Welding Metallurgy Practice Test

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• Which of the following is a consequence of slow travel speed?
• What describes AC operation in GTAW?
• Can a single welding procedure specification include more than one welding position?
• A very shallow flux layer may lead to:
• In FCAW, which polarity is used to maximize penetration?
• Electrode holders used in ERW are designed as which of the following?
• Base metal thickness in a WPS is usually shown as what?
• Why does argon provide better shielding at lower flow rates when welding in the downhand position?
• What are the two distinct pressures required to produce a spot weld?
• During upset welding, what is the typical sequence of actions?
• Which features are commonly found on ERW electrode holders?
• Which factors are considered when selecting GTAW filler metal?
• What should be listed for preheat and interpass temp control in a WPS form?
• Which components are commonly projection welded to a sheet metal part?
• What should be listed for post weld heat treatment in a WPS form?
• Which statement is true about DCEN in GTAW?
• In the GTAW electrode classification ERXXS-Z, what does the 'E' denote?
• In ERW, how is electrical current supplied to the workpiece?
• GTAW can be used in which welding positions?
• In a WPS, which element is described by grooves, angles, root face dimensions, and root spacing with tolerances?
• The shielding gas atmosphere can behave as carburizing or decarburizing depending on which factor?
• A strip electrode in SAW provides which type of weld bead?
• What should be listed for back gouging in a WPS form?
• In upset welding, fusion occurs across the entire abutting surfaces, not just at localized points.
• What are the typical SAW wire sizes?
• What does increasing the contact tube to work distance do?
• Which list correctly enumerates the four types of SAW wires?
• Which factors influence the decision to apply preheat and interpass temperature controls?
• When are Thoriated and Ceriated electrodes typically used in GTAW?
• For which processes is the flux type typically identified in the WPS?
• Which feature of ERW electrode holders facilitates electrode removal?
• What are the three fundamental components of all ERW machines?
• An excessively low voltage leads to which effects?
• Which factor affects the shape and dimensions of electrode tips?
• Which statement best describes the purpose of polarity options in GTAW?
• Which statement correctly describes the relationship between WPS and PQR?
• If the carbon content in base metal and electrode is below 0.05%, what may happen under CO2 shielding?
• What is done when a welding procedure needs qualifying?
• Why is DCEP not commonly used with GTAW?
• FCAW can be performed in which modes?
• Unfused flux after solidification is handled how in SAW?
• Upset welding is defined as fusion produced simultaneously over which area?
• What bead characteristics are associated with very high travel speeds in FCAW?
• What is a defining feature of hot wire GTAW?
• Which statement best describes a fundamental difference between argon and helium in GTAW?
• Why might SAW filler wires be copper-coated?
• In a WPS, omitting which item requires qualification of a new procedure if the item is listed?
• Which description defines a parallel connection in multi-wire welding?
• What are the four periods of time that must be controlled during the spot weld cycle?
• Functions of the metal tube of sheath over the wire for FCAW?
• How is agglomerated flux made in relation to bonded flux?
• What information is typically listed in the weld passes table of a WPS?
• What is the role of slag covering in FCAW?
• The total heat input generated in ERW is a function of which variables?
• Base metal thickness in a WPS is usually stated as a range; pipe diameters may also be provided. Which is correct?
• What does a broken arrow indicate in welding symbols?
• Larger SAW wires (3/32 inch and up) are typically used for what condition?
• Which of the following is a function of SAW flux?
• What happens to the electrode pressure after the weld current has ceased?
• Downsides of using self-shielded FCAW include
• How is bonded flux made?
• Which method uses an inert gas environment to prevent contamination during GTAW?
• Which effects result from changing the welding current in SAW?
• What does the WPS specify about cleaning between welding passes?
• What should be listed for the flux in a WPS form?
• Compared with SMAW, FCAW has which advantage?
• For a given current, a decrease in wire size will result in which effect?
• Projection welding is primarily used to join a stamped, forged or machined part to another part.
• In the SAW filler metal wire code EL8K, what does the letter L indicate?
• In GTAW electrode classification ERXXS-Z, what does the 'S' designate?
• Which statement describes oxide behavior during AC GTAW?
• What does a welding procedure detail?
• Which statement is NOT a consideration when selecting GTAW filler metal?
• GTAW uses what type of electrode?
• Which of the following is a step in developing a PQR?
• What does electrical stickout (ESO) refer to in FCAW?
• A change in arc voltage can affect which variables?
• What is a key difference between FCAW and GMAW?
• Which materials are commonly welded with AC in GTAW?
• What is the role of the tap switch on the primary transformer in spot welding?
• Back gouging is categorized in a WPS as which item?
• Which statement about GTAW torches is true?
• Which factor influences the final shielding gas choice for GTAW?
• In FCAW, what provides shielding for the weld?
• What does a Procedure Qualification Record (PQR) provide?
• Which statement accurately reflects common spot welding applications?
• What does the 'Z' denote in the GTAW electrode classification ERXXS-Z?
• Which metals can FCAW be used with?
• A weld symbol indicates what?
• In FCAW, the flux-cored wire provides shielding through a slag and a gaseous shield.
• Which FCAW version uses a tubular electrode and relies on the flux for shielding rather than an external shielding gas?
• Which shielding gas is NOT commonly used with GTAW?
• Which color code represents pure tungsten for GTAW electrodes?
• What is a consequence of excessive arc voltage in FCAW?
• During welding, which items must be monitored?
• Which statement best describes ERW as a group of processes?
• Which modification directly increases the deposition rate by adding material into the weld pool?
• Which statement correctly describes a possible role of SAW flux in terms of alloying?
• What is the Weld Procedure Specification (WPS)?
• What does a welding symbol provide when assembled?
• What is the difference between the arrow side and the other side in welding symbols?
• Which process is typically used to join a sheet metal part to a fastening device such as bolts or nuts?
• Which of the following is a type of ERW?
• What is peening?
• Which process achieves fusion over the entire abutting surface rather than just at points?
• SAW stands for?
• Using DCEN polarity in SAW improves which aspects?
• GTAW is described as an all-position process and is especially suitable for which type of sections?
• Argon arc is less penetrating, making it preferred for which type of section?
• Peening in welding is sometimes used to relieve residual stresses and reduce distortion. What is a common code-related restriction when peening is used?
• Excessively high current leads to which of the following effects?
• What will a change in travel speed affect during welding?
• In F4103, what does the digit '3' denote?
• Where is the information for the arrow side placed on a welding symbol?
• In gas-shielded FCAW, which statement is true?
• GTAW stands for what welding process?
• Why is spot welding often chosen over riveting or screwing?
• What might very low current cause in FCAW?
• What can cause deterioration of the electrodes?
• Which of the following is a consequence of fast travel speed?
• Why should data sheets from the wire manufacturer be consulted for FCAW?
• Low arc voltage in FCAW typically results in which bead characteristics?
• Flux types for SAW manufactured by method of manufacture are which of the following?
• At elevated temperatures, electrodes experience which type of stresses?
• AC is generally not used with FCAW. Which statement best reflects this?
• Which is a true characteristic of DCEN with GTAW?
• Which of the following is NOT a SAW process variable?
• How does increasing travel speed affect heat input and penetration in FCAW?
• What is one effect of increasing arc voltage in FCAW?
• What component in flux helps compensate the oxidizing effect of CO2 shielding gas?
• What should be listed for electrical characteristics in a WPS form?
• Which documents must be referenced before welding can take place?
• Squeeze time is defined as the time between which two events?
• Which statement best describes CO2 shielding gas behavior at room temperature?
• Joint details in a WPS are often presented how?
• What should be listed for welding position in a WPS form?
• How is pressure applied in ERW?
• Which non-destructive examination (NDE) methods may be used in developing a PQR?
• The depth of the flux layer will affect the bead shape and penetration. A flux layer that is deep may result in:
• What happens to the SAW flux when it is molten?
• The size and shape of the welded nugget is determined by the size and the what?
• How is fused flux made?
• In F4103, what does the digits '410' denote?
• Excessively high voltage leads to which effects?
• Why would you increase the electrical stickout in SAW?
• Which is a true characteristic of DCEP with GTAW?
• What shielding gas is used for FCAW?
• In gas-shielded FCAW, what is true?
• Which version is more suited for outdoor use?
• F-numbers and A-numbers in ASME indicate respectively what aspects of filler metals?
• What should be listed for cleaning in a WPS form?
• How is the type of destructive testing determined?
• In projection welding, which characteristic determines where heat will be generated?
• When are pure tungsten or zirconiated electrodes used in GTAW?
• Which of the following lists the process variables for submerged arc welding (SAW)?
• What will the flux/wire combination used affect?
• Peening is included in the WPS as which type of item?
• Why is 50 deg F listed as the minimum preheat temperature?
• Which method is commonly used to initiate the arc in GTAW?
• For CSA Z662, which tests are used in destructive testing?
• Two versions of the FCAW process are:
• In F4103, what does the 'xxxx' denote?
• Changes in electrode diameter typically influence which parameters for proper operation?
• The weld passes table typically lists which parameters?
• How can damp SAW flux be re-dried?
• Which are the four basic components that form a welding symbol?
• In regards to polarity, which polarity is used for deep penetration?
• Which statement about ERW is true?
• In GTAW, filler metal is often not used with which joints?
• What sizes are GTAW electrodes available in?
• What is another function of SAW flux regarding the weld deposit?
• In projection welding, the points where heating occurs are determined by what?
• When using pure tungsten or zirconiated electrodes on AC, what forms at the tip of the electrode?
• What should be listed for welding progression in a WPS form?
• What happens when voltage is applied in flash welding?
• If you need to join a stamped bracket to a sheet metal panel with a fastener-like feature, which process is most appropriate?
• In GTAW, the current in the arc zone is conducted through what medium?
• What is a primary advantage of using smaller SAW filler metal wires (5/64 inch)?
• What are the two types of spot welders?
• Which of the following is a disadvantage of GTAW?
• What is backup purge in GTAW?
• In the FCAW designation E4802T-9, what does the '2' indicate?
• Self-shielded FCAW can utilize a long stick-out technique to increase deposition.
• Base metals in a WPS are often grouped by what criteria to reduce the number of procedures?
• In GTAW, what protects the electrode, arc, and weld puddle from atmospheric contamination?
• What is the electrical property of SAW flux when cold?
• In the code F4103, what does the letter 'F' represent?
• Disadvantages of FCAW include:
• If ESO is increased while welding at the same current, what happens to the deposition rate and why?
• Which polarity is generally used for gas shielded FCAW?
• How hot does the GTAW arc reach?
• In the GTAW electrode classification ERXXS-Z, what does the 'R' denote?
• In EL8K, what does the digit 8 indicate?
• What is a primary benefit of gas-shielded FCAW over self-shielded FCAW?
• Filler metals in a WPS are specified and classified by which organization, with ASME providing F-numbers and A-numbers?
• How does self-shielded FCAW achieve shielding?
• Which is a function of the flux in SAW besides providing a protective shield?
• FCAW self-shielded is most similar to SMAW because both electrodes contain a flux that provides metallurgical benefits.
• What type of electrodes are used with GTAW?
• Which materials are commonly spot welded?
• In the SAW filler metal wire code EL8K, what does the letter K denote?
• Which item is not listed as an operating variable for FCAW?
• In submerged arc welding, the welding current flows through which component to reach the weld puddle?
• For ASME, which tests are used in destructive testing?
• Which statement correctly identifies a SAW process variable that can influence bead shape and penetration?
• ERW is a group of processes in which heat produced by resistance to the flow of current is used to join metals that are held under pressure. Which statement expresses this principle correctly?
• Which welding process uses end-to-end contact with flashing heating the ends?
• How are FCAW wires manufactured?
• What should be listed for shielding gas in a WPS form?
• What are the main components of a GTAW torch, from the front toward the back?
• Which polarity is used where shallow penetration is desired or when increased deposition rate is required?
• Why are base metals often grouped in codes when preparing a WPS?
• For thicker sections like butt and tee joints, what is fed into the weld pool?
• In ERW, is there external heat source, filler metal, or flux?
• In GTAW, the arc flows from what type of electrode?
• Where is the flux deposited relative to the arc in SAW?
• How can filler wire be fed in GTAW?
• In flash welding, how are the workpieces held before welding?
• What is intermittent welding?
• What does resistance seam welding produce along a lap joint?
• Functions of flux core wire in FCAW?
• Excessive current in FCAW can cause which problem?
• Which properties are listed as being affected by variables in the weld procedure?
• Which material is commonly weldable with GTAW?
• Which statement describes a series connection?
• What is the primary purpose of a Procedure Qualification Record (PQR)?
• If travel speed is increased, which of the following is most likely true?
• What equipment is used for FCAW?
• Which process concentrates heating at predetermined points?
• Which statement best describes projection welding?
• Which of the following is an advantage of FCAW?
• Where is information for the other side placed on a welding symbol?
• What are the effects of increasing welding current in FCAW?
• Resistance seam welding uses what method to create a seam?
• To avoid issues with electrode performance, care must be taken to prevent which problems?
• What does the term pitch refer to in welding symbols?
• Which of the following is a common use of GTAW?
• What are typical back gouging methods?
• Which statement is true about FCAW disadvantages?
• Which material is compatible with GTAW?
• FCAW is more tolerant to windy conditions than GMAW.
• SAW systems can be adaptable to which automation modes?
• Hold time in the spot weld cycle is defined as:
• Describe the filler wire used in SAW.
• What is the function of SAW flux regarding slag formation and shielding?
• How is current typically controlled in spot welding?
• In EL8K, what does the letter E indicate?
• Which statement is an advantage of GTAW?
• In the heat input equation H = I^2 R T, which variable is squared?
• Low current leads to which of the following effects?
• Preheat and interpass temperature control is listed as which type of variable in a WPS?
• Which of the following is NOT a principal function of the electrode?