456A SMAW Stick 2

Question 1

What is the recommended arc length for general SMAW welding?

Accepted Answer

Approximately equal to the diameter of the electrode core wire

Answer

The correct arc length for SMAW is approximately equal to the diameter of the electrode core wire (e.g., about 3.2 mm for a 3.2 mm electrode). Too long an arc causes porosity, spatter, and loss of shielding. Too short an arc can cause the electrode to stick, and may result in an inconsistent bead or short-circuiting.

Question 2

What causes porosity in a SMAW weld?

Accepted Answer

Gas entrapment from moisture in electrodes, contaminated base metal, too long an arc length, or wind blowing away shielding gas

Answer

Porosity (gas pockets in the weld metal) in SMAW is caused by: moisture in the electrode coating (especially low-hydrogen types), contaminated or wet base metal, excessive arc length (allows atmospheric contamination), drafts disrupting the shielding gas, and improper welding technique. Prevention focuses on dry electrodes, clean base metal, and proper arc length.

Question 3

When welding in the vertical-up position with E7018, what technique is commonly used?

Accepted Answer

A weave pattern (triangle, J, or zigzag) with pauses at the toes to allow proper fusion and build-up, using lower amperage than flat position

Answer

Vertical-up welding with E7018 typically uses a weaving technique (triangle, J-weave, or zigzag pattern) with deliberate pauses at the toes (edges) of the weld to ensure proper fusion with the base metal. Amperage is reduced 10-15% compared to flat position to control the puddle against gravity.

Question 4

What is undercutting in a weld and what causes it?

Accepted Answer

A groove melted into the base metal at the toe of the weld that is not filled by weld metal; caused by excessive amperage, incorrect angle, or excessive travel speed

Answer

Undercut is a groove or channel melted into the base metal along the toe (edge) of the weld bead that is not filled by weld metal. It reduces the cross-section of the base metal, creating a stress concentration. Common causes include excessive amperage, improper electrode angle, excessive travel speed, or incorrect weaving technique.

Question 5

What determines the correct amperage setting for a SMAW electrode?

Accepted Answer

The electrode diameter, type, position, and joint design — manufacturers provide recommended ranges for each electrode size

Answer

Correct amperage depends primarily on electrode diameter (larger = more current), electrode type (coating characteristics), welding position (reduced for vertical and overhead), and joint design. Manufacturers specify amperage ranges for each size. A common rule of thumb for mild steel is approximately 1 amp per 0.001 inch of electrode diameter.

Red Seal Welder 456A Practice Test

Red Seal Welder 456A Practice Test

456A SMAW Stick 2