Welding Defects and Remedies Quiz
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Questions and Answers

What is a possible cause of lack of penetration in welding?

  • Arc length too long
  • Excessive heat input
  • Voltage too low
  • Improper joint penetration (correct)

Which corrective action can be taken to address burn through?

  • Select lower amperage (correct)
  • Use a larger electrode
  • Increase travel speed
  • Reduce arc length

What is one way to manage distortion during the welding process?

  • Weld with a longer electrode
  • Increase voltage significantly
  • Maximize travel speed
  • Use restraint clamp (correct)

Which of the following is NOT a corrective action for high voltage/amperage issues?

<p>Increase arc length (D)</p> Signup and view all the answers

What is a likely cause for excessive heat input in welding?

<p>Incorrect travel speed (D)</p> Signup and view all the answers

What defines welding defects?

<p>Weld surface irregularities and imperfections. (A)</p> Signup and view all the answers

What is porosity in welding?

<p>Small cavities or holes in the weld metal. (C)</p> Signup and view all the answers

Which corrective action is recommended for reducing porosity caused by a long arc length?

<p>Reduce the arc length. (A)</p> Signup and view all the answers

What can cause excessive spatter in welding?

<p>Voltage or amperage being too high for the electrode. (B)</p> Signup and view all the answers

Which of the following is a corrective action for excessive spatter due to high voltage?

<p>Decrease amperage or select a larger electrode. (D)</p> Signup and view all the answers

What is a corrective action to reduce distortion in welding?

<p>Weld in small segments and allow cooling between welds. (A)</p> Signup and view all the answers

Which of the following is a possible cause of incomplete fusion in welding?

<p>Workpiece dirty. (D)</p> Signup and view all the answers

What corrective action can be taken to address excessive penetration in welds?

<p>Select lower amperage. (A)</p> Signup and view all the answers

Which factor is NOT a cause of excessive heat input in welding?

<p>Lower travel speeds. (B)</p> Signup and view all the answers

What is a recommended action to prevent incomplete fusion?

<p>Hold the arc on the groove side walls when using the weaving technique. (A)</p> Signup and view all the answers

Flashcards

High Voltage/Amperage Issues

Welding issues caused by voltage or amperage settings being too high, or excessive arc length leading to incorrect weld quality.

Lack of Penetration

Welding issue where the weld doesn't fully penetrate the joint.

Burn Through

Welding issue caused by excessive heat input, resulting in the weld puddle melting through.

Distortion in Welding

Welding issue with unwanted shape changes caused by heat input impacting the base metal.

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Corrective Actions for Amperage

Adjusting amperage to address welding issues like lack of penetration, burn through, or distortion, by either increasing or decreasing.

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Welding Defects

Irregularities, discontinuities, and imperfections in welded parts.

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Porosity Cause - Arc Length

Large gaps in welds caused by excessive space between the welding electrode and the workpiece.

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Porosity Remedy: Dirty Work Piece

Cleaning the work surface before welding prevents trapped gas and porosity.

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Excessive Spatter Cause - High Voltage

Too much molten metal flying off the welding arc caused by high voltage settings.

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Spatter Remedy - Correct Current

Lower the welding current to reduce molten material ejection.

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Welding Distortion

Unwanted shape changes in the weld caused by heat affecting the base metal.

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Incomplete Fusion

Weld does not fully join the base; it's like a gap.

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Excessive Penetration

Weld goes too deep into the base.

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Excessive Heat Input

Using too much heat during welding.

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Welding Restraint

Holding the metal in place using clamps to prevent distortion during welding.

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Study Notes

Welding Defects, Causes, and Remedies

  • Welding defects are surface irregularities, discontinuities, or inconsistencies in welded parts.
  • Defects can lead to rejection of parts, costly repairs, and reduced performance.
  • In extreme cases, catastrophic failures with loss of property and life are possible.

Porosity

  • Possible Causes:

    • Arc length too long
    • Work piece dirty
    • Damp electrode

  • Corrective Actions:

    • Reduce arc length
    • Remove grease, oil, rust, paint, coating, slag & dirt from work surface before welding.
    • Use dry electrode

Excessive Spatter

  • Possible Causes:

    • Voltage too high amperage too high for electrode
    • Arc length too long or voltage too high

  • Corrective Actions:

    • Decrease amperage or select larger electrode
    • Reduce arc length or voltage

Lack of Penetration

  • Possible Causes:

    • Improper joint penetration
    • Improper weld technique
    • Insufficient heat input

  • Corrective Actions:

    • Material too thick, joint penetration & design must provide access to bottom of groove
    • Keep arc on leading of weld puddle
    • Reduce travel speed/increase amperage, select larger electrode & increase amperage

Burn Through

  • Possible Causes:

    • Excessive heat input

  • Corrective Actions:

    • Select lower amperage, use smaller electrode
    • Increase/ maintain steady travel speed

Distortion

  • Possible Causes:

    • Excessive heat input

  • Corrective Actions:

    • Use restraint clamp to hold base metal in position
    • Make tack weld along joint before starting weld operations
    • Predict anticipated weld distortion & pre camber base metal
    • Select lower amperage for electrode
    • Increase travel speed
    • Weld in small segments & allow cooling between welds

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Description

Test your knowledge on common welding defects, their causes, and corrective actions. This quiz covers various issues such as porosity, excessive spatter, and lack of penetration, providing insights into maintaining weld quality. Perfect for students and professionals in the welding field.

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