Welding Final
An acetylene cylinder pressure gauge reading of ___________ would indicate the tank is about half full.
125 psi
Acetylene gas becomes unstable when compressed above _____ psi.
15 psi
What is the AWS welding position classification when the pipe or tube is placed vertical, the weld is done horizontal, and the metal is not rotated?
2G
Which of the following is not an AWS welding position for pipe or tube welds?
3F
If a plate is vertical and the axis of the weld is vertical, then the groove weld would be classified as _______.
3G
The air carbon arc cutting process requires compressed air in the range of ____ psi to _____ psi.
40-100psi
What does the "H8" designation stand for in the FCAW classification of E71T-1H8?
8mL of hydrogen per 100g of weld metal
AC
ALTERNATING CURRENT an electrical current that has alternating + and - values
ANSI
AMERICAN NATIONAL STANDARDS INSTITUTE oversees the development of voluntary standards for products, services, processes, systems and personnel in the US
AWS
AMERICAN WELDING SOCIETY sets standards/specifications and is stamped on some electrodes
CFH
CUBIC FEET PER HOUR volume flow rate of gas
A test that uses a weighted pendulum which strikes a notched test specimen is called _______.
Chappy Impact Test
Which of the following tests is responsible for testing a weld or metal's toughness?
Charpy Impact Test
A ___________ allows the flow of liquid or gas in one direction only.
Check Valve
The air carbon arc cutting process most commonly uses a(n) ______ current.
DCEP
_______ is the preferred polarity with GMAW.
DCEP
DCEP
DIRECT CURRENT ELECTRODE POSITIVE current flows from electrode to workpiece (2/3 heat on workpiece)
FCAW-SS
FLUX CORE ARC WELDING SELF SHIELDED shielding is exclusively provided by a flux contained within the tubular electrode
A neutral flame for OAW has a temperature of approximately 4489 degrees F. T/F
False
The reference line, arrow, and tail are required in each weld symbol. T/F
False
The size of a welding tip needed depends on the amount of pressure used. T/F
False
The specification for milk steel covered arc welding electrodes is AWS A5.55. T/F
False
The standard potential energy of the raised pendulum in its corresponding destructive test is 5,500J. T/F
False
H4,-8,-16
HYDROGEN LIMIT
NDT
NON DESTRUCTIVE TESTING testing to determine the suitability of a material or component for its intended purpose using techniques not affecting its serviceability
__________ drive rolls are designed for soft welding wires.
U Shaped
When oxy-acetylene welding the filler rod should be dipped, _______.
in the center of the puddle
The number _____ in the second to last position of the AWS electrode classification indicates that the electrode can be used in all positions.
1
What is indicated by the welding symbol shown?
1/4" fillet welds 2 inches long on 6" centers
An acetylene cylinder contains _____% reserve volume for safety precautions.
10%
AMP
AMPERE basic unit of measure for an electrical current
Ar
ARGON most common shielding gas for GTAW, mixed with 25% CO2 for FCAW
Which letter in the welding symbol below indicates the weld must have a concave shape?
C
CO2
CARBON DIOXIDE most common shielding gas for FCAW-GS and provides the deepest penetration
CC
CONSTANT CURRENT (POWER SOURCE) the ability to vary the voltage across an electric circuit and maintain a constant electric current. SMAW and GTAW
CV
CONSTANT VOLTAGE the ability to vary current and maintain a constant voltage
Plasma Arc Cutting most commonly uses a(n) _______ current.
DCEN
In the GTAW process, ___________ current provides a cleaning action.
DCEP
DC
DIRECT CURRENT
DCEN
DIRECT CURRENT ELECTRODE NEGATIVE current flows from workpiece to electrode (2/3 heat on electrode)
DCEN is an acronym for ____________.
Direct Current Electrode Negative
ESO
ELECTRODE STICK OUT the distance from the end of the contact tip to the end of the electrode
Which of the following examples best represents an AWS electrode classification for the GTAW process?
EWCe-2
What does the last number in the electrode classification E-6010 represent?
Electrode Characteristics, Type of Current, Type of Coating
The E-6020 electrode belongs in which of the F groups?
F1- Fast Fill
F1
FAST FILL ELECTRODES high deposition (big welds), shallow penetration, slow solidification, flat/horiz. positions only -20 -24
F3
FAST FREEZE ELECTRODES low deposition (small welds), deep penetration, fast solidification, all positions, -10 -11
In the ________ process, shielding gas is provided exclusively by the flux core within the electrode.
FCAW-S
F2
FILL FREEZE ELECTRODES medium deposition, penetration, and low solidification, all positions -12, -13
F4
FILL FREEZE LOW HYDROGEN med. deposition, penetration, and solidification nearly all position -16 -18 -48
FCAW-GS
FLUX CORE ARC WELDING GAS SHIELDED shielding is provided by external gas
A wraparound bend test clamps one end of a test specimen into place and rolls the piece 360 degrees around a cylindrical mandrel. T/F
False
Acetylene cylinders are seamless vessels that contain a welded neck ring. T/F
False
Air carbon arc cutting requires low amperage settings. T/F
False
An advantage of air carbon arc cutting is that it produces a smooth finish along the cut edge. T/F
False
An advantage of plasma cutting equipment is that it is a multi-process machine and can be used for other operations. T/F
False
DCEP is the preferred current choice when welding stainless steel with the GTAW process. T/F
False
Drive rollers for FCAW electrodes are v-shaped to consistently feed the electrode into the weld pool. T/F
False
Duty cycle is the percentage of time during a 24 hour period that a welding machine can be operated at its rated load without exceeding temperature limits. T/F
False
E-7024 is used for overhead butt joints. T/F
False
Fillet welds are completed with butt joints. T/F
False
Oxyacetylene welding is most commonly used for welding heavy steel. T/F
False
Oxygen cylinders contain fusible plugs that release when the cylinder is subjected to high temperatures. T/F
False
Preheat holes are used to blow molten metal away from a cutting section. T/F
False
RG 60 has a tensile strength of 6,000 psi and is widely used on carbon steel pipes. T/F
False
The SMAW process uses a non-consumable electrode. T/F
False
The T in the electrode classification for Flux Cored Electrodes means that the electrode is tough. T/F
False
The acetylene cylinder valve should be opened all the way. T/F
False
The flux on SMAE electrodes produces O2 to shield the molten weld pool. T/F
False
The letter S in the electrode designation ER70S-3 stands for short circuiting transfer. T/F
False
The welding symbol on the right indicates a groove opening of 50 degrees on the other side of the indicated weld. T/F
False
The yoke with MT is placed parallel to the weld to locate an indication. T/F
False
Voltage is increased by increasing the wire feed speed in the GMAW process. T/F
False
Voltage is the number of electrons flowing in a circuit at a given time. T/F
False
Weld metal that does not fuse to the base metal and sits on top of the surface is called undercut. T/F
False
When combined with oxygen, natural gas offers the coldest neutral flame as compared to other fuel gas options. T/F
False
When using the GMAW process on stainless steels, 100% argon is commonly used as a shielding gas. T/F
False
Which group would an electrode with high deposition rate, heavy slag, iron power flux, and almost no spatter belong to?
Fast Fill
________ equipment should be used to keep smoke and fumes from entering a welder's helmet.
Fume Extraction
GMAW
GAS METAL ARC WELDING process that uses an arc between a continuous wire electrode and the weld pool
GTAW
GAS TUNGSTEN ARC WELDING shielding gas protects the arc between a non-consumable tung. electrode and base metal
The ___________ is responsible for distributing shielding gas around the welding wire and contact tip.
Gas diffuser
Oxygen hoses are ___________ and have __________ threads.
Green, Right
Of the following, which test can assist in judging a weld's soundness?
Guided Bend Test
HAZ
HEAT AFFECTED ZONE portion of the base metal whose mechanical properties have been altered by the heat of welding
____________ allows a GTAW arc to be started without touching the base metal.
High Frequency
IPM
INCHES PER MINUTE measurement of how fast wire is coming out of the feeder
___________ power sources are electronically controlled and are more efficient than alternative choices.
Inverters
MT
MAGNETIC PARTICLE TESTING intentionally creates a magnetic field and then adds an iron oxide powder to locate discontinuities
MAPP
METHYLACETYLENE PROPADIENE PROPANE very stable gas that can be used in OFW with deoxidized filler
NEMA
NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION sets the standards for electrical equipment
OSHA
OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION creates rules and guidelines regarding safety in the workplace
OFC
OXY FUEL CUTTING a group of cutting processes that use high heat temperatures generated by burning a fuel gas in oxygen to accelerate the chemical reaction between oxygen and the base metal to sever and remove the metal
OFW
OXYFUEL GAS WELDING uses heat from combustion of oxygen and a fuel mixture to fuse base metals and filler
O2
OXYGEN green hoses, held in cylinders 244 cu ft at 2,200 psi when full
PPE
PERSONAL PROTECTIVE EQUIPMENT protective gear like glasses and helmets and gloves that are worn to protect from hazards
____________ determines whether current flows to the workpiece or toward the electrode in a DC Circuit.
Polarity
RT
RADIOGRAPHIC TESTING uses x rays to detect various internal discontinuities
Which of the following best represents an AWS filler metal classification for OAW?
RG 45
The __________ applies a minor and a major load to its test specimen to complete its application.
Rockwell Hardness Test
SMAW
SHIELDED METAL ARC WELDING uses flux covered electrode held in a conductive clamp which supplies electrical current from machine
ANSI indicates that the suggested shade number for medium duty Oxy-fuel welding is_________.
Shade 5
The __________ test is used to test weld and metal strength.
Tensile
The first two (or three) digits in an AWS numerical electrode classification designates the minimum allowable __________ of the weld metal. The number is then multiplied by one thousand pounds per square inch.
Tensile Strength
__________ can be used to determine the correct connections to be made when using oxygen and acetylene gases.
Thread Direction, Hose Color, Notched Connecting Nuts
2FR is a horizontal fillet weld with pipe or tubing that can be rotated. T/F
True
A constant-current machine is commonly used for shielded metal arc welding. T/F
True
A constant-voltage welding machine is commonly used for GMAW. T/F
True
A full oxygen cylinder contains 2200 psi of oxygen gas. T/F
True
A pull type wire feeder is used welding with soft and small diameter electrodes. T/F
True
A rockwell hardness test determines the relative hardness of a weld area and base metal. T/F
True
A transformer changes AC current from one level to another. T/F
True
An electrode with the classification E70T-9 uses a DCEN current. T/F
True
An under-bead crack is a cold crack. T/F
True
Arc length should be maintained at approximately 1/8" for an 1/8" SMAW electrode. T/F
True
As arc length increases, voltage increases. T/F
True
Couplets uses for UT can be composed of water, oil, glycerin and/or grease. T/F
True
DCEN produces a deeper penetrating weld than DCEP with the GTAW process. T/F
True
Destructive testing requires that a part be permanently removed from service for further testing. T/F
True
Distortion control is necessary to overcome poor fit up and undesirable stresses. T/F
True
Distortion creates undesirable dimensional changes in weld metals. T/F
True
E-6013 can be used with DCEN, DCEP and AC. T/F
True
FCAW produces less distortion and smoother, more uniform beads than SMAW. T/F
True
FCAW-SS welding guns have a metal shield to protect the welder's hand from excessive heat and spatter. T/F
True
Gas nozzle sizes are determined by the diameter of the tungsten electrode being used. T/F
True
Gas tungsten arc welding uses a non-consumable electrode. T/F
True
In a tensile test, a test specimen is pulled until it breaks. T/F
True
In the 4F position, one plate must be horizontal. T/F
True
Inadequate gas shielding is one cause of porosity. T/F
True
Inclusions can occur between weld passes or between pieces of metals. T/F
True
Low hydrogen electrodes must be kept in a moisture free oven. T/F
True
Needle valves on the torch regulate the flow of oxygen and acetylene. T/F
True
Oxygen and acetylene cylinders must be chained in a vertical position at all times during use and when stored. T/F
True
Porosity consists of cavity type discontinuities formed by gas entrapment during solidification. T/F
True
Properly planning the sequence of welds may help in counteracting shrinkage forces. T/F
True
Some FCAW electrodes can be used without the addition of a shielding gas. T/F
True
The correct oxygen and acetylene pressures of a particular torch are determined by following manufacturer recommendations. T/F
True
The protector cap must be in place when transporting cylinders. T/F
True
The recommended current range for a specific electrode is approximate and must be adjusted as necessary to achieve a satisfactory weld. T/F
True
The tail of the welding symbol may include information such as the electrode that needs to be used on the weld. T/F
True
The two types of oxyfuel cutting torches are straight cutting torch and combination torch. T/F
True
The welder should stand to one side of the regulator when opening the cylinder valves. T/F
True
Tubular electrodes are used for FCAW. T/F
True
When depositing a horizontal groove weld, the plates are in the vertical position. T/F
True
When welding in the 1G position on pipe or tubing, the weld is deposited at or near the top of the connection. T/F
True
UT
ULTRASONIC TESTING a NDE method that introduces ultrasonic waves to determine various attributes of the material from its effects on the ultrasonic waves
Sound energy is used as a probing medium during which NDT method?
UT
VT
VISUAL TESTING most common NDE; used to find surface indications before, during, and after welding
V
VOLT amount of electrical pressure in a circuit
The limitation of ________ is that there is no way to detect internal defects in the weld area.
VT
What is the basic element of evaluation in any quality control program?
VT
WFS
WIRE FEED SPEED rate at which wire is fed through a welding machine for GMAW and FCAW; measured in inches per minute
Who produced the video "The Prevention and Control of Distortion in Arc Welding"?
Walt Disney Productions
Acetylene cylinders are packed with a porous material that is saturated in _________ to allow the safe storage of acetylene.
acetone
What fuel gas produces the hottest neutral flame when combined with oxygen and is the most popular choice for oxy-fuel cutting?
acetylene
To ignite the flame on the cutting torch, the _______ is opened first.
acetylene needle valve
Oxygen with ______ can be used for flame cutting operations.
acetylene, natural gas, and propane
How far should the oxygen cylinder valve be turned when opened?
as far as it will open
___________ welding is a welding sequence in which short weld passes are made in the direction opposite of the overall process of welding.
back-step
What type of welds are measured and welded directly across from each other on both sides of a welded joint?
chain intermittent
When a weld is to extend completely around a joint, what symbol is placed where the arrow connects to the reference line?
circle
A ______________ crack is a crack that develops after solidification is complete.
cold
The _________ conducts the welding current to the electrode and is an essential part of the GTAW torch set up.
collet
The _________ conducts the current from the welding gun to the welding wire.
contact tip
2 members located approximately at right angles to each other in the form of an L form a __________ joint.
corner
Which of the following in NOT true about the welding symbol shown? a)staggered intermittent fillet welds b)reference 6 c)weld all the way around d)grind convex finish
d. Grind Convex Finish
A(n) ___________ is a material that is applied to the test surface to accelerate bleed out and enhance the contrast of indications.
developer
What is the material removed when cutting called?
dross
What is the term for the time period when the penetrant is drawn into any surface discontinuities?
dwell time
2 or more parallel or nearly parallel members comprise a __________ joint.
edge
The correct diameter filler metal is approximately _______ the thickness of the base metal.
equal to
Which of the following will increase distortion?
excessive reinforcement
__________ is a recession of the flame into the mixing chamber in a flame torch.
flashback
PIPE WELDING 1F 2F 2FR 4F 5F 6F
flat fillet weld horiz. fillet weld horiz. fillet weld rotated overhead fillet weld multiple fillet weld multiple fillet weld (at angle)
PLATE WELDING 1F 2F 3F 4F
flat fillet weld horiz. fillet weld vert. fillet weld overhead fillet weld
PIPE WELDING 1G 2G 5G 6G
flat groove weld horiz. groove weld multiple groove welds mult. groove welds (at angle)
PLATE WELDING 1G 2G 3G 4G
flat groove weld horiz. groove weld vert. groove weld overhead groove weld
________ occurs when welding in windy conditions and results in inadequate shielding of the weld area.
gas drift
What is not a variable when FCAW-SS welding?
gas flow rate
_________ direct the shielding gas to the weld zone.
gas nozzle
Stainless steel produces harmful _______ fumes with the PAC process so extra care must be taken.
hexavalent chromium
Crater cracks are _____ cracks formed by improperly _________ the welding arc in the crater of the weld.
hot; ending
Of the following discontinuities, which is less likely to be detected by visual inspection?
inclusions
__________ welding is performed by depositing weld metal in evenly spaced increments.
intermittent
Ferrous metal refers to metal that contains _____.
iron
Steel must be raised to ______ temperature in order to properly cut it.
kindling
The two forms of shrinkage are _____.
longitudinal and transverse
The flame cutting process is made possible by rapidly _________ the metal by introducing oxygen under pressure.
oxidizing
What type of flame has excessive oxygen?
oxidizing
The _________ control lever activates the flow of gas through the center hole of the cutting tip.
oxygen
________ is stretching the weld metal to counteract its tendencies while it cools.
peening
The oxyfuel welding torch should be held like a _____.
pencil or hammer
Acetylene fittings are _____ color and have _____ handed threads.
red, left
In which direction should a welder who is right handed weld with the OAW process?
right to left
When welding GTAW steel, high frequency should be set to _____________.
start only
___________ is controlled heating of a weld to an elevated temperature followed by controlled cooling.
stress relief
A __________ is a mechanical restraint that is attached by welding or clamping to both workpieces to maintain alignment during welding and prevent distortion.
strongback
When several radiographers interpret the same radiograph, which one accepts the weld?
the radiographer designated to evaluate the radiograph
The second number representing an OFC cutting tip is for the ______.
tip series
_____________ shrinkage is shrinkage that occurs perpendicular to the weld axis.
transverse
The rate at which the electrode is moved along the weld joint is the __________.
travel speed
Which of the following is a disadvantage of oxy-fuel cutting?
unable to perform stack cutting
When the base metal is melted away and is left without being refilled with weld metal, __________ has occurred.
undercut
The gas metal arc welding process uses a _________ wire electrode.
uses a continuous wire electrode
Wire feed speed determines the __________.
welding current
Which of the following is not a feature of GMAW?
well suited to outdoor applications
The higher the ________, the higher the welding current.
wire feed speed
After the arc is struck, the voltage drops to the _______________, which is between 18V and 36V.
working voltage
When welding with DCEP, electrons flow from the _________ to the ________.
workpiece; electrode