Flux Cored Welding Quiz:

30 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.

Ed made these overhead and vert up ship welds,

[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_____________________________________

Do you think your weld personnel should be able to answer the above questions. With Ed's unique flux cored and MIG process control training programs, in a few hours all your weld personnel will have full control of the world's most important welding processes.