Spray Transfer Weld Quiz

[1] Complete the following, to reduce weld spatter when using spray transfer you typically have to increase or decrease what parameter?

Ans._______________________________________________________________

[2] You wish to reduce weld burn through potential when using spray transfer should you increase or decrease the push angle?

Ans.________________________________________________________________

[3] You are using a robot, an argon 15% CO2 mix, with an 0.035 (1mm) E70S-6 electrode. You will be welding carbon steel parts 2.5 mm thick. You wish to use spray transfer. As you will require a low current spray setting, you will need to know the spray transfer wire feed start point, select one of the following.

[a] 250 in./min
[b] 350 in./min
[c] 450 in./min
[d] 550 in./min

[4] With a traditional CV power source and wire feed control, a typical spray transfer weld current range for an 0.035 electrode is

[a] 170 to 270 amps
[b] 220 to 370 amps
[c] 280 to 390 amps

[5] Inductance when added to a spray transfer can,

[a] Makes the weld more fluid.
[b] Affect the arc starts.
[c] Make the weld freeze faster

[6] You are using a robot, an argon 10 % CO2 mix, with an 0.045 (1.2mm) E70S-6 electrode. You will require a low current spray setting, you will need to know the spray transfer wire feed start point, select one of the following.

[a] 260 in./min
[b] 380 in./min
[c] 420 in./min
[d] 460 in./min

[7] With a traditional CV power source and wire feed control, plus an argon mix containing 20 % CO2, a typical spray transfer weld current range for an 0.045 (1.2mm) electrode is,

[a] 210 to 320 amps
[b] 230 to 390 amps
[c] 250 to 410 amps

[8] You are using a robot, an 0.045 carbon steel wire and an argon 10% CO2 mix. At the weld start excess weld spatter is produced. You unknowingly put globular transfer weld data into the robot arc start weld data. Select data which will produce globular transfer.

[a] wire feed 210 in./min, volts 17
[b] wire feed 250 in./min, volts 19
[c] wire feed 300 in./min, volts 23
[d] wire feed 380 in./min, volts 27

[9] You are using spray transfer and welding with a robot. You decide to increase the weld travel rate by 20%. The resulting weld size is fine, however to stabilize the arc you will have to make a weld parameter change? What is that change?

Ans.______________________________________________________________________

[10] Fill in the following. You are about to robot weld a ¼ (6mm) fillet weld on clean plate. You are using an 0.045 (1.2mm) E70S-6 electrode and a 10% CO2 gas mix. Without reference to a text book, procedure or without playing with the weld parameters fill in the required weld data.

[a] Wire feed rate._______in./min or ________m/min. [b] Weld voltage._________

[c] Weld travel speed. _______ [d]Weld start wire feed._______ [e]Weld start voltage._______

[f] Weld end wire feed rate.______ [g] Weld end voltage.________

Weld process control comes from weld process knowledge. If you have to go to a text book to find the answers to these practical questions you have not mastered your craft. Ed has written training text books and produced a video that provides these answers in an easy to remember format. Check his web site at www.weldreality.com