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All Textbook Solutions for Welding: Principles and Applications (MindTap Course List)
What type of welding uses a hammer to join heated and softened metal?What advantage does resistance welding have over forge welding?What term describes the fusion or growing together of the grain structure of the materials being welded?Welding is defined as a joining process that produces coalescence of materials by heating them with or without the application of what?Name three items that are manufactured using welding.Name three popular welding processes.What does shielded metal arc welding (SMAW) use to conduct the welding current from the electrode holder to the work?What is the purpose of the solid flux that covers the electrode?What protects the molten weld metal from atmospheric contamination in GTAW welding?Why is it important to clean all contamination such as oxides, oil, and dirt off of the surface of the part being welded with GTA welding?What welding process uses a solid electrode wire that is continuously fed from a spool, through the welding cable assembly, and out through the gun?What are the advantages of GMA welding?How is a flux cored arc welding (FCAW) electrode wire different from a gas metal arc welding (GMAW) electrode wire?What two welding processes are semiautomatic processes?How is a high-temperature flame produced at the torch tip in oxyacetylene welding (OAW) and torch brazing (TB)?Name two commonly used thermal cutting processes.Which cutting process uses a forceful stream of oxygen flowing out a center hole in the tip to burn away hot steel?What cutting process uses a stiff, highly ionized, extremely hot column of gas to almost instantly vaporize the metal being cut?List three factors that can help determine which welding process to select for a certain job.Name three methods used to perform welding, cutting, or brazing operations.Name five different types of welding career opportunities.What are some skills that entry-level welders need?What are the names of the two American Welding Society (AWS) levels of certification for welders?What does the AWS abbreviation “SENSE” stand for?What practical knowledge subject areas are covered in Module 1 of the SENSE program?What four welding processes are covered in the SENSE program?What is the name of the organization that sponsors a series of welding skill competitions for welding students?What is the key to preventing accidents in a welding shop?Who is ultimately responsible for the welder’s safety?Describe the three classifications of burns.What emergency steps should be taken to treat burns?List the three types of light that may be present during welding.Which type of light is the most likely to cause burns? Why?What can be done on the job site to reduce the danger of reflected light?What is the name of the eye burn that can occur in a fraction of a second?In what two ways can ultraviolet light burn the eyes?Why is it important to seek medical treatment for eye burns?What fabric(s) are the best choice to wear as general work clothing in a welding shop?Describe the ideal work shirt, pants, boots, and caps that should be worn in a welding shop.Why is it unsafe to carry butane lighters or matches in your pockets while welding?What special protective items can be worn to provide extra protection for a welder's hands, arms, body, waist, legs, and feet?Why must eye protection be worn at all times in the welding shop?What types of injuries can occur to the ears during welding?What types of protection are available to protect the ears during welding?What types of information should be covered in a respirator training program?Name two types of respirators and describe how they work.List the materials that can give off dangerous fumes during welding and require forced ventilation.Why must metal that has been used before be cleaned prior to welding?Under what conditions can natural ventilation be used?Name two advantages of recycling scrap metal.When must forced ventilation be used?Who must be provided with safety data sheets (SDSs)?Describe an acceptable storage area for a cylinder of fuel gas.How must high-pressure gas cylinders be stored so they cannot be accidentally knocked over?What should be done with a leaking cylinder if the leak cannot be stopped?Why is it important for acetylene cylinders to not be stored horizontally?What is hot work?How far away should highly combustible materials be from any welding or cutting?When is a fire watch needed?List the four types of fire extinguishers and the types of material for which they are used.Why is it important to have a planned maintenance program for tools and equipment?Why is it important to keep a welding area clean?What should you do if you have to leave a piece of hot metal unattended?Why must a mushroomed chisel or hammer be reground?What causes most electric shock in the welding industry?According to the Welding Safety Checklist in Figure 244, what are the factors necessary for a confined space hazard?What can happen if too much power is being carried by a cable?Why must equipment be turned off and unplugged before working on the electrical terminals?According to Table 2-2, what gauge wire size would be needed for a power tool that has a nameplate amperage of 9 and a cord length of 100 ft?What is a GFCI?List five safety tips for safe extension cord use.List 10 safety rules for the safe use of portable electric tools.Why is it important to not weld when everything is wet?List two types of grinders used by welders.How close to the grinding stone face should the tool rest be adjusted?Name metal cutting machines used in the welding shop and their advantages.Describe how a person should safely lift a heavy object.List the things that should be inspected on a ladder.List and explain five ladder use safety rules.Describe the relation between voltage and amperage for welding current.What produces the heat during a shielded metal arc weld?Voltage can be described as ____________ .Amperage can be described as _____________.Wattage can be described as___________.What determines the exact temperature of the shielded metal welding arc?Does all of the heat produced by an SMA weld stay in the weld? Why or why not?What do the following abbreviations mean: AC, DCEN, DCEP, DCSP, and DCRP?Sketch a welding machine, an electrode lead, an electrode holder, an electrode, a work lead, and work connected for DCEN welding.Sketch a welding machine, an electrode lead, an electrode holder, an electrode, a work lead, and work connected for DCEP welding.Why is SMA welding current referred to as constant current?What is the higher voltage at the electrode before the arc is struck called? What is its advantage to welding?Referring to the graph in Figure 3-9, what would the voltage be for the CC power supply at 110 amps? What would the watts be?How does arc blow affect welding?How can arc blow be controlled?How does a welding transformer work?What are taps on a welding transformer?What would the approximate amperage setting be if a welder were set to the high range (150 to 350 amps) and the fine adjustment knob were pointing at 5 on a 10-point scale?What are the advantages of the inverter-type welding power supply?What is the difference between the welding current produced by alternators and by generators?What are the advantages of alternators over generators?What must be checked before using the 110-volt power plug on a portable welder?What is meant by a welder's duty cycle?Why must a welding machine's duty cycle never be exceeded?Why is copper better than aluminum for welding cables?A splice in a welding cable should never be any closer than _______to the electrode holder.Why must the electrode holder be correctly sized?What can cause a properly sized electrode holder to overheat?What problem can occur if welding machines are stacked or placed too closely together?Why must welding cables never be tied to scaffolding or ladders?Describe two methods of striking an arc with an electrode.Why is it important to strike the arc only in the weld joint?What problems may result by using an electrode at too low of a current setting?What problems may result by using an electrode at too high of a current setting?According to Table 4-1, what would the amperage range be for the following electrodes? a.1/8 in. (3.2 mm), (70-130) b.5/32 in. g mm), E7018 (125-220) c.3/32 in. (2.4 mm), E7016 (75-105) d.1/8 in. (3.2 mm), 6011 (85-125)What makes some spatter “hard?”Why should you never change the current setting during a weld?What factors should be considered when selecting an electrode size?What can a welder do to control overheating of the metal pieces being welded?What problems can result from too long or too short of an arc length?What arc problems can occur in deep or narrow weld joints?Describe the difference between using a leading and a trailing electrode angle.Can all electrodes be used with a leading angle? Why or why not?What characteristics of the weld bead do the weaving of the electrode cause?What are some of the applications for the circular pattern in the flat position?Using a pencil and paper, draw two complete lines of the weave patterns you are most comfortable making.Why is it important to find a good welding position?Which electrodes would be grouped in the following F numbers: B, F2, F4?Give one advantage of using electrodes with cellulose-based fluxes.What are stringer beads?Describe an ideal tack weld.What effect does the root opening or root gap have on a butt joint?What can happen if the fillet weld on a lap joint does not have a smooth transition?Which plate heats up faster on a tee joint? Why?Can a tee weld be strong if the welds on both sides do not have deep penetration? Why or why not?List some applications that use low-pressure piping.List some applications that use medium-pressure piping.List some applications that use high-pressure piping.Describe the differences between pipe and tubing.What are the advantages of welded piping systems over other joining methods?Why must the ends of pipe be beveled before being welded?How can the ends of a pipe be beveled?Why is the end of a pipe beveled at a 371/2 angle?What causes root suck-back or a concave root face?Why are arc strikes outside the welding zone considered a problem on pipe?What are the purposes of backing rings?What is the purpose of a hot pass?Why must the weld crater be cleaned before starting a new electrode?What is the maximum width of the cover pass? Why?When is the 1G welding position used?What can make welding in the 2G vertical fixed pipe position difficult?What supports the welds on a 2G pipe joint?On 5G welds, what usually determines the direction of the root pass?What angle is the pipe at in the 6G position?In addition to continuously changing the weld pattern, what other changes must be continually made when welding in the 6G position?What is the first weld bead of a multiple pass weld called?What is the purpose of using ceramic backup tapes on groove welds?How can discontinuities in the root face be removed?Describe the motion of the electrode in keyhole welding.What is the purpose of placing an assembled test plate on an anvil and striking it with a hammer?If the key hole becomes smaller and smaller, what can be done to increase the molten weld pool size and maintain the key hole?What is the purpose of a hot pass?What are the best ways to remove slag between filler weld passes?What is the last weld bead on a multipass weld called?What is the purpose of grooving a joint before welding on thick plate?After a weld is back gouged and a groove is formed, what should be done?When stopping an SMA welding bead on a pipe, what should be done to make restarting it more uniform?What is the purpose of preheating metal before it is welded?What is the purpose of postheating the metal after welding?What is interpass temperature?The AWS Visual Inspection Criteria allows one small porosity per inches of weld.What is the difference between a transverse face bend and a transverse root bend?What changes can be made to successfully make a weld in a poorly fitted joint?Using Table 7-1, list the six different fuel gases in rank order according to their temperature.What metals can be cut with the oxyfuel gas process?What other term is used to refer to the OFC process?What is a combination welding and cutting torch?State one advantage of owning a combination welding and cutting torch as opposed to just having a cutting torch.State one advantage of owning a dedicated cutting torch as compared to having a combination welding and cutting torch.What is a mixing chamber? Where is it located?Define the term equal-pressure torch. How does it work?How does an injector-type mixing chamber work?State the advantages of having two oxygen regulators on a machine cutting torch.Why are some copper alloy cutting tips chrome-plated?Using Table 7-4, answer the following: a . Oxygen pressure for cutting 1/4-in. (6-mm)-thick metal b. Acetylene pressure for cutting 1-in. (25-mm)-thick metal c. Tip cleaner size for a tip for 2-in. (51 -mm)-thick metal d. Drill size for a tip for 1/2-in. (13-mm)-thick metalWhat determines the amount of preheat flame requirements of a torch?What can happen if acetylene is used on a tip designed to be used with propane or other such gas?Why are some propane and natural gas tips made with a deep, recessed center?What types of tip seals are used with cutting torch tips?If a cutting tip sticks in the cutting head, how should it be removed?How can cutting torch tip seals be repaired?What is used to reduce the high cylinder or system gas pressure to the lower working pressure?What do the two pressure gauges on a regulator show?Why must the gas pressure be released and the adjusting screw backed out when welding is finished and the cylinders are turned off?What should be done if the torch flashes back?What is the purpose of a reverse flow valve?Why must the reverse flow valve and the flashback arrestor be checked on a regular basis?How can a hose be checked for leaks?Why is the oxygen valve turned on before starting to clean a cutting tip?Why does the preheat flame become slightly oxidizing when the cutting lever is released?What causes the tiny ripples in a hand cut?Why is a slight forward torch angle helpful for cutting?Why should cans, drums, tanks, or other sealed containers not be opened with a cutting torch?Why is the torch tip raised as the cutting lever is depressed when cutting a hole?Why are the preheat holes not aligned in the kerf when making a bevel cut?Sketch the proper end shape of a soapstone that is to be used for marking metal.What are two methods you can use to determine what working pressure to set on the regulator?What is the best way to set the oxygen pressure for cutting?Why is it important to have extra ventilation and/or a respirator when cutting some used metal?What factors regarding a cut can be read from the sides of the kerf after a cut?What is hard slag?Why is it important to make good-quality cuts?When using an ordinary welding table, what can be done to avoid cutting through the tabletop?Describe the methods of controlling distortion when making cuts.List three things that can become a problem when cutting and affect your ability to make a quality cut.How does cutting small-diameter pipe differ from cutting large-diameter pipe?List the types of metal that a plasma torch can be used to cut.What two charged particles exist in a plasma?What is the approximate temperature of a plasma stream?To prevent a manual-type torch from damage, it is made of a special plastic that resists what?How are high-power plasma torches cooled?What is the name of the torch part made of copper with a very small tungsten embedded in the end?What is the name of the material that resists oxidation at elevated temperatures so air can be used as a plasma gas?What does the nozzle insulator provide to the plasma torch?What are two other names that the shield is sometimes called?How often should cables, control wiring, and hoses be inspected?What may be on a coolant reservoir to indicate the coolant level?Why is the cooling water switched on and off with the plasma?Why must a filter dryer be used on the air supply to a plasma torch?List the four common variations of the conventional plasma cutting process and describe the benefits of each.Define standoff distance.What two terms refer to the squareness of a cut?What is the pilot arc?List five factors that can affect the kerf width.What factors affect the bevel angle left on the sides of all plasma cuts?List five things that are affected by changes in the PAC gas(es).What is dross?List some advantages of using a water table.Why are most hand PAC torches limited to 100 amperes or less?List five special safety concerns for the PAC process.Describe the three techniques for piercing a plate to start a cut: raising the torch, running start, and angling the torch.26RDescribe the use of the following processes: LBO LBW, and LBC.How is laser light formed?What type of laser is most often used with a low-power continuous or high-powered pulse?What effect does a materials surface have on the Laser beam?Using Table 9-1, what material can be cut with nitrogen?What are reactive laser assist gases called? How do they work?7RWhat would be one advantage of combining LBW and GMAW?What would be one advantage of combining LBW and GTAW?What is CAC-A?Using Table 9-2, give the recommended procedure for air carbon arc gouging of carbon steel, magnesium alloys, and low alloy copper.12RWhat may occur if an SMA welding machine has below minimum arc voltage for air carbon arc gouging?14RWhy are the chances of receiving arc burns much higher with the shielded metal arc welding process?What is the purpose of U-grooving?How are oxygen lance cuts usually started?What unusual material can be cut with an oxygen lance?19RWhat applications are arc cutting electrodes used for?Why is usage of the term GWW preferable to MIG for gas metal arc welding?Using Table 10-1, answer the following: a. What maintains the arc in machine welding? b. What feeds the filler metal in manual welding? c. What provides the joint travel in automatic welding? d. What provides the joint guidance in semiautomatic welding?What factors must be considered when selecting which mode of metal transfer to use?In short-circuiting transfer, what type of current alloys the liquid metal at the electrode tip to be transferred by direct contact with the molten weld pool?Describe the globular transfer process.In what form is metal transferred across the arc in the axial spray metal transfer method of GMA welding?What three conditions are required for the spray transfer process to occur?Using Table 10-3, answer the following: a. What should the wire-feed speed and voltage ranges be to weld 1/8-in. (3 mm) metal with 0035-in. (0.90-mm) wire using argon shielding gas? b. What should the amperage and voltage range be using 98Ar+2%O2 to weld 1/4-in. (6-mm) metal with 0.045-in. (1.2-mm) wire?Describe the current produced by the pulsed-arc metal transfer mode.In the pulsed-arc metal transfer current cycle, what is the term used to describe how the electric current in a transformer takes a few milliseconds to build up the magnetic field to full strength once the coil is energized?List five advantages of the modulated current and pulsed-arc metal transfer process.What is the difference between the wire melting rate and the deposition rate?Using Figure 10-13, what is the approximate voltage at 175 amps at 200 in./min?Using Table 10-6, what would the amperage be for 0035-in. (0.9-mm) wire at 200 in./min (5 m/min)?The shielding gas selected can affect what properties of a weld?What may happen if the GMA welding electrode is allowed to strike the base metal outside of the molten weld pool?What effect does shortening the electrode extension have on weld penetration?Describe the weld produced by a forehand welding angle.Describe the weld produced by a backhand welding angle.What components make up a GMA welding system?Why must GMA welders have a 100 duty cycle?What can happen if rollers of the wrong shape are used on aluminum wire?Where is the drive motor located in a pull-type wire-feed system?How is the wire-feed speed changed with a linear feed system?What type of liner should be used for aluminum wire?What parts of a typical GMA welding gun can replaced?Describe the spot welding process using a GMA welder.What items make up a basic semiautomatic welding system?What must be done to the shielding gas cylinder before the valve protection cap is removed?Why is the shielding gas valve "cracked" before the flow-meter regulator is attached?What causes the electrode to bird-nest?Why must all fittings and connections be tight?What parts should be activated by depressing the gun switch?What benefit does a welding wire's cast provide?What are the advantages of using a feed roller pressure that is as light as possible?Why should the feed roller drag prevent the spool from coasting to a stop when the feed stops?Why must you always wind the wire tightly into a ball or cut it into short lengths before discarding it in the proper waste container?How is the amperage adjusted on a GMA welder?What effect on the welding current does increasing the wire-feed speed have?