Deck 13: Flux Cored Arc Welding

Question 1

Backing strips used in root passes are usually made from a piece of metal that is ____ thick and ____ wide.

A) 1 inch, 1/4 inch
B) 1/2 inch, 2 inches
C) 1/2 inch, 1 inch
D) 1/4 inch, 1 inch

Answer 1

D

Question 2

The ____ pass is used to fill the groove with weld metal.

A) root
B) filler
C) cover
D) guard

Answer 2

B

Question 3

Which of the following is true of thin-gauge welding?

A) It is rarely done with fillet welds.
B) It usually uses a butt-type joint.
C) It is rarely used to join a thin member to a thicker member.
D) It is the type of weld used to put panels in frames.

Answer 3

D

Question 4

The backing strip should be ____ longer than the base plates to serve as startup and runoff tabs for the weld.

A) 1 inch
B) 2 inches
C) 3 inches
D) 4 inches

Question 5

To achieve complete root fusion, move ____ the leading edge of the weld pool.

A) the arc as close as possible to
B) the base plate as close as possible to
C) the arc as far as possible from
D) the base plate as far as possible from

Question 6

A short-out of the contact tube will ____.

A) cause a skip in the weld bead
B) destroy the tube
C) cause excess spatter
D) increase circuit resistance

Question 7

Which of the following is true of FCA welding?

A) It produces little ultraviolet light.
B) Forced ventilation and possibly a respirator must be used.
C) Special protective clothing is not necessary.
D) It produces very little fumes.

Question 8

A fillet weld is the type of weld made on ____.

A) stringer beads
B) weave beads
C) a V-groove joint
D) a lap or tee joint

Question 9

Too large a ____ pass can trap slag under overlap along the lower edge of the weld.

A) root
B) filler
C) cover
D) guard

Question 10

A major skill requirement for making consistently accurate FCA welds is ________________.

A) knowing your skill limitations
B) not to drink coffee because it can cause your hand to shake too much
C) the ability to set up the welding system
D) to use smaller diameter electrode wire sizes

Question 11

What can cause the filler wire to form a bird's nest?

A) Too high of a wire feed speed and too low of an amperage setting.
B) The wire not going through the outfeed side conduit.
C) Too loose of a tension on the wire feed rollers.
D) The wrong type of wire feed rollers for the wire being used.

Question 12

The ____ pass establishes the depth of weld metal penetration.

A) root
B) filler
C) cover
D) guard

Question 13

Too light a roller pressure will ____.

A) cause the wire to feed erratically
B) crush some wires
C) cause flux to be dropped inside the wire liner
D) jam the gun

Question 14

Which of the following is true of weld penetration into the base metal at the start of a bead?

A) It can be obtained by using a quick start.
B) It can be obtained by quickly reversing the weld direction.
C) It is not possible for the start of the weld to have deep penetration.
D) Excess heat prevents deep penetration.

Question 15

A small molten weld pool can be achieved by using ____ current settings and ____ traveling speeds

A) lower, slower
B) lower, faster
C) higher, slower
D) higher, faster

Question 16

FCA welding practice plates thicker than 1/2 inch ____.

A) can be shorter than 12 inches
B) must be shorter than 12 inches
C) must be greater than 12 inches
D) must be greater than 7 inches

Question 17

Why do some wire reels have covers?

A) To keep the wire from slipping off of the reel and tangling each time the wire feed stops.
B) To protect them from dirt and dust.
C) So it will be easier to rewind the wire after your test runs have been completed.
D) It makes it easier to install new wire reels when needed.

Question 18

What is the advantage of cutting out old FCA practice welds?

A) So the practice plates can be reused.
B) To give you more practice with a cutting torch.
C) To make the pieces of scrap smaller and easier to recycle.
D) It is a way of making your practice weld smaller and lighter to carry in your backpack.

Question 19

The ____ pass is the last weld pass on a multipass weld.

A) root
B) filler
C) cover
D) guard

Question 20

The welding wire conduit must be securely attached to the gas diffuser and ____ to prevent wire jams caused by misalignment.

A) solenoid
B) gun lead
C) contact tube
D) power source

Question 21

What is the maximum reinforcement for the cover pass?

A) 1/16 in. (1.5 mm)
B) 1/32 in. (0.8 mm)
C) 1/8 in. (3 mm)
D) 3/32 in. (2.4 mm)

Question 22

When making the lap or tee joints of a fillet weld in the flat position, the plates must be at a(n) ____________________ degree angle so that the surface of the weld will be flat.

Question 23

Explain the criteria for evaluating a cover pass.

Question 24

Describe what to do if burn-through occurs.

Question 25

FCAW is set up and manipulated in a manner similar to that of ____________________.

Question 26

What can happen if the plates of a tee joint are held tightly together?

A) The joint overall tolerance may not be within specifications.
B) Underbead cracking or lamellar tearing can occur.
C) It makes it more difficult to see the root weld.
D) The root of the weld may not have 100% fusion.

Question 27

If the molten weld pool is large and fluid, use a "C" or "J" ____________________ to allow a longer time for the molten weld pool to cool.

Question 28

A tack weld added to the center of a lap joint prevents ____________________.

Question 29

How much should stringer beads overlap on a filler pass?

A) 10 to 20%
B) 25 to 5-%
C) 60% or more
D) The edge should not overlap at all.

Question 30

Base plate cracking can be controlled by placing ____________________ in the joint before welding.

Question 31

A weld that is high and has little or no fusion is too ____________________.

Question 32

Summarize the disadvantages of having to bevel a plate prior to welding.

Question 33

Explain why proper set up of an FCA weld station is important.

Question 34

How is a plate prepared for a plug weld?

A) The edge of the plate is ground smooth.
B) The top plate is hammered flat onto the bottom plate.
C) A hole is cut or drilled in the top plate.
D) It is tack welded along the side near the hole to be welded.

Question 35

Faster travel speed and/or slightly wider weave patterns can be used to control the ____________________.

Question 36

Sometimes plug welds are used to make ________ welds that would not show after the weldment is finished.

Question 37

If an open-root weld is needed, the root pass may be put in with a(n) ____________________ electrode.

Question 38

Open-root joints are often avoided on ____________________ welds.

Question 39

Explain how to thread FCAW wire.

Question 40

What is an advantage of making a square-groove weld?

A) The welds are more uniform in width.
B) It is easier to follow the joint and make straight welds.
C) You never need to use any weave to make the weld.
D) Less heat input in the joint means less distortion.