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