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
What does an unstable or erratic arc in SAW most commonly indicate when all electrical parameters appear correct?
Answer: Contaminated wire, dirty contact tip, or poor workpiece ground connection
Erratic arc behavior with correct settings usually points to a contaminated consumable, worn contact tip, or poor electrical grounding.
A worker must enter a confined space where SAW has recently been performed. What is the mandatory first step?
Answer: Test the atmosphere for oxygen level and toxic gases before entry
Confined space entry requires atmospheric testing for oxygen deficiency and toxic gases before any worker enters the space.
During SAW troubleshooting, the weld shows a rough, irregular surface profile with inconsistent width. Which parameter should be investigated first?
Answer: Wire feed speed consistency and drive roll tension
Irregular bead surface and width variations are classic symptoms of inconsistent wire feed caused by slipping drive rolls or feed motor issues.
What is the correct procedure when an SAW electrode wire runs out mid-weld on a critical joint?
Answer: Stop, mark the stop point, properly terminate the weld, and follow the procedure for resuming interrupted welds
An interrupted SAW weld on a critical joint must be properly terminated and restarted per qualified weld procedure to ensure soundness at the stop/start point.
When SAW produces undercut along one side of the weld bead consistently, what is the most likely cause?
Answer: Off-center wire placement relative to the joint or incorrect work angle
One-sided undercut in SAW is typically caused by the wire electrode being offset from the joint centerline or incorrect torch tilt angle.
What respiratory protection is required when working in areas where SAW flux dust is suspended in the air during material handling?
Answer: NIOSH-approved respirator rated for the specific flux dust particulates
SAW flux dust can contain silica and metal compounds requiring NIOSH-approved respiratory protection appropriate for the flux composition.
A high-amperage SAW installation requires water-cooled equipment. What safety check must be performed before energizing the welding circuit?
Answer: Confirm water flow is established and there are no leaks in the cooling circuit
Water-cooled SAW equipment must have confirmed coolant flow before energizing to prevent thermal damage and potential electrical hazards from steam or leaks.