Weld 120 SMAW Worksheet

Weld 140 GMAW Chapter Reviews
Name: _______________________________________
Date: _____________
SUMMER SCHEDULE
Required Reading: Welding Principals and Applications 7th Edition Larry Jeffus
Due Week 1:
Review Test Chapter 10 – Gas Metal Arc Welding Equipment, Setup and Operation (23 points).
Review Test Chapter 11 – Gas Metal Arc Welding (27 points).
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Weld 140 GMAW Review Test Chapt. 10
Name: _______________________________________
Date: _____________
Required Reading: (Welding Principals and Applications 7th Edition Larry Jeffus Chapter 10)
Review Test Chapter 10 answer all questions 1 through 23 Total Points (23)
1. Why is usage of the term GMAW preferable to MIG for gas metal arc welding?
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2. Using Table 10-1, answer the following:
a. What maintains the arc in machine welding? ____________________
b. What feeds the filler metal in manual welding? ____________________
c. What provides the joint travel in automatic welding? ____________________
d. What provides the joint guidance in semiautomatic welding? ____________________
3. In what form is metal transferred across the arc in the axial spray metal transfer method of GMA
welding?
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4. What three conditions are required for the spray transfer process to occur?
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5. Using Table 10-3, answer the following:
a. What should the wire-feed speed and voltage ranges be to weld 1/8-in. (3 mm) metal with
0.035-in. (0.90mm) wire using argon shielding gas? ____________________
b. What should the amperage and voltage range be using 98% Ar + 2% O2 to weld 1/4-in. metal
with 0.045-in. wire? ____________________
6. What ranges does the pulsed-arc metal transfer shift between?
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7. Why is helium added to argon when making some spray or pulsed-spray transfer welds?
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8. Why does DCEP help with welds on metals such as aluminum?
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Weld 140 GMAW Review Test Chapt. 10
Name: _______________________________________
Date: _____________
9. Why is CO2 added to argon when making GMA spray transfer welds?
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10. *Using Figure 10-12 (page 245), what is the approximate voltage at 150 amps at 200 in./min?
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11. Using Table 10-6, what would the amperage be for 0.035-in. (0.9-mm) wire at 200 in./min (5 m/min)?
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12. What may happen if the GMA welding electrode is allowed to strike the base metal outside of the
molten weld pool?
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13. What effect does shortening the electrode extension have on weld penetration?
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14. Describe the weld produced by a backhand welding angle.
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15. Describe the weld produced by a forehand welding angle.
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16. What components make up a GMA welding system?
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17. Why must GMA welders have a 100% duty cycle?
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18. What can happen if rollers of the wrong shape are used on aluminum wire?
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19. Where is the drive motor located in a pull-type wire-feed system?
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20. How is the wire-feed speed changed with a linear feed system?
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21. What type of liner should be used for aluminum wire?
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Weld 140 GMAW Review Test Chapt. 10
Name: _______________________________________
Date: _____________
22. What parts of a typical GMA welding gun can be replaced?
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23. Describe the spot welding process using a GMA welder.
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Weld 140 GMAW Review Test Chapt. 11
Name: _______________________________________
Date: _____________
Required Reading: (Welding Principals and Applications 7th Edition Larry Jeffus Chapter 11)
Review Test Chapter 11 answer all questions 1 through 27 Total Points (27)
1. What items make up a basic semiautomatic welding system?
_____________________________________________________________________________________
_____________________________________________________________________________________
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2. What must be done to the shielding gas cylinder before the valve protection cap is removed?
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3. Why is the shielding gas valve “cracked” before the flowmeter regulator is attached?
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4. What causes the electrode to bird nest?
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5. Why must all fittings and connections be tight?
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6. What parts should be activated by depressing the gun switch?
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7. What benefit does a welding wire’s cast provide?
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8. What can be done to determine the location of a problem that stops the wire from being successfully
fed through the conduit?
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9. What are the advantages of using a feed roller pressure that is as light as possible?
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10. Why should the feed roller drag prevent the spool from coasting to a stop when the feed stops?
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Weld 140 GMAW Review Test Chapt. 11
Name: _______________________________________
Date: _____________
11. Why must you always wind the wire tightly into a ball or cut it into short lengths before discarding it
in the proper waste container?
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12. What reactive gases are used with argon for GMA welding on steels?
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13. What effect on the welding current does increasing the wire feed speed have?
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14. Why would the flowmeter ball float at different heights with different shielding gases if the shielding
gases are flowing at the same rate?
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15. Using Table 11-1, determine the amperage if 400 in. (10.2 m/min) of 0.45-in. (1.2-mm) steel wire is
fed in one minute.
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16. How is the amperage adjusted on a GMA welder?
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17. What happens to the weld as the electrode extension is lengthened?
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18. What is the effect on the weld of changing the welding angle from a dragging to a pushing angle?
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19. What are the advantages of adding oxygen or CO2 to argon for welds on steel?
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20. What are the advantages of using CO2 for making GMA welds on steel?
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21. What is mill scale?
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22. What type of porosity is most often caused by mill scale?
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23. What should the welder watch if the view of the weld is obstructed by the shielding gas nozzle?
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Weld 140 GMAW Review Test Chapt. 11
Name: _______________________________________
Date: _____________
24. When making a vertical weld and it appears that the weld metal is going to drip over the shelf, what
should you do?
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25. What are the advantages of making vertical down welds?
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26. How can small weld beads be maintained during overhead welds?
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27. How can spatter be controlled on the nozzle when making overhead welds?
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