Free Millwright Welding and Cutting Processes Questions and Answers

Question 1

Which welding process uses a non-consumable tungsten electrode and a separate filler metal?

Accepted Answer

Gas Tungsten Arc Welding (GTAW)

Answer

GTAW, also known as TIG welding, is characterized by its non-consumable tungsten electrode which creates the arc. A separate filler rod is manually fed into the weld pool, and an inert shielding gas protects the weld from atmospheric contamination.

Question 2

Which thermal cutting process is most suitable for cutting non-ferrous metals like aluminum and stainless steel?

Accepted Answer

Plasma arc cutting

Answer

Plasma arc cutting uses an ionized gas jet to melt and expel material, making it effective on any electrically conductive metal. Oxy-fuel cutting relies on the oxidation of iron and is therefore not effective on stainless steel or aluminum.

Question 3

A weld bead exhibits a groove melted into the base metal adjacent to the weld toe that is not filled by weld metal. What is this defect called?

Accepted Answer

Undercut

Answer

Undercut is a common weld defect caused by excessive current, incorrect electrode angle, or too fast of a travel speed. It creates a stress concentration point at the toe of the weld, which can lead to cracking.

Question 4

When setting up an oxy-acetylene torch, what is the maximum safe working pressure for acetylene?

Accepted Answer

15 psi

Answer

Acetylene becomes unstable and can decompose explosively at pressures above 15 psi. For safety, it should never be used at a pressure exceeding this limit in its free state.

Question 5

In Shielded Metal Arc Welding (SMAW), what is the primary function of the flux coating on the electrode?

Accepted Answer

To provide a shielding gas, deoxidizers, and a slag covering

Answer

The flux coating serves multiple purposes: it vaporizes to create a shielding gas that protects the molten weld pool from the atmosphere, it contains elements that clean and deoxidize the weld metal, and it forms a protective slag layer over the solidifying weld.

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Free Millwright Welding and Cutting Processes Questions and Answers