Term
Question 1)
Why is it important to make sure that an FCA welding system is set up properly if out-of-position welds are going to be made? |
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Definition
| Set up becomes even more important for out-of-position welds. Making vertical and overhead welds can be difficult for a student welder with a properly set up system, but it becomes impossible with a system that is out of adjustment. (page 318) |
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Question 2)
What major safety concerns should an FCA welder be aware of? |
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Definition
| FCA welding produces a lot of ultra-violet light, heat, sparks, slag and welding fumes. Proper personal protective clothing and special protective clothing must be worn to prevent burns from ultraviolet light and hot weld metal. Eye protection must be worn to prevent injury from flying sparks and slag. Forced ventilation and possibly a respirator must be used to prevent fume-related injuries. (page 319) |
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Question 3 )
Why should FCA welding practice plates be large? |
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Definition
| For several reasons the FCA welding practice plates will be larger than other practice plates. Welding heat and welding speed are the major factors that necessitate this increased size. FCA welding is both high energy and fast, and the welding energy (heat) input is so great that small practice plates may glow red by the end of a single welding pass. (page 319) |
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Question 4)
Why should the FCA welds be of substantial length? |
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Definition
Because of the higher welding speeds, longer plates are usually used.
Plates less than 1/2" (13mm) thick will be 12" (305mm)long for most practices. In addition to controlling the heat build-up, the longer plates are needed to give the welder enough time to practice welding. Learning to make longer welds is a skill that must also be practiced because the FCA welding process is used in the industry to make long production welds. (page 319) |
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Term
Question 5)
What must be done to a shielding gas cylinder before its cap is removed? |
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Definition
| If the shielding gas is to be used and it comes from a cylinder, the cylinder must be chained securely in place before the valve protection cap is removed. (page 320) |
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Question 6)
What can happen if to the wire if the conduit is misaligned at the feed rollers? |
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Definition
| The conduit or an extension should be aligned with the groove in the roller and set as close to the roller as possible without touching. Misalignment at this point can contribute to a bird's nest. (page 321) |
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Question 7)
Why is it a good idea for a new student welder to use a gas nozzle even if a shielding gas is not being used? |
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Definition
| If a gas nozzle is not needed for a shielding gas, it may still be installed. Because it is easy for a student to touch the work with the contact tube during welding, an electrical short may occur. This short-out of the contact tube will immediately destroy the tube. Although the gas nozzle may interfere with some visibility, it may be worth the trouble for a new welder. (page 321) |
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Question 8)
Why is the curl in the wire end straightened out? |
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Definition
| The wire has a natural curl known as a cast. Straighten out about 12" (300mm) of the curl to make threading easier. (page 321) |
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Question 9)
What problems can high-feed roller pressure cause? |
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Definition
| Too high a pressure can crush some wires, causing some flux to be dropped inside the wire liner. If this happens, you will have a continual problem with the wire not feeding smoothly or jamming. |
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Term
Question 10 a)
Referring to table 13-1, answer the following:
What would the range of the feed speed be for an amperage of 150 at 25 volts for an E70T-1 0.035-in (0.9mm)electrode? |
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Definition
| 288 - 380 IPM (732 - 975 cm/min) |
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Question 10 b)
Referring to table 13-1, answer the following:
What would the approximate amperage be for an E70T-5 0.045-in (1.2mm) electrode if it is being fed at a rate of 200" per minute (508 cm per minute)? |
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Definition
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Question 11)
What are the disadvantages of beveling plates for welding? |
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Definition
There are several disadvantages of having to bevel a plate before welding:
1- Beveling the edge of a plate adds an operation to the fabrication process.
2- Both more filler metal and welding time are required to fill a beveled joint than are required to make a square-joint weld. (page 323) |
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Question 12)
FCA welds with 100% joint penetration can be made in plates up to what thickness? |
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Definition
| These full joint penetrating welds can be made in plates that are 1/4" (6mm) or less in thickness. |
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