Auto 112 module 1, 2, 3, 4, 5

Polarity

115 volt welders may be originally set up for flux-cored wire and require a conversion kit for solid wire. These machines may also require the.............. be switched for Collision Repair welding.

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remove

Avoid removing the sink coating when cleaning mating surfaces. ......... weld through primer from the immediate weld Zone.

Short-Circuit

Because less heat is generated and the metal stays cooler, the.......-............ transfer method is the preferred method for welding on sheet metal.

Instruction

Before setting up a welding machine read the equipment makers...................

70000

ER: electrode rod 70: tensile strength of at least........... PSI S: solid electrode wire 6: chemical makeup of wire and ability to keep oxygen out of weld

one

For every .025 mm (.001) of metal thickness,............ amp is required.

Triangler

GMA (MIG) Fillet welds are.........shaped beads deposited in a corner formed by a lap, corner, or T-joint.

90°

GMA (MIG) plug welds are made by Amy the electrode, at a............ angle, at the base metal through the hole in the top peace and circling around the hole to fuse the edges.

AC DC

GMA (MIG) welders are plugged into an.............. power source and the power is converted to a............. output.

Fusion

GMA (MIG) welding is a consumable electron, wire feed,................ welding process.

plug

GMA (MIG)............. welds join two or more lap pieces together and are used to replace Factory spot welds.

High

If the pressure of the roles against the wire is not high enough, the wire will not be pulled through the wire feeder. is a pressure of the drive rolls against the wire is too............... the wire made the Forum in Wind into a spiral that cause it to bind.

Galvanized

It is important that surfaces to be welded or clean of all finish undercoating, corrosion, dirt, oil, and grease. Do not remove any.............. coatings.

3mm (1/8")

to pass a visual inspection, a butt joint with backing will must have the joint completely filled with no cracks or undercut. Porosity, skips, and avoids can be no greater than..........mm (..........") and the total of all should not exceed 6mm (1/4").

Type

Test plug weld should be made on the same............ and thickness metal and in the same position as that to be welded on the vehicle. Weld through primer should be used if it is going to be used on the vehicle. Test well should be visually and destructively testing.

Current

The amount of heat put into the base metal during GMA (MIG) welding is a function of voltage and................ outputs of the welding machine and the travel speed at which the welding gun is moving.

Filled

to pass a visual inspection, and open butt joint weld must have the joint completely........... With no cracks or undercut. Porosity, skips, and voids can be no greater then 3 mm (1/8") and the total of all should not exceed 6mm (1/4").

root

to destructively test and open butt joint weld: 1. band the pieces along the whale axes, with the........Of the weld on the face of the bend. 2. Hammer the sample flat. 3. inspect for weld metal cracks. Cracks are allowed as long as they show no visibly detective flaws and the pieces do not completely separate.

tearout

two destructively test a butt joint with backing weld: 1. Bend top pieces towards each other. 2. Bend the backing piece and towards itself. 3. hammer the sample flat. 4. tighten the top pieces in a vice, just below the joint. 5. Rock the backing back and forth Until It Breaks free. 6. look for complete Fusion. There should be metal......... From the pieces that the weld separates from, and the weld should remain firmly on the other piece.

plug

when making a butt joint with backing weld on a vehicle, some procedures may call for the backing to have.......... Weld in one or both of the top pieces.

70°

when making a fillet weld the electrode should be aimed at the base metal and the welding gun held at a.......... travel angle.

Stitch

when making an open butt joint weld on a vehicle, it may be necessary to make the well as a series of short....... Welds just to avoid burn through.

good

melt through that creates a ripple is a sign of............ weld penetration.

work

........... angle is the angle that the plane of the welding gun has in relation to the Joint being welded. It controls where the wire is being pointed at the joint, and effects penetration shielding gas coverage, and undercut.

Undercut

............ is a groove cut into the base metal at one or both sides of the weld bead, and may be caused by unbalanced voltage and amperage settings, or improper welding gun angles.

Travel

............. angle is the angle the welding gun is pointed either towards or away from the direction of gun travel. It affects well deep penetration and shielding gas coverage.

Alternating

............. plug welds are made by randomly alternating the location that plugs welds are made at and not making two or more welds next to each other concurrently.

Flux-Cored

.............-............Wire requires no shielding gas and is not recommended for metal thinner than 18 gauge.

A skip weld

.............. welds are made by making short 13-19 mm (1/2-3/4") long welds in random locations along the joint and then filling in the spaces.

Tapered

................ shielding gas nozzles are typically used with the short circuit transfer method.

AWS ER 70s-7

...............Wire can also be used for Collision Repair welding, but its availability may be limited.

reverse

..............Polarity is when the electrode is positive and the workpiece is negative, and is used with solid electrode wire. It is used most often for Collision repairs because it provides a stable Arc with the best Fusion and less weld surface to grind off.

Burn through

..............may be caused by heat settings that are too high, travel speed too slow, stick out that is too short, incorrect welding gun angles, and root caps that are too wide.

straight

............Polarity is when the workpiece is positive and the electrode is negative. It puts most of the heat on the workpiece and is used with flux cored electrode wire.

Distorted or uneven

A.......... bead may be caused by an unsteady hand, a worn contact tip, too much stick out, voltage setting too high, and uneven travel speeds.

Stitch

A............ weld is made by starting and stopping briefly between welds.

small

Advantages of GMA (MIG) welding include: *a.......... heat affected Zone. * that it can be used to weld all Commercial Metals and alloys. * it works well in all welding positions. * it requires minimal post weld cleaning.

spatter

Causes of.......... include unbalanced voltage and amperage settings, worn or recessed contact tips, improper shielding gas flow, excessive welding gun angles, and contamination or corrosion of the base metal.

bird nesting

Causes of.............. include too much Drive roll tension, Tangled wire, clogged gun liner, and too small a contact it for that wire Diameter.

decrease

Changes and stick out result in changes and resistance, which causes a change in amperage output. Increasing stick out............. the amperage output and therefore the penetration of the weld, and decreasing stick out increases these same parameters.

Ten

Duty cycle is how many minutes out of............ a welding machine can operate continuously at a rated amperage.

clean

Making plug welds on a vehicle: 1............ The Mating surfaces. 2. Drill or punch holes the size recommended by the vehicle maker, or 8 mm 5/16 if no recommendation exist, in the same location as the spot welds being replaced. 3. Prime bare metal with weld through primer if applicable. 4. Clamp The Joint tightly together.

remove

Making plug welds on a vehicle: 5.......... weld through primer form the immediate weld Zone. 6. Attach the word clamp as close to the Well site as possible. 7. Make the plug welds, ensuring that the hole is completely filled. 8. Dress the welds if necessary.

8mm. (5/16")

Plug weld holes should be the size recommended by the vehicle maker or............mm (.......") is no recommendation exist. When plug welding three pieces together, the hole in the top piece should be larger than the hole in the middle piece.

5mm (3/16")

Plug welds maybe destructively tested using tensile shear testing or by doing a Twist test. How to do a twist test on a plug weld: 1. Secure in a vise 2. Twist top piece off 3. Measure nugget hole diameter The Nugget hole diameter for a plug weld made through an 8mm (5/16") hole must be at least...........mm (..........").

CO2

Pure.......... shielding gas produces a much hotter weld bead, and therefore is not recommended for welding on high strength steel.

Inside

Shielding gas nozzles can have an anti spatter compound applied to the............... to reduce the buildup of spatter between the nozzle and contact tip.

porosity

Shielding gas protects the weld from gases that cause...............

melt-through

The backside of the fillet weld must have.........-......... as evidence of penetration. The melt through width should be 5 mm (3/16") or less and melt through height can be no more than 1.5 mm (1/16).

diameter

The cast of a spool of electrode wire should have a............. of at least 300 mm(12"). The helux of a spool of electrode wire should have a height of not more than 25 mm (1").

Current

The contact tip transfers........ ...... to the electro wire and must match the electrode wire diameter.

output

The current, or amperage,...............of a GMA (MIG) welder is adjusted by changing the wire speed setting.

6-13mm. (1/4-1/2)

The distance from the end of the contact tip to the end of the wire is called stick out. For 0.6mm (.023") wire, Steak-Out should be............mm (..........").

amperage

The electrode wire diameter used depends on the............... required for the welding being done.

25-30

The shielding gas flow meter should be set at............ cfh for Collision Repair welding.

constant

The voltage output of a typical GMA (MIG) welder remains.............. once set. The voltage controls the rate at which the electrode wire Burns and must be matched to the current or amperage being used.

Feeding

The welding gun liner guides the electrode why are from the dry rolls to the contact tip. The inside diameter must be matched to the diameter or the electro wire mean use. Copper coated wire chance to leave copper particles that can build up in the liner and affect wire.......... liners can be cleaned off copper particles by blowing compressed air through them.

Close

The word clam completes the output Circuit of the welder and is not the electrical ground for the welding machine. the work lamp should be placed as............. to the Weld site as possible.

Backside

The......... of a plug weld should show melt through as evidence of penetration, but have a melt through height no greater than 1.5 mm (1/16").

Push

The........... technique decreases penetration and is when the welding gun is pointed and pushed away from the weld bead. It produces a flatter, wider bead.

Pull

The............ technique increases penetration and is when the welding gun is pointed at and drag away from the weld bead. It produces a higher, narrower bead.

Fusion

To destructively test a fillet weld on lap joint: 1. Secure the bottom piece in a vise. 2. Rock the top piece back and forth Until It Breaks free. 3. Look for evidence of complete........... metal should pull out of the top piece along the entire length of the weld Karma and the world should hold firm to the bottom piece.

No porosity

To pass a visual inspection, a fillet weld must have the joint completely filled with no cracks or undercut............, skips, and voids, can be no greater than 3 mm (1/8") and the total of all not to exceed 6 mm (1/4).

Penetration

Travel speed is how fast the technician moves the welding gun along the joint and effects weld bead........... size, and shape.

Removed

Weld through primer does not allow proper at henshin of other Coatings and should have any excess........... before applying additional top coats. Some vehicle makers do not recommend the use of weld through primer.

Overhead position

Welding positions include: • flat this is the easiest position to weld in. • horizontal this is the easiest if the welding gun is angled upward. • vertical on thin gauge metal this is easiest if the welding gun is angled upward and pulled downward. •............... this requires lower heat settings than the other positions.

Thickness

When tuning a welding machine, use the same.............. metal ass that to be welded on the vehicle, use proper stick out, and test the strength of the sample weld.

Pull

When visually inspecting a plug well, the........... must be completely filled, with a nugget height of No More Than 3 mm (1/8"), with no cracks, porosity, or undercut.

Er70s-6

Wire is the recommended electrode wire for collision repair welding.

Argon

a mix of 75%............. 25% CO2 is the preferred gas for collision repair welding on mild and high-strength steels. Pure argon Shooting Games for Welding aluminum or When using silicon in bronze electrode wire.

butted

an open butt joint is two pieces in the same plane........ Against each with a gap between of 0 1 times the metal thickness.

Penetration

and butt joint with backing S2 pieces nearly butted against each other with a backing piece usually the same thickness as the other pieces behind the joint. the root gap between the top pieces should be two three time's the metal thickness. The size of the root Gap will affect weld..............into the backing piece.

close

attach the work clamp as..........to the weld site a possible.

penetration

causes of poor weld........... include too low of heat setting, travel speed too fast, stick out too long, and improper root gaps.

penetration

causes of poor weld.............. include too low of heat settings,

porosity

causes of......... include: • shielding gas not turned on • shielding gas flow rate too low • pinched or leaking shielding gas hose • improper shielding gas type • dirty electrode wire •Dirty of plug shielding gas nozzle • contaminated base metal • stick out too long

dressing

do not reduce the thickness of the surrounding matter when....... welds.

Distortion

heat management techniques that can be used limited Heat build up and help avoid metal............. include Stitch welds, skip welds, and alternating plug welds.

1.5mm 0-1/16"

the backside of the butt joint with backing weld must have melt-through as evidence of penetration. the melt-through widths should be.........mm (........") or less and melt-through height can be no more than 1.5mm (1/16").

1.5mm 0-1/16"

the backside of the open butt joint weld must have melt through as evidence of penetration. the melt through width should be the same as the weld bead on the front side, and melt through height can be no more than...... mm (.......).

90°

the butt joint with backing weld is made using a........... work angle in 70° travel angle. The electrode wire is aimed at the backing piece and the weld is either pushed or pulled.

Center

the open butt joint weld is made using a 90° work angle and a 70° travel angle. The electrical wire is aim at the......... All of the joint and the weld is either pushed or pulled.