Question 1

Which welding process uses a non-consumable tungsten electrode?

Accepted Answer

Gas Tungsten Arc Welding (GTAW) uses a non-consumable tungsten electrode to produce the arc. Filler metal is added separately if needed.

Question 2

In the SMAW electrode classification E7018, what does the '1' indicate?

Accepted Answer

The digit '1' in E7018 indicates that the electrode is suitable for all welding positions (flat, horizontal, vertical, overhead).

Question 3

Which shielding gas is most commonly used for GMAW of aluminum?

Accepted Answer

Argon is the standard inert shielding gas for aluminum GMAW to prevent oxidation and ensure arc stability. CO2 is reactive and cannot be used with aluminum.

Question 4

What is the primary function of the flux in Submerged Arc Welding (SAW)?

Accepted Answer

The granular flux in SAW covers the arc and molten pool, shielding it from atmospheric contamination (nitrogen and oxygen) and preventing porosity.

Question 5

Which welding process is generally characterized by the highest deposition rate?

Accepted Answer

Submerged Arc Welding (SAW) typically has the highest deposition rates among arc welding processes due to high current capacity and efficiency.

Question 6

In GMAW, which mode of metal transfer is best suited for welding thin sheet metal in all positions?

Accepted Answer

Short-circuiting transfer uses low heat input and a small, fast-freezing puddle, making it ideal for thin gauge materials and out-of-position welding.

Question 7

Which current polarity provides the deepest penetration in GTAW?

Accepted Answer

DCEN (Straight Polarity) concentrates about 70% of the heat at the work piece, resulting in deep, narrow penetration.

Question 8

What type of drive rolls should be used for feeding aluminum wire in GMAW?

Accepted Answer

U-groove drive rolls are designed for soft metals like aluminum to prevent deforming or shaving the wire, which can cause feeding issues.

Question 9

A 'low hydrogen' electrode, such as E7018, must be stored in:

Accepted Answer

Low hydrogen electrodes must be kept dry. Once opened, they are stored in a holding oven (typically 250°F min) to prevent moisture absorption.

Question 10

Which process is most susceptible to 'arc blow'?

Accepted Answer

Arc blow (magnetic deflection of the arc) occurs primarily with DC current due to magnetic fields set up by the current flow. AC current minimizes this effect.

Question 11

In FCAW-S (Self-Shielded), shielding is provided by:

Accepted Answer

Self-shielded flux cored wires contain gas-generating compounds in the core that decompose in the arc to provide the necessary shielding gas.

Question 12

Which welding process is NOT an arc welding process?

Accepted Answer

Electroslag Welding (ESW) is a resistance process. Once started, the heat is generated by electrical resistance through the molten slag pool, not an arc.

Question 13

For GMAW spray transfer, the shielding gas must contain at least what percentage of argon?

Accepted Answer

To achieve true spray transfer, the shielding gas mixture generally requires at least 80% Argon.

Question 14

Which parameter has the most direct effect on the depth of penetration in SAW?

Accepted Answer

Amperage (current) is the primary variable controlling depth of penetration. Higher amperage increases penetration.

Question 15

An E6010 electrode is designed to be used with which polarity?

Accepted Answer

E6010 electrodes (cellulosic sodium coating) are designed specifically for use with DCEP (Direct Current Electrode Positive).

Question 16

Which of the following is a key advantage of FCAW over GMAW?

Accepted Answer

Self-shielded FCAW can withstand cross-drafts better than gas-shielded processes like GMAW, making it suitable for outdoor field work.

Question 17

In the AWS classification ER70S-6, what does the 'S' stand for?

Accepted Answer

The 'S' in ER70S-6 indicates a Solid wire electrode.

Question 18

When using GMAW on carbon steel with 100% CO2 shielding gas, which transfer mode is NOT possible?

Accepted Answer

Spray transfer cannot be achieved with 100% CO2 shielding gas; it requires an argon-rich mixture (typically >80% Argon).

Question 19

Which welding process produces the narrowest Heat Affected Zone (HAZ)?

Accepted Answer

High energy density processes like Laser Beam Welding (LBW) and Electron Beam Welding (EBW) produce very narrow welds and minimal HAZ.

Question 20

Excessive electrical stickout (CTWD) in GMAW typically results in:

Accepted Answer

Increasing stickout increases resistance in the wire, which drops the welding current (amperage), resulting in a colder weld and less penetration.

Question 21

E7024 electrodes are classified as:

Accepted Answer

E7024 contains a high percentage of iron powder in the coating (approx 50%), classifying it as a 'fast fill' electrode with high deposition rates.

Question 22

In GTAW, cleaning action on aluminum occurs during which half-cycle of AC welding?

Accepted Answer

Cathodic cleaning (oxide removal) occurs during the Electrode Positive (DCEP) half-cycle when electrons flow from the workpiece, breaking up the oxide layer.

Question 23

Which defect is most likely if the travel speed is too high in SAW?

Accepted Answer

Excessive travel speed does not allow enough filler metal to fill the joint edges properly, often resulting in undercut along the toes of the weld.

Question 24

What is the main purpose of the 'drag angle' in SMAW?

Accepted Answer

A drag (backhand) angle uses the arc force to push the molten slag back, preventing it from running ahead of the pool and getting trapped (slag inclusion).

Question 25

Which welding process typically requires the highest degree of joint cleanliness?

Accepted Answer

GTAW is very sensitive to contamination (oil, grease, rust) because there is no flux to scavenge impurities. The base metal must be very clean.

Question 26

For E7018 electrodes, the maximum exposure time to the atmosphere before redrying is required is typically:

Accepted Answer

Per AWS D1.1, E7018 (low hydrogen) electrodes have a maximum exposure limit of 4 hours. If exceeded, they must be baked/redried.

Question 27

Which type of welding power source is essentially a constant voltage (CV) machine?

Accepted Answer

GMAW (and FCAW) typically uses Constant Voltage (CV) power sources to maintain a constant arc length by self-regulating the current.

Question 28

A CWI notices a welder using a 'whipping' motion with an E7018 electrode. This technique is:

Accepted Answer

Whipping moves the arc away from the puddle, removing the gas shield. For low hydrogen electrodes like E7018, this often causes porosity. A steady drag or slight weave is preferred.

Question 29

The 'O' in the AWS classification E70T-1 stands for:

Accepted Answer

Wait, let's correct this. In FCAW, '0' (as in E70T-1) indicates flat and horizontal positions. '1' indicates all positions. The question asks about 'O'. Actually, the digit is a zero '0'. Explanation: The '0' indicates the electrode is intended for flat and horizontal positions.

Question 30

Which GMAW gas mixture is commonly associated with 'globular' transfer on carbon steel?

Accepted Answer

100% CO2 shielding gas typically results in globular transfer (erratic, spatter) unless specialized pulse equipment is used.

Question 31

In PAW (Plasma Arc Welding), the term 'keyhole' refers to:

Accepted Answer

The 'keyhole' technique in PAW involves a focused arc that punches completely through the material, allowing full penetration in a single pass on thicker materials.

Question 32

What is the primary reason for using a backing gas (purge) when welding stainless steel pipe roots with GTAW?

Accepted Answer

Stainless steel oxidizes rapidly at high temperatures. A backing gas (purge) of Argon displaces oxygen inside the pipe to prevent 'sugaring' (heavy oxidation) on the root bead.

Question 33

A welder is experiencing 'stubbing' while using GMAW. This is most likely caused by:

Accepted Answer

Stubbing occurs when the wire hits the base metal without melting (arc doesn't ignite or maintain). This usually means the wire feed speed is too fast for the set voltage/amperage.

Question 34

Which welding process uses a vacuum chamber?

Accepted Answer

Electron Beam Welding (EBW) typically requires a high vacuum to prevent electrons from scattering by colliding with air molecules.

Question 35

In Resistance Spot Welding (RSW), the nugget size is primarily controlled by:

Accepted Answer

Heat generation in RSW follows Joules Law (H=I²Rt). Current, weld time, and electrode pressure are the critical variables.

Question 36

The coating on E6013 electrodes is primarily:

Accepted Answer

E6013 has a high titania potassium coating, designed for shallow penetration and a smooth arc, often used on sheet metal.

Question 37

Which discontinuity is most associated with incorrect start/stop technique in GTAW?

Accepted Answer

Abruptly terminating the arc in GTAW leaves a concave crater which creates high shrinkage stress, often resulting in 'crater cracks'. Using a downslope or adding filler at the stop prevents this.

Question 38

For SAW, if the flux layer is too shallow, what visual defect occurs?

Accepted Answer

If the flux is too thin, the arc breaks through (flashes), losing shielding protection and allowing atmospheric nitrogen/oxygen to cause porosity.

Question 39

Which process generally has the lowest heat input?

Accepted Answer

GMAW Short Circuit transfer has very low heat input compared to the others, making it suitable for thin gauge materials.

Question 40

What is the purpose of the copper coating on GMAW wire?

Accepted Answer

The thin copper coating improves electrical contact at the contact tip and prevents the steel wire from rusting during storage.

Question 41

In vertical-up SMAW, a weave bead width should generally not exceed:

Accepted Answer

While codes vary slightly, general good practice and many AWS guides suggest limiting weave width to 3-4 times the core wire diameter to maintain shielding and heat control.

Question 42

A CWI observes a welder using GMAW. The welder increases the contact tip to work distance (CTWD) significantly. What happens to the welding current?

Accepted Answer

In CV welding (GMAW), increasing CTWD increases resistance. Per Ohm's law, increased resistance results in decreased current (amperage).

Question 43

Oxyacetylene flame temperature is approximately:

Accepted Answer

Oxyacetylene produces the hottest gas flame, typically around 5,600°F to 6,300°F depending on the mixture ratio.

Question 44

Which shielding gas promotes the 'finger' penetration profile in GMAW?

Accepted Answer

Argon-rich shielding gases typically produce a deep, narrow, 'finger-like' penetration profile in the center of the weld.

Question 45

Electrode extension in SAW is measured from:

Accepted Answer

Electrode extension (stickout) is the distance from the end of the contact tube/tip to the work piece (or arc).

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