Welding Techniques & Process Control 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 Welding Techniques & Process Control flashcards as text
In SAW, what is the purpose of 'run-on' and 'run-off' tabs at weld starts and stops?
Answer: To relocate weld defects (craters and porosity) outside the finished joint
Run-on and run-off tabs extend the weld path so that start porosity and end craters occur on removable scrap material, not the finished weld.
Which variable change would most effectively reduce undercut in an SAW fillet weld?
Answer: Reduce arc voltage or shift electrode toward the vertical plate
Lowering voltage reduces arc spread at the toes, and repositioning the electrode ensures adequate fusion at the vertical plate without gouging the horizontal plate toe.
What does 'flux consumption ratio' refer to in SAW operations?
Answer: The ratio of flux weight melted to wire weight deposited
Flux consumption ratio (typically 1:1 by weight) indicates how much flux is consumed relative to the wire deposited, used for cost and inventory planning.
A welder is producing SAW welds with excessive spatter outside the flux zone. What is the most likely cause?
Answer: Arc voltage too high causing the arc to escape the flux blanket
If voltage is too high, the arc elongates and can pierce through the flux layer, exposing the arc and ejecting spatter.
In SAW of low-alloy high-strength steel, why is preheat critical?
Answer: It prevents hydrogen-induced cracking by slowing cooling and allowing hydrogen to diffuse out
Preheating slows the cooling rate of the heat-affected zone, reducing hardness and giving hydrogen time to diffuse before cold cracking can initiate.
What is the function of the 'contact tip' (contact tube) in an SAW torch?
Answer: It transfers welding current to the electrode wire
The contact tip makes electrical contact with the continuously fed wire electrode, transferring current from the power source to the arc.
When two SAW passes are required for a thick plate groove weld, what interpass temperature control is most important?
Answer: Keeping interpass temperature within the specified range to control heat input and HAZ properties
Interpass temperature must be controlled within the WPS limits to prevent excessive grain growth, maintain toughness, and avoid hot or cold cracking.