Fundamental Process Control Questions from weldreality.com.
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?
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.
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
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.
You set the correct E71T-1 flux core wire feed setting and you get globular transfer
spatter, name two things you should check.
Why is the use of a flux cored wire for an open pipe root weld not recommended?
Why be concerned with manual flux cored weld weaves wider than 12 mm?
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?
What are worm track? [b] Name three reasons worm tracks occur.
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?
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?
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?
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?
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.
You feel that 0.052 (1.4mm) vertical up E71T-1 weld can take more heat, you increase
what control and in what increment?
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?
Excess weld spatter with your flux cored welds mean,
Answer Volts too
____ or Amps too _____
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.
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.
Name three things you can do to minimize flux cored weld porosity?
b] What caused the porosity in the picture on the right
With the 0.045 (1.2 mm) wire and straight CO2 gas, most vertical up and overhead
welds will be,
120 to 200 amps
[b] 150 to 200
[c] 200 to 230
[d] 250 to 300 amps
Provide three things you can do to minimize slag entrapment in your weld?
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.
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;
The wire feed setting.
[b] The weld voltage.
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?
What would you change___________
 You see the weld wire
running into the weld, what is the first weld parameter you should adjust?
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,
With multipass horizontal fillet welds, why should you limit the single pass weld
size to 5/16.
 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____________.
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.
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