Deck 12: Flux Cored Arc Welding Equipment, Setup, and Operation

Question 1

____ are added to the flux and form a slag.

A) Carbon, chromium, and vanadium
B) Aluminum, silicon, and titanium
C) Potassium, sodium, and zirconium
D) Oxygen, argon, and nitrogen

Answer 1

C

Question 2

Which of the following is true of wire electrodes?

A) They must be wrapped in sealed plastic bags.
B) Some wire electrodes require storage in an electric rod oven.
C) Electrodes should never be wrapped in paper.
D) They should not be shipped in cardboard boxes.

Answer 2

B

Question 3

In FCAW ____ % of the electrode is used.

A) 11
B) 50
C) 70
D) nearly 100

Answer 3

D

Question 4

____ can be added to improve hardness, strength, creep resistance, and corrosion resistance.

A) Carbon, chromium, and vanadium
B) Aluminum, silicon, and titanium
C) Potassium, sodium, and zirconium
D) Oxygen, argon, and nitrogen

Question 5

FCA welding deposition rates of more than ____ lb./hr.of weld metal are possible.

A) 10
B) 15
C) 25
D) 50

Question 6

Which of the following is a similarity between FCAW and GMAW?

A) Both use CC welding power supplies.
B) Both use CP welding power supplies.
C) Both use the same welding power supply as stick welding.
D) Both must use constant welding current power supplies.

Question 7

The main limitation of flux cored arc welding is that ____.

A) the molten weld pool is difficult to control
B) visibility is impaired by the shielding gas nozzle
C) it is confined to ferrous metals and nickel-based alloys
D) high deposition rates are not possible

Question 8

____ all help remove oxides and/or nitrides in the weld.

A) Carbon, chromium, and vanadium
B) Aluminum, silicon, and titanium
C) Potassium, sodium, and zirconium
D) Oxygen, argon, and nitrogen

Question 9

In the flux classification system, the letter "G" is used to indicate ____.

A) "shielding gas"
B) "grade"
C) an unspecified strength
D) an unspecified classification

Question 10

Which of the following is true of FCAW?

A) When bevels are cut, the joint-included angle must be larger than 35 percent.
B) The addition of deoxidizers eliminates most of the precleaning required.
C) Welds cannot be made on plates with mill scale.
D) Edge-beveling preparation is required on all joints up to 1/2 inch.

Question 11

In FCAW, atmospheric shielding is ____.

A) provided solely by flux sealed within the tubular electrode
B) provided completely through a nozzle in the same way as GMAW
C) not necessary
D) provided by flux sealed within the tubular electrode, but extra shielding may be supplied through a nozzle as in GMAW

Question 12

Atmospheric contamination of molten weld metal occurs ____.

A) as it travels across the arc gap and within the pool before it solidifies
B) after it solidifies
C) infrequently
D) when the atmosphere reacts with the flux inside the electrode

Question 13

The major atmospheric contaminations come from ____.

A) carbon monoxide
B) carbon dioxide and nitrogen
C) oxygen and nitrogen
D) ozone

Question 14

The most popular electrode diameters range from ____ to ____.

A) .035 inch, 3/32 inch
B) .030 inch, 5/32 inch
C) .030 inch, .035 inch
D) 3/32 inch, 5/32 inch

Question 15

Which of the following is true of making high-quality welds?

A) It is affected by the weather.
B) Hydrogen entrapment ensures the weld will be high quality.
C) Evaporating moisture helps prevent porosity.
D) Humidity draws moisture out of the weld zone.

Question 16

From 75% to 90% of the weight of ____ electrodes is metal, whereas ____ electrodes have a maximum of 75% filler metal.

A) large diameter, small diameter
B) SMAW, FCAW
C) FCAW, SMAW
D) small diameter, large diameter

Question 17

____ rapidly expand and push the surrounding air away from the molten weld pool.

A) Oxides
B) Alloying elements
C) Slag formers
D) Gas formers

Question 18

____ helps the weld by protecting the hot metal from the effects of the atmosphere.

A) Slag
B) Heat
C) Oxides
D) Gas-forming agents

Question 19

The addition of ____ gives FCAW the high level of reliability needed for welding on boilers, pressure vessels, and structural steel.

A) flux
B) small diameter electrodes
C) slags
D) bevels

Question 20

Which of the following is true of lime-based flux?

A) It is acidic.
B) It is generally unsuitable for out-of-position welding.
C) It produces a stable, smooth arc.
D) It produces less spatter.

Question 21

​Unmounted coils are available in weights of around ___________

A) ​1000 lb (454 kg).
B) ​4 lb (1.8 kg).
C) ​60 lb (27 kg).
D) ​25 lb (11 kg).

Question 22

FCA welding guns are available as water-cooled or air-cooled.The ____________________-cooled gun is more portable because it has fewer hoses.

Question 23

​How is the amperage adjusted on a FCA welding machine?

A) ​By changing the voltage setting on the welder.
B) ​You move the welding lead from one amperage setting to the next amperage setting.
C) ​Changes in the wire feed speed automatically change the amperage.
D) ​The amperage is pre-set by the electrician and cannot be adjusted in the shop.

Question 24

​What can be added to FCAW electrode fluxes to affect the arc resistance?

A) ​deoxidizers
B) ​arc stabilizers
C) ​alloying elements
D) ​slag formers

Question 25

​What can be added to FCAW electrode fluxes to remove oxides?

A) ​deoxidizers
B) ​arc stabilizers
C) ​alloying elements
D) ​slag formers

Question 26

​Which of the following is true of fluxes?

A) ​Fluxes cause undercutting along the junction of the weld and the base metal.
B) ​Fluxes decrease the stability of the arc.
C) ​Fluxes provide oxidation.
D) ​Fluxes are slag formers.

Question 27

​What two electrical terms have the same meaning?

A) ​impedance and amperage
B) ​potential and voltage
C) ​resistance and current
D) ​ohms and potential

Question 28

​What is the term sometimes used to refer to refractory fluxes?

A) ​lime-based
B) ​gas forming
C) ​fast-freeze
D) ​slag formers

Question 29

FCA welding guns are available as water-cooled or air-cooled.The ____________________-cooled gun is more efficient at removing waste heat.

Question 30

____________________ may convert small amounts of surface oxides like mill scale back into pure metal.

Question 31

​If the voltage and wire feed speed are not changed but a larger wire size is used, the _________.

A) ​amperage would automatically go up
B) ​electrode would short out to the weld because more amps are needed for the larger wire size
C) ​voltage would decrease because the larger wire would have less resistance
D) ​voltage would decrease because the larger wire would have less resistance

Question 32

​Which of the following is not a reason to use recirculation cooling water systems on FCA welding systems.

A) ​To conserve water.
B) ​Better gun cooling.
C) ​More portable.
D) ​Chemicals in the water can prevent freezing.

Question 33

​Why is the water pressure on water cooled torches kept below 35 psi (241 kg/mm2)?

A) ​To limit the amount of water that is wasted.
B) ​To slow the flow of water through the gun.
C) ​Higher pressures produce higher water flows, and that can cool the welding too much so it would be harder to get a stable arc.
D) ​Higher water pressures can burst the hoses.

Question 34

____________________ controls the bead shape by serving as a dam or mold, and also serves as a blanket to slow the weld's cooling rate, which improves its physical properties.

Question 35

When the electrode provides all of the shielding, it is called ____.

A) protective
B) rutile
C) a shielding gas
D) self shielding

Question 36

The American Welding Society defines ____ as the linear rate at which the arc is moved along the weld joint.

A) arc length
B) current
C) travel speed
D) weld bead

Question 37

An electrode specifically designed for use with 100% CO2 will have higher levels of ____ to compensate for the losses to oxidization.

A) silicon and manganese
B) argon and carbon
C) titanium and vanadium
D) aluminum and potassium

Question 38

​What device can be added to a FCA welding gun to help control fumes?

A) ​Smoke extraction nozzle.
B) ​Filter screen.
C) ​Small fan.
D) ​Dust mask.

Question 39

If you feed out ten feet of wire electrode and cut it off, and then lay it on the floor where it forms a circle, the diameter of the circle is known as the ____________________ of the wire.

Question 40

​What does the letter "C" stand for in the FCA electrode E70C?

A) ​metal-cored
B) ​flux-cored
C) ​alloy-filled core
D) ​CO2 shielding gas required

Question 41

When an externally supplied shielding gas is added to provide the needed protection of the molten weld pool, it is called ____________________.

Question 42

​FCAW electrodes have a flux that is mineral based, often called ____________.

Question 43

Explain how a fast travel speed can cause undercut.

Question 44

In the electrode classification system, the "T" in E70T-10 stands for ____________________.

Question 45

Summarize the limitations of flux cored arc welding.

Question 46

Summarize the advantages and disadvantages of the forehand technique.

Question 47

The electrode classification E70T-10 can have some optional identifiers added to the end of the number such as E70T-10MJH8.Explain the meaning of the optional identifiers, MJH8.

Question 48

As the percentage of CO2 increases in the argon mixture, weld penetration ____________________.

Question 49

If you feed out ten feet of wire electrode and cut it off, and then lay it on the floor where it forms a circle, it does not lay flat.One end is higher than the other, and this height is known as the ____________________ of the wire.

Question 50

Summarize the advantages and disadvantages of the backhand technique.