Second Year Welding > AIT > Flashcards

AIT Flashcards

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1
Q

Smaw fillet welds on mild steel

Hot pass is a first fill

A

.

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2
Q

Electrode angle =

A

Half the included angle

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3
Q

Another term for inclination is

A

Work angle

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4
Q

Smaw electode inclination
Flat and overhead

A

. 5-15

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5
Q

Forehand

A

Flatter wider smoother metal flow less pen

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6
Q

Backhand

A

Deeper pen narrow bead more build up

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7
Q

Inclination for vertical

A

0-10 forehand

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8
Q

6010

A

DCRP - reverse polarity
DCEP

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9
Q

Weave bead should not exceed

A

2-3 times electrode diameter

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10
Q

The herringbone variation eliminates

A

Undercut

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11
Q

Weave techniques

A

Herringbone
Crescent weave
Lazy L
Sawtooth weave

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12
Q

Groove welds must be reinforced at the center of the weld at least….

A

1.6 (1/16) for material buildup
10 percent material thickness

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13
Q

E4310 (E6010)
1/8
Current type
Polarity
Amps

A

DCEP
DCRP reverse polarity
80-140

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14
Q

E4918 (E7018)
3/33
Currently
Polarity
Amps

A

AC DC
DCEP
DCRP
70-120

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15
Q

E4918 (E7018)
1/8
Current
Polarity
Amps

A

AC DC
DCEP
DCRP
80 - 175

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16
Q

Electrode starting methods

A

Scratch
Tapping

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17
Q

Good polarity checking rod

A

6010 bc it only works on DCRP

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18
Q

Electrode with added potassium

A

6011 has added potassium to stabilize the arc for AC welding

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19
Q

25.4 mm = 1”

A
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20
Q

F system
F1. F2. F3. F4.

A

F1 : iron
F2 : Rutile
F3 : Cellulose
F4 : Lime

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21
Q

Hermetically sealed rods
Temp
Re- bake temp

A

7018 - prevent moisture build up
50 - 250 F

Re-bake
500 - 800F

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22
Q

6010 moisture content

A

3-7 percent

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23
Q

7018 polarity

A

AC or DCRP

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24
Q

Short arc in Smaw
Penetration
Amps and volts

A

High amps low bolts
High narrow deep pen

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25
Long arc in Smaw Penetration Amps and bolts
Low amps high volts More fluid puddle, blends better Less pen
26
Starting arc volts
50-100 amps
27
Maintaining an arc
17-40
28
Electromotive force EMF
Voltage
29
Blow machine out with
High volume Low pressure air
30
Percentages of carbon and what they make
Low - .05-.30 Nails Mild .15-.30 General fab Med .30-.45 Preheat needed, engine connecting rods High .45-.75 Preheat and post head, springs, crankshafts Very high .75-1.5 Files Cast iron 2-4.5
31
CSA and ASTM
Structural steel plates and shapes
32
AISI
Steel sheet stock
33
SAE and AISI
Steel bar stock
34
CSA system AT
Atmospheric corrosion resistant weldable notch tough
35
CSA WT
Weldable notch tough
36
CSA R
Atmospheric corrosion resistance steel
37
SAE that begins with a number greater than one is
Alloy steel
38
Steel is ….. percent iron
95 percent 5 percent other
39
Deoxidizers 5
Aluminum Titanium Manganese Silicon Zirconium
40
Hot shortness
Brittle at high temp
41
High strength low alloy steels Percentage addy
2 percent
42
Positions welding
1. All positions 2. Flat and horizontal 3. Flat only 4. Down hand, overhead, horizontal, flat
43
Major alloy designations A, B, C, D, G, M, NM
A: carbon moly B: chrome moly C: nickel D: manganese moly G: all other low alloy electrodes M: military NM: nickel moly
44
Pig iron is made in a blast furnace with these three ingredients
Iron ore Coke Limestone
45
Pig iron carbon content
4-5 percent
46
Tuyeres
Blow oxygen rich air to remove carbon as CO2 that bubbles out in the blast furnace
47
Cast iron furnaces
Cupola Induction furnace (uses electricity)
48
Steel production furnaces
Basic oxygen steel making furnace Electric arc furnace (high quality steels)
49
Cast iron 2-4.5 percent Types…
Grey : excellent wear resistance ability to absorb noise and vibration - engine block White : not weldable - better wear resistance then grey Malleable : easy to be cold worked - annealed white cast iron - plumbing fittings Ductile or Nodular : highest strength and ductility of cast irons alloyed with rare earth elements and manganese
50
Steel classification by deoxidization process
1. Killed steel - fully deoxidized 2. Semi killed - some deoxidizers added 3. Rimmed - no deoxidizers added 4. Capped - no deoxidizers - cap added to slow cooling
51
Non ferrous vs ferrous metals
Ferrous metals contain iron
52
GTAW applications
Spot welding Hot wire (wire is preheated with AC current) Cold wire High amp (200 + amps) Orbital Welding
53
GTAW Adv and disadvantages
Metals and alloys High quality Excellent mechanical properties Filler metal not always required Slow Gas shielding Asphyxiation hazard Not suitable for outdoors
54
GTAW shade
11 - aluminum with argon gas go up a shade to 12
55
Chlorinated degreasing solvent and UV make
Phosgene gas
56
GTAW machine is
Constant current Drooping volt amp curve Adv accuracy and repeatability of current levels
57
Flow meter
Volume CFH cubic feet per hour LPM litres per min
58
Regulator
Brings bottle pressure to a working pressure Steps it down
59
Post purge
1 second of purge time per 10 amps
60
GTAW downslope and upslope
Downslope - reduces crater size decreases amps from peak to 0 Upslope - from 0 to peak
61
Pulse
Good for thin metals Keeps the HAZ narrow Better grain structure The background maintains the arc Average amps of the background and peak
62
Ionic bombardment
Happens during the positive cycle of the sine wave with high frequency AC
63
GTAW 1/16 - DCEN Penetration
Deep
64
GTAW 1/4 DCEP Penetration
Shallow
65
Arc rectification
Unstable arc not able to break threw the oxide layer on aluminum
66
Water cooled torches
200 + amps 60 percent duty cycle 350 amps 100 percent duty cycle Left hand threads
67
GTAW Nozzles and size
Use the smallest nozzle the lip of which will not melt under the concentrated heat of the arc Ceramic Alumina Fused quartz (glass) Metal (cross fire with HF AC) Measured in 1/16ths
68
Argon gas GTAW
10-20 CFH Gas should flow in a LAMINAR fashion
69
Solenoid valve
Electronically operated valve that turns on and off the controls for the Shielding gas Coolant Arc With a foot pedal or hand remote
70
Helium
Hose needs to be plastic or it will leak out passed 20 psi
71
GTAW polarity
DCEN Argon gas 10-20 CFH EWTh-2 Red - industry standard Conical prep 2-6 x D Flush or 1/4 “ 0-30 forehand
72
GTAW Inclination
0-30 forehand 70 degrees from horizontal Filler rod 15-30 from base metal 90 degree relation with each other
73
GTAW fit up
1/8 - 5/32 Bigger gap to fit filler rod in between the bevels
74
SMAW groove welds Why do u tack back side
Ensure proper fusion When extinguishing the arc pull vertically out, will eliminate creators known as blisters Tack length should be equal material thickness
75
SMAW groove welds 1,3,4 G fit up
1/2 included joint angle 0-10 backhand for all passes 3/32-1/8 land and gap
76
SMAW groove welds If u can’t change your heat which two rods weld at same temp
1/8 - 6010 ————80-140 3/32 - 7018 ———-70-120
77
SMAW 2 G fit up
0-20 backhand Preset 3-4 degrees 3/32 - 1/8 land and gap 3 pass stringer cap (7 passes) Low current settings with a long arc will trap slag
78
CWB SMAW 1GF fit up What is the included angle
30 degrees is the included angle 1/2 “ gap Start weld on fillet side Grind parallel to the bend (transverse) 1/8 allowance for impurities
79
CWB test plate Root bends
Two root bends on the stop and starts One face bend in the middle First stop at 4.5” Second stop at 1.5” 4-7 passes 2GF gap is 8 mm 1, 3, 4GF gap is 13mm
80
Non permanent backers are made from
Carbon Ceramics Copper Fluxes Removed after weld is finished
81
SMAW Fillet welds Electrode inclination
5-15 backhand
82
Smaw fillet vertical
O-10 forehand
83
SMAW fillet Weave bead
Should not exceed 2-3 times electrode diameter
84
SMAW fillet Herringbone weave
Eliminates undercut
85
SMAW filler Weave patterns
Herringbone (flat, vertical, overhead) Crescent weave (vertical and overhead) Lazy L (horizontal) Sawtooth
86
SMAW fillet Weld size 1/16 material your working on 10 percent material thickness
.
87
SMAW fillet welds Starting methods
Tapping Scratch method
Second Year Welding
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