WIT-07
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WIT-07

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What is a chief advantage of gas metal arc welding (GMAW)?

  • Reduction in labor costs due to lbs/hr of metal deposited (correct)
  • Ability to draw atmospheric gases into the weld zone
  • Relatively clean process due to the presence of flux
  • High portability of the equipment

    • What is a disadvantage of gas metal arc welding (GMAW) compared to shielded metal arc welding (SMAW)?

  • Increased possibility of mechanical problems affecting weld quality (correct)
  • Requirement for frequent electrode changes
  • Higher complexity of equipment
  • Higher chance of atmospheric gas contamination

    • What contributes to the increased operator productivity in gas metal arc welding (GMAW)?

  • Continuous spool of wire requiring less frequent changes than individual electrodes in SMAW (correct)
  • Presence of flux ensuring a clean process
  • Versatility of equipment and electrodes
  • High flow rates drawing atmospheric gases into the weld zone

    • What is a benefit of gas metal arc welding (GMAW) in terms of process cleanliness?

    <p>Relatively clean process due to absence of flux</p> Signup and view all the answers

    What do the suffixes 3, 4, 6, 7, 8, 10, 11, 13, and 14 designate for Flux Cored Arc Welding (FCAW) electrodes?

    <p>Tensile strength</p> Signup and view all the answers

    What does the two-digit number marked on FCAW electrodes indicate?

    <p>Tensile strength and welding position suitability</p> Signup and view all the answers

    What are the two main types of FCAW defined as?

    <p>FCAW-G and FCAW-S</p> Signup and view all the answers

    What gas combinations are used for FCAW-G?

    <p>CO2 or 75% Argon—25% CO2</p> Signup and view all the answers

    In which industries is FCAW gaining acceptance?

    <p>Construction and shipbuilding</p> Signup and view all the answers

    What type of materials is FCAW widely used for?

    <p>Ferrous materials only</p> Signup and view all the answers

    What does FCAW provide in terms of productivity and arc penetration?

    <p>High productivity and deep arc penetration</p> Signup and view all the answers

    How does FCAW compare to GMAW in terms of base metal contamination tolerance?

    <p>FCAW can tolerate more contamination than GMAW</p> Signup and view all the answers

    What are some discontinuities that FCAW is subject to?

    <p>Incomplete joint penetration, slag inclusions, and porosity</p> Signup and view all the answers

    What type of electrode does Gas Tungsten Arc Welding (GTAW) use?

    <p>Non-consumable tungsten electrode</p> Signup and view all the answers

    What are the limitations of GTAW?

    <p>Need for smoke extraction systems and potential health hazards</p> Signup and view all the answers

    How does the equipment required for FCAW compare to that for SMAW?

    <p>FCAW equipment is more complex than SMAW equipment</p> Signup and view all the answers

    What is a characteristic of Gas Tungsten Arc Welding (GTAW)?

    <p>Produces high-quality welds with an excellent visual appearance</p> Signup and view all the answers

    What is true about filler metals in Gas Tungsten Arc Welding (GTAW)?

    <p>Numerous filler metals exist in wire form for a wide range of metal alloys</p> Signup and view all the answers

    What is a challenge of Gas Tungsten Arc Welding (GTAW)?

    <p>Requires extremely clean base and filler metals</p> Signup and view all the answers

    What can lead to porosity in the weld deposit in Gas Tungsten Arc Welding (GTAW)?

    <p>Contamination from base metal, filler metal, or shielding gas</p> Signup and view all the answers

    What covers the solidified weld metal in Submerged Arc Welding (SAW)?

    <p>Slag and still-granular flux</p> Signup and view all the answers

    What does Submerged Arc Welding (SAW) use for specific applications?

    <p>Separate electrode and flux</p> Signup and view all the answers

    What does the American Welding Society identification system consist of for Submerged Arc Welding (SAW)?

    <p>Designations for both the electrode and flux</p> Signup and view all the answers

    What components are used in the equipment for submerged arc welding?

    <p>Wire feeders, power sources, and welding torches</p> Signup and view all the answers

    What is 'hand held SAW' in semi-automatic Submerged Arc Welding (SAW)?

    <p>The operator provides the travel along the joint</p> Signup and view all the answers

    What type of power source is mostly used in submerged arc welding?

    <p>Constant voltage</p> Signup and view all the answers

    What are common problems in Gas Tungsten Arc Welding (GTAW)?

    <p>Tungsten inclusions, porosity, and contamination</p> Signup and view all the answers

    What are common problems in Submerged Arc Welding (SAW)?

    <p>Slag and granular flux covering the solidified weld metal</p> Signup and view all the answers

    What is the primary element required for gas tungsten arc welding (GTAW)?

    <p>Power source</p> Signup and view all the answers

    Which inert gases are typically used for shielding in gas tungsten arc welding (GTAW)?

    <p>Argon and helium</p> Signup and view all the answers

    What does the presence of thoria or zirconia aid in for gas tungsten arc welding?

    <p>Improving the electrical characteristics of tungsten</p> Signup and view all the answers

    What type of current is most commonly used for welding steels in gas tungsten arc welding (GTAW)?

    <p>DCEN</p> Signup and view all the answers

    What is the primary purpose of the flux in flux-cored arc welding (FCAW)?

    <p>To provide shielding for the molten weld metal</p> Signup and view all the answers

    What is critical to maintain in flux-cored arc welding (FCAW) to prevent solidified slag from becoming trapped in the finished weld?

    <p>Proper travel speed</p> Signup and view all the answers

    What type of welding power sources have been developed for welding aluminum in gas tungsten arc welding (GTAW)?

    <p>Square Wave AC</p> Signup and view all the answers

    What is the primary method for adding filler metal in gas tungsten arc welding (GTAW)?

    <p>Manually</p> Signup and view all the answers

    What is the classification letter that stands for electrode in the AWS tungsten electrode classification system?

    <p>E</p> Signup and view all the answers

    What does GTAW stand for?

    <p>Gas Tungsten Arc Welding</p> Signup and view all the answers

    What is the ability of gas tungsten arc welding (GTAW) that makes it suitable for use on extremely thin metals?

    <p>Welding at extremely low currents</p> Signup and view all the answers

    What is the purpose of the high frequency generator in gas tungsten arc welding (GTAW)?

    <p>Aids in the initiation of the welding arc</p> Signup and view all the answers

    What type of current is typically used for welding aluminum in Gas Tungsten Arc Welding (GTAW)?

    <p>AC</p> Signup and view all the answers

    What type of gas is commonly used for shielding in Gas Tungsten Arc Welding (GTAW)?

    <p>Argon</p> Signup and view all the answers

    What is the purpose of thoria or zirconia in tungsten electrodes in Gas Tungsten Arc Welding (GTAW)?

    <p>Enhances arc initiation and electrical characteristics</p> Signup and view all the answers

    What type of electrode is typically used for aluminum welding in Gas Tungsten Arc Welding (GTAW)?

    <p>Pure tungsten electrode</p> Signup and view all the answers

    What type of power source is required for Gas Tungsten Arc Welding (GTAW) equipment?

    <p>Constant current power source</p> Signup and view all the answers

    What is the purpose of a high frequency generator in Gas Tungsten Arc Welding (GTAW)?

    <p>Aids in arc initiation</p> Signup and view all the answers

    What type of current can be used in Gas Tungsten Arc Welding (GTAW)?

    <p>DCEP, DCEN, or AC</p> Signup and view all the answers

    What is the primary purpose of filler metal in Gas Tungsten Arc Welding (GTAW)?

    <p>Contribute to the weld pool</p> Signup and view all the answers

    What is the purpose of a remote current control in Gas Tungsten Arc Welding (GTAW)?

    <p>To adjust arc length</p> Signup and view all the answers

    What are the common industries where Gas Tungsten Arc Welding (GTAW) has numerous applications?

    <p>Aerospace and petrochemical</p> Signup and view all the answers

    What is the primary method of gas shielding in Gas Tungsten Arc Welding (GTAW)?

    <p>Inert gas flow over the weld pool</p> Signup and view all the answers

    What type of electrode classification system is used for tungsten electrodes in Gas Tungsten Arc Welding (GTAW)?

    <p>Color code system</p> Signup and view all the answers

    What is a primary problem associated with Gas Metal Arc Welding (GMAW)?

    <p>Porosity</p> Signup and view all the answers

    What can cause arc instability in Gas Metal Arc Welding (GMAW)?

    <p>Contamination or loss of shielding</p> Signup and view all the answers

    Why is Gas Metal Arc Welding (GMAW) considered unsuitable for field welding?

    <p>Sensitive to drafts or wind</p> Signup and view all the answers

    What type of electrode does Flux Cored Arc Welding (FCAW) use?

    <p>Tubular electrode containing granular flux</p> Signup and view all the answers

    What does excessive moisture in the gas supply cause in Flux Cored Arc Welding (FCAW)?

    <p>Porosity</p> Signup and view all the answers

    What does the electrode identification system for Flux Cored Arc Welding (FCAW) denote?

    <p>Minimum tensile strength, electrode type, and chemical composition</p> Signup and view all the answers

    What can certain classifications of Flux Cored Arc Welding (FCAW) electrodes be performed without?

    <p>Additional shielding other than that contained within the electrode</p> Signup and view all the answers

    What is a key advantage of Gas Metal Arc Welding (GMAW) over Flux Cored Arc Welding (FCAW)?

    <p>Enhanced control due to the absence of slag</p> Signup and view all the answers

    What is a limitation of Gas Metal Arc Welding (GMAW) compared to Flux Cored Arc Welding (FCAW)?

    <p>Lower deposition rates</p> Signup and view all the answers

    What is a characteristic of Flux Cored Arc Welding (FCAW) electrodes?

    <p>Some are designed to provide all necessary shielding internally</p> Signup and view all the answers

    What is a crucial factor in alleviating problems associated with unstable wire feeding in Gas Metal Arc Welding (GMAW)?

    <p>Equipment maintenance</p> Signup and view all the answers

    How can porosity be reduced in Gas Metal Arc Welding (GMAW)?

    <p>Cleaning parts before welding and protecting the weld zone from excessive wind</p> Signup and view all the answers

    Study Notes

    Welding Inspection Technology: Metal Joining and Cutting Processes

    • Gas Tungsten Arc Welding (GTAW) is known for producing high-quality welds with an excellent visual appearance and is suitable for welding most metals, including thin sections.
    • GTAW can be performed without additional filler metal if joint design permits, but numerous filler metals exist in wire form for a wide range of metal alloys.
    • GTAW is slow compared to other welding processes, requires extremely clean base and filler metals, and demands a high skill level when used as a manual process.
    • Contamination from base metal, filler metal, or shielding gas can lead to porosity in the weld deposit, and tungsten inclusions are a common problem in GTAW due to various reasons such as contact of the electrode tip with molten metal and inadequate tightening of the collet.
    • Slag and still-granular flux cover the solidified weld metal in Submerged Arc Welding (SAW), and the granular flux can be salvaged and mixed with new flux for reuse.
    • SAW uses a separate electrode and flux, with combinations available for specific applications to provide an alloyed weld deposit.
    • The American Welding Society identification system consists of designations for both the electrode and flux to properly describe the filler material for SAW.
    • The equipment used for submerged arc welding includes components like wire feeders, power sources, and welding torches, and can be used as a fully mechanized or semiautomatic method.
    • In semiautomatic SAW, the wire and flux are fed through a gun, and the operator provides the travel along the joint, known as "hand held SAW."
    • Most submerged arc welding is performed with a constant voltage power source, but there are certain applications where a constant current type is preferred.
    • Tungsten inclusions, porosity, and contamination are common problems in gas tungsten arc welding, while submerged arc welding involves slag and granular flux covering the solidified weld metal.
    • Gas Tungsten Arc Welding (GTAW) is slow compared to other welding processes, requires extremely clean base and filler metals, and demands a high skill level when used as a manual process.

    Gas Metal Arc Welding (GMAW) and Flux Cored Arc Welding (FCAW) Processes

    • GMAW allows the welder to observe the arc and molten puddle easily, enhancing control due to the absence of slag.
    • Primary inherent problems in GMAW include porosity, incomplete fusion, and arc instability caused by contamination or loss of shielding, short circuiting transfer, and worn liners and contact tips.
    • To reduce porosity, parts should be cleaned before welding and the weld zone should be protected from excessive wind using enclosures or windbreaks.
    • Excessive moisture in the gas supply can cause porosity, and the use of shielding gas instead of flux can also lead to porosity if the base metal is excessively contaminated.
    • GMAW is sensitive to drafts or wind, making it unsuitable for field welding.
    • Incomplete fusion is a real problem for GMAW, especially when short circuiting transfer is used, as the absence of flux can lead to arc instability.
    • Increasing the gas flow rate above recommended limits will not guarantee adequate shielding, and high flow rates may increase the possibility of porosity.
    • Equipment maintenance is crucial in alleviating problems associated with unstable wire feeding in GMAW.
    • Flux Cored Arc Welding (FCAW) uses a tubular electrode containing granular flux instead of solid wire.
    • FCAW electrodes may or may not require an externally-supplied shielding gas, and some are designed to provide all necessary shielding internally.
    • The electrode identification system for FCAW denotes the minimum tensile strength, electrode type, and chemical composition, among other specific information for the category.
    • Certain classifications of FCAW electrodes can be performed without any additional shielding other than that contained within the electrode.

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    Welding Inspection Technology PDF

    Description

    Test your knowledge of welding inspection technology with this quiz on gas tungsten arc welding (GTAW) and submerged arc welding (SAW) processes. Learn about the equipment, filler metals, common problems, and applications of these metal joining and cutting techniques.

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