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1.
Why is it generally good practice to aim at using the least amount of consumable materials and
keep joint preparation to a minimum?
To reduce costs and with less weld metal there is the probability of fewer weld faults.
2.
In generally, MIG/MAG mode of transfer. Best suited for welding thin material sheet is;
Short Circuiting transfer & Dip transfer ( Welding thin material & low voltage & low Amp)
Note;
Globular transfer (mode transfer between dip transfer and spray transfer & produce
excessive spatter)
Spray transfer (must used Argon & Helium gas for shielding)
The pulsed transfer MIG/MAG process also can welding flat & overhead position.
3.
4.
When welding GMAW (also known as MIG/MAG) process, straight argon may be successfully
used as a shielding gas when welding material?
Aluminium
5.
The primary advantage of a 75% Ar, 25% CO2 gas mixture over pure CO2 in the FCAW process
is;
Very significant reduction in weld spatter.
6.
7.
8.
9.
10. Following may contribute to the formation of porosity in the weld deposit;
Low welding current
Contamination of the weld joint surfaces.
Use of contamination electrodes, damp flux.
Air entrapment in gas shielding.
High arc voltage, arc length.
In correct / insufficient dioxide in electrode, filler or parent metal.
11. when using GMAW process for welding of aluminum, the liner should made of;
Nylon or Teflon.
Note;
41. Penetration inspection and magnetic particle inspection are mainly used to;
Aid visual inspection.
42. Defect outside of the limits specified in the standard should always be;
Reported to a senior person
43. MIG welding tends to be susceptible to lack of fusion problem. This is because of;
Poor maintenance of equipment.
Incorrect setting.
Poor inter run cleaning.
44. MMA electrode can be grouped into 3 main type.
Basic
Cellulose
Rutile
45. The main causes of porosity in welded joint are;
poor access
loss of gas shield
dirty material
46. Crack in welds may be due to;
Solidification problem
Hydrogen problem
Excessive stresses
49. A fatigue failure is characteristic by the appearance of the facture surface. It would be;
Smooth
61. The steel composition in structure contrast is changed from 0.15% carbon, 0.6% manganese, to
0.2% carbon , 1.2% manganese. Might this influence the incidence of;
Cracking in the weld area.
64. Pre-Heating carbon steel. MMA welding is carried out to minimize the risk of;
Parent metal cracking
65. In UK practice, BS499 Part 2 specified that the drawing dimension quoted for fillet weld is the;
Leg length
66. For open site, MMA welding the following equipment is available and choose for safe working
area.
Diesel engine driven motor generator
67. If SAW is to be used to make butt weld, which would you be most critical of;
The root gap tolerance
68. During CO2 welding, the arc length is most likely to be effected by;
The current return connections
69. Preheating for arc welding applies to;
Assembly and tack welding.
70. What will effected on the carbon steel, when welder using an oxy-acetylene flame with a long
feathered inner cone;
The weld could be hard and brittle
71. A welder qualification test is to verify:
The skill of the welder
72. A fabrication procedure calls for fillet weld to be blended in by grinding. This is to influence;
Fatigue life
73. Bend test specimen has been taken from 25mm a thick carbon steel butt weld. Which would show
lack of inter run fusion;
Side bend
74. Lamellar tearing has occurred in steel fabrication. Before welding could it have been found;
It would not have been found by any inspection method
Note: It only found after welding and form when welding stress act it the short transverse direction of the
material.
75. You are overseeing the arc welding of some machined fitting and find they are cadmium plated.
What your action;
Stop the operation at once
76. Movement of the arc by magnetic force in MMA welding is termed;
Arc blow
77. A metallurgical problem most associated with SAW is;
Solidification cracking in the weld metal
78. Oxy pressure and nozzle size would influence what in flame cutting;
The depth of cut obtained
79. The main usage of arc cutting / gouging process is in;
The removal of deposit welds
80. Following process joint metals plastically;
Friction welding
100% Argon
84. The type of SAW flux is more resistance to moisture absorption;
Fused
Note; Agglomerated flux ~ to avoid high H2 level granular.
85. The flame temperature of oxy / acetylene mixture gas is given as;
3200C
86. A large grain structure (annealing & normalizing) in steels said to produce;
Low fracture toughness value
87. The like hood of brittle fracture in steels will increase with;
A reduction of in-service temperature to sub zero levels (Fast cooling)
88. Repair welding is often more difficult than production due to;
The material being ingrained with in-service contaminates
Restricted access within repair area
The possible position of the weld repair
89. Hydrogen cracking in the weld metal is likely when welding;
Micro alloyed steel (HSLA)
95. A crack type most associated with the submerged arc welding process is;
Solidification cracking.
96. Electrode and current type used for the TIG welding nickel and alloys.
Cerium electrode, DC ve
97. What are the possible result of having a heat input to low and high.
LOW HEAT INPUT ~ entrapment hydrogen, increased hardness and lack of fusion.
HIGH HEAT INPUT ~ low toughness, reduction in strength.
98. Main reason using back purge. When welding stainless steel with TIG;
Prevent the formation of the dance oxide layer forming in the root.
99. Possible effect when Travel speed to fast;
High hardness, slag inclusions and narrow thin weld bead.
100. If ARC BLOW exist when welding with MMA welding process, this can be reduce or eliminate by;
A change from DC to AC current.
101. The inclusion of inductance in the welding circuit. When using MIG / MAG welding process is to;
Control the rate of spatter in the dip transfer mode.
102. An undesirable property of aluminium oxide residue, when welding is;
Requires more heat to melt it, when compare to aluminium.
103. When considering the TIG welding process. What is the purpose of the down slope / up slope (slope
out / slope in) control?
SLOPE OUT ~ to help prevent the formation of crater pipe and possible cracking.
SLOPE IN ~ to prevent burn through.
104. When considering Thermal cutting local hardening can be reduce by;
Pre heating the material to be cut out.
105. Semi- automatic (MIG/MAG) welding process. Following shielding gas would normally give a
deepest penetration on steel.
100% CO2
106. Following welding process, after weld is completed normally requires a PWHT to restore toughness
values.
ESW
107. TIG process. When welding of aluminium, following current are used;
AC
108. When considering hydrogen, following welding process would produce the lowest levels in the
completed weld (under controlled condition)
TIG
109. In steel the element with the greatest effect on hardness is;
Carbon
110. MMA welding voltage current setting, when the arc length is shortened & high?
ARC length shortened ~the voltage will decrease.
ARC length high ~ the voltage will increase.
111. What is purpose of a rectifier in a welding sets electrical circuit?
To convert AC current to DC current.
112. When calibrating a mechanized MAG welding plant, which of the following applies (WFS = wire feed
speed)
Check gas flow rate, stick out of length, WFS and current.
113. What is effect of Tempering after Quenching;
Toughness increased and strength reduced.
114. Ratio between leg length & design throat thickness;
1.414 to 1
115. HEAT INPUT = Amp x Volt
x 60
Travel speed mm/sec x 1000
116. The toughness & yield strength of steel reduce by;
Increasing heat input.
117. Typical appearance of ductile fracture surface.
Rough randomly torn and reduction in area.
118. Increased carbon;
Increased hardness, decrease toughness
119. Effect of full annealing compared to normalizing.
An increase in grain size.
120. Following element may cause hot & cold shortness;
COLD SHORTNESS ~ phosphorous
HOT SHORTNESS ~ sulfur
121. Following material most susceptible to HICC in weld zone;
Carbon manganese steel (also occur in HAZ)
136. In general, the amount of oxygen in a mixed gas used for (GMAW) should be limited to;
2% maximum
137. Using GMAW process, straight ARGON may successfully used as a shielding gas when welding;
Aluminum
138. A 70% duty cycle means that a machine may, at its rated output, run;
7minute out of every 10minutes
139. In GMAW, spray transfer may achieve using shielding gas containing;
More than 85% ARGON
140. A constant current power source is suitable for;
GTAW & Plasma GTAW