Gas Metal Arc Welding (GMAW) Flashcards

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Questions and Answers

Define and describe the GMAW process in detail.

Joins metal by heating them with electric arc established between a continuously fed filler metal electrode and the workpiece.

The gas metal arc welding process is also known as:

  • Robotic Welding
  • Stick Welding
  • TIG Welding
  • MIG Welding (correct)

GMAW is recommended for use on which of the following metals?

  • Steel
  • Aluminum
  • Stainless Steel
  • All of the above (correct)

List the basic equipment components required for the set-up of GMAW outfit.

<p>Volts and wire speed.</p> Signup and view all the answers

How will penetration be affected when stickout is increased?

<p>Will decrease penetration (C)</p> Signup and view all the answers

Changing the gun inclination will:

<p>Cause the wire to feed unevenly (B), Change the penetration of the weld (D)</p> Signup and view all the answers

Describe how GMAW equipment is likely to behave when the contact tip is worn out.

<p>Cause gas flow turbulence, resulting in porosity and poor quality welds.</p> Signup and view all the answers

Excessive splatter build up in the gun nozzle can cause:

<p>Inadequate gas coverage (B)</p> Signup and view all the answers

Moisture and dirt on the surface of the wire electrode is likely to cause:

<p>Porosity (A)</p> Signup and view all the answers

Excessive drag from a dirty liner is likely to cause:

<p>Damage to the liner and contact tip (B)</p> Signup and view all the answers

When arc hunting occurs, the problem is likely in the:

<p>Wire feeder drive motor or the motor gearbox (D)</p> Signup and view all the answers

Stubbing is caused by excessive:

<p>Wire feed speed (D)</p> Signup and view all the answers

List four causes of porosity.

<p>Lack of gas coverage, wet shielding gas, excessive tip to work distance, excessive gas flow.</p> Signup and view all the answers

Describe what whiskers are and how they are caused.

<p>Whiskers are lengths of unmelted electrode wire welded to and protruding from the root side of an open root groove weld.</p> Signup and view all the answers

Describe the procedure for clearing a bird nest.

<ol> <li>De-energize the power source and feeder, 2. Cut the wire at the back end of the cable liner, 3. Remove the contact tip, pull the wire through the gun and cable assembly, 4. Clean or replace the liner and/or contact tip, 5. Relieve tension on or remove the idler rolls, 6. Remove bird nested wire, check for damage to drive roll assembly, 7. Tie off wire to spool.</li> </ol> Signup and view all the answers

How often should you clean the conduit liner of wire drive setup?

<p>Every time the wire spool is changed (B)</p> Signup and view all the answers

What should you do when the liner becomes kinked?

<p>Cut the kinked portion out and rejoin using manufacturer approved fittings (B)</p> Signup and view all the answers

List six things you should check for if the arc becomes unstable.

<p>Loose cable connections, badly worn or dirty contact tip, loose work lead connection.</p> Signup and view all the answers

What can result from a poor work lead connection?

<p>An unstable arc (C)</p> Signup and view all the answers

List four things you should check for when you see porosity in the weld when using GMAW.

<p>Increase gas flow, use wind break, spatter buildup from nozzle, leaks, kinks, disconnected or blocked gas lines, frozen regulators.</p> Signup and view all the answers

The use of shielding gases for GMAW increases the need for:

<p>Good ventilation (A)</p> Signup and view all the answers

High ultraviolet radiation emissions from GMAW can cause atmospheric oxygen in the vicinity of the arc to convert to:

<p>Ozone (D)</p> Signup and view all the answers

A potential source of poisonous chemical fume when welding is:

<p>Chlorinated degreasing solvents (C)</p> Signup and view all the answers

Flashcards

Gas Metal Arc Welding (GMAW)

A welding process using a continuously fed filler metal electrode and an electric arc to join metals.

MIG welding

Another name for Gas Metal Arc Welding (GMAW), often used interchangeably.

Stickout

The distance between the contact tip and the workpiece in GMAW.

Gun Inclination

The angle at which the welding gun is held relative to the workpiece in GMAW.

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Splatter

The metal droplets transferred from the electrode to the workpiece during GMAW.

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Porosity

A common GMAW defect caused by insufficient gas coverage or wet shielding gas, resulting in holes or voids in the weld.

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Whiskers

The small, unmelted wire protrusions sticking out from the weld groove in GMAW.

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Bird Nest

The twisted wire clump that can form inside a GMAW gun when the wire spool runs out, requiring de-energizing and cleaning.

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Liner

The internal tubing in a GMAW gun that guides the welding wire to the contact tip.

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Contact Tip

The part of a GMAW gun where the welding wire contacts the arc, creating a welding circuit.

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Arc Hunting

The erratic movement of the welding arc that can be a sign of problems with the wire feed motor or gearbox.

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Unstable Arc

A situation where the welding arc is unstable or inconsistent, leading to a poor weld.

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Shielding Gas

An essential aspect of GMAW to ensure safety and quality, as it protects the molten weld from oxidation.

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Ventilation

The process of ensuring appropriate ventilation during GMAW to remove harmful fumes and gases.

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Ultraviolet Radiation

A high-energy radiation form emitted during GMAW, which can lead to health risks if not properly shielded from.

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Ozone

A chemical compound produced by the interaction of ultraviolet radiation with atmospheric oxygen, posing health risks in welding environments.

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Chlorinated Degreasing Solvents

Cleaning agents used to remove grease and oil, which can produce harmful fumes, highlighting the importance of safety.

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Lack of Penetration

The improper penetration of the welding arc into the base metal, potentially caused by excessive stickout.

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Excessive Drag

A GMAW defect characterized by increased arc voltage and a reduced wire feeding rate, potentially caused by a dirty contact tip.

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Wire Feed Speed

The adjustment in a GMAW machine that controls the speed at which the welding wire feeds, influencing the welding parameters.

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Voltage Setting

The voltage setting in a GMAW machine that determines the arc intensity and melting rate, impacting the welding parameters.

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Tip-to-Work Distance

The distance between the contact tip and the workpiece, impacting penetration and shielding gas coverage in GMAW.

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Study Notes

Gas Metal Arc Welding (GMAW) Overview

  • GMAW, also known as MIG welding, joins metals using an electric arc between a continuously fed filler metal electrode and the workpiece.
  • Recommended for use on various metals, making it versatile for different applications.

Equipment and Setup

  • Basic components required for GMAW include voltage settings and wire speed adjustments.
  • Importance of equipment maintenance is highlighted, especially monitoring the condition of the contact tip to prevent gas flow turbulence.

Welding Process Considerations

  • Increasing stickout will decrease penetration in welds.
  • Gun inclination affects both penetration depth and the feeding smoothness of the wire.
  • Managing excessive splatter and dirt build-up in the gun nozzle is crucial to ensure adequate gas coverage during welding.

Common Issues and Solutions

  • Moisture and dirt on the wire electrode can cause porosity in welds, compromising quality.
  • Dirty liners can lead to excessive drag, damaging the liner and contact tip.
  • Arc hunting indicates potential issues with the wire feeder drive motor or gearbox.

Porosity and Defects

  • Common causes of porosity include insufficient gas coverage, wet shielding gas, excessive tip-to-work distance, and high gas flow.
  • Whiskers are unmelted wire protrusions from the groove, often caused by an incorrect root opening or face thickness.

Maintenance Procedures

  • Clearing a "bird nest" requires de-energizing equipment, removing the wire, and cleaning or replacing parts as necessary.
  • Liner cleaning should occur every time the wire spool is changed; kinked liners must be replaced or repaired using approved fittings.

Addressing Unstable Arcs

  • When experiencing an unstable arc, check for loose cable connections, worn contact tips, and secure work lead connections.
  • Poor connections can lead to unstable arcs.

Troubleshooting Porosity

  • Solutions for porosity issues include increasing gas flow, eliminating spatter buildup, and ensuring gas lines are clear of leaks.

Safety Considerations

  • The use of shielding gases in GMAW necessitates good ventilation to ensure safety during operation.
  • High ultraviolet radiation from GMAW can convert atmospheric oxygen into ozone, posing additional health risks.
  • Chlorinated degreasing solvents are a source of poisonous fumes, underscoring the need for proper safety measures.

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