Equipment Setup & Operation 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 Equipment Setup & Operation flashcards as text
What effect does increasing travel speed have on a SAW weld bead (all other parameters held constant)?
Answer: Narrower, higher-crowned bead with less penetration
Higher travel speed reduces the time the arc dwells on a given spot, producing a narrower, more crowned bead with reduced penetration and lower heat input.
In a SAW power source, what does a 'constant voltage' (CV) characteristic mean for operation?
Answer: The output voltage remains nearly constant while current varies to maintain arc length
A CV power source self-regulates by varying current output to maintain the preset voltage, which keeps arc length stable when wire feed speed is fixed.
Which of the following correctly describes the role of 'run-on' and 'run-off' tabs in SAW?
Answer: They allow the arc to start and stop off the main workpiece, preventing crater defects at weld ends
Run-on and run-off tabs extend the joint beyond the base metal so weld initiation and termination defects (cracking, porosity) occur on disposable material.
A SAW operator notices that the arc is wandering erratically during welding. The most likely cause is:
Answer: Worn or misaligned contact tip causing poor current transfer
A worn or misaligned contact tip creates inconsistent electrical contact, causing the arc to wander as current path varies.
What is the recommended minimum flux coverage depth during SAW to ensure adequate shielding?
Answer: 13–38 mm (½–1½ in)
Flux coverage of approximately 13–38 mm (½–1½ in) is generally recommended to fully bury the arc and prevent flash-through while allowing proper slag formation.
When welding with a SAW system on a rotating positioner, the joint should ideally be positioned at:
Answer: Slightly in front of the top position in the direction of rotation so the weld pool solidifies flat
Positioning the joint slightly before the apex (in the direction of rotation) ensures the molten weld pool travels to the top and solidifies in a flat position without running.
Which SAW wire electrode diameter is most appropriate for high-deposition, heavy structural applications requiring currents above 800 A?
Answer: 4.0 mm (5/32 in)
Larger diameter electrodes (4.0 mm / 5/32 in) are used for very high current applications because they have greater current-carrying capacity and produce high deposition rates.