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

Question 1

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

Answer 1

A

Question 2

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

Answer 2

C

Question 3

____ 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 3

C

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

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 6

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 7

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

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

Question 8

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 9

The major atmospheric contaminations come from ____.

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

Question 10

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 11

Which of the following is not an advantage of inverter welding machines?

A) They produce much more internal heat.
B) They are more energy efficient.
C) They are more accurate when setting voltage and amperage.
D) They are much lighter than traditional transformer-type welding machines.

Question 12

How is the amperage adjusted on an 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 13

____ 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 14

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 15

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 16

____ 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 17

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 18

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 19

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

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

Question 20

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.

Question 21

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

Question 22

If you feed out 10 feet of wire electrode and cut it off, then lay it on the floor where it forms a circle, the diameter of the circle is known as the ____________________ of the wire.

Question 23

Explain how a fast travel speed can cause undercut.

Question 24

____________________ 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 25

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 26

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

Question 27

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 28

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

Question 29

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 30

Multifunction ____________________ welding machines have become the standard machines most shops are using today.

Question 31

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 32

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

Question 33

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 34

Summarize the advantages and disadvantages of the backhand technique.

Question 35

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

Question 36

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

A) Deoxidizers
B) Arc stabilizers
C) Alloying elements
D) Slag formers

Question 37

If you feed out 10 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 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

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

Question 40

As the percentage of CO₂increases in the argon mixture, weld penetration ____________________.