Robotics Welding and Materials Quiz

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Questions and Answers

What is the purpose of the plyers in MIG welding?

To cut the wire to length, remove spatter from the nozzle, and remove the weld tip

What is crucial when setting up a MIG weld path?

The move before the weld start position is linear, along the tool Z direction

What is a critical safety aspect in MIG welding?

Standing back with little to no exposed skin

What is a hazard associated with MIG welding?

UV rays Signup and view all the answers

What is the purpose of the fume extractor nozzle in MIG welding?

To position the fume extractor appropriately to the work piece Signup and view all the answers

What is essential for a robotic MIG weld path?

A fine point at the start of the weld Signup and view all the answers

Why is it important to stand back when MIG welding?

To minimize exposure to UV rays, welding spatter, and heat transfer Signup and view all the answers

What is a safety item used in MIG welding?

All of the above Signup and view all the answers

What is the primary purpose of the flux in the FCAW welding process?

To generate gas and liquid slag Signup and view all the answers

What determines the weld current in robotic MIG welding?

Wire feed speed Signup and view all the answers

What is the typical range of stick out length in robotic welding?

5/8 to 3/4 of an inch Signup and view all the answers

What is the difference between GMAW and FCAW welding processes?

GMAW uses a solid consumable wire, while FCAW uses a flux core wire Signup and view all the answers

What is the purpose of the shielding gas in GMAW welding?

To protect the weld from the atmosphere Signup and view all the answers

What determines the arc length in robotic MIG welding?

Arc voltage Signup and view all the answers

What is the relationship between wire feed speed and weld current in robotic MIG welding?

Increasing WFS increases weld current Signup and view all the answers

What factors must be considered when selecting a weld mode for robotic welding?

Type of material being welded and wire size Signup and view all the answers

What is the first step in setting up a weld torch wire?

Remove the wire tip from the diffuser Signup and view all the answers

How do you feed the wire forward using the pendant?

Press SHIFT and Wire + Signup and view all the answers

What is the primary purpose of the shielding gas in GMAW welding?

To shield the weld from contaminants in the air Signup and view all the answers

What should you be aware of when feeding the wire backwards using the pendant?

The wire might come off the spool Signup and view all the answers

What is the importance of having the pendant in a safe location when working on a feeder?

To ensure safe operation Signup and view all the answers

What is GMAW welding?

A welding process that uses an electric arc and a consumable wire electrode Signup and view all the answers

What is the consequence of feeding the wire backwards excessively?

The wire might come off the spool Signup and view all the answers

What should you do after feeding the weld wire through the whip?

Slide the tip onto the wire and then tighten into the diffuser Signup and view all the answers

Study Notes

Robotic MIG Welding Applications

Robotic MIG welding is used in various applications, including welding of metals and materials.

Safety Awareness When MIG Welding

Welding safety items include:
- Plyers to cut wire to length, remove spatter from the nozzle, and remove weld tip
- Fume extractor nozzle to remove welding fumes
Safety precautions:
- Wear protective clothing, including welding jacket and gloves
- Stand back when welding with minimal exposed skin
- Avoid sunburns, sparks, and heat transfer
- Be aware of UV rays, welding spatter, and hot parts

MIG Weld Basic Path Overview

MIG weld basic path involves a linear move before the weld start position, moving along the tool Z direction, and starting about 50mm away from the start of the weld (Pre-Weld)
The start of the weld must be a fine point

Teaching Practice for MIG Welding

Guidelines for teaching robotic weld path:
- Use a linear move before the weld start position
- Move along the tool Z direction
- Start about 50mm away from the start of the weld (Pre-Weld)
- Common shielding gases used include Argon and CO2

Common Types of Robotic Welding

FCAW (Flux Core Arc Welding):
- Uses a tubular consumable electrode containing flux
- Flux generates gas and liquid slag to protect the weld from the atmosphere
GMAW (Gas Metal Arc Welding):
- A welding process in which an electric arc forms between a consumable wire electrode and the workpiece metal
- Uses a shielding gas to shield the weld from contaminants in the air

MIG Welding Parameters

Variables that affect robotic MIG welding performance:
- Arc voltage (Volts)
- WFS (Wire Feed Speed)
- Robot travel speed
- Wire stick out
Most modern power sources determine a theoretical optimum voltage based on WFS and wire diameter

Weld Modes

Modes depend on:
- Type of material being welded
- Wire size
- Desired weld mode
Pulse mode is used for welding in lab

Trim Breakdown

Optimal wire stick out length varies depending on the application
A good average starting stick out length is 5/8 to 3/4 of an inch (10-19 mm)

Fanuc Weld Path Instructions

Weld torch wire setup:
- Remove wire tip from diffuser
- Feed wire through the whip
- Slide wire tip onto the wire and tighten into the diffuser
Wire feed control:
- Feed wire forward and backward with the pendant using SHIFT and Wire +/-
- Be aware of wire and its spool when feeding wire backward