SAW Welding Techniques & Process Control 3

Question 1

What happens to weld bead convexity when arc voltage is set too low in SAW?

Accepted Answer

The bead becomes high and narrow (ropy)

Answer

Low arc voltage produces a short, constricted arc that deposits metal in a high, narrow, ropy bead shape.

Question 2

In SAW, what is 'electrode extension' (also called stick-out) and how does increasing it affect the process?

Accepted Answer

Distance from contact tip to work; increasing it raises deposition rate via resistive heating

Answer

Electrode extension is the wire length from contact tip to arc; longer stick-out increases resistive preheating, boosting deposition rate while reducing penetration.

Question 3

Which condition causes 'cold lapping' (lack of fusion at the toes) in SAW?

Accepted Answer

Insufficient current for the joint thickness

Answer

Insufficient welding current delivers too little heat to fuse the base metal at the weld toes, causing lack-of-fusion defects.

Question 4

What is the recommended action if porosity is found in an SAW weld and the flux was stored in a humid environment?

Accepted Answer

Re-dry the flux at the manufacturer's recommended temperature and time

Answer

Absorbed moisture in flux releases hydrogen and steam during welding, causing porosity; re-drying at the correct temperature removes it.

Question 5

In SAW process control, what does a 'constant voltage' (CV) power source primarily regulate?

Accepted Answer

Arc voltage, allowing current to vary with arc length changes

Answer

A CV power source maintains a preset voltage, and the arc self-regulates by drawing more or less current as arc length fluctuates.

(SAW) Submerged Arc Welding Certification Practice Test

(SAW) Submerged Arc Welding Certification Practice Test

SAW Welding Techniques & Process Control 3