The
MIG Process Control Weld Test.
From
Ed Craig. www.weldreality.com.
How
important is "MIG process control knowledge"
to your career and
this organization?
[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.
[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?
[a]12 - 18 volts [b]17
- 24 volts [c]13 - 18 volts [d]16 - 20 volts
Answer.
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.
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 robot weld data for the following 1/8 (3 mm) steel parts. The parts are
welded in the position shown. 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? 9b What is MIG gas dissociation?
[a]
oxygen, [b] argon [c] helium (d) carbon dioxide.
Answer.
A _____________________________B
[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.
WF __ipm Voltage__ Travel Rate___ inch/min
[13]
What robot wire feed rate, voltage, weld travel rate, position and welding gas
would you use TO weld a 1 mm steel galvanealed, gage application with an 0.035
wire?
Answer.
Wire Feed___ Voltage___ Weld Travel Rate___ Part Position.
[14]
Robot Weld. 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.
[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?
[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.
[17]
Which of these gas mixes will provide the most weld fusion and lowest weld 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 CO2
Answer.
[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 multi-pass, 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?
[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 parameters 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 parameters would you adjust and why?
Answer. Peak Back Ground Wire Feed
Weld
Amps Pulsed frequency Why?
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 CO2
Answer
_________________
[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?
