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Troubleshooting & Diagnostics Flashcards

7 cards from real AWS practice questions. Tap to flip, then mark Knew It or Still Learning — missed cards come back until you master them.

Read the first 7 Troubleshooting & Diagnostics flashcards as text

  1. During GMAW short-circuit transfer, the welder hears a loud, popping sound rather than a smooth frying sound. What is the most likely problem?

    Answer: Voltage too high for the wire feed speed

    A popping sound during short-circuit transfer indicates the voltage is too high relative to the wire feed speed, causing erratic short-circuit events.

  2. Overlap (cold lap) is observed on a fillet weld. What is the primary cause?

    Answer: Insufficient amperage or too slow travel speed

    Overlap occurs when molten metal flows over the base metal without fusing to it, typically due to insufficient heat from low amperage or very slow travel speed.

  3. A welder using SMAW finds that the slag is very difficult to remove after each pass. What is the most likely cause?

    Answer: Incorrect electrode angle causing slag entrapment under the bead

    Incorrect electrode work angle can cause molten slag to flow ahead of the arc and become trapped under the weld bead, making it difficult to remove.

  4. A welder is testing a joint with a bend test and notices cracks at the root. What welding defect does this indicate?

    Answer: Incomplete joint penetration or lack of fusion at the root

    Root cracks in a bend test indicate incomplete joint penetration or lack of fusion at the root, which acts as a stress concentrator during bending.

  5. During FCAW with CO2 shielding gas, the welder notices increased spatter compared to Ar/CO2 blend. This is because:

    Answer: CO2 produces a more oxidizing arc that causes more turbulent metal transfer

    Pure CO2 creates a more oxidizing, energetic arc with less stable droplet transfer compared to Ar/CO2 blends, resulting in higher spatter levels.

  6. A radiographic test reveals scattered rounded indications throughout a weld. These are most consistent with:

    Answer: Porosity

    Scattered rounded indications on a radiograph are the classic signature of porosity—gas pockets trapped in the solidified weld metal.

  7. After welding, a welder notices the workpiece has distorted significantly. Which practice would have been most effective in minimizing distortion?

    Answer: Tacking and sequencing welds to balance heat input

    Properly tacking the assembly and using a balanced weld sequence minimizes net distortion by distributing heat input symmetrically.