Deck 20: Shop Math and Weld Cost

Question 1

A ____ is a number that uses a decimal point to denote a unit that is smaller than 1.

A) fraction
B) mixed unit
C) decimal fraction
D) whole number

Answer 1

C

Question 2

Because ____ costs are figured on an hourly basis, they can be controlled only by increasing productivity.

A) scrap
B) material
C) process
D) labor

Answer 2

D

Question 3

To reduce any number of inches equal to or larger than 12 to feet and inches, you divide the inches by ____.

A) 10
B) 12
C) 14
D) 16

Answer 3

B

Question 4

A ____ is two or more numbers used to express a unit smaller than one.

A) fraction
B) decimal fraction
C) whole number
D) mixed unit

Question 5

Postwelding cleanup, grinding, and painting add to the weldment's ____ cost.

A) process
B) material
C) finishing
D) overhead

Question 6

The weight of weld metal required to fill the groove or make the fillet weld is determined by ____.

A) multiplying the weld volume times the density of the metal
B) dividing the weld volume by the density of the metal
C) adding the weld volume and the density of the metal
D) subtracting the weld volume from the density of the metal

Question 7

For groove welds, knowing the ____, the filler metal volume can be calculated.

A) bevel angle
B) root opening
C) bead depth
D) plate thickness

Question 8

____ costs include building rent or mortgage, advertising, insurance, utilities, taxes, licenses, governmental fees, accounting, loan payments, and property upkeep.

A) Scrap
B) Overhead
C) Material
D) Process

Question 9

It is often possible to help control ____ costs by getting bids from several suppliers and combining as many jobs as possible in order to get any discount for larger quantities purchased.

A) overhead
B) material
C) finishing
D) process

Question 10

Most weldments use a tolerance of ± ____ inch or ± ____ inch.

A) 1/32, 1/16
B) 1/16, 1/8
C) 1/8, 1/4
D) 1/4, 1/2

Question 11

The cross-sectional area of the weld groove is equal to ____.

A) the root opening times the bevel depth
B) the plate thickness times the root gap
C) one-half of the root opening times the bevel depth
D) the groove volume times the weld length

Question 12

____ use(s) units of degrees, minutes, and seconds.

A) Weight
B) Time
C) Angular dimensions
D) Linear dimensions

Question 13

____ is the math that most welders use on a daily basis.

A) Geometry
B) Trigonometry
C) Arithmetic
D) Calculus

Question 14

Because it is difficult for most manual welding to work with fractions smaller than ____ of an inch, these smaller dimensions are not commonly used in fabrication.When they are used, it is most often with some form of automated or machine welding or cutting process.

A) 1/16
B) 1/8
C) 1/4
D) 1/2

Question 15

The deposition efficiency of the argon-shielded GMA process is about ____%.

A) 85
B) 90
C) 95
D) 100

Question 16

____ are measurements containing numbers that are expressed in two or more different units.

A) Fractions
B) Decimal fractions
C) Whole numbers
D) Mixed units

Question 17

In the ____ process, when the loss due to flux handling and flux recovery systems is considered, the average ratio of flux to wire is approximately 1.4 pounds of flux for each pound of wire consumed.

A) FCAW
B) SMAW
C) GMAW
D) SAW

Question 18

____ are numbers used to express units in increments of 1, so they can be divided evenly by the number 1.

A) Decimal fractions
B) Whole numbers
C) Mixed units
D) Fractions

Question 19

____ use(s) units of feet and inches (SI: meters, centimeters, and millimeters).

A) Angular dimensions
B) Linear dimensions
C) Weight
D) Time

Question 20

The deposition rate will ____ as the welding current is ____.

A) decrease, maintained
B) decrease, increased
C) increase, decreased
D) increase, increased

Question 21

A(n) ____________________ is a mathematical statement of the relationship of items.

Question 22

____________________ are commonly used in welding fabrication for dimensioning a distance that is less than an inch.

Question 23

​Why is it that small job shops often continue using the SMAW process even though it has a relatively low operating factor?

A) ​The setup time for some more efficient processes can be lengthy and that can cause the operating factor to drop.
B) ​Most small shops would not have the necessary skills to operate a GMA or FCA welding system.
C) ​More productive welding processes are not available to small shops.
D) ​Most welders would rather stick weld anyway.

Question 24

​Which of the following would not be on a bill of materials?

A) ​operating factor
B) ​pounds of filler metal
C) ​shop time
D) ​quantity of metal

Question 25

The ____ of a welding process refers to the percentage of the welding filler material that actually becomes part of the weld deposit.

A) deposition rate
B) deposition efficiency
C) productivity rate
D) productivity efficiency

Question 26

To add 1/2 and 1/16 where both denominators are different, you must first find the ____________________.

Question 27

​What is the area of a square that is 21.5 ft.by 10 ft.?

A) ​250 ft2
B) ​215 ft2
C) ​430 ft2
D) ​2.15 ft2

Question 28

A compelling reason for replacing covered electrodes with ____ wires is that the deposition rates in the vertical position can be increased from about 2 lb.per hour to over 5 lb.per hour.

A) large diameter solid
B) small diameter solid
C) large diameter cored
D) small diameter cored

Question 29

​How many cubic yards of concrete would be needed to fill a foundation hole that is 3 ft.wide, 6 ft.long and 3 ft.deep?

A) ​1
B) ​2
C) ​3
D) ​6

Question 30

​How does the flux in a FCAW wire compare to a SMAW electrode and what does it affect?

A) ​FCAW has less flux but the wire is fed into the weld faster so there is more slag on a weld as compared to a SMA weld.
B) ​Both processes' filler metals have the same amount of flux, but only the FCAW flux gets pushed deeper into the molten weld pool.
C) ​FCAW wire has a lower flux to metal ratio so it is more efficient than SMAW.
D) ​SMAW filler rods are a lot bigger than FCAW wire but there is more flux to filler metal in the FCAW filler wire.

Question 31

A 45% (0.45) operating factor means that only 45% of the welder's day is spent on ____.

A) welding and installing a new electrode or wire
B) welding
C) welding and cleaning spatter from the welding gun
D) welding and cleaning slag

Question 32

​What are some of the applications of angles in welding?

A) ​To lay out parts for cutting.
B) ​To locate the spot for drilling.
C) ​To align parts for welding.
D) ​All of the above

Question 33

When using solid or flux cored wires, the deposition rate will ____ as the electrical stickout is ____ and the same welding current is maintained.

A) increase, increased
B) increase, decreased
C) decrease, maintained
D) decrease, increased

Question 34

​Convert 0.6875 to a fraction.

A) ​23/32
B) ​43/64
C) ​11/16
D) ​23/32

Question 35

​Which of the following is not part of the labor cost?

A) ​benefits
B) ​overtime
C) ​tool rental
D) ​hourly rate of pay

Question 36

The most common use of math in welding shops is for ____________________ and pricing.

Question 37

The formula for efficiency including stub loss is important.It must always be used when estimating the cost of depositing weld metal by the ____ method.

A) SMAW
B) SAW
C) GMAW
D) FCAW

Question 38

​Which welding process has the lowest operating factor?

A) ​GMAW
B) ​GTAW
C) ​SMAW
D) ​FCAW

Question 39

​What is the name of a triangle that has two sides that are the same and two angles that are the same?

A) right triangle
B) ​equilateral triangle
C) ​isosceles triangle
D) ​None of the above

Question 40

____________________ costs are those expenses that must be paid each and every day, week, month, or year, regardless of work or production.

Question 41

Total ____________________ cost includes wages and benefits.

Question 42

The ____________________ is the rate at which weld metal can be deposited by a given electrode or welding wire, expressed in pounds per hour.

Question 43

The ____________________ tells us how many pounds of weld metal can be produced from a given weight of the electrode of welding wire.

Question 44

Describe the efficiency of solid wires for SAW.

Question 45

Describe the approach employed by large shops to estimate the costs of welding.

Question 46

Describe the approach employed by small shops to estimate the costs of welding.

Question 47

Describe the order of operations to be performed when a formula has more than one mathematical operation.

Question 48

____________________ costs are those expenses that change with the quantity of work being produced.

Question 49

____________________ is the arc time in hours divided by the total hours worked.

Question 50

Describe two ways for reducing fractions.