Deck 13: Flux Cored Arc Welding

Question 1

Which of the following is a benefit of FCA welding?

A) FCA requires beveling the plate prior to welding.
B) A much lower skill level is required.
C) The ability to make 100%-joint-penetrating welds without beveling the edges of the plates.
D) Welding thick plates is very easy.

Answer 1

C

Question 2

The ____ pass must be uniform in width, reinforcement, and appearance.

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

Answer 2

C

Question 3

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

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

Answer 3

B

Question 4

The ____ pass establishes the depth of weld metal penetration.

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

Question 5

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 6

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 7

Pressing the gun switch to start the wire feeder is called ____.

A) arcing the gun
B) short-circuiting
C) dragging the feed
D) triggering the gun

Question 8

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 9

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 10

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

A) one inch
B) two inches
C) three inches
D) four inches

Question 11

____ weld faces tend to trap slag along the toe of the weld.

A) Concave
B) Flat
C) Dirty
D) Convex

Question 12

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 13

The visual inspection of the cover pass looks to see that ____.

A) there is no trapped slag
B) the weld does not penetrate too deeply
C) the weld is not porous
D) the weld is uniform in width and reinforcement

Question 14

A fillet weld should be built up to be ____ the thickness of the plate.

A) equal to
B) half the thickness of
C) slightly thicker than
D) much thicker than

Question 15

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

Question 16

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 17

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

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

Question 18

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 19

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 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 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 22

​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 23

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.

Question 24

​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.

Question 25

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

Question 26

Open-root joints are often avoided on ____________________ welds.

Question 27

​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 28

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

Question 29

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 30

​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 31

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

Question 32

​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 33

​What type of weld works best for horizontal and overhead positions for FCA welds?

A) ​stringer beads
B) ​zig-zag beads
C) ​side-to-side weave beads
D) ​vertical down beads

Question 34

To control the amount of spatter, a ____ is needed.

A) shorter stickout
B) longer stickout
C) longer nozzle
D) shorter nozzle

Question 35

​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 36

When welding in the overhead position, spatter may fall into or on the nozzle and contact tube, which may ____.

A) cause the nozzle to explode
B) cause the contact tube to spark
C) cause the contact tube to short out to the gas nozzle
D) create extra spatter

Question 37

​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 38

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 39

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

Question 40

​Why are plug welds used on thin sections of metal?

A) ​Because the edge of the thin plate is easily melted away.
B) ​To make it easier to make overhead welds.
C) ​So that 100% root penetration welds can be made in all positions.
D) ​It is a way of saving filler metal.

Question 41

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

Question 42

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

Question 43

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

Question 44

Explain the criteria for evaluating a cover pass.

Question 45

Describe what to do if burn-through occurs.

Question 46

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 47

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

Question 48

Explain how to thread FCAW wire.

Question 49

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 50

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