456A FCAW 2

Question 1

When should slag be removed between passes in multi-pass FCAW welding?

Accepted Answer

All slag must be completely removed between every pass using a chipping hammer and wire brush to prevent slag inclusions

Answer

Complete slag removal between every pass is mandatory in FCAW to prevent slag inclusions — one of the most common defects in flux-cored welding. Use a chipping hammer to break the slag, followed by vigorous wire brushing. Pay special attention to the toes of the weld and any undercuts where slag can become trapped.

Question 2

What CSA standard governs the use of FCAW in structural steel welding in Canada?

Accepted Answer

CSA W59 (Welded Steel Construction) specifies the requirements, and CSA W47.1 (Certification of Companies for Fusion Welding of Steel) governs company certification

Answer

CSA W59 provides the technical requirements for welded steel construction in Canada, including approved processes (FCAW is listed), preheat requirements, WPS requirements, and acceptance criteria. CSA W47.1 certifies welding companies and requires welders to be qualified under supervised testing. Both standards reference FCAW as an approved process.

Question 3

What are the advantages of gas-shielded FCAW (FCAW-G) over solid-wire GMAW?

Accepted Answer

Higher deposition rates, better out-of-position performance, greater tolerance for mill scale and surface contaminants, and deeper penetration capability

Answer

Gas-shielded FCAW offers several advantages over solid-wire GMAW: higher deposition rates (more metal deposited per hour), better performance in vertical and overhead positions due to the slag support, greater tolerance for surface contaminants, and typically deeper penetration. The trade-off is the need for slag removal between passes.

Question 4

What filler wire classification does E71T-1C/1M represent?

Accepted Answer

A gas-shielded flux-cored wire: E = electrode, 7 = 70 ksi tensile, 1 = all positions, T = tubular (flux-cored), 1 = usability/performance, C = CO₂ shielding (M = mixed gas)

Answer

In the AWS/CSA classification: E = electrode, 7 = minimum tensile strength (70,000 psi / 490 MPa), 1 = all-position capability, T = tubular (flux-cored), 1 = usability and performance characteristics, C = designed for CO₂ shielding, M = designed for mixed gas (argon/CO₂). E71T-1 is the most widely used structural FCAW wire.

Question 5

What is the proper technique for FCAW vertical-up welding?

Accepted Answer

Reduce voltage and wire feed speed compared to flat position, use a weave or stringer technique with pauses at the toes, and maintain proper stick-out

Answer

Vertical-up FCAW requires reduced parameters (typically 10-15% less voltage and WFS compared to flat) to control the puddle against gravity. Use a weave or oscillation technique with brief pauses at the toes to ensure fusion. Maintain consistent stick-out and a slight drag angle. The slag helps support the puddle in vertical position.

Red Seal Welder 456A Practice Test

Red Seal Welder 456A Practice Test

456A FCAW 2