The WeldReality MIG Weld
Process Control Test.
We
are all aware of the focus and importance of weld skills.
How important is
weld process expertise to your career?
[1] You have a 70S-3 (0.035 1mm) MIG wire and argon - 20% CO2 gas mix. You have to set robot parameters to weld 0.080 gage parts. The lap weld has gaps approx. 0.060. What wire feed setting, (or amps), volts and weld travel speed would you set?Answer. Wire feed ___ Amps____ Volts_____ Weld Travel _____ipm
[2a] Provide what you believe is optimum short circuit wire feed setting, weld current and voltage with an 0.045 (1.2mm) wire and 80 argon - 20 CO2 gas.
Answer. Wire feed ___ Amps____ Volts_____
[3] The robot weld requires a 220 amp spray transfer weld, using the argon - 10 CO2 mix and an 0.035 1mm wire. In the robot pendant you have to set the wire feed speed.
[a] What wire feed rate would you set?
[b] What is the weld deposition at this wire feed rate?Answer.[a]_____________[b]________________
[4] Which of the following is considered an optimum short circuit "weld voltage range" for either an 035 or 045 (1 - 1.2 mm) wire?
12 - 18 volts [b]17 - 24 volts [c]13 - 18 volts [d]16 - 20 voltsAnswer.______________________________
[5a] Why don't we use the back hand technique for welding thin gauge?
[5b] What is the best "weld position" for that 18 steel box?
Answer.[a] _______________________________
Answer [b]________________________________
[6] Which of the following is the manual welded recommended "thickness range" when using an 0.035 (1mm) wire and the short circuit transfer?
[a] 26 gauge to 16 gauge, [b] 18 gauge to 12 gauge, [c] 14 gauge to 8 gauge?
Answer.______________________________________________
[7] Provide the robot weld data for the following 1/8 (3 mm) steel parts. The parts are welded vertical down. The parts have a 0.100 gap. Conventional CV. MIG power source. Wire 0.035. (1mm). Gas Ar 75% - CO2 25%;
[a] wire feed setting.
[b] volts.
[c] weld travel rate,
Answer. Wire Feed Rate_________Volts_____Weld Position____Weld Travel Rate_______
[8a] Why does a robot allow you to MIG weld thinner gauge than a manual welder can weld?
[8b] What minimum steel thickness you can weld with an 0.035 wire and the spray transfer mode?
Answer.[a]__________________________[b]___________________
[9a] Which MIG gas provides "dissociation" in the arc, influencing the weld fusion profile?
[a] oxygen, [b] argon [c] helium (d) carbon dioxide.
[9b] What is gas dissociation?
Answer. The MIG gas that provides dissociation is___Gas dissociation is _________________.
[10] Your robot application can use a low spray transfer setting. What is the minimum wire feed rate and weld voltage required with an 0.035 (1mm) wire to attain a low spray transfer weld using an argon 10% CO2 gas mix.
Answer. WF_____inch/min__________Volts__________
[11] You are ready to robot weld a 3/16 (5mm) fillet weld. Using spray transfer and an 0.045 (1.2mm) carbon steel wire, select the wire feed rate, voltage, weld deposition and robot weld travel rate range most applicable.
Answer. WF____inch/min. Volts____Deposition_____lb/hr. Weld Speed_______inch/min
[12] To provide an optimum 1/4 (6 mm) fillet weld, using spray transfer and an 0.045 wire start out at what wire feed setting, what voltage and what weld travel rate.
Answer. WF_________ipm Voltage_______ Travel rate______inch/min
[13] What robot wire feed rate, voltage, weld travel rate, position and welding gas would you use for this common 1 mm steel gage application welding with an 0.035 wire?
Answer. Wire Feed_____ Voltage___ Weld Travel Rate_____Pos_______Weld Gas_____
[14] With a robot, and without changing the wire feed setting you increase the robot weld travel rate. Which of the following would you typically have to adjust to compensate.
Answer. [a] increase weld volts, [b] decrease weld volts. Explain why____________
[15] When robot welding, you have to change the contact tip more than once a day due to wire burn backs at the weld start. For the weld and start data you are using an 0.045 (1.2mm) wire set at 480 ipm with 30 weld volts. What changes would you make to the weld start data to eliminate wire burn backs?
Answer. ____________________________Why will this data work?___________________
WITH ED'S UNIQUE PROCESS CONTROL TRAINING AND EDUCATIONAL RESOURCES, YOU WOULD HAVE THE ABILITY WITHOUT REFERENCE TO NOTES TO INSTANTLY PROVIDE ANSWERS FOR THESE WELD QUESTIONS.
[16] You are robot welding with an 0.045 wire and 80 argon 20 CO2. The weld and end data wire feed is 320 inch/min with 24 volts. There are many weld start issues explain why
Answer: [a] wire feed rate_____ [b] travel rate ______ [c] volts_____
[17a] Which of these gas mixes will provide the most weld fusion and lowest porosity when welding with an 0.045 wire in the spray mode and why?
[a] argon - 2 oxy [b] argon - 5 oxy [c] argon - 10 CO2
[d] argon - 8 Co2 - 2 oxy [e] argon - 20 CO2Answer _________________
[18] Watching your robot weld, you note a globular weld transfer with your 0.035 1 mm wire and 80argon - 20%CO2 mix welding 5 mm steel parts. The weld transfer is causing extensive spatter what adjustments to the robot weld parameters do you make and why?Answer. ___________________________Why?_____________________
[19] You need to establish a multipass, MIG weld procedure for a vee groove flat position weld on 25 mm steel parts. With the 0.045 (1.2mm) wire, provide the wire feed rate, voltage, travel rate, and deposition rate.
Answer. Gas Mix_____Why this gas mix? _______________
Wire Feed Rate_____Volts____Travel Rate_____Deposition Rate_________
[20] At the robot weld completion, you note a large weld drop attached on the wire tip, what do you adjust in the robot weld data to eliminate the weld drop on the wire tip?
Answer. ___________________Why______________________________
[21] You have to weld thin gauge (0.060) stainless with an 0.035, 309L MIG wire and the common three part helium tri mix, 90 He / 7.5 Ar / 2.5 CO2. Why is this popular global gas mix the wrong gas choice? What is the optimum gas mix and why. (note Ed developed it)
Answer. The tri mix is a poor choice because__________________________________________The correct gas choice for the thin stainless is? _____________________________
[22] You are pulsed or spray transfer welding an aluminum application. The aluminum parts are clean, however extensive black soot occurs either side of the weld. What simple weld parameter adjustment will instantly decrease the black soot. Why does this parameter adjustment work?
Answer. The weld parameter adjustment is _______________________________________________
This adjustment works because___________________________________________________
[23] You are pulsed MIG welding a steel part. The part thickness and weld needs an average weld current of 240 amps. Provide the pulsed peak current and back ground current to attain 240 amps?
Answer. _______________________________________________
[24] With that robot or manual weld what is the maximum fillet weld size for
[a] a horizontal fillet. Why?
[b] a flat fillet. Why?
Answer. [a]_____________[b]______________why?_____________________
[25] What is the minimum weld voltage when robot welding with spray transfer, using either an 0.035 or 0.045 wire (1 - 1.2 mm) and argon 20% CO2?
Answer. [a] 22 volts [b] 23 volts [c] 25 volts [d] 27 volts [e] 29 volts
[26] Using an 0.052, 1.4 mm steel MIG wire, what is the minimum part thickness you can spray weld without weld burn through issues.
Answer._____________________________________
[27] With an 0.045 wire you are welding a 10 gauge carbon steel part and the weld current is 240 amps with 25 volts. The parts are covered with spatter and the tips need changing every hour. Why?
Answer____________________________________________________________________________
[28] Your pulsed steel or stainless MIG weld is too narrow and convex, which pulsed parameter do you change to make the weld wider? [a] Why will this change give the results?
Answer_______________________[a]_____________________________________
[29] Your pulsed steel or stainless MIG weld is erratic and there is no more adjustment from the arc trim. Which of the following pulsed paramaters would you adjust and why?
Answer. Peak___Back Ground___Wire Feed ___
Weld Amps ____Pulsed frequency___Why?________________
[30] Your pulsed steel or stainless MIG weld droplets are too large. Which of the following pulsed paramaters would you adjust and why?
Answer. Peak___Back Ground___Wire Feed ___Answer. Weld Amps ____Pulsed frequency___Why?________________
I COULD PROVIDE A 100 OF THESE QUESTIONS. THE REAL QUESTION IS, HOW IMPORTANT DO YOU BELIEVE WELD PROCESS KNOWLEGE LIKE THIS IS FOR ROBOT WELD QUALITY AND PRODUCTIVITY OPTIMIZATION, AND FOR YOU TO FURTHER YOUR CAREER?
ED'S BOOKS AND TRAINING PROGRAMS PROVIDE THIS DATA AND MUCH MORE.
CALL ED AT 828 658 3574 IF YOU WANT MORE INFORMATION.
