Preventive Maintenance Procedures Flashcards
7 cards from real SAW practice questions. Tap to flip, then mark Knew It or Still Learning — missed cards come back until you master them.
Read the first 7 Preventive Maintenance Procedures flashcards as text
A SAW operator notices the flux depth over the arc has been inconsistent, sometimes causing flash-through. Which maintenance item is most likely the root cause?
Answer: Clogged or misadjusted flux nozzle discharge port
A clogged or misadjusted flux nozzle discharge port restricts flux flow, creating insufficient flux depth that allows UV flash-through and exposes the arc.
During SAW preventive maintenance, what is the correct method for verifying the accuracy of the wire feed speed tachometer?
Answer: Use a handheld calibrated tachometer or time the wire output over a measured length
A calibrated handheld tachometer or timed wire-length measurement provides ground-truth verification of actual feed speed independent of the machine's own sensors.
What is the primary maintenance concern with leaving reclaimed wet or damp flux in the flux recovery system hopper overnight?
Answer: Damp flux will cake and clog the hopper gate, and moisture causes weld porosity on next use
Damp flux cakes into solid masses that block the hopper gate and, if used without rebaking, introduces hydrogen into the weld pool causing porosity.
When should SAW wire conduit liners be replaced as part of a preventive maintenance program?
Answer: When liner bore shows wear exceeding 1.5x the wire diameter or when wire feeding resistance increases
Worn conduit liners allow wire to snake inside the liner, increasing feed resistance and causing arcing irregularities; replacement is indicated by bore wear or feeding difficulty.
Which preventive maintenance task specifically helps prevent hydrogen cracking in SAW joints made on high-strength steels?
Answer: Verifying the flux drying oven temperature calibration and rebaking flux to specification
Flux moisture is the primary hydrogen source in SAW; verifying oven calibration and rebaking flux to specified temperatures (typically 500–700°F) ensures diffusible hydrogen remains below critical levels.
During SAW preventive maintenance, the ground connection between the power source chassis and the building ground is found to be loose. What is the correct action?
Answer: Retighten the connection immediately before any further welding operations
A loose chassis ground connection creates a shock hazard because fault currents may flow through the operator instead of the ground path; immediate correction is mandatory.
What preventive maintenance record is most valuable for predicting future SAW component failures and optimizing maintenance intervals?
Answer: A time-stamped maintenance history tracking component replacements, hours at replacement, and failure modes
A detailed maintenance history with component lifespans and failure modes enables trend analysis to predict when components will fail and optimize replacement intervals before failures occur.