Deck 30: Other Welding Processes

Question 1

____ welding is accomplished by using roller-type electrodes.

A) Seam
B) Ultrasonic
C) Flash
D) Upset

Answer 1

A

Question 2

In resistance welding, ____ is applied to ensure a continuous electrical circuit and to forge the heated parts together.

A) heat
B) a chemical spray
C) a plasma arc
D) pressure

Answer 2

D

Question 3

The ____ the period during which the electrode force is applied and the welding current is shut off.

A) squeeze time
B) weld time
C) hold time
D) off period

Answer 3

C

Question 4

Temperatures up to ____ F are generated by electron beam welding machines.

A) 800°
B) 1,800°
C) 18,000°
D) 180,000°

Question 5

____ are used where work is too large to be moved.

A) Rocker-arm spot welders
B) Press-type spot welders
C) Portable spot welders
D) Resistance welders

Question 6

The heat produced in a weld is expressed in the formula ____.

A) H = I2R
B) H = IR2
C) H = IR
D) H = (IR)2

Question 7

Resistance welding machines contain a(n) ____ to hold the workpiece and apply the electrode force.

A) mechanical system
B) electrical circuit
C) current regulator
D) control system

Question 8

____ welding is a form of friction welding.

A) Resistance spot welding
B) Ultrasonic
C) Electron beam
D) Inertia

Question 9

The ____ is the time between the first application of electrode force and the first application of welding current.

A) squeeze time
B) weld time
C) hold time
D) off period

Question 10

The ____ is the time during which the electrodes are not contacting the workpieces.

A) squeeze time
B) weld time
C) hold time
D) off period

Question 11

Both kVa and watts are ____ measurements.

A) energy
B) heat
C) voltage
D) power

Question 12

In resistance welding, a ____ is used to convert the high line voltage power to the welding high-amperage current at a low voltage.

A) regulator
B) transformer
C) capacitor
D) converter

Question 13

The term kVa stands for ____.

A) kilovoltage
B) kerf volt amps
C) kilovolt amps
D) kilovolt amplifier

Question 14

Material from ____ thick may be joined by spot welding.

A) 0.05 in.to 2 in.
B) 0.01 in.to 0.1 in.
C) 0.001 in.to 2 in.
D) 0.001 in.to 1 in.

Question 15

Cooling in seam welding is accomplished by ____.

A) immersion in salt water
B) a constant stream of water directed to the electrode near the weld
C) allowing the weld to cool at room temperature
D) blowing air over the weld area

Question 16

Laser beams have a heat input of ____ joules.

A) 0.001 to 0.01
B) 0.01 to 0.1
C) 0.1 to 10
D) 1 to 10

Question 17

In ____, the movement of the upper electrode is controlled by a pneumatic or hydraulic cylinder.

A) rocker-arm spot welders
B) press-type spot welders
C) portable spot welders
D) resistance welders

Question 18

In ____, the lower electrode is stationary while movement is transferred to the upper electrode by means of an arm, which moves about a pivot point.

A) rocker-arm spot welders
B) press-type spot welders
C) portable spot welders
D) resistance welders

Question 19

Resistance welding machines contain a(n) ____ to regulate the timing of the weld cycle.

A) mechanical system
B) electrical circuit
C) current regulator
D) control system

Question 20

____ are used in the mass production of automobiles, aircraft, railroad cars, home appliances, and similar products where relatively thin sheets are to be welded.

A) Rocker-arm spot welders
B) Press-type spot welders
C) Portable spot welders
D) Resistance welders

Question 21

​Strip electrodes can be as wide as ____ inches.

A) ​two
B) ​three
C) ​four
D) ​five

Question 22

​Electrode classifications are prefixed with the letter ____.

A) ​E
B) ​F
C) ​K
D) ​L

Question 23

​Submerged arc welding was introduced in the ____.

A) ​1930s
B) ​1940s
C) ​1950s
D) ​1960s

Question 24

​One carbon point equals ____ percent carbon.

A) ​.01
B) ​.1
C) ​1
D) ​10

Question 25

​SAW filler metals are available in wires that come in sizes ____.

A) ​of 1/16 inch
B) ​from 1/16 inch to 1/8 inch
C) ​from 1/8 inch to 1/4 inch
D) ​from 1/16 inch to 1/4 inch

Question 26

​If the letter K is used, it refers to ____.

A) ​the normal carbon point
B) ​the range of manganese
C) ​silicon-killed, oxidized steel
D) ​an electrode

Question 27

In hardfacing, deposited layers may be as thin as ____ in.

A) 1/32
B) 1/16
C) 3/32
D) 3/16

Question 28

​If an electrode is classified as EH12, it has a normal carbon point of ____ percent carbon.

A) ​.1
B) ​.12
C) ​1
D) ​12

Question 29

​If an electrode is classified EL5K, which of the following is true?

A) ​It has high manganese.
B) ​It has five percent carbon.
C) ​It was drawn from silicon-killed, deoxidized steel.
D) ​It has no carbon.

Question 30

​With SAW, ESW, and EGW, the total cost of fabrication is ____, and it provides the same or ____ service.

A) ​higher, better
B) ​higher, worse
C) ​lower, better
D) ​lower, worse

Question 31

​The classification of flux depends on ____.

A) ​its chemical composition
B) ​the mechanical properties of the weld metal deposited
C) ​the range of manganese
D) ​the carbon points

Question 32

Laser beams have an intensity of more than ____ watts per square centimeter.

A) 100
B) 1,000
C) 10,000
D) 100,000

Question 33

​The basic flux classification is prefixed with the letter ____.

A) ​E
B) ​F
C) ​K
D) ​L

Question 34

​____ is(are) used for surfacing applications.

A) ​Strip electrodes
B) ​Backing strips
C) ​Twisted wire
D) ​Bulk wire

Question 35

In which of the following general groups are tungsten carbide and chromium electrodes classified?

A) Resistance to impact
B) Resistance to severe abrasion
C) Resistance to severe impact
D) Resistance to moderate abrasion

Question 36

​In SAW, the molten weld pool is protected from the surrounding atmosphere by ____.

A) ​shielding gas
B) ​self-shielding electrodes
C) ​oxygen in the air
D) ​molten flux and slag

Question 37

In hardfacing operations, ____ welding permits the surfacing layer to be deposited by flowing molten filler metal into the underlying surface.

A) arc
B) oxyfuel
C) gas shielded arc
D) carbon arc

Question 38

Laser welds are ____.

A) small, generally less than 0.0001 inches
B) small, sometimes less than 0.001 inches
C) always at least 0.01 inches
D) always at least 0.1 inches

Question 39

​The letter that refers to the range of manganese can either be ____.

A) ​M, N, or K
B) ​E, F, or G
C) ​L, M, or H
D) ​E, F, or K

Question 40

​In SAW, the heat is produced from ____.

A) ​a chemical reaction in the flux
B) ​an arc between the work and a metal electrode
C) ​heat applied to granular flux material
D) ​the atmosphere reacting with the flux

Question 41

____________________ is the process of obtaining desired properties or dimensions by applying an integral layer of metal of one composition onto a surface of a base metal of another composition.

Question 42

​If a flux is classified as F3A2, it has ____ psi minimum tensile strength.

A) ​3
B) ​2,000
C) ​20,000
D) ​30,000

Question 43

​More than ____ lb./hr.can be deposited using large diameter SAW wires.

A) ​40
B) ​50
C) ​60
D) ​70

Question 44

____________________ welding is a process for joining similar and dissimilar metals by introducing high-frequency vibrations into the overlapping metals in the area to be joined.

Question 45

In ____________________ welding, fusion is obtained simultaneously over the entire area of the contacting surfaces.

Question 46

____________________ welding is a process where fusion between the parts' surfaces occurs as a result of the heat produced by the electric resistance between the parts' contacting surfaces.

Question 47

​Which of the following is an advantage of electroslag welding?

A) ​Inexpensive welding equipment
B) ​Quick setup time
C) ​Can be used on any thickness of plate
D) ​Minimum distortion

Question 48

In ____________________ welding, a plasma jet is produced by forcing gas to flow along an arc restricted electromagnetically as it passes through a nozzle.

Question 49

Explain the resistance projection welding process.

Question 50

​In the flux classification system, the letter P indicates ____.

A) ​the psi minimum tensile strength of the weld
B) ​the weld metal was tested in pre-weld condition
C) ​the weld was tested after the postweld heat treatment
D) ​the foot-pound impact strength test

Question 51

What shielding gas or gases work(s) well with electrogas welding?

A) helium (He)
B) ​nitrogen (N)
C) ​argon (Ar)
D) a mixture of carbon dioxide (CO2) and argon (Ar)

Question 52

____________________ welding is used in the auto, electronics, pipeline, shipbuilding, aerospace, and high-speed welded tubing industries.

Question 53

____________________ is the term used to describe vapors of materials that are raised to a higher energy level than the ordinary gaseous state.

Question 54

____________________ welding is a semiautomatic or automatic arc welding process.An arc is drawn between a metal stud and the surface to which it is to be joined.

Question 55

​In EGW, the molten weld pool is protected from the atmosphere by ____ or by a flux core in the filler electrode.

A) ​oxygen in the atmosphere
B) ​a thick blanket of slag
C) ​shielding gas
D) ​a thick blanket of molten flux

Question 56

​The first digit in the flux classification system indicates ____.

A) ​the lowest temperature at which the weld metal will meet the 20 foot-pound impact strength test
B) ​the 10,000 psi minimum tensile strength of the weld
C) ​the 10 psi minimum tensile strength of the weld
D) ​the weld was tested and classified after the postweld heat treatment

Question 57

In ____________________ welding, fusion is produced over the ends of stock by heat produced from the resistance to the flow of electric current between the two surfaces.

Question 58

​In the flux classification system, the letter Z indicates ____.

A) ​no impact strength test is required
B) ​no tensile strength test is required
C) ​the flux passed the minimum impact strength test
D) ​the flux passed the minimum tensile strength test

Question 59

​Which of the following is true of electroslag welding?

A) ​The arc is produced below the molten flux surface.
B) ​The heat for welding is produced by current transferred from the electrode to the work.
C) ​The slags produced are highly conductive in a molten state.
D) ​The slags must be relatively shallow to maintain the circuit.

Question 60

In ____________________ welding, fusion is obtained by directing a highly concentrated beam of coherent light to a very small spot.

Question 61

Explain how electron beam welding works.

Question 62

Summarize the process of thermal spraying.

Question 63

Explain how laser beams work.

Question 64

Explain the process of upset welding, and the difference between upset welding and flash welding.