducers

c)

silicon diodes

d)

transformers

34.

Of the following, the only material that CANNOT be GTAW is

a)

aluminum

b)

copper

c)

monel

d)

carbon.

35.

When welding a butt joint from one side using the GTAW process, the metal should be beveled if it exceeds

a)

1/16" T

b)

1/8" T

c)

1/4" T

d)

3/8" T.

36.

The best penetration, when welding stainless steel with GTAW and argon, is obtained with

a)

DCRP

b)

ACHF

c)

DCSP

d)

AC.

37.

When gas tungsten arc welding, using a shielding gas of helium instead of argon will

a)

produce better arc stability at lower currents

b)

prevent burn-thru on light gauge metals

c)

give better coverage at lower flow rates

d)

produce higher arc voltage at the same amperage.

38.

In the gas tungsten arc welding of type 304 stainless steel pipe with a consumable insert, the gas backing recommended for best results is

a)

oxygen

b)

nitrogen

c)

argon

d)

carbon dioxide.

39.

In GTAW of aluminum and magnesium, the current supply recommended for best results is

a)

direct current, reverse polarity

b)

direct current, straight polarity

c)

alternating current, high frequency

d)

direct current, reverse polarity, high frequency.

40.

In GTAW of carbon steel pipe, the maximum penetration with a small weld puddle is achieved by using

a)

direct current, straight polarity

b)

direct current, reverse polarity

c)

alternating current, high frequency

d)

direct current, reverse polarity, high frequency.

41.

When welding with the GTAW process, the welding bead is terminated by

a)

lifting the arc torch abruptly

b)

increasing the welding speed to decrease the size of the weld or using the remote control to decrease the amperage prior to breaking the arc.

c)

advancing weld puddle rapidly and increasing the arc length as the size of the weld puddle decreases

d)

holding a short arc and advancing rapidly and then snuffing the arc out in the weld puddle.

42.

When welding with GTAW and using DCSP with a 3/32" diameter tungsten electrode at 140 amperes, what would happen if the machine was switched to DCRP?

a)

The electrode would melt instantly with possible damage to the gas cup and torch body.

b)

The electrode would strike an arc but the arc would be erratic.

c)

Nothing except a sacrifice of penetration would be noticed in the root of the weld.

d)

The arc would be "wild" and burn-thru would result.

43.

The advantage of inert gas backing, when welding pipe systems with GTAW, is that it

a)

helps chill the root pass

b)

helps control the interpass temperature

c)

eliminates the formation of oxides on the underside of the root pass

d)

enables the welder to use drastically reduced currents.

44.

Argon and helium gases are considered to be

a)

inert

b)

reactive

c)

reducing

d)

oxidizing.

45.

When using GTAW, porosity would be caused by

a)

an increased argon flow

b)

the use of filler wires with deoxidizers

c)

increased voltages above the normal range of the electrode

d)

a loose argon connection that permits atmosphere to enter the inert gas supply.

46.

A good method to locate leaks in a GTAW setup is

a)

approved leak test solution

b)

the sense of hearing (listen for escaping gas)

c)

the falling pressure technique

d)

chalk dust.

47.

The pure tungsten electrode is color-coded with which color band?

a)

brown

b)

green

c)

red

d)

yellow

48.

Inert gas flow meters are calibrated to indicate the flow in

a)

PSI

b)

CFH

c)

PSIG

d)

CFM

49.

For maximum cleaning action, which polarity should be used when welding aluminum with GTAW?

a)

DCSP

b)

ACHF

c)

DCEN

d)

DCHF

50.

Inert gas is kept flowing after the welding arc is broken in order to

a)

shield the ceramic cup

b)

purge the torch lines of argon

c)

shield the tungsten and the work from contamination

d)

keep the flow meter from freezing up

51.

What polarity should be used when welding stainless steel with the GTAW welding process?

a)

DCSP

b)

ACHF

c)

DCRP

d)

DCEP

52.

Why is DCRP usually not used on GTAW?

a)

DCRP does not provide sufficient penetration.

b)

DCRP provides no cleaning action.

c)

DCRP provides too much penetration.

d)

DCRP provides too much heat at the electrode.

53.

What is the name of the measuring device used with inert gas?

a)

pressure gauge

b)

regulator

c)

two-stage regulator

d)

flow meter

54.

When welding aluminum with the GTAW process, the high-frequency setting should be

a)

continuous with AC

b)

continuous with DCSP

c)

start only with AC

d)

start only with DCRP

55.

What is the measurement on the 1" scale below?

a)

3/16"

b)

1/2"

c)

1 1/16"

d)

3/4"

56.

What is the reading on the micrometer below?

a)

.480

b)

.412

c)

.458

d)

.408

57.

A combination square is used to measure

a)

90° angles

b)

45° angles

c)

depth measure

d)

all of the above

58.

A divider set at 2" will scribe a circle of what diameter?

a)

2"

b)

4"

c)

6"

d)

8"

59.

A protractor is used to measure angles from

a)

0 - 90 degrees

b)

90 - 180 degrees

c)

0 - 180 degrees

d)

none of the above

60.

Which of the following numbers is the smallest?

a)

.5000

b)

.0500

c)

.0050

d)

.0005

61.

A Vernier caliper can be used to measure which of the following?

a)

inside dimension

b)

outside dimension

c)

depth dimensions

d)

all of the above

62.

What precision tool would best measure the root opening before welding of a joint assembly?

a)

Vernier caliper

b)

Hermophodite caliper

c)

tape measure

d)

micrometer

63.

What file would be preferred for the finishing of a root face?

a)

rattail

b)

bastard

c)

smooth cut mill file

d)

half round bastard

64.

What type of wire brush is preferred for cleaning of aluminum before and after welding?

a)

carbon steel

b)

brass

c)

stainless steel

d)

nylon

65.

In the guided bend test, the maximum acceptable length of a visible crack on the convex surface of the specimen bend is generally specified to be

a)

1/64"

b)

1/32"

c)

1/16"

d)

1/8"

66.

The percentage of elongation of a welded specimen is usually determined by a test of what type?

a)

tensile

b)

root bend

c)

face bend

d)

hardness

67.

When a welder fails to meet the requirements for one test specimen, most welding codes require a retest immediately

a)

on that type specimen

b)

on all original type specimens

c)

consisting of two test welds of each type failed

d)

by making four times as many of each type specimen

68.

A guided bend test for plate groove weld for qualification requires how many coupons to be tested?

a)

3

b)

1

c)

2

d)

4

69.

A test position on pipe material that is not rotated and is at a 45° angle is what position?

a)

1G

b)

3G

c)

5G

d)

6G

70.

Visual inspection during welding of qualification test include(s)

a)

inspection for porosity

b)

proper cleaning between passes

c)

proper filler metal used

d)

all of the above

71.

A qualification test may be terminated at any stage of testing when

a)

the welder is not following the WPS

b)

the welder does not have skill to produce satisfactory results

c)

both A and B

d)

neither A nor B

72.

Direction of finish grinding marks of weld coupons to be tested should be done

a)

parallel to axis of weld

b)

perpendicular to axis of weld

c)

does not matter

d)

none of the above

73.

Performance qualification tests are usually made on groove welds using the test

a)

extrusion

b)

tee-joint

c)

guided bend

d)

V-notch

74.

According to code standards, unlimited thickness overhead position in groove welds qualifies

a)

flat and overhead positions

b)

flat, horizontal and overhead positions

c)

vertical and overhead positions

d)

overhead only

75.

A tee joint certification in the vertical position, according to code standards, qualifies the welder in

a)

groove and fillet welding

b)

flat, horizontal and vertical fillet welding

c)

vertical groove welding

d)

vertical fillet welding

76.

“Written verification that a welder has produced welds meeting a prescribed standard of welder performance” is referred to as

a)

welder performance qualification

b)

welder certification

c)

welder registration

d)

welder testing

77.

What is operating factor?

a)

ratio of time versus voltage

b)

ratio of arc time versus total time

c)

ratio of hours worked versus hours in a day

d)

ratio of travel speed versus current

78.

Doubling the leg size of a fillet weld requires as much filler material.

a)

the same

b)

twice

c)

four times

d)

eight times

79.

Which of the following is NOT a welding cost consideration?

a)

time for positioning of work

b)

time for cleaning

c)

time for purchasing

d)

time for fixture loading/unloading

80.

A welding operator welds for 27 minutes out of one hour. What is the operating factor?

a)

2.2%

b)

4.5%

c)

45%

d)

222%

81.

A flat, 1/4" fillet weld weighs .129# per foot. How many pounds would be required for 626 inches of weld?

a)

6.73

b)

66.05

c)

80.75

d)

135.13

82.

If one inch of GMAW cost $ .37 to deposit for a particular application, how much would it cost to deposit 16 feet of weld?

a)

$5.92

b)

$47.36

c)

$59.20

d)

$71.04

83.

Argon shielding gas cost $12.50 per 100 cubic feet. How much would a cylinder that holds 330 cubic feet cost?

a)

$4.12

b)

$41.25

c)

$412.50

d)

$4,125.00

84.

One pound of E-6010 SMAW electrode costs $ .596/#. How much would 100# cost?

a)

$5.96

b)

$39.60

c)

$59.60

d)

$596.00

85.

In cost consideration, the least expensive type joint in thin sheet is

a)

single V

b)

single U

c)

square butt

d)

single J

86.

As a rule, to control cost, speed of construction and quality of weld, you should

a)

use a 1/4" electrode for vertical fillet welds

b)

use direct current whenever possible

c)

weld in the flat position whenever possible

d)

do all of the above.