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Flux Cored and MIG weld process controls

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Manual MIG Welding Process Control

(Also in Spanish)
" Proceso de Soldadur MIG Manual "

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Robot MIG welding. Best Weld Practices and Process Controls

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Manual MIG Welding. Best Weld Practices and Process Controls

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MIG Welding Process Controls
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Flux Cored Welding Quiz:

Flux Cored Books

30 Fundamental Process Control Questions from weldreality.com.


[1] Welding vertical up with that 0.045 (1.2 mm) E71T-1 flux cored wire, you have the correct wire feed setting yet the weld is too fluid, which is the fiorst thing you look to adjust?

Answers. _____________Why?____________


[2] Welding that single pass 1/4 (6 mm) horizontal fillet weld with an 0.045 E71T-1 wire and an automated carriage, provide;

[a] the wire feed, [b] voltage and [c] weld speed.

Answer. [a]______________[b]______________[c]______________


[3] Provide a common, "optimum volt setting" used to weld a vertical up,1/4 (6 mm) flux cored fillet welds with an 0.045 (1.2mm), or 0.052 (1.4 mm) E71T-1 wire.

Answer ______volts


[4] Welding a 3/4 (18 mm) carbon steel plate, you are going to weld the first hot pass in a "horizontal vee groove" with an 0.045 E71T-1 wire, provide an optimum wire feed (WF) inch/min and voltage.

Answer. WF______Volts_______


[5] You set the correct E71T-1 flux core wire feed setting and you get globular transfer with high spatter, name two things you should check.

Answer. [1]____________[2]_______________

[6] Why is the use of a flux cored wire for an open pipe root weld not recommended?


[7] Why be concerned with manual flux cored weld weaves wider than 12 mm?



[8] What effects will an excess arc length have on a vertical up E71T-1 fillet weld and how do you know the arc length set is correct?



[9] What are worm track? [b] Name three reasons worm tracks occur.



[10] Welding horizontal stringer, cap welds, in an 18 mm 50 degree vee groove, would you use a slight fore hand or back hand for the stringer passes?

Answer. __________Why_________________________________

[11] With an 18 mm, horizontal vee groove flux cored weld, what will be the two most common weld defects and where will most of the weld defects be located?

Answer: [1] ________________[2]_________________________

[12] In manually welding fill passes in any narrow groove welds in steels thicker than 12 mm, which is the logical choice, stringers or a weave?

Answer. __________________Why____________________

[13] Welding in the flat position or horizontal position. Should you use the fore hand or back hand technique when welding a root across a vee groove joint with "ceramic" backing and why?



[14] You are ready to weld an automated vertical up cap pass on a 12 mm wall, 50 cm diameter pipe, provide the wire feed, travel rate and voltage start point for that 0.045 (1.2 mm) E71T-1 wire.

Answer.WF____________inch/min. Travel ________inch/min. Volts____________


[15] You feel that 0.052 (1.4mm) vertical up E71T-1 weld can take more heat, you increase what control and in what increment?

Answer. ________________________Why______________________


[16] You are about to weld the first "fill pass" in a 30 mm plate vee groove weld made in the flat position.

[a] What position is the gun and why?

[b] To ensure optimum weld data before you strike an arc in the vee groove, what should you do?

Answer. [a] .____________________Why__________________

Answer. [b] .____________________Why__________________

[17] Excess weld spatter with your flux cored welds mean,

Answer Volts too ____ or Amps too _____

[18] Provide an optimum wire feed and volt setting for welding plate, (6 -20 mm), vertical up fillet using that
0.045 1.2mm E71T-1 wire.



[19] Provide an optimum wire feed and voltage setting for an "0.052" (1.4 mm) E71T-1 wire, welding a 1/4 (6mm) fillet weld vertical up.



[20] Name three things you can do to minimize flux cored weld porosity?


[20 b] What caused the porosity in the picture on the right

Answer. ________

[21] With the 0.045 (1.2 mm) wire and straight CO2 gas, most vertical up and overhead welds will be,

[a] 120 to 200 amps
[b] 150 to 200
[c] 200 to 230
[d] 250 to 300 amps



[22] Provide three things you can do to minimize slag entrapment in your weld?

Answer. [1]_________________[2]_________________[3]__________


[23] You want to set your mechanized carriage to weld with 1/16 (1.6mm) E70T-1 wire to weld a single pass 5/16 horizontal fillet. Provide the WF, Volts and travel.

Answer. WF___________Volts_______________Travel________________



[24] Welding a 1/2 fillet on 3/4 steel in the flat position. You are using an automatic carriage and a 3/32 (2.4 mm) E71T-1 wire, with CO2, provide the optimum;

[a] The wire feed setting.
[b] The weld voltage.
[c] Travel

Answers WF___________Volts_______________Travel______________

[25] You are welding mostly flat and horizontal 6 - 8 mm fillet welds with an 0.045 E71T-1 wire, and argon 25% CO2, the weld surface has pock marks, why?

Answer.____________________ What would you change___________

[26] You see the weld wire running into the weld, what is the first weld parameter you should adjust?



[27] In the picture below we have a 6 mm flux cored filet made in the over head and vertical up positions. Provide the required automated weld settings for both using an 0.045 E71T-1 wire with argon 25%CO2?

Answer Vert Up WF ____Travel____Volts_______ Over Head WF ____Travel____Volts.

Ed made these overhead and vert up ship welds,

[28] With multipass horizontal fillet welds, why should you limit the single pass weld size to 5/16.


[29] You want more energy in your E71T-1 wires so you change the 75 argon - 25% CO2 shielding gas mix to what?

Answer_______________Why does this work____________.


[30] The job is mostly vert up fillet welds made with an 0.045 wire set at 280 inch/min? The welders average 30 minutes arc on time each hour. How much weld wire will be required for each welder per 8 hr/day.


Do you think your weld personnel should be able to answer the above questions. With Ed's unique flux cored and MIG process control training programs, in a few hours all your weld personnel will have full control of the world's most important welding processes.

If you are looking to attain process optimization through teaching your self, or providing weld process control training for others, the following resources are all you need.

The Book: "A Management & Engineers Guide To MIG W
eld Quality, Productivity & Costs"

Item 2.
A unique robot MIG training or self teaching resource.
"Optimum Robot MIG Welds from Weld Process Controls".

Item 3.
A unique MIG training or self teaching resource.
" Manual MIG Weld Process Optimization from Weld Process Controls".

Item. 4. A unique flux cored training or self teaching resource."Optimum Manual and Automated Flux Cored Plate and Pipe welds.

Item 5a."Proceso de Soldadura MIG Manual" (MIG Made Simple. Self teaching in Spanish).

Item 6a. The Self Teaching MIG Book/ Video. (MIG Made Simple in English).

Visit Ed's MIG / flux cored process control books and CD training resources.

Back to all Flux cored programs at www.weldreality.com