Safety Procedures & Troubleshooting 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 Safety Procedures & Troubleshooting flashcards as text
A welder notices the SAW flux is clumping and contains visible moisture. What is the correct action before welding?
Answer: Dry the flux in an oven at the manufacturer's recommended temperature and time
Wet or clumped flux must be dried in an oven per manufacturer specifications to prevent hydrogen-induced cracking and porosity.
During SAW operation, the flux hopper develops a leak causing flux to spill onto the hot workpiece. What is the immediate safety concern?
Answer: Risk of flux igniting and creating a fire hazard or burn injuries from hot flux contact
Hot flux spilling from a leaking hopper can cause burn injuries and may ignite nearby combustibles, requiring immediate shutdown.
What personal protective equipment is specifically required when chipping SAW slag after weld completion?
Answer: Safety glasses or face shield, leather gloves, and protective clothing
Chipping hot slag can propel sharp fragments at high velocity, requiring eye protection, gloves, and full protective clothing.
An SAW machine is producing a weld bead that wanders off the joint centerline. Which troubleshooting step should be performed first?
Answer: Check and recalibrate the seam tracking system or torch alignment
Bead wandering is typically caused by misaligned torch position or a malfunctioning seam tracker, which must be corrected before continuing.
A technician is troubleshooting excessive spatter deposits on the workpiece beside an SAW bead. What is the most likely cause?
Answer: Insufficient flux depth allowing arc exposure
Inadequate flux coverage exposes the arc, causing spatter deposits similar to open-arc processes instead of a fully submerged arc.
What is the primary hazard when restarting an SAW process on a joint that contains solidified but uncleaned slag from a previous pass?
Answer: Slag inclusion in the new weld pass creating a subsurface defect
Welding over unremoved slag traps it between passes, creating slag inclusions that compromise weld integrity.
When performing SAW on a pressurized vessel that has been taken out of service, what critical safety step must be completed before welding begins?
Answer: Verify the vessel is fully depressurized, purged of hazardous contents, and locked out
Welding on any vessel without full depressurization and lockout/tagout verification risks explosion or toxic exposure.