SAW Transmission & Drivetrain Systems 2

Question 1

When applying SAW to rebuild worn drive shaft journals, which parameter most directly controls heat input to minimize distortion?

Accepted Answer

Travel speed

Answer

Travel speed is the primary control for heat input per unit length, and faster travel reduces total heat delivered to the journal.

Question 2

A transmission housing weld made with SAW shows porosity concentrated at weld start locations. The most likely cause is:

Accepted Answer

Contaminated flux at run-on tabs

Answer

Flux at run-on tabs can absorb moisture or contaminants, releasing gas into the first molten pool and causing start porosity.

Question 3

SAW overlays on ring gear blanks require low dilution to preserve hardfacing alloy composition. Which technique best achieves this?

Accepted Answer

Use electrode negative (DCEN) polarity

Answer

DCEN polarity concentrates more heat at the wire tip, producing shallower penetration and lower dilution of the base metal.

Question 4

A differential carrier housing requires a circumferential SAW weld. The correct torch positioning for a horizontal rotating fixture is:

Accepted Answer

Slightly before 12 o'clock against rotation

Answer

Positioning the torch slightly behind top-dead-center against rotation lets gravity help pool control and prevents the molten metal from running ahead of the arc.

Question 5

Which flux characteristic is most critical when SAW welding high-carbon drivetrain shafts to avoid hydrogen cracking?

Accepted Answer

High basicity index

Answer

A high basicity index flux produces lower weld metal hydrogen levels, reducing the risk of hydrogen-induced cracking in high-carbon steels.

(SAW) Submerged Arc Welding Certification Practice Test

(SAW) Submerged Arc Welding Certification Practice Test

SAW Transmission & Drivetrain Systems 2