SAW Safety Procedures & Troubleshooting 2

Question 1

A welder notices the SAW flux is clumping and contains visible moisture. What is the correct action before welding?

Accepted Answer

Dry the flux in an oven at the manufacturer's recommended temperature and time

Answer

Wet or clumped flux must be dried in an oven per manufacturer specifications to prevent hydrogen-induced cracking and porosity.

Question 2

During SAW operation, the flux hopper develops a leak causing flux to spill onto the hot workpiece. What is the immediate safety concern?

Accepted Answer

Risk of flux igniting and creating a fire hazard or burn injuries from hot flux contact

Answer

Hot flux spilling from a leaking hopper can cause burn injuries and may ignite nearby combustibles, requiring immediate shutdown.

Question 3

What personal protective equipment is specifically required when chipping SAW slag after weld completion?

Accepted Answer

Safety glasses or face shield, leather gloves, and protective clothing

Answer

Chipping hot slag can propel sharp fragments at high velocity, requiring eye protection, gloves, and full protective clothing.

Question 4

An SAW machine is producing a weld bead that wanders off the joint centerline. Which troubleshooting step should be performed first?

Accepted Answer

Check and recalibrate the seam tracking system or torch alignment

Answer

Bead wandering is typically caused by misaligned torch position or a malfunctioning seam tracker, which must be corrected before continuing.

Question 5

A technician is troubleshooting excessive spatter deposits on the workpiece beside an SAW bead. What is the most likely cause?

Accepted Answer

Insufficient flux depth allowing arc exposure

Answer

Inadequate flux coverage exposes the arc, causing spatter deposits similar to open-arc processes instead of a fully submerged arc.

(SAW) Submerged Arc Welding Certification Practice Test