AWS Troubleshooting & Diagnostics 2 — Questions and Answers
Question 1: A welder notices excessive spatter during GMAW. Which parameter adjustment is most likely to reduce spatter?
- Increase wire feed speed
- Decrease voltage to match wire feed speed (Correct answer)
- Increase travel speed
- Decrease shielding gas flow rate
Correct answer: Decrease voltage to match wire feed speed
Excessive spatter in GMAW is often caused by voltage being too low or too high relative to wire feed speed; matching voltage to wire feed speed stabilizes the arc.
Question 2: During SMAW, the electrode sticks to the base metal repeatedly. What is the most likely cause?
- Amperage set too high
- Amperage set too low (Correct answer)
- Arc length too long
- Travel speed too fast
Correct answer: Amperage set too low
Electrode sticking in SMAW is most commonly caused by amperage set too low, which cannot sustain a stable arc.
Question 3: A welder observes undercut along the toes of a fillet weld. Which corrective action is most appropriate?
- Increase amperage
- Increase travel speed
- Reduce amperage or slow travel speed (Correct answer)
- Increase electrode angle
Correct answer: Reduce amperage or slow travel speed
Undercut is caused by excessive heat or travel speed that melts the base metal faster than filler can fill; reducing amperage or slowing travel speed corrects this.
Question 4: During FCAW, the weld bead has a rough, convex profile with poor tie-in to the base metal. What is the most likely cause?
- Voltage too high
- Voltage too low (Correct answer)
- Wire feed speed too low
- Shielding gas flow too high
Correct answer: Voltage too low
Low voltage in FCAW produces a convex, ropy bead with poor fusion because the arc is not wide enough to wet out properly.
Question 5: A GTAW welder notices tungsten inclusions in the weld. What is the most probable cause?
- Shielding gas purity too low
- Tungsten contacted the weld pool (Correct answer)
- Travel speed too slow
- Current too low
Correct answer: Tungsten contacted the weld pool
Tungsten inclusions occur when the tungsten electrode touches the molten weld pool, causing pieces to break off and become embedded.
Question 6: A welder is making a groove weld and notices lack of fusion on one sidewall. Which is the best corrective action?
- Increase travel speed
- Direct the arc toward the unfused sidewall (Correct answer)
- Use a smaller diameter electrode
- Reduce preheat temperature
Correct answer: Direct the arc toward the unfused sidewall
Directing the arc toward the unfused sidewall ensures adequate heat penetration and fusion in that area.
Question 7: During SAW, the weld bead shows a humped or rippled surface with irregular width. Which parameter is most likely misadjusted?
- Travel speed too high (Correct answer)
- Flux depth too shallow
- Voltage too high
- Wire feed speed too low
Correct answer: Travel speed too high
Excessively high travel speed in SAW causes the bead to become narrow and humped because the weld pool cannot spread uniformly.
AWS Troubleshooting & Diagnostics 2
A welder notices excessive spatter during GMAW.
Which parameter adjustment is most likely to reduce spatter?