Electrical Systems & Wiring Flashcards
7 cards from real SAW practice questions. Tap to flip, then mark Knew It or Still Learning — missed cards come back until you master them.
Read the first 7 Electrical Systems & Wiring flashcards as text
What is the primary electrical reason SAW produces less spatter than GMAW?
Answer: The arc is submerged under flux, preventing expulsion of molten droplets into open air
The flux blanket physically contains the arc and molten metal, preventing the explosive droplet ejection that causes spatter in open-arc processes.
A SAW technician measures 32V at the power source terminals but only 28V at the work clamp connection. This 4V difference indicates:
Answer: Voltage drop due to resistance in the welding cables and connections
The 4V drop represents resistive losses in the cables and connections between the power source and work, per Ohm's Law (V = IR).
Which of the following best describes the electrical role of the SAW flux during welding?
Answer: Molten flux acts as an electrical conductor completing the circuit between electrode and workpiece
Molten slag formed from the flux becomes electrically conductive, helping sustain the arc and completing part of the electrical path.
When troubleshooting a SAW system with excessive voltage fluctuation, the first electrical component to inspect is:
Answer: The electrode cable connections and contact tip for looseness or contamination
Loose or corroded cable connections and a worn contact tip are the most common sources of resistance variation that cause voltage fluctuation.
In SAW, 'electrode extension' (also called 'stick-out') electrically functions as:
Answer: A resistive element that preheats the wire before it enters the arc, affecting melt-off rate
The electrode extension between contact tip and arc acts as a resistor; I²R heating in this section preheats the wire and increases melt-off rate.
What is the consequence of using a welding cable with an amperage rating significantly below the actual welding current in SAW?
Answer: The cable overheats, creating a fire hazard and causing significant voltage drop
Undersized cables overheat from excessive current density, creating fire or burn hazards and causing voltage drops that degrade weld quality.
For SAW welding of thick plate requiring maximum penetration, which electrical parameter setting combination is most effective?
Answer: High amperage, moderate voltage, DCEP polarity
High amperage drives maximum heat into the base metal, DCEP focuses that heat for deep penetration, and moderate voltage maintains a stable, concentrated arc.