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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?
Answer.________________________________________________
[7]
Why be concerned with manual flux cored weld weaves wider than 12 mm?
Answer.________________________________________________
[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?
Answer.________________________________________________
[9]
What are worm track? [b] Name three reasons worm tracks occur.
Answer._______________________[b]_________________________
[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?
Answer.__________________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.
Answer_______________________Why_____________________________
[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.
Answer._____________________Why___________________________
[20]
Name three things you can do to minimize flux cored weld porosity?
[1]_____________[2]________3]_______
[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
Answer__________________________________________
[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?
Answer.___________Why______
[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.
[28]
With multipass horizontal fillet welds, why should you limit the single pass weld
size to 5/16.
Answer__________________________
[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.
Answer_____________________________________
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