Weld 120 SMAW Worksheet

Weld 156 GTAW Chapter Reviews
Name: _______________________________________
Date: _____________
SUMMER SCHEDULE
Required Reading: Welding Principals and Applications 7th Edition Larry Jeffus
Due Week 2:
Review Test Chapter 15 – Gas Tungsten Arc Welding Equipment, Setup and Filler Metals (33 points).
Review Test Chapter 16 – Gas Tungsten Welding of Plate (27 points).
Due Week 6:
Review Test Chapter 17 – Gas Tungsten Welding of Pipe (31 points).
Weld 156 GTAW Chapter Reviews Page 1 of 13
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Weld 156 GTAW Review Test Chapt. 15
Name: _______________________________________
Date: _____________
Required Reading: (Welding Principals and Applications 7th Edition Larry Jeffus Chapter 15)
Review Test Chapter 15 answer all questions 1 through 33 Total Points (33)
1. What early advancements made the GTA welding process more effective and reduced its cost?
_____________________________________________________________________________________
2. What metals were weldable only by the GTAW process before GMAW was developed?
_____________________________________________________________________________________
3. Which two of tungsten’s properties make it the best choice for GTA welding?
_____________________________________________________________________________________
4. Why must the tip of the tungsten be hot?
_____________________________________________________________________________________
_____________________________________________________________________________________
5. Why does some tungsten erosion occur?
_____________________________________________________________________________________
6. What function regarding tungsten heat do the collet and torch play?
_____________________________________________________________________________________
_____________________________________________________________________________________
7. What problem can an excessively large tungsten cause?
_____________________________________________________________________________________
8. What holds the molten ball of tungsten in place at the tip of the electrode during DCEP welding?
_____________________________________________________________________________________
9. Using Table 15-1, answer the following:
a. What color identifies EWTh-1? __________________
b. What is the composition of EWCe-2? __________________
10. What does adding thorium oxide do for the tungsten electrode?
_____________________________________________________________________________________
11. How can the end of a tungsten electrode be shaped?
_____________________________________________________________________________________
_____________________________________________________________________________________
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Weld 156 GTAW Review Test Chapt. 15
Name: _______________________________________
Date: _____________
12. Why should a grinding stone that is used for sharpening tungsten not be used for other metals?
_____________________________________________________________________________________
13. Why should the grinding marks run lengthwise on the tungsten electrode end?
_____________________________________________________________________________________
14. What are three ways of breaking off the contaminated end of a tungsten electrode?
_____________________________________________________________________________________
15. What is the correct color to use on the balled end of a pointed and remelted tungsten tip on DCEP?
_____________________________________________________________________________________
16. Why should the torch be as cool as possible?
_____________________________________________________________________________________
17. What will happen to a water-cooled torch cable if the flow of cooling water stops?
_____________________________________________________________________________________
18. Why must shielding gas hoses not be made from rubber?
_____________________________________________________________________________________
19. What materials can be used to make nozzles?
_____________________________________________________________________________________
20. What problem can a long nozzle cause to the tungsten?
_____________________________________________________________________________________
21. Why must the tube of a flowmeter be vertical?
_____________________________________________________________________________________
22. What is the heat distribution with DCEN welding current?
_____________________________________________________________________________________
23. What is the heat distribution with DCEP welding current?
_____________________________________________________________________________________
24. What is the heat distribution with AC welding current?
_____________________________________________________________________________________
25. Why must AC welding power use high frequencies in order to work?
_____________________________________________________________________________________
_____________________________________________________________________________________
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Weld 156 GTAW Review Test Chapt. 15
Name: _______________________________________
Date: _____________
26. Why are argon and helium known as inert gases?
_____________________________________________________________________________________
27. Why is argon’s ease of ionization a benefit?
_____________________________________________________________________________________
28. What makes helium difficult to use for manual welding?
_____________________________________________________________________________________
_____________________________________________________________________________________
29. What are the benefits of adding hydrogen to argon for welding?
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
30. What is the purpose of a hot start?
_____________________________________________________________________________________
_____________________________________________________________________________________
31. Using Table 15-3, determine the gas postflow time for a 3/32-inch (2.4-mm) tungsten.
_____________________________________________________________________________________
32. What functions can a remote control provide the welder?
_____________________________________________________________________________________
33. Using Table 15-4, determine the minimum gas flow rate for a 1/2-inch (13-mm) nozzle.
_____________________________________________________________________________________
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Weld 156 GTAW Chapter Reviews Page 6 of 13
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Weld 156 GTAW Review Test Chapter 16
Name: _______________________________________
Date: _____________
Required Reading: (Welding Principals and Applications 7th Edition Larry Jeffus Chapter 16)
Review Test Chapter 16 answer all questions 1 through 27 Total Points (27)
1. What effect does torch angle have on the shielding gas protective zone?
_____________________________________________________________________________________
2. Why must the end of the filler rod be kept in the shielding gas protective zone?
_____________________________________________________________________________________
_____________________________________________________________________________________
3. What can cause tungsten contamination?
_____________________________________________________________________________________
4. What determines the correct current setting for a GTA weld?
_____________________________________________________________________________________
_____________________________________________________________________________________
5. What is the lowest acceptable amperage setting for GTA welding?
_____________________________________________________________________________________
6. List the factors that affect the gas flow setting for GTA welding.
_____________________________________________________________________________________
_____________________________________________________________________________________
7. When should the minimum gas flow rates be increased?
_____________________________________________________________________________________
8. What is the minimum gas flow rate for a nozzle size?
_____________________________________________________________________________________
9. What is the maximum gas flow rate for a nozzle size?
_____________________________________________________________________________________
_____________________________________________________________________________________
10. Which incorrect welding parameters does stainless steel show clearly?
_____________________________________________________________________________________
_____________________________________________________________________________________
11. Using Table 16-4, determine the approximate temperature of metal that has formed a dark blue color.
_____________________________________________________________________________________
12. Using Tables 16-3, Table 16-5, and Table 16-6, list the filler metals for the following metals.
a. 1020 low carbon steel _________________________________
b. 309 stainless steel _________________________________
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Weld 156 GTAW Review Test Chapter 16
Name: _______________________________________
Date: _____________
13. Why is it possible to control a large aluminum weld bead?
_____________________________________________________________________________________
14. What may happen to the end of the aluminum welding rod if it is held too close to the arc?
_____________________________________________________________________________________
15. What should be done if someone comes in contact with a cleaning chemical?
_____________________________________________________________________________________
_____________________________________________________________________________________
16. Using Table 16-7, determine the suggested setting for GTA welding of mild steel using a 3/32-in.
(2.4-mm) tungsten.
_____________________________________________________________________________________
_____________________________________________________________________________________
17. What can be done to limit oxide formation on stainless steel?
_____________________________________________________________________________________
18. How should the filler metal be added to the molten weld pool?
_____________________________________________________________________________________
19. How can the rod be freed if it sticks to the plate?
_____________________________________________________________________________________
20. How is an outside corner joint assembled?
_____________________________________________________________________________________
_____________________________________________________________________________________
21. What must be done with the weld craters when back stepping a weld? Why?
_____________________________________________________________________________________
22. How is the lap joint tested for 100% penetration?
_____________________________________________________________________________________
23. What can prevent both sides of a stainless steel tee joint from being welded?
_____________________________________________________________________________________
24. How is the filler metal added for a 3F weld?
_____________________________________________________________________________________
_____________________________________________________________________________________
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Weld 156 GTAW Review Test Chapter 16
Name: _______________________________________
Date: _____________
25. What can cause undercutting on a 3F tee joint?
_____________________________________________________________________________________
_____________________________________________________________________________________
26. What helps hold the weld in place on a 2F lap joint?
_____________________________________________________________________________________
27. What helps hold the weld in place on a 4G weld?
_____________________________________________________________________________________
_____________________________________________________________________________________
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Weld 156 GTAW Review Test Chapt. 17
Name: _______________________________________
Date: _____________
Required Reading: (Welding Principals and Applications 7th Edition Larry Jeffus Chapter 17)
Review Test Chapter 17 answer all questions 1 through 31 Total Points (31)
1. What types of industries require GTAW-quality pipe welds?
_____________________________________________________________________________________
2. What are the grooves most often used for welding on mild steel pipe?
_____________________________________________________________________________________
3. What condition must the prepared edges of a pipe be in before welding?
_____________________________________________________________________________________
4. How is the depth of root penetration measured?
_____________________________________________________________________________________
_____________________________________________________________________________________
5. What problem can incomplete fusion cause?
_____________________________________________________________________________________
_____________________________________________________________________________________
6. What are the common causes of a concave root surface?
_____________________________________________________________________________________
_____________________________________________________________________________________
7. What problems can excessive root reinforcement cause?
_____________________________________________________________________________________
_____________________________________________________________________________________
8. What can cause root contamination?
_____________________________________________________________________________________
_____________________________________________________________________________________
9. What gases are used as backing gases?
_____________________________________________________________________________________
10. How long would it take to purge a 15-ft section of 6-in.-diameter pipe using a flow rate of 35 cfh?
a. V = _____________________________________________
b. FR = _____________________________________________
c. T = _____________________________________________
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Weld 156 GTAW Review Test Chapt. 17
Name: _______________________________________
Date: _____________
11. How long would it take to purge a 10-mm section of a 20-cm-diameter pipe using a flow rate of 17
L/min?
a. V = _____________________________________________
b. FR= _____________________________________________
c. T= _____________________________________________
12. How can filler metal be added to make a root pass?
_____________________________________________________________________________________
13. What information must be supplied when ordering consumable inserts?
_____________________________________________________________________________________
14. How is the tack weld ended so that it will not crack?
_____________________________________________________________________________________
15. What is the 1G pipe position?
_____________________________________________________________________________________
16. After the weld is set up and ready to begin, how might the welder want to check for freedom of
movement?
_____________________________________________________________________________________
17. What type of weld can be made using the nozzle walking technique?
_____________________________________________________________________________________
18. What two problems can be corrected by a hot pass?
_____________________________________________________________________________________
19. Why must you brace yourself when making a weld?
_____________________________________________________________________________________
20. What can happen to the weld pool if the torch movement is too long?
_____________________________________________________________________________________
21. What technique should be used when stopping a weld?
_____________________________________________________________________________________
_____________________________________________________________________________________
22. What is the maximum width that a weave pattern should be?
_____________________________________________________________________________________
23. Why should the filler pass penetration be limited in depth?
_____________________________________________________________________________________
_____________________________________________________________________________________
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Weld 156 GTAW Review Test Chapt. 17
Name: _______________________________________
Date: _____________
24. How much filler metal should be added to a filler bead?
_____________________________________________________________________________________
25. How large should a cover pass be on a pipe with a 1/4-in. (6-mm) wall thickness?
_____________________________________________________________________________________
_____________________________________________________________________________________
26. What is the 5G pipe position?
_____________________________________________________________________________________
27. Why should the starting point of the beads be staggered?
_____________________________________________________________________________________
_____________________________________________________________________________________
28. How should the torch be held to allow good visibility on a 2G weld?
_____________________________________________________________________________________
29. Why should the root bead be small on a 2G weld?
_____________________________________________________________________________________
30. Why are stringer beads in the 6G position kept small?
_____________________________________________________________________________________
31. Why are the downhill side filler welds put in first on 6G pipe?
_____________________________________________________________________________________
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