Upload
others
View
4
Download
0
Embed Size (px)
Citation preview
Student Name: ______________________
Teacher: ______________________ Date: ___________
District: Buncombe County
Test: 9_12 T and I 7661 - Welding Technology I Test 1
Description: Shelded metal arc welding
Form: 501
1. With DCEP welding current, the electrode is:
A. Grounded.
B. Negative.
C. Neutral.
D. Positive.
2. Which electrode is classified as a fast-fill electrode?
A. E-6010
B. E-6013
C. E-7018
D. E-7024
3. An E7024 electrode is classified as a:
A. Fast-freeze electrode.
B. Fill-freeze electrode.
C. Fast-fill electrode.
D. Low-hydrogen.
4. Proper primary electrical grounding of the welding machine is required to:
A. Prevent arc flash.
B. Prevent electrical shock.
C. Stabilize the arc.
D. Strike the arc.
5. Terminations of SMAW beads are made at:
A. Both the beginning and end of all weld passes.
B. The beginning of all welds.
C. The beginning of new weld passes only.
D. The ends of welds.
6. For SMAW, operating voltage:
A. Has no relation to open circuit voltage.
B. Is always lower than open circuit voltage.
C. Is always higher than open circuit voltage.
D. May be higher or lower than open circuit voltage.
7. Why should gas cylinders NEVER be welded on?
A. The cylinders do not conduct electricity.
B. The cylinders will explode.
C. The paint will be melted off the cylinders.
D. The welding machine will ground out.
8. Which electrode is classified as a fast-freeze electrode?
A. E-6011
B. E-6013
C. E-7014
D. E-7018
9. One way to compensate for arc blow is to:
A. Run the weld bead in the opposite direction.
B. Shorten the arc length.
C. Use a full length electrode.
D. Whip the electrode tip.
10. When referring to electrical current, what is the number of cycles per second?
A. Amperage
B. Frequency
C. Period
D. Voltage
11. Which electrode is the largest?
A. 3/32"
B. 1/8"
C. 3/16"
D. 5/32" Please use the following figure for this question.
12. Using the cable size chart above, determine the size welding cable needed for welding using 650 amps at 60% duty cycle 195 feet from the power source and 100 feet above ground level?
A. #1/0
B. #2/0
C. #3/0
D. #4/0
13. In SMAW open circuit voltage is usually between:
A. 20 and 30 volts.
B. 30 and 40 volts.
C. 50 and 100 volts.
D. 100 and 150 volts.
14. The point in the weld where one weld bead stops and another begins is a/an:
A. Convex point.
B. Oscillation point.
C. Restart point.
D. Weld termination.
15. An all-position, deep penetrating SMAW electrode with a light slag coating would fall into the:
A. Fast-freeze electrode group.
B. Fill-freeze electrode group.
C. Fast-fill electrode group.
D. Low-hydrogen electrode group.
16. How is the size of a workpiece clamp designated?
A. The distance in inches that the clamp jaws will spread to grasp the workpiece
B. The length in inches from the cable connection to the end of the clamp
C. The rated amperage that it can carry without overheating
D. The rated resistance it has to the current flow
17. What is added to the flux coatings of SMAW electrodes to change the chemical composition and strength of the deposited weld metal?
A. Alloys
B. Hydrogen
C. Nitrogen
D. Oxygen
18. The standard length of a 1/8" SMAW electrode is:
A. 10".
B. 12".
C. 14".
D. 16".
19. To compensate for the recessed electrode core when welding with heavier flux-coated electrodes (such as E7018 or E6013), the visible arc length should be:
A. Angled.
B. Lengthened.
C. Shortened.
D. Whipped. Please use the following figure for this question.
20. In the chart shown above, what is the maximum length of a #1/0 welding lead that can carry 300 amps?
A. 50 Feet
B. 100 Feet
C. 150 Feet
D. 250 Feet
Please use the following figure for this question.
21. Using the fillet weld profiles shown above, what is the problem with fillet weld "1"?
A. Excessive convexity
B. Excessive undercut
C. Insufficient leg
D. Insufficient throat
22. Which electrode angle in SMAW will give the deepest penetration?
A. 5° opposite the direction of travel
B. 45° opposite the direction of travel
C. Leading angle
D. Trailing angle
Please use the following figure for this question.
23. Using the cable size chart above, determine the size welding cable needed for welding using 200 amps at 60% duty cycle 80 feet from the power source?
A. #1
B. #2
C. #3
D. #4
24. Which electrode is used to make welds on galvanized, plated, or painted surfaces?
A. E-6010
B. E-6013
C. E-7014
D. E-7018
25. What are lugs used for with SMAW equipment?
A. Connect the electrode to the electrode holder
B. Connect the workpiece clamp to the workpiece
C. Connect the welding cable to the electrode holder or ground clamp
D. Connect the welding cables to the machine current terminals
26. When restarting a bead in SMAW, the arc should be struck:
A. 1/4" behind the crater on the bead deposited.
B. 1/4" to 3/8" in front of the crater.
C. In the back center of the crater.
D. To one side of and behind the crater.
27. What is the AWS specification for low-alloy electrodes?
A. A5.1
B. A5.5
C. A5.11
D. A5.24
28. In SMAW the crater at the end of each bead should be filled by:
A. Starting and stopping the arc several times until the crater is filled.
B. Holding a long arc over the crater until the crater is filled slightly larger than the bead.
C. Breaking the arc and then start the arc again for several seconds holding a very short arc.
D. Reversing the electrode angle and moving 1/8 inch toward the start of the weld.
29. To change the chemical composition and strength of the deposited weld metal, some electrodes have:
A. Powdered metal in the flux.
B. Carbon in the flux.
C. Fibers in the flux.
D. Inert gas in the flux.
30. What does the acronym LASH refer to in SMAW?
A. Arc length, angle, speed, and heat
B. Leave a small hole
C. Load, amperage, and slow heat
D. Low angle and slow heat
31. The heat energy developed by electric arc welding is the result of:
A. Resistance to current flow across the arc.
B. The amp setting on the power source.
C. The duty cycle of the welding machine.
D. Volts across the arc. Please use the following figure for this question.
32. In the chart shown above, what size welding cable is needed to weld at 200 amps using a welding machine with 50% duty cycle and leads 225 feet long?
A. #1/0
B. #2/0
C. #3/0
D. #4/0
33. A SMAW electrode designed for welding high sulfur, phosphorus and medium-to high-carbon steels which have a tendency to underbead cracking, would fall into the:
A. Fast-freeze electrode group.
B. Fill-freeze electrode group.
C. Fast-fill electrode group.
D. Low-hydrogen group.
34. Two types of harmful rays that SMAW produces are:
A. Alpha and beta.
B. Gamma and x-ray.
C. Infrared and ultraviolet.
D. Supersonic and ultrasonic.
35. Which electrode is classified as a fill-freeze electrode?
A. E-6010
B. E-6011
C. E-6013
D. E-7018
36. Welding machines are classified by the:
A. Maximum amperage they can produce.
B. Open circuit voltage they require.
C. Operating voltage they require.
D. Type(s) of welding current produced.
37. Arc blow tends to be the biggest problem when:
A. Building up thick overlapping beads.
B. Using very low hydrogen electrodes.
C. Using very high hydrogen electrodes.
D. Welding on the ends of base metal.
38. What type weld is shown below?
A. Concave fillet
B. Concave groove
C. Convex fillet
D. Convex groove
39. A SMAW electrode with a high deposition rate, shallow penetration and a heavy slag coating, and that is designated for flat and horizontal fillet welds would fall into the:
A. Fast-freeze electrode group.
B. Fill-freeze electrode group.
C. Fast-fill electrode group.
D. Low-hydrogen group.
40. In SMAW, DCEP is recommended for:
A. Flat position welding.
B. Increased base metal heat.
C. Out-of-position welding.
D. Shallow penetration.
41. What is the size of a welding cable based on?
A. Amount of amperage the insulation can withstand before breaking down
B. Diameter of the cable including insulation and any reinforcement cord
C. Length of the cable from the welding machine to the electrode holder
D. Number of copper strands it contains which determines the cable diameter
42. A good electrode to use for sheet metal would be:
A. E7018.
B. E6013.
C. E7024.
D. E8018-C1.
43. The traceability requirements of welding filler materials vary according to the:
A. Base metal.
B. Client requirements and specifications.
C. State and local law.
D. Welder type.
44. When Shielded Metal Arc Welding up to 200 amps, the filter lens recommended is a:
A. Number 4.
B. Number 6.
C. Number 10.
D. Number 14.
Please use the following figure for this question.
45. Using the fillet weld profiles shown above, what is the problem with fillet weld "5"?
A. Excessive convexity
B. Excessive undercut
C. Inadequate penetration
D. Insufficient leg
46. Voltage is the measure of:
A. Alternating current frequency.
B. Current flow rate.
C. Electromotive forces.
D. Heat energy.
47. How can porosity be reduced in a SMAW weldment?
A. Weld faster and turn the welding current down
B. Weld faster and turn the welding current up
C. Weld slower and turn the welding current down
D. Weld slower and turn the welding current up
Please use the following figure for this question.
48. In the chart shown above, what size welding cable is needed to weld at 225 amps using a welding machine with 20% duty cycle and leads 90 feet long?
A. #2
B. #3
C. #1/0
D. #2/0
49. Which electrode has the highest tensile strength?
A. E9018
B. E8018
C. E7018
D. E6011
50. When receiving a new shipment of low-hydrogen electrodes and one container? seal has been broken, what should be done?
A. Put the damaged container in the oven
B. Reject the damaged container
C. Use the damaged container first
D. Wrap the damaged container in plastic
51. Welding current traveling through bearings, seals or valves:
A. Can cause an increase in the open circuit voltage.
B. Can cause severe damage.
C. Will cause no damage.
D. Will cause the amperage to vary.
52. When working with electricity the abbreviation AC refers to:
A. Accurate calculations.
B. Alternate classification.
C. Alternating circuit.
D. Alternating current. Please use the following figure for this question.
53. The drawing above shows the bead sequence for a horizontal fillet weld using SMAW. What is electrode angle "C" for the sixth pass?
A. 15°
B. 20°
C. 45°
D. 70°
54. One way to compensate for arc blow is to:
A. Change the electrode angle.
B. Lengthen the arc length.
C. Use a shorter electrode.
D. Weave the weld bead.
55. What should the selection of the proper size electrode holder for SMAW be based on?
A. Depth of penetration and position of weld
B. Electrodes and amperage being used
C. Length and diameter of the electrodes
D. Size and strength of the welders hand
56. When using SMAW to weld flat beads, place the electrode at a 90° angle, then lean it:
A. 10° to 20°
B. 20° to 40°
C. 40° to 60°
D. 45° to 65°
57. SMAW electrodes manufactured in the United States:
A. Can have either the AWS OR manufacturer? classification printed on them.
B. Must have the AWS classification number printed on them.
C. Must have the manufacturer? classification printed on them.
D. Must NOT be printed on because the ink destabilizes the arc.
58. How is the speed of a SMAW weld bead measured?
A. Feet per hour
B. Feet per minute
C. Inches per hour
D. Inches per minute
59. Before plugging a welding machine into an outlet:
A. Set the amperage to zero.
B. Switch to open circuit voltage.
C. Locate the electrical disconnect.
D. Connect the ground clamp.
60. The welding electrode that is the LEAST penetrating is:
A. E6010.
B. E6011.
C. E6013.
D. E7010.
61. An arc welding power source rated at 250 amps, 50% duty cycle, can be used at 250 amps for:
A. About 50 hours and then cooled.
B. 2 minutes out of every 10 minutes.
C. 5 minutes out of every 10 minutes.
D. 6 minutes out of every 10 minutes. Please use the following figure for this question.
62. Using the diagram of a SMAW setup shown above, what is the polarity?
A. AC
B. DCEN (DCSP)
C. DCEP (DCRP)
D. HFAC
63. Which SMAW electrode is HARDEST to strike an arc with?
A. E6010
B. E6011
C. E7018
D. E7024 Please use the following figure for this question.
64. Using the fillet weld profiles shown above, what is the problem with fillet weld "6"?
A. Excessive convexity
B. Excessive undercut
C. Inadequate fusion
D. Overlap
65. Which type of current CANNOT be used with E6010 and E-7010 electrodes?
A. AC
B. DCEN
C. DCEP
D. DCRP
66. What may happen if gloves are not worn when putting an electrode in a SMAW electrode holder?
A. Electrode may be damaged from moisture on the hands
B. Warranty on the electrode may be voided
C. Welder inserting the electrode may be shocked
D. Welding machine may be grounded out
67. The acceptance criteria for the size of an SMAW overhead fillet weld is plus or minus:
A. 1/8".
B. 3/16".
C. 5/32".
D. 1/16".
68. What is the AWS specification for carbon steel electrodes?
A. A5.1
B. A5.5
C. A5.11
D. A5.24
69. Which electrode is classified as a low-hydrogen electrode?
A. E-6010
B. E-6013
C. E-7014
D. E-7018
70. What are the characteristics of a SMAW weld bead, if the arc length is too short?
A. Excessive spatter
B. High and narrow
C. Undercut
D. Wide and flat
71. Electrode storage ovens should be set at about:
A. 75°
B. 120°
C. 250°
D. 600°
72. What piece of SMAW equipment is shown below?
A. Electrode holder
B. Lug
C. Quick disconnector
D. Workpiece clamp
73. Smaller diameter electrodes require:
A. Higher amperage current.
B. Lower amperage current.
C. Shorter arc gaps.
D. Square butt gaps.
74. What causes the heat in SMAW?
A. Dirty metal
B. Electric arc
C. High frequency current
D. Moisture in the flux
75. What is the maximum exposure time of E-7018 electrodes to the atmosphere?
A. 1 hour
B. 2 hours
C. 4 hours
D. 6 hours
76. What is the term for the outside surface of a ball?
A. Concave
B. Convex
C. Convoluted
D. Refracted
77. Arc blow can cause:
A. Arc stability.
B. Electrodes to cool.
C. Excess penetration.
D. Spatter and porosity.
78. What type of current is used with an E6010?
A. AC
B. ACHF
C. DCEN
D. DCEP Please use the following figure for this question.
79. The drawing above shows the bead sequence for a horizontal fillet weld using SMAW. What is electrode angle "A" for the fifth pass?
A. 20°
B. 45°
C. 70°
D. 90°
80. What does the flux coating of an SMAW electrode do to the molten metal when it melts?
A. Anneals and hardens
B. Cleans and deoxidizes
C. Lubricates for ductility
D. Softens and anneals
Please use the following figure for this question.
81. The drawing above shows the bead sequence for a horizontal fillet weld using SMAW. What is electrode angle "B" for the fourth pass?
A. 90°
B. 70°
C. 45°
D. 20°
Please use the following figure for this question.
82. Using the fillet weld profiles shown above, what is the problem with fillet weld "2"?
A. Excessive convexity
B. Inadequate penetration
C. Insufficient leg
D. Insufficient throat
83. An E6013 electrode is classified as a:
A. Fast-freeze electrode.
B. Fill-freeze electrode.
C. Fast-fill electrode.
D. Low-hydrogen.
84. The rectifier type welding machine converts primary current from commercial power lines into:
A. AC current.
B. ACHF current.
C. DC current.
D. HF current.
85. What does the term, traceability, mean in reference to SMAW electrodes?
A. The ability to follow a previously completed weld with the next bead
B. The ability to follow a soap stone line when producing the weld
C. The ability to follow and document the type of electrode that was used
D. The ability to reproduce a weld exactly as it was done before
86. Which type electrode picks up moisture faster than any other type of electrode?
A. Fast-freeze electrode
B. Fill-freeze electrode
C. Fast-fill electrode
D. Low-hydrogen
87. Polarity refers to:
A. The distance between the electrode and work.
B. The direction AC current flows.
C. High voltage welding current.
D. The direction of DC welding current.
88. Before starting an engine-driven generator:
A. Connect the ground lead.
B. Perform pre-start checks.
C. Set the amperage.
D. Add fuel.
89. Arc flash is:
A. A sudden surge of welding current caused by improper grounding.
B. Dangerous and can cause burns to the eyes and skin.
C. Flying debris caused by the arc contacting the work.
D. The high voltage necessary to initiate the arc.
90. If work is to be located a good distance from the welding machine, use a larger cable to the electrode holder so that the cable:
A. Can be run over without being cut.
B. Does not overheat.
C. Is not stretched.
D. Will not be moved.
91. When using SMAW the filler metal should match the chemical composition and mechanical properties of the:
A. Base metal.
B. Flux coating.
C. Shielding gas.
D. Slag.
92. What do governors on engine driven generator and alternator welding machines control?
A. Primary power
B. Rectifier
C. Speed
D. Temperature
93. An all-position, shallow penetrating SMAW electrode with a medium slag coating would fall into the:
A. Fast-freeze electrode group.
B. Fill-freeze electrode group.
C. Fast-fill electrode group.
D. Low-hydrogen group.
94. Low hydrogen electrodes that exceed the maximum exposure time can be:
A. Dried once.
B. Dried repeatedly.
C. Used on any job.
D. Used on higher standard jobs.
95. When welding with DCEN, the electrons flow from the:
A. Work to the electrode.
B. Electrode to the work.
C. Electrode to the work and back to the electrode.
D. Ground to the work.
96. Prior to opening, electrode containers:
A. Can be stored anywhere as long as they are covered.
B. Should be stored close to their point of use.
C. Should be stored off the floor on pallets or shelves.
D. Should be stored in an oven.
97. Arc welding current is:
A. AC or DC.
B. AC or HF.
C. DC only.
D. AC only.
98. Primary current is:
A. Another name for DC current.
B. Another name for the welding current produced by a transformer.
C. Electrical current which comes from commercial power lines.
D. Not needed when using transformers.
99. The direction in which the current flows in a circuit determines:
A. Amperage.
B. Arc length.
C. Polarity.
D. Resistance.
Please use the following figure for this question.
100. In the chart shown above, what is the maximum length of a #1/0 welding lead that can carry 200 amps?
A. Up to 50 Feet
B. 50-100 Feet
C. 150-200 Feet
D. 200-250 Feet
101. Work clothes worn by welders should NOT contain:
A. Synthetics.
B. Leather.
C. Cotton.
D. Wool.
102. Electrical current is the flow along a conductor of:
A. Atoms.
B. Electrons.
C. Neutrons.
D. Protons.
103. When using E7018 electrodes, set the current to:
A. DCEN.
B. DCEP.
C. DCSP.
D. HFDC.
104. Which electrode is used to minimize the danger of weld cracking in thick or highly restrained mild or alloy steels in any position?
A. E-6010
B. E-6013
C. E-7014
D. E-7018
105. In the United States the frequency of alternating current is almost always:
A. 25 cycles per second.
B. 40 cycles per second.
C. 50 cycles per second.
D. 60 cycles per second.
106. Non-low-hydrogen electrodes may be used if their coatings are not damaged and they have not come in direct contact with:
A. Chipped slag.
B. Direct sunlight.
C. Oil and water.
D. The ground.
107. When can the welding leads be wrapped around the arm, shoulder, waist, and/or the body?
A. Anytime
B. Occasionally
C. Never
D. When needed for steadiness
108. When performing SMAW you should NOT wear:
A. Coveralls.
B. Dark clothing.
C. A welding cap.
D. Low top shoes.
109. The size of a SMAW machine is determined by its duty cycle and:
A. Current frequency.
B. Its rated amperage output.
C. The amount of open circuit voltage produced.
D. The amount of primary current used.
110. The conductors inside of an arc welding cable are made of fine strands of:
A. Aluminum.
B. Copper.
C. Gold.
D. Steel.
111. The suffix on the end of the electrode classification E-8018-C2 indicates:
A. All position electrode.
B. Minimum tensile strength.
C. Alloy steel electrode.
D. Flux coated electrode.
Please use the following figure for this question.
112. The drawing above shows the bead sequence for a horizontal fillet weld using SMAW. What is electrode angle "A" for the first pass?
A. 90°
B. 70°
C. 45°
D. 20°
113. When selecting welding cable size, determine the amperage load and the:
A. Distance the current will travel.
B. Type of welding machine.
C. Voltage.
D. Welding process to be used.
114. What temperature does the SMAW arc exceed?
A. 11,000°F
B. 16,000°F
C. 20,000°F
D. 30,000°F
115. What type weld bead can be made using a variety of patterns that produce a side-to-side motion of the electrode?
A. Arc
B. Key hole
C. Stringer
D. Weave
116. Proper electrical grounding of the welding machine is required:
A. For an arc to be struck and stabilized continuously.
B. To prevent arc flash when the electrode is too close.
C. To prevent electrical shock or possible electrocution.
D. To prevent ultraviolet and infrared ray skin burns.
117. What part of the fillet weld is described as convex or concave?
A. Face
B. Leg
C. Root
D. Throat
118. Which code requires that low hydrogen electrodes receive special handling?
A. AWS
B. ASME
C. OSHA
D. All codes
119. In the E7014 the 4 denotes:
A. Chemical analysis of the coating.
B. Position recommended for welding.
C. Tensile strength after welding.
D. Tensile strength before heat treating.
120. Why should wet welding gloves NOT be worn when welding?
A. The operator could be shocked.
B. The skin becomes irritated
C. They shrink when exposed to heat.
D. They will contain fungus or mold.
121. What is the name for a welding bead with little or no side-to-side movement?
A. Outside
B. Stringer
C. Vertical
D. Weave
122. What is the high-voltage, low-amperage current from commercial power lines coming into the welding machine called?
A. Primary
B. Rectified
C. Secondary
D. Variable
123. Electrode selection is very important for any welding job and is related to the type and thickness of the base metal. One rule of thumb is:
A. The electrode diameter should be no more than 1/3 of the base metal thickness.
B. The electrode diameter should be smaller in diameter than the base metal thickness.
C. The electrode diameter should be two times the base metal thickness.
D. The electrode diameter should be one half the base metal thickness.
Student Name: ______________________
Teacher: ______________________ Date: ___________
District: Buncombe County
Test: 9_12 T and I 7661 - Welding Technology I Test 1
Description: Shelded metal arc welding
Form: 502
1. If work is to be located a good distance from the welding machine, use a larger cable to the electrode holder so that the cable:
A. Can be run over without being cut.
B. Does not overheat.
C. Is not stretched.
D. Will not be moved.
2. Non-low-hydrogen electrodes may be used if their coatings are not damaged and they have not come in direct contact with:
A. Chipped slag.
B. Direct sunlight.
C. Oil and water.
D. The ground.
3. What is the AWS specification for low-alloy electrodes?
A. A5.1
B. A5.5
C. A5.11
D. A5.24
4. Which electrode is classified as a fast-fill electrode?
A. E-6010
B. E-6013
C. E-7018
D. E-7024
5. Which electrode is classified as a fast-freeze electrode?
A. E-6011
B. E-6013
C. E-7014
D. E-7018
6. When welding with DCEN, the electrons flow from the:
A. Work to the electrode.
B. Electrode to the work.
C. Electrode to the work and back to the electrode.
D. Ground to the work.
7. When working with electricity the abbreviation AC refers to:
A. Accurate calculations.
B. Alternate classification.
C. Alternating circuit.
D. Alternating current.
8. How is the speed of a SMAW weld bead measured?
A. Feet per hour
B. Feet per minute
C. Inches per hour
D. Inches per minute
9. An all-position, deep penetrating SMAW electrode with a light slag coating would fall into the:
A. Fast-freeze electrode group.
B. Fill-freeze electrode group.
C. Fast-fill electrode group.
D. Low-hydrogen electrode group.
10. The suffix on the end of the electrode classification E-8018-C2 indicates:
A. All position electrode.
B. Minimum tensile strength.
C. Alloy steel electrode.
D. Flux coated electrode.
11. In the United States the frequency of alternating current is almost always:
A. 25 cycles per second.
B. 40 cycles per second.
C. 50 cycles per second.
D. 60 cycles per second. Please use the following figure for this question.
12. The drawing above shows the bead sequence for a horizontal fillet weld using
SMAW. What is electrode angle "C" for the sixth pass?
A. 15°
B. 20°
C. 45°
D. 70°
13. When using SMAW the filler metal should match the chemical composition and mechanical properties of the:
A. Base metal.
B. Flux coating.
C. Shielding gas.
D. Slag.
14. How can porosity be reduced in a SMAW weldment?
A. Weld faster and turn the welding current down
B. Weld faster and turn the welding current up
C. Weld slower and turn the welding current down
D. Weld slower and turn the welding current up
15. What is added to the flux coatings of SMAW electrodes to change the chemical composition and strength of the deposited weld metal?
A. Alloys
B. Hydrogen
C. Nitrogen
D. Oxygen
Please use the following figure for this question.
16. Using the diagram of a SMAW setup shown above, what is the polarity?
A. AC
B. DCEN (DCSP)
C. DCEP (DCRP)
D. HFAC
17. Electrode storage ovens should be set at about:
A. 75°
B. 120°
C. 250°
D. 600°
18. What should the selection of the proper size electrode holder for SMAW be based on?
A. Depth of penetration and position of weld
B. Electrodes and amperage being used
C. Length and diameter of the electrodes
D. Size and strength of the welders hand
19. Terminations of SMAW beads are made at:
A. Both the beginning and end of all weld passes.
B. The beginning of all welds.
C. The beginning of new weld passes only.
D. The ends of welds. Please use the following figure for this question.
20. The drawing above shows the bead sequence for a horizontal fillet weld using SMAW. What is electrode angle "A" for the first pass?
A. 90°
B. 70°
C. 45°
D. 20°
21. Which SMAW electrode is HARDEST to strike an arc with?
A. E6010
B. E6011
C. E7018
D. E7024
22. What part of the fillet weld is described as convex or concave?
A. Face
B. Leg
C. Root
D. Throat
23. What does the acronym LASH refer to in SMAW?
A. Arc length, angle, speed, and heat
B. Leave a small hole
C. Load, amperage, and slow heat
D. Low angle and slow heat
24. A SMAW electrode with a high deposition rate, shallow penetration and a heavy slag coating, and that is designated for flat and horizontal fillet welds would fall into the:
A. Fast-freeze electrode group.
B. Fill-freeze electrode group.
C. Fast-fill electrode group.
D. Low-hydrogen group.
25. When performing SMAW you should NOT wear:
A. Coveralls.
B. Dark clothing.
C. A welding cap.
D. Low top shoes.
26. When using E7018 electrodes, set the current to:
A. DCEN.
B. DCEP.
C. DCSP.
D. HFDC. Please use the following figure for this question.
27. The drawing above shows the bead sequence for a horizontal fillet weld using SMAW. What is electrode angle "B" for the fourth pass?
A. 90°
B. 70°
C. 45°
D. 20°
28. Before plugging a welding machine into an outlet:
A. Set the amperage to zero.
B. Switch to open circuit voltage.
C. Locate the electrical disconnect.
D. Connect the ground clamp.
29. Electrode selection is very important for any welding job and is related to the type and thickness of the base metal. One rule of thumb is:
A. The electrode diameter should be no more than 1/3 of the base metal thickness.
B. The electrode diameter should be smaller in diameter than the base metal thickness.
C. The electrode diameter should be two times the base metal thickness.
D. The electrode diameter should be one half the base metal thickness.
30. Which type electrode picks up moisture faster than any other type of electrode?
A. Fast-freeze electrode
B. Fill-freeze electrode
C. Fast-fill electrode
D. Low-hydrogen
31. Welding current traveling through bearings, seals or valves:
A. Can cause an increase in the open circuit voltage.
B. Can cause severe damage.
C. Will cause no damage.
D. Will cause the amperage to vary. Please use the following figure for questions 32 through 33:
32. Using the fillet weld profiles shown above, what is the problem with fillet weld "2"?
A. Excessive convexity
B. Inadequate penetration
C. Insufficient leg
D. Insufficient throat
33. Using the fillet weld profiles shown above, what is the problem with fillet weld "5"?
A. Excessive convexity
B. Excessive undercut
C. Inadequate penetration
D. Insufficient leg
34. What type weld bead can be made using a variety of patterns that produce a side-to-side motion of the electrode?
A. Arc
B. Key hole
C. Stringer
D. Weave
35. When Shielded Metal Arc Welding up to 200 amps, the filter lens recommended is a:
A. Number 4.
B. Number 6.
C. Number 10.
D. Number 14.
36. When referring to electrical current, what is the number of cycles per second?
A. Amperage
B. Frequency
C. Period
D. Voltage
37. Arc blow tends to be the biggest problem when:
A. Building up thick overlapping beads.
B. Using very low hydrogen electrodes.
C. Using very high hydrogen electrodes.
D. Welding on the ends of base metal. Please use the following figure for this question.
38. Using the cable size chart above, determine the size welding cable needed for welding using 200 amps at 60% duty cycle 80 feet from the power source?
A. #1
B. #2
C. #3
D. #4
39. How is the size of a workpiece clamp designated?
A. The distance in inches that the clamp jaws will spread to grasp the workpiece
B. The length in inches from the cable connection to the end of the clamp
C. The rated amperage that it can carry without overheating
D. The rated resistance it has to the current flow
Please use the following figure for this question.
40. Using the cable size chart above, determine the size welding cable needed for welding using 650 amps at 60% duty cycle 195 feet from the power source and 100 feet above ground level?
A. #1/0
B. #2/0
C. #3/0
D. #4/0
41. Which electrode angle in SMAW will give the deepest penetration?
A. 5° opposite the direction of travel
B. 45° opposite the direction of travel
C. Leading angle
D. Trailing angle
42. What does the term, traceability, mean in reference to SMAW electrodes?
A. The ability to follow a previously completed weld with the next bead
B. The ability to follow a soap stone line when producing the weld
C. The ability to follow and document the type of electrode that was used
D. The ability to reproduce a weld exactly as it was done before
43. When selecting welding cable size, determine the amperage load and the:
A. Distance the current will travel.
B. Type of welding machine.
C. Voltage.
D. Welding process to be used.
44. What are the characteristics of a SMAW weld bead, if the arc length is too short?
A. Excessive spatter
B. High and narrow
C. Undercut
D. Wide and flat
45. The welding electrode that is the LEAST penetrating is:
A. E6010.
B. E6011.
C. E6013.
D. E7010.
46. An all-position, shallow penetrating SMAW electrode with a medium slag coating would fall into the:
A. Fast-freeze electrode group.
B. Fill-freeze electrode group.
C. Fast-fill electrode group.
D. Low-hydrogen group.
47. What type of current is used with an E6010?
A. AC
B. ACHF
C. DCEN
D. DCEP
48. The size of a SMAW machine is determined by its duty cycle and:
A. Current frequency.
B. Its rated amperage output.
C. The amount of open circuit voltage produced.
D. The amount of primary current used.
49. The point in the weld where one weld bead stops and another begins is a/an:
A. Convex point.
B. Oscillation point.
C. Restart point.
D. Weld termination.
50. The standard length of a 1/8" SMAW electrode is:
A. 10".
B. 12".
C. 14".
D. 16".
51. Arc welding current is:
A. AC or DC.
B. AC or HF.
C. DC only.
D. AC only.
52. The traceability requirements of welding filler materials vary according to the:
A. Base metal.
B. Client requirements and specifications.
C. State and local law.
D. Welder type.
53. An E6013 electrode is classified as a:
A. Fast-freeze electrode.
B. Fill-freeze electrode.
C. Fast-fill electrode.
D. Low-hydrogen.
54. What is the high-voltage, low-amperage current from commercial power lines coming into the welding machine called?
A. Primary
B. Rectified
C. Secondary
D. Variable
55. What does the flux coating of an SMAW electrode do to the molten metal when it melts?
A. Anneals and hardens
B. Cleans and deoxidizes
C. Lubricates for ductility
D. Softens and anneals
56. The direction in which the current flows in a circuit determines:
A. Amperage.
B. Arc length.
C. Polarity.
D. Resistance.
57. When receiving a new shipment of low-hydrogen electrodes and one container? seal has been broken, what should be done?
A. Put the damaged container in the oven
B. Reject the damaged container
C. Use the damaged container first
D. Wrap the damaged container in plastic
58. In the E7014 the 4 denotes:
A. Chemical analysis of the coating.
B. Position recommended for welding.
C. Tensile strength after welding.
D. Tensile strength before heat treating. Please use the following figure for this question.
59. The drawing above shows the bead sequence for a horizontal fillet weld using SMAW. What is electrode angle "A" for the fifth pass?
A. 20°
B. 45°
C. 70°
D. 90°
60. Arc blow can cause:
A. Arc stability.
B. Electrodes to cool.
C. Excess penetration.
D. Spatter and porosity.
61. The rectifier type welding machine converts primary current from commercial power lines into:
A. AC current.
B. ACHF current.
C. DC current.
D. HF current. Please use the following figure for this question.
62. Using the fillet weld profiles shown above, what is the problem with fillet weld "6"?
A. Excessive convexity
B. Excessive undercut
C. Inadequate fusion
D. Overlap
63. Which electrode has the highest tensile strength?
A. E9018
B. E8018
C. E7018
D. E6011
64. Which electrode is the largest?
A. 3/32"
B. 1/8"
C. 3/16"
D. 5/32"
65. Which electrode is used to minimize the danger of weld cracking in thick or highly restrained mild or alloy steels in any position?
A. E-6010
B. E-6013
C. E-7014
D. E-7018
66. What is the maximum exposure time of E-7018 electrodes to the atmosphere?
A. 1 hour
B. 2 hours
C. 4 hours
D. 6 hours
67. Low hydrogen electrodes that exceed the maximum exposure time can be:
A. Dried once.
B. Dried repeatedly.
C. Used on any job.
D. Used on higher standard jobs.
68. Welding machines are classified by the:
A. Maximum amperage they can produce.
B. Open circuit voltage they require.
C. Operating voltage they require.
D. Type(s) of welding current produced.
69. What are lugs used for with SMAW equipment?
A. Connect the electrode to the electrode holder
B. Connect the workpiece clamp to the workpiece
C. Connect the welding cable to the electrode holder or ground clamp
D. Connect the welding cables to the machine current terminals
70. Smaller diameter electrodes require:
A. Higher amperage current.
B. Lower amperage current.
C. Shorter arc gaps.
D. Square butt gaps.
71. SMAW electrodes manufactured in the United States:
A. Can have either the AWS OR manufacturer? classification printed on them.
B. Must have the AWS classification number printed on them.
C. Must have the manufacturer? classification printed on them.
D. Must NOT be printed on because the ink destabilizes the arc.
72. Which type of current CANNOT be used with E6010 and E-7010 electrodes?
A. AC
B. DCEN
C. DCEP
D. DCRP
73. What is the AWS specification for carbon steel electrodes?
A. A5.1
B. A5.5
C. A5.11
D. A5.24
74. In SMAW, DCEP is recommended for:
A. Flat position welding.
B. Increased base metal heat.
C. Out-of-position welding.
D. Shallow penetration.
75. In SMAW the crater at the end of each bead should be filled by:
A. Starting and stopping the arc several times until the crater is filled.
B. Holding a long arc over the crater until the crater is filled slightly larger than the bead.
C. Breaking the arc and then start the arc again for several seconds holding a very short arc.
D. Reversing the electrode angle and moving 1/8 inch toward the start of the weld.
76. One way to compensate for arc blow is to:
A. Change the electrode angle.
B. Lengthen the arc length.
C. Use a shorter electrode.
D. Weave the weld bead.
77. Voltage is the measure of:
A. Alternating current frequency.
B. Current flow rate.
C. Electromotive forces.
D. Heat energy.
78. What do governors on engine driven generator and alternator welding machines control?
A. Primary power
B. Rectifier
C. Speed
D. Temperature
79. When can the welding leads be wrapped around the arm, shoulder, waist, and/or the body?
A. Anytime
B. Occasionally
C. Never
D. When needed for steadiness
80. An E7024 electrode is classified as a:
A. Fast-freeze electrode.
B. Fill-freeze electrode.
C. Fast-fill electrode.
D. Low-hydrogen.
81. What may happen if gloves are not worn when putting an electrode in a SMAW electrode holder?
A. Electrode may be damaged from moisture on the hands
B. Warranty on the electrode may be voided
C. Welder inserting the electrode may be shocked
D. Welding machine may be grounded out
82. For SMAW, operating voltage:
A. Has no relation to open circuit voltage.
B. Is always lower than open circuit voltage.
C. Is always higher than open circuit voltage.
D. May be higher or lower than open circuit voltage.
83. Which code requires that low hydrogen electrodes receive special handling?
A. AWS
B. ASME
C. OSHA
D. All codes Please use the following figure for this question.
84. Using the fillet weld profiles shown above, what is the problem with fillet weld "1"?
A. Excessive convexity
B. Excessive undercut
C. Insufficient leg
D. Insufficient throat
85. Prior to opening, electrode containers:
A. Can be stored anywhere as long as they are covered.
B. Should be stored close to their point of use.
C. Should be stored off the floor on pallets or shelves.
D. Should be stored in an oven.
86. A SMAW electrode designed for welding high sulfur, phosphorus and medium-to high-carbon steels which have a tendency to underbead cracking, would fall into the:
A. Fast-freeze electrode group.
B. Fill-freeze electrode group.
C. Fast-fill electrode group.
D. Low-hydrogen group.
87. Arc flash is:
A. A sudden surge of welding current caused by improper grounding.
B. Dangerous and can cause burns to the eyes and skin.
C. Flying debris caused by the arc contacting the work.
D. The high voltage necessary to initiate the arc.
88. What causes the heat in SMAW?
A. Dirty metal
B. Electric arc
C. High frequency current
D. Moisture in the flux
Please use the following figure for this question.
89. In the chart shown above, what is the maximum length of a #1/0 welding lead that can carry 200 amps?
A. Up to 50 Feet
B. 50-100 Feet
C. 150-200 Feet
D. 200-250 Feet
90. Why should gas cylinders NEVER be welded on?
A. The cylinders do not conduct electricity.
B. The cylinders will explode.
C. The paint will be melted off the cylinders.
D. The welding machine will ground out.
91. What temperature does the SMAW arc exceed?
A. 11,000°F
B. 16,000°F
C. 20,000°F
D. 30,000°F
Please use the following figure for this question.
92. In the chart shown above, what size welding cable is needed to weld at 200 amps using a welding machine with 50% duty cycle and leads 225 feet long?
A. #1/0
B. #2/0
C. #3/0
D. #4/0
93. An arc welding power source rated at 250 amps, 50% duty cycle, can be used at 250 amps for:
A. About 50 hours and then cooled.
B. 2 minutes out of every 10 minutes.
C. 5 minutes out of every 10 minutes.
D. 6 minutes out of every 10 minutes.
94. Which electrode is classified as a low-hydrogen electrode?
A. E-6010
B. E-6013
C. E-7014
D. E-7018
95. Why should wet welding gloves NOT be worn when welding?
A. The operator could be shocked.
B. The skin becomes irritated
C. They shrink when exposed to heat.
D. They will contain fungus or mold.
96. What is the term for the outside surface of a ball?
A. Concave
B. Convex
C. Convoluted
D. Refracted
97. What piece of SMAW equipment is shown below?
A. Electrode holder
B. Lug
C. Quick disconnector
D. Workpiece clamp
98. One way to compensate for arc blow is to:
A. Run the weld bead in the opposite direction.
B. Shorten the arc length.
C. Use a full length electrode.
D. Whip the electrode tip.
Please use the following figure for this question.
99. In the chart shown above, what size welding cable is needed to weld at 225 amps using a welding machine with 20% duty cycle and leads 90 feet long?
A. #2
B. #3
C. #1/0
D. #2/0
100. What type weld is shown below?
A. Concave fillet
B. Concave groove
C. Convex fillet
D. Convex groove
101. What is the size of a welding cable based on?
A. Amount of amperage the insulation can withstand before breaking down
B. Diameter of the cable including insulation and any reinforcement cord
C. Length of the cable from the welding machine to the electrode holder
D. Number of copper strands it contains which determines the cable diameter
102. What is the name for a welding bead with little or no side-to-side movement?
A. Outside
B. Stringer
C. Vertical
D. Weave
103. Electrical current is the flow along a conductor of:
A. Atoms.
B. Electrons.
C. Neutrons.
D. Protons.
104. Work clothes worn by welders should NOT contain:
A. Synthetics.
B. Leather.
C. Cotton.
D. Wool.
105. The conductors inside of an arc welding cable are made of fine strands of:
A. Aluminum.
B. Copper.
C. Gold.
D. Steel.
106. Proper primary electrical grounding of the welding machine is required to:
A. Prevent arc flash.
B. Prevent electrical shock.
C. Stabilize the arc.
D. Strike the arc.
107. Primary current is:
A. Another name for DC current.
B. Another name for the welding current produced by a transformer.
C. Electrical current which comes from commercial power lines.
D. Not needed when using transformers.
108. With DCEP welding current, the electrode is:
A. Grounded.
B. Negative.
C. Neutral.
D. Positive.
109. A good electrode to use for sheet metal would be:
A. E7018.
B. E6013.
C. E7024.
D. E8018-C1.
110. Polarity refers to:
A. The distance between the electrode and work.
B. The direction AC current flows.
C. High voltage welding current.
D. The direction of DC welding current.
111. Before starting an engine-driven generator:
A. Connect the ground lead.
B. Perform pre-start checks.
C. Set the amperage.
D. Add fuel.
112. Which electrode is classified as a fill-freeze electrode?
A. E-6010
B. E-6011
C. E-6013
D. E-7018
113. The heat energy developed by electric arc welding is the result of:
A. Resistance to current flow across the arc.
B. The amp setting on the power source.
C. The duty cycle of the welding machine.
D. Volts across the arc.
114. When using SMAW to weld flat beads, place the electrode at a 90° angle, then lean it:
A. 10° to 20°
B. 20° to 40°
C. 40° to 60°
D. 45° to 65°
115. The acceptance criteria for the size of an SMAW overhead fillet weld is plus or minus:
A. 1/8".
B. 3/16".
C. 5/32".
D. 1/16".
116. In SMAW open circuit voltage is usually between:
A. 20 and 30 volts.
B. 30 and 40 volts.
C. 50 and 100 volts.
D. 100 and 150 volts.
117. When restarting a bead in SMAW, the arc should be struck:
A. 1/4" behind the crater on the bead deposited.
B. 1/4" to 3/8" in front of the crater.
C. In the back center of the crater.
D. To one side of and behind the crater.
118. Two types of harmful rays that SMAW produces are:
A. Alpha and beta.
B. Gamma and x-ray.
C. Infrared and ultraviolet.
D. Supersonic and ultrasonic.
119. Which electrode is used to make welds on galvanized, plated, or painted surfaces?
A. E-6010
B. E-6013
C. E-7014
D. E-7018 Please use the following figure for this question.
120. In the chart shown above, what is the maximum length of a #1/0 welding lead that can carry 300 amps?
A. 50 Feet
B. 100 Feet
C. 150 Feet
D. 250 Feet
121. Proper electrical grounding of the welding machine is required:
A. For an arc to be struck and stabilized continuously.
B. To prevent arc flash when the electrode is too close.
C. To prevent electrical shock or possible electrocution.
D. To prevent ultraviolet and infrared ray skin burns.
122. To change the chemical composition and strength of the deposited weld metal,
some electrodes have:
A. Powdered metal in the flux.
B. Carbon in the flux.
C. Fibers in the flux.
D. Inert gas in the flux.
123. To compensate for the recessed electrode core when welding with heavier flux-coated electrodes (such as E7018 or E6013), the visible arc length should be:
A. Angled.
B. Lengthened.
C. Shortened.
D. Whipped.
Student Name: ______________________
Teacher: ______________________ Date: ___________
District: Buncombe County
Test: 9_12 T and I 7661 - Welding Technology I Test 1
Description: Shelded metal arc welding
Form: 503
1. Which SMAW electrode is HARDEST to strike an arc with?
A. E6010
B. E6011
C. E7018
D. E7024
Please use the following figure for this question.
2. Using the diagram of a SMAW setup shown above, what is the polarity?
A. AC
B. DCEN (DCSP)
C. DCEP (DCRP)
D. HFAC
Please use the following figure for this question.
3. The drawing above shows the bead sequence for a horizontal fillet weld using SMAW. What is electrode angle "A" for the first pass?
A. 90°
B. 70°
C. 45°
D. 20°
Please use the following figure for this question.
4. In the chart shown above, what size welding cable is needed to weld at 225 amps using a welding machine with 20% duty cycle and leads 90 feet long?
A. #2
B. #3
C. #1/0
D. #2/0
5. One way to compensate for arc blow is to:
A. Run the weld bead in the opposite direction.
B. Shorten the arc length.
C. Use a full length electrode.
D. Whip the electrode tip.
6. When restarting a bead in SMAW, the arc should be struck:
A. 1/4" behind the crater on the bead deposited.
B. 1/4" to 3/8" in front of the crater.
C. In the back center of the crater.
D. To one side of and behind the crater.
Please use the following figure for this question.
7. In the chart shown above, what is the maximum length of a #1/0 welding lead that can carry 300 amps?
A. 50 Feet
B. 100 Feet
C. 150 Feet
D. 250 Feet
8. The rectifier type welding machine converts primary current from commercial power lines into:
A. AC current.
B. ACHF current.
C. DC current.
D. HF current.
9. What type weld is shown below?
A. Concave fillet
B. Concave groove
C. Convex fillet
D. Convex groove
10. Electrode selection is very important for any welding job and is related to the type and thickness of the base metal. One rule of thumb is:
A. The electrode diameter should be no more than 1/3 of the base metal thickness.
B. The electrode diameter should be smaller in diameter than the base metal thickness.
C. The electrode diameter should be two times the base metal thickness.
D. The electrode diameter should be one half the base metal thickness.
11. What part of the fillet weld is described as convex or concave?
A. Face
B. Leg
C. Root
D. Throat
12. The direction in which the current flows in a circuit determines:
A. Amperage.
B. Arc length.
C. Polarity.
D. Resistance. Please use the following figure for this question.
13. In the chart shown above, what is the maximum length of a #1/0 welding lead that can carry 200 amps?
A. Up to 50 Feet
B. 50-100 Feet
C. 150-200 Feet
D. 200-250 Feet
14. The traceability requirements of welding filler materials vary according to the:
A. Base metal.
B. Client requirements and specifications.
C. State and local law.
D. Welder type.
15. When welding with DCEN, the electrons flow from the:
A. Work to the electrode.
B. Electrode to the work.
C. Electrode to the work and back to the electrode.
D. Ground to the work.
16. An E6013 electrode is classified as a:
A. Fast-freeze electrode.
B. Fill-freeze electrode.
C. Fast-fill electrode.
D. Low-hydrogen.
17. What type of current is used with an E6010?
A. AC
B. ACHF
C. DCEN
D. DCEP
18. What does the acronym LASH refer to in SMAW?
A. Arc length, angle, speed, and heat
B. Leave a small hole
C. Load, amperage, and slow heat
D. Low angle and slow heat
19. The standard length of a 1/8" SMAW electrode is:
A. 10".
B. 12".
C. 14".
D. 16".
20. What causes the heat in SMAW?
A. Dirty metal
B. Electric arc
C. High frequency current
D. Moisture in the flux
21. Proper primary electrical grounding of the welding machine is required to:
A. Prevent arc flash.
B. Prevent electrical shock.
C. Stabilize the arc.
D. Strike the arc.
22. What is added to the flux coatings of SMAW electrodes to change the chemical composition and strength of the deposited weld metal?
A. Alloys
B. Hydrogen
C. Nitrogen
D. Oxygen
23. Which electrode is classified as a fast-freeze electrode?
A. E-6011
B. E-6013
C. E-7014
D. E-7018
24. What does the flux coating of an SMAW electrode do to the molten metal when it melts?
A. Anneals and hardens
B. Cleans and deoxidizes
C. Lubricates for ductility
D. Softens and anneals
25. What is the term for the outside surface of a ball?
A. Concave
B. Convex
C. Convoluted
D. Refracted
26. When referring to electrical current, what is the number of cycles per second?
A. Amperage
B. Frequency
C. Period
D. Voltage
27. Before plugging a welding machine into an outlet:
A. Set the amperage to zero.
B. Switch to open circuit voltage.
C. Locate the electrical disconnect.
D. Connect the ground clamp.
28. The point in the weld where one weld bead stops and another begins is a/an:
A. Convex point.
B. Oscillation point.
C. Restart point.
D. Weld termination.
29. When working with electricity the abbreviation AC refers to:
A. Accurate calculations.
B. Alternate classification.
C. Alternating circuit.
D. Alternating current.
30. The welding electrode that is the LEAST penetrating is:
A. E6010.
B. E6011.
C. E6013.
D. E7010.
31. An E7024 electrode is classified as a:
A. Fast-freeze electrode.
B. Fill-freeze electrode.
C. Fast-fill electrode.
D. Low-hydrogen.
32. What do governors on engine driven generator and alternator welding machines control?
A. Primary power
B. Rectifier
C. Speed
D. Temperature
Please use the following figure for questions 33 through 34:
33. The drawing above shows the bead sequence for a horizontal fillet weld using SMAW. What is electrode angle "B" for the fourth pass?
A. 90°
B. 70°
C. 45°
D. 20°
34. The drawing above shows the bead sequence for a horizontal fillet weld using SMAW. What is electrode angle "C" for the sixth pass?
A. 15°
B. 20°
C. 45°
D. 70°
35. An all-position, deep penetrating SMAW electrode with a light slag coating would fall into the:
A. Fast-freeze electrode group.
B. Fill-freeze electrode group.
C. Fast-fill electrode group.
D. Low-hydrogen electrode group.
36. Which electrode is classified as a fast-fill electrode?
A. E-6010
B. E-6013
C. E-7018
D. E-7024
37. What are the characteristics of a SMAW weld bead, if the arc length is too short?
A. Excessive spatter
B. High and narrow
C. Undercut
D. Wide and flat
38. One way to compensate for arc blow is to:
A. Change the electrode angle.
B. Lengthen the arc length.
C. Use a shorter electrode.
D. Weave the weld bead.
39. Primary current is:
A. Another name for DC current.
B. Another name for the welding current produced by a transformer.
C. Electrical current which comes from commercial power lines.
D. Not needed when using transformers.
40. The suffix on the end of the electrode classification E-8018-C2 indicates:
A. All position electrode.
B. Minimum tensile strength.
C. Alloy steel electrode.
D. Flux coated electrode.
41. When using E7018 electrodes, set the current to:
A. DCEN.
B. DCEP.
C. DCSP.
D. HFDC.
42. Two types of harmful rays that SMAW produces are:
A. Alpha and beta.
B. Gamma and x-ray.
C. Infrared and ultraviolet.
D. Supersonic and ultrasonic.
43. Which type of current CANNOT be used with E6010 and E-7010 electrodes?
A. AC
B. DCEN
C. DCEP
D. DCRP
Please use the following figure for this question.
44. Using the cable size chart above, determine the size welding cable needed for welding using 200 amps at 60% duty cycle 80 feet from the power source?
A. #1
B. #2
C. #3
D. #4
45. How is the size of a workpiece clamp designated?
A. The distance in inches that the clamp jaws will spread to grasp the workpiece
B. The length in inches from the cable connection to the end of the clamp
C. The rated amperage that it can carry without overheating
D. The rated resistance it has to the current flow
46. When using SMAW to weld flat beads, place the electrode at a 90° angle, then lean it:
A. 10° to 20°
B. 20° to 40°
C. 40° to 60°
D. 45° to 65°
Please use the following figure for this question.
47. Using the fillet weld profiles shown above, what is the problem with fillet weld "1"?
A. Excessive convexity
B. Excessive undercut
C. Insufficient leg
D. Insufficient throat
48. When using SMAW the filler metal should match the chemical composition and mechanical properties of the:
A. Base metal.
B. Flux coating.
C. Shielding gas.
D. Slag.
49. Non-low-hydrogen electrodes may be used if their coatings are not damaged and they have not come in direct contact with:
A. Chipped slag.
B. Direct sunlight.
C. Oil and water.
D. The ground.
Please use the following figure for this question.
50. The drawing above shows the bead sequence for a horizontal fillet weld using SMAW. What is electrode angle "A" for the fifth pass?
A. 20°
B. 45°
C. 70°
D. 90°
51. Which electrode is classified as a fill-freeze electrode?
A. E-6010
B. E-6011
C. E-6013
D. E-7018
52. Welding current traveling through bearings, seals or valves:
A. Can cause an increase in the open circuit voltage.
B. Can cause severe damage.
C. Will cause no damage.
D. Will cause the amperage to vary.
53. When Shielded Metal Arc Welding up to 200 amps, the filter lens recommended is a:
A. Number 4.
B. Number 6.
C. Number 10.
D. Number 14.
54. What are lugs used for with SMAW equipment?
A. Connect the electrode to the electrode holder
B. Connect the workpiece clamp to the workpiece
C. Connect the welding cable to the electrode holder or ground clamp
D. Connect the welding cables to the machine current terminals
55. How can porosity be reduced in a SMAW weldment?
A. Weld faster and turn the welding current down
B. Weld faster and turn the welding current up
C. Weld slower and turn the welding current down
D. Weld slower and turn the welding current up
56. Arc blow tends to be the biggest problem when:
A. Building up thick overlapping beads.
B. Using very low hydrogen electrodes.
C. Using very high hydrogen electrodes.
D. Welding on the ends of base metal.
57. SMAW electrodes manufactured in the United States:
A. Can have either the AWS OR manufacturer? classification printed on them.
B. Must have the AWS classification number printed on them.
C. Must have the manufacturer? classification printed on them.
D. Must NOT be printed on because the ink destabilizes the arc.
58. Arc blow can cause:
A. Arc stability.
B. Electrodes to cool.
C. Excess penetration.
D. Spatter and porosity.
59. Electrical current is the flow along a conductor of:
A. Atoms.
B. Electrons.
C. Neutrons.
D. Protons.
60. Proper electrical grounding of the welding machine is required:
A. For an arc to be struck and stabilized continuously.
B. To prevent arc flash when the electrode is too close.
C. To prevent electrical shock or possible electrocution.
D. To prevent ultraviolet and infrared ray skin burns.
61. What type weld bead can be made using a variety of patterns that produce a side-to-side motion of the electrode?
A. Arc
B. Key hole
C. Stringer
D. Weave
62. Arc flash is:
A. A sudden surge of welding current caused by improper grounding.
B. Dangerous and can cause burns to the eyes and skin.
C. Flying debris caused by the arc contacting the work.
D. The high voltage necessary to initiate the arc.
63. In SMAW open circuit voltage is usually between:
A. 20 and 30 volts.
B. 30 and 40 volts.
C. 50 and 100 volts.
D. 100 and 150 volts.
64. Arc welding current is:
A. AC or DC.
B. AC or HF.
C. DC only.
D. AC only.
65. Which type electrode picks up moisture faster than any other type of electrode?
A. Fast-freeze electrode
B. Fill-freeze electrode
C. Fast-fill electrode
D. Low-hydrogen
66. When receiving a new shipment of low-hydrogen electrodes and one container? seal has been broken, what should be done?
A. Put the damaged container in the oven
B. Reject the damaged container
C. Use the damaged container first
D. Wrap the damaged container in plastic
67. Low hydrogen electrodes that exceed the maximum exposure time can be:
A. Dried once.
B. Dried repeatedly.
C. Used on any job.
D. Used on higher standard jobs.
68. Which electrode has the highest tensile strength?
A. E9018
B. E8018
C. E7018
D. E6011
69. Polarity refers to:
A. The distance between the electrode and work.
B. The direction AC current flows.
C. High voltage welding current.
D. The direction of DC welding current.
70. Which electrode is used to minimize the danger of weld cracking in thick or highly restrained mild or alloy steels in any position?
A. E-6010
B. E-6013
C. E-7014
D. E-7018
71. Voltage is the measure of:
A. Alternating current frequency.
B. Current flow rate.
C. Electromotive forces.
D. Heat energy.
72. A SMAW electrode with a high deposition rate, shallow penetration and a heavy slag coating, and that is designated for flat and horizontal fillet welds would fall into the:
A. Fast-freeze electrode group.
B. Fill-freeze electrode group.
C. Fast-fill electrode group.
D. Low-hydrogen group.
73. Work clothes worn by welders should NOT contain:
A. Synthetics.
B. Leather.
C. Cotton.
D. Wool.
74. In the E7014 the 4 denotes:
A. Chemical analysis of the coating.
B. Position recommended for welding.
C. Tensile strength after welding.
D. Tensile strength before heat treating.
75. What is the high-voltage, low-amperage current from commercial power lines coming into the welding machine called?
A. Primary
B. Rectified
C. Secondary
D. Variable
76. Welding machines are classified by the:
A. Maximum amperage they can produce.
B. Open circuit voltage they require.
C. Operating voltage they require.
D. Type(s) of welding current produced.
77. In SMAW the crater at the end of each bead should be filled by:
A. Starting and stopping the arc several times until the crater is filled.
B. Holding a long arc over the crater until the crater is filled slightly larger than the bead.
C. Breaking the arc and then start the arc again for several seconds holding a very short arc.
D. Reversing the electrode angle and moving 1/8 inch toward the start of the weld.
78. Which electrode is the largest?
A. 3/32"
B. 1/8"
C. 3/16"
D. 5/32" Please use the following figure for this question.
79. Using the fillet weld profiles shown above, what is the problem with fillet weld "2"?
A. Excessive convexity
B. Inadequate penetration
C. Insufficient leg
D. Insufficient throat
80. Which electrode is used to make welds on galvanized, plated, or painted surfaces?
A. E-6010
B. E-6013
C. E-7014
D. E-7018
81. Terminations of SMAW beads are made at:
A. Both the beginning and end of all weld passes.
B. The beginning of all welds.
C. The beginning of new weld passes only.
D. The ends of welds.
82. Electrode storage ovens should be set at about:
A. 75°
B. 120°
C. 250°
D. 600°
83. A SMAW electrode designed for welding high sulfur, phosphorus and medium-to high-carbon steels which have a tendency to underbead cracking, would fall into the:
A. Fast-freeze electrode group.
B. Fill-freeze electrode group.
C. Fast-fill electrode group.
D. Low-hydrogen group.
84. To compensate for the recessed electrode core when welding with heavier flux-coated electrodes (such as E7018 or E6013), the visible arc length should be:
A. Angled.
B. Lengthened.
C. Shortened.
D. Whipped.
85. What is the AWS specification for low-alloy electrodes?
A. A5.1
B. A5.5
C. A5.11
D. A5.24
86. The acceptance criteria for the size of an SMAW overhead fillet weld is plus or minus:
A. 1/8".
B. 3/16".
C. 5/32".
D. 1/16".
87. Which electrode angle in SMAW will give the deepest penetration?
A. 5° opposite the direction of travel
B. 45° opposite the direction of travel
C. Leading angle
D. Trailing angle
88. What piece of SMAW equipment is shown below?
A. Electrode holder
B. Lug
C. Quick disconnector
D. Workpiece clamp
89. When selecting welding cable size, determine the amperage load and the:
A. Distance the current will travel.
B. Type of welding machine.
C. Voltage.
D. Welding process to be used.
90. Why should wet welding gloves NOT be worn when welding?
A. The operator could be shocked.
B. The skin becomes irritated
C. They shrink when exposed to heat.
D. They will contain fungus or mold.
91. What is the size of a welding cable based on?
A. Amount of amperage the insulation can withstand before breaking down
B. Diameter of the cable including insulation and any reinforcement cord
C. Length of the cable from the welding machine to the electrode holder
D. Number of copper strands it contains which determines the cable diameter
92. Before starting an engine-driven generator:
A. Connect the ground lead.
B. Perform pre-start checks.
C. Set the amperage.
D. Add fuel.
93. The conductors inside of an arc welding cable are made of fine strands of:
A. Aluminum.
B. Copper.
C. Gold.
D. Steel.
94. To change the chemical composition and strength of the deposited weld metal, some electrodes have:
A. Powdered metal in the flux.
B. Carbon in the flux.
C. Fibers in the flux.
D. Inert gas in the flux.
95. What is the maximum exposure time of E-7018 electrodes to the atmosphere?
A. 1 hour
B. 2 hours
C. 4 hours
D. 6 hours
Please use the following figure for this question.
96. Using the cable size chart above, determine the size welding cable needed for welding using 650 amps at 60% duty cycle 195 feet from the power source and 100 feet above ground level?
A. #1/0
B. #2/0
C. #3/0
D. #4/0
97. With DCEP welding current, the electrode is:
A. Grounded.
B. Negative.
C. Neutral.
D. Positive.
98. For SMAW, operating voltage:
A. Has no relation to open circuit voltage.
B. Is always lower than open circuit voltage.
C. Is always higher than open circuit voltage.
D. May be higher or lower than open circuit voltage.
99. The size of a SMAW machine is determined by its duty cycle and:
A. Current frequency.
B. Its rated amperage output.
C. The amount of open circuit voltage produced.
D. The amount of primary current used.
100. Which code requires that low hydrogen electrodes receive special handling?
A. AWS
B. ASME
C. OSHA
D. All codes
101. Which electrode is classified as a low-hydrogen electrode?
A. E-6010
B. E-6013
C. E-7014
D. E-7018
102. Prior to opening, electrode containers:
A. Can be stored anywhere as long as they are covered.
B. Should be stored close to their point of use.
C. Should be stored off the floor on pallets or shelves.
D. Should be stored in an oven.
103. An arc welding power source rated at 250 amps, 50% duty cycle, can be used at 250 amps for:
A. About 50 hours and then cooled.
B. 2 minutes out of every 10 minutes.
C. 5 minutes out of every 10 minutes.
D. 6 minutes out of every 10 minutes. Please use the following figure for this question.
104. Using the fillet weld profiles shown above, what is the problem with fillet weld "6"?
A. Excessive convexity
B. Excessive undercut
C. Inadequate fusion
D. Overlap
105. What may happen if gloves are not worn when putting an electrode in a SMAW electrode holder?
A. Electrode may be damaged from moisture on the hands
B. Warranty on the electrode may be voided
C. Welder inserting the electrode may be shocked
D. Welding machine may be grounded out
106. How is the speed of a SMAW weld bead measured?
A. Feet per hour
B. Feet per minute
C. Inches per hour
D. Inches per minute
Please use the following figure for this question.
107. In the chart shown above, what size welding cable is needed to weld at 200 amps using a welding machine with 50% duty cycle and leads 225 feet long?
A. #1/0
B. #2/0
C. #3/0
D. #4/0
108. In the United States the frequency of alternating current is almost always:
A. 25 cycles per second.
B. 40 cycles per second.
C. 50 cycles per second.
D. 60 cycles per second.
109. What should the selection of the proper size electrode holder for SMAW be based on?
A. Depth of penetration and position of weld
B. Electrodes and amperage being used
C. Length and diameter of the electrodes
D. Size and strength of the welders hand
110. When performing SMAW you should NOT wear:
A. Coveralls.
B. Dark clothing.
C. A welding cap.
D. Low top shoes.
111. Smaller diameter electrodes require:
A. Higher amperage current.
B. Lower amperage current.
C. Shorter arc gaps.
D. Square butt gaps.
112. What is the name for a welding bead with little or no side-to-side movement?
A. Outside
B. Stringer
C. Vertical
D. Weave
113. What is the AWS specification for carbon steel electrodes?
A. A5.1
B. A5.5
C. A5.11
D. A5.24
114. When can the welding leads be wrapped around the arm, shoulder, waist, and/or the body?
A. Anytime
B. Occasionally
C. Never
D. When needed for steadiness Please use the following figure for this question.
115. Using the fillet weld profiles shown above, what is the problem with fillet weld "5"?
A. Excessive convexity
B. Excessive undercut
C. Inadequate penetration
D. Insufficient leg
116. An all-position, shallow penetrating SMAW electrode with a medium slag coating would fall into the:
A. Fast-freeze electrode group.
B. Fill-freeze electrode group.
C. Fast-fill electrode group.
D. Low-hydrogen group.
117. In SMAW, DCEP is recommended for:
A. Flat position welding.
B. Increased base metal heat.
C. Out-of-position welding.
D. Shallow penetration.
118. What temperature does the SMAW arc exceed?
A. 11,000°F
B. 16,000°F
C. 20,000°F
D. 30,000°F
119. The heat energy developed by electric arc welding is the result of:
A. Resistance to current flow across the arc.
B. The amp setting on the power source.
C. The duty cycle of the welding machine.
D. Volts across the arc.
120. What does the term, traceability, mean in reference to SMAW electrodes?
A. The ability to follow a previously completed weld with the next bead
B. The ability to follow a soap stone line when producing the weld
C. The ability to follow and document the type of electrode that was used
D. The ability to reproduce a weld exactly as it was done before
121. If work is to be located a good distance from the welding machine, use a larger cable to the electrode holder so that the cable:
A. Can be run over without being cut.
B. Does not overheat.
C. Is not stretched.
D. Will not be moved.
122. A good electrode to use for sheet metal would be:
A. E7018.
B. E6013.
C. E7024.
D. E8018-C1.
123. Why should gas cylinders NEVER be welded on?
A. The cylinders do not conduct electricity.
B. The cylinders will explode.
C. The paint will be melted off the cylinders.
D. The welding machine will ground out.
Student Name: ______________________
Teacher: ______________________ Date: ___________
District: Buncombe County
Test: 9_12 T and I 7661 - Welding Technology I Test 1
Description: Shelded metal arc welding
Form: 504
1. If work is to be located a good distance from the welding machine, use a larger cable to the electrode holder so that the cable:
A. Can be run over without being cut.
B. Does not overheat.
C. Is not stretched.
D. Will not be moved.
2. Which electrode has the highest tensile strength?
A. E9018
B. E8018
C. E7018
D. E6011
Please use the following figure for this question.
3. Using the fillet weld profiles shown above, what is the problem with fillet weld "6"?
A. Excessive convexity
B. Excessive undercut
C. Inadequate fusion
D. Overlap
4. Prior to opening, electrode containers:
A. Can be stored anywhere as long as they are covered.
B. Should be stored close to their point of use.
C. Should be stored off the floor on pallets or shelves.
D. Should be stored in an oven.
5. Two types of harmful rays that SMAW produces are:
A. Alpha and beta.
B. Gamma and x-ray.
C. Infrared and ultraviolet.
D. Supersonic and ultrasonic.
6. When using SMAW the filler metal should match the chemical composition and mechanical properties of the:
A. Base metal.
B. Flux coating.
C. Shielding gas.
D. Slag.
7. For SMAW, operating voltage:
A. Has no relation to open circuit voltage.
B. Is always lower than open circuit voltage.
C. Is always higher than open circuit voltage.
D. May be higher or lower than open circuit voltage.
8. The standard length of a 1/8" SMAW electrode is:
A. 10".
B. 12".
C. 14".
D. 16".
9. Which electrode angle in SMAW will give the deepest penetration?
A. 5° opposite the direction of travel
B. 45° opposite the direction of travel
C. Leading angle
D. Trailing angle
10. Arc blow can cause:
A. Arc stability.
B. Electrodes to cool.
C. Excess penetration.
D. Spatter and porosity.
Please use the following figure for this question.
11. In the chart shown above, what is the maximum length of a #1/0 welding lead that can carry 300 amps?
A. 50 Feet
B. 100 Feet
C. 150 Feet
D. 250 Feet
12. What is the maximum exposure time of E-7018 electrodes to the atmosphere?
A. 1 hour
B. 2 hours
C. 4 hours
D. 6 hours
13. SMAW electrodes manufactured in the United States:
A. Can have either the AWS OR manufacturer? classification printed on them.
B. Must have the AWS classification number printed on them.
C. Must have the manufacturer? classification printed on them.
D. Must NOT be printed on because the ink destabilizes the arc.
14. When referring to electrical current, what is the number of cycles per second?
A. Amperage
B. Frequency
C. Period
D. Voltage
15. The direction in which the current flows in a circuit determines:
A. Amperage.
B. Arc length.
C. Polarity.
D. Resistance.
16. The point in the weld where one weld bead stops and another begins is a/an:
A. Convex point.
B. Oscillation point.
C. Restart point.
D. Weld termination. Please use the following figure for this question.
17. Using the cable size chart above, determine the size welding cable needed for welding using 200 amps at 60% duty cycle 80 feet from the power source?
A. #1
B. #2
C. #3
D. #4
18. In SMAW the crater at the end of each bead should be filled by:
A. Starting and stopping the arc several times until the crater is filled.
B. Holding a long arc over the crater until the crater is filled slightly larger than the bead.
C. Breaking the arc and then start the arc again for several seconds holding a very short arc.
D. Reversing the electrode angle and moving 1/8 inch toward the start of the weld.
Please use the following figure for this question.
19. Using the fillet weld profiles shown above, what is the problem with fillet weld "2"?
A. Excessive convexity
B. Inadequate penetration
C. Insufficient leg
D. Insufficient throat
20. In the E7014 the 4 denotes:
A. Chemical analysis of the coating.
B. Position recommended for welding.
C. Tensile strength after welding.
D. Tensile strength before heat treating.
21. Non-low-hydrogen electrodes may be used if their coatings are not damaged and they have not come in direct contact with:
A. Chipped slag.
B. Direct sunlight.
C. Oil and water.
D. The ground.
22. How can porosity be reduced in a SMAW weldment?
A. Weld faster and turn the welding current down
B. Weld faster and turn the welding current up
C. Weld slower and turn the welding current down
D. Weld slower and turn the welding current up
23. Arc flash is:
A. A sudden surge of welding current caused by improper grounding.
B. Dangerous and can cause burns to the eyes and skin.
C. Flying debris caused by the arc contacting the work.
D. The high voltage necessary to initiate the arc.
24. To compensate for the recessed electrode core when welding with heavier flux-coated electrodes (such as E7018 or E6013), the visible arc length should be:
A. Angled.
B. Lengthened.
C. Shortened.
D. Whipped.
25. What are lugs used for with SMAW equipment?
A. Connect the electrode to the electrode holder
B. Connect the workpiece clamp to the workpiece
C. Connect the welding cable to the electrode holder or ground clamp
D. Connect the welding cables to the machine current terminals
26. What does the flux coating of an SMAW electrode do to the molten metal when it melts?
A. Anneals and hardens
B. Cleans and deoxidizes
C. Lubricates for ductility
D. Softens and anneals
27. What does the acronym LASH refer to in SMAW?
A. Arc length, angle, speed, and heat
B. Leave a small hole
C. Load, amperage, and slow heat
D. Low angle and slow heat
28. Why should wet welding gloves NOT be worn when welding?
A. The operator could be shocked.
B. The skin becomes irritated
C. They shrink when exposed to heat.
D. They will contain fungus or mold.
29. The size of a SMAW machine is determined by its duty cycle and:
A. Current frequency.
B. Its rated amperage output.
C. The amount of open circuit voltage produced.
D. The amount of primary current used.
30. Welding current traveling through bearings, seals or valves:
A. Can cause an increase in the open circuit voltage.
B. Can cause severe damage.
C. Will cause no damage.
D. Will cause the amperage to vary. Please use the following figure for this question.
31. In the chart shown above, what size welding cable is needed to weld at 200 amps using a welding machine with 50% duty cycle and leads 225 feet long?
A. #1/0
B. #2/0
C. #3/0
D. #4/0
32. Before starting an engine-driven generator:
A. Connect the ground lead.
B. Perform pre-start checks.
C. Set the amperage.
D. Add fuel.
33. How is the size of a workpiece clamp designated?
A. The distance in inches that the clamp jaws will spread to grasp the workpiece
B. The length in inches from the cable connection to the end of the clamp
C. The rated amperage that it can carry without overheating
D. The rated resistance it has to the current flow
34. When welding with DCEN, the electrons flow from the:
A. Work to the electrode.
B. Electrode to the work.
C. Electrode to the work and back to the electrode.
D. Ground to the work.
35. What is added to the flux coatings of SMAW electrodes to change the chemical composition and strength of the deposited weld metal?
A. Alloys
B. Hydrogen
C. Nitrogen
D. Oxygen
36. What may happen if gloves are not worn when putting an electrode in a SMAW electrode holder?
A. Electrode may be damaged from moisture on the hands
B. Warranty on the electrode may be voided
C. Welder inserting the electrode may be shocked
D. Welding machine may be grounded out
37. What type weld is shown below?
A. Concave fillet
B. Concave groove
C. Convex fillet
D. Convex groove
38. The welding electrode that is the LEAST penetrating is:
A. E6010.
B. E6011.
C. E6013.
D. E7010.
39. Before plugging a welding machine into an outlet:
A. Set the amperage to zero.
B. Switch to open circuit voltage.
C. Locate the electrical disconnect.
D. Connect the ground clamp.
40. Proper primary electrical grounding of the welding machine is required to:
A. Prevent arc flash.
B. Prevent electrical shock.
C. Stabilize the arc.
D. Strike the arc.
41. Which type electrode picks up moisture faster than any other type of electrode?
A. Fast-freeze electrode
B. Fill-freeze electrode
C. Fast-fill electrode
D. Low-hydrogen
42. The acceptance criteria for the size of an SMAW overhead fillet weld is plus or minus:
A. 1/8".
B. 3/16".
C. 5/32".
D. 1/16".
43. In SMAW open circuit voltage is usually between:
A. 20 and 30 volts.
B. 30 and 40 volts.
C. 50 and 100 volts.
D. 100 and 150 volts.
44. When receiving a new shipment of low-hydrogen electrodes and one container? seal has been broken, what should be done?
A. Put the damaged container in the oven
B. Reject the damaged container
C. Use the damaged container first
D. Wrap the damaged container in plastic
45. The suffix on the end of the electrode classification E-8018-C2 indicates:
A. All position electrode.
B. Minimum tensile strength.
C. Alloy steel electrode.
D. Flux coated electrode.
46. One way to compensate for arc blow is to:
A. Run the weld bead in the opposite direction.
B. Shorten the arc length.
C. Use a full length electrode.
D. Whip the electrode tip.
47. Primary current is:
A. Another name for DC current.
B. Another name for the welding current produced by a transformer.
C. Electrical current which comes from commercial power lines.
D. Not needed when using transformers.
48. Which electrode is classified as a fill-freeze electrode?
A. E-6010
B. E-6011
C. E-6013
D. E-7018
49. What type weld bead can be made using a variety of patterns that produce a side-to-side motion of the electrode?
A. Arc
B. Key hole
C. Stringer
D. Weave
50. Electrical current is the flow along a conductor of:
A. Atoms.
B. Electrons.
C. Neutrons.
D. Protons.
51. To change the chemical composition and strength of the deposited weld metal, some electrodes have:
A. Powdered metal in the flux.
B. Carbon in the flux.
C. Fibers in the flux.
D. Inert gas in the flux.
52. A good electrode to use for sheet metal would be:
A. E7018.
B. E6013.
C. E7024.
D. E8018-C1.
53. Electrode selection is very important for any welding job and is related to the type and thickness of the base metal. One rule of thumb is:
A. The electrode diameter should be no more than 1/3 of the base metal thickness.
B. The electrode diameter should be smaller in diameter than the base metal thickness.
C. The electrode diameter should be two times the base metal thickness.
D. The electrode diameter should be one half the base metal thickness. Please use the following figure for this question.
54. In the chart shown above, what size welding cable is needed to weld at 225 amps using a welding machine with 20% duty cycle and leads 90 feet long?
A. #2
B. #3
C. #1/0
D. #2/0
55. An E6013 electrode is classified as a:
A. Fast-freeze electrode.
B. Fill-freeze electrode.
C. Fast-fill electrode.
D. Low-hydrogen.
Please use the following figure for this question.
56. In the chart shown above, what is the maximum length of a #1/0 welding lead that can carry 200 amps?
A. Up to 50 Feet
B. 50-100 Feet
C. 150-200 Feet
D. 200-250 Feet
57. When using E7018 electrodes, set the current to:
A. DCEN.
B. DCEP.
C. DCSP.
D. HFDC.
58. Terminations of SMAW beads are made at:
A. Both the beginning and end of all weld passes.
B. The beginning of all welds.
C. The beginning of new weld passes only.
D. The ends of welds.
59. What is the name for a welding bead with little or no side-to-side movement?
A. Outside
B. Stringer
C. Vertical
D. Weave
60. When using SMAW to weld flat beads, place the electrode at a 90° angle, then lean it:
A. 10° to 20°
B. 20° to 40°
C. 40° to 60°
D. 45° to 65°
61. The conductors inside of an arc welding cable are made of fine strands of:
A. Aluminum.
B. Copper.
C. Gold.
D. Steel.
62. What are the characteristics of a SMAW weld bead, if the arc length is too short?
A. Excessive spatter
B. High and narrow
C. Undercut
D. Wide and flat
63. Electrode storage ovens should be set at about:
A. 75°
B. 120°
C. 250°
D. 600°
64. Voltage is the measure of:
A. Alternating current frequency.
B. Current flow rate.
C. Electromotive forces.
D. Heat energy.
65. Which electrode is the largest?
A. 3/32"
B. 1/8"
C. 3/16"
D. 5/32"
66. What type of current is used with an E6010?
A. AC
B. ACHF
C. DCEN
D. DCEP Please use the following figure for this question.
67. Using the fillet weld profiles shown above, what is the problem with fillet weld "5"?
A. Excessive convexity
B. Excessive undercut
C. Inadequate penetration
D. Insufficient leg
68. The rectifier type welding machine converts primary current from commercial power lines into:
A. AC current.
B. ACHF current.
C. DC current.
D. HF current.
69. Arc welding current is:
A. AC or DC.
B. AC or HF.
C. DC only.
D. AC only.
70. Polarity refers to:
A. The distance between the electrode and work.
B. The direction AC current flows.
C. High voltage welding current.
D. The direction of DC welding current.
71. In the United States the frequency of alternating current is almost always:
A. 25 cycles per second.
B. 40 cycles per second.
C. 50 cycles per second.
D. 60 cycles per second.
Please use the following figure for this question.
72. Using the cable size chart above, determine the size welding cable needed for welding using 650 amps at 60% duty cycle 195 feet from the power source and 100 feet above ground level?
A. #1/0
B. #2/0
C. #3/0
D. #4/0
73. Which SMAW electrode is HARDEST to strike an arc with?
A. E6010
B. E6011
C. E7018
D. E7024
74. Smaller diameter electrodes require:
A. Higher amperage current.
B. Lower amperage current.
C. Shorter arc gaps.
D. Square butt gaps.
75. With DCEP welding current, the electrode is:
A. Grounded.
B. Negative.
C. Neutral.
D. Positive.
76. Which type of current CANNOT be used with E6010 and E-7010 electrodes?
A. AC
B. DCEN
C. DCEP
D. DCRP
77. What should the selection of the proper size electrode holder for SMAW be based on?
A. Depth of penetration and position of weld
B. Electrodes and amperage being used
C. Length and diameter of the electrodes
D. Size and strength of the welders hand
78. What temperature does the SMAW arc exceed?
A. 11,000°F
B. 16,000°F
C. 20,000°F
D. 30,000°F
79. Which electrode is classified as a fast-fill electrode?
A. E-6010
B. E-6013
C. E-7018
D. E-7024
80. Which electrode is used to minimize the danger of weld cracking in thick or highly restrained mild or alloy steels in any position?
A. E-6010
B. E-6013
C. E-7014
D. E-7018
81. When Shielded Metal Arc Welding up to 200 amps, the filter lens recommended is a:
A. Number 4.
B. Number 6.
C. Number 10.
D. Number 14.
82. An E7024 electrode is classified as a:
A. Fast-freeze electrode.
B. Fill-freeze electrode.
C. Fast-fill electrode.
D. Low-hydrogen.
83. How is the speed of a SMAW weld bead measured?
A. Feet per hour
B. Feet per minute
C. Inches per hour
D. Inches per minute
84. In SMAW, DCEP is recommended for:
A. Flat position welding.
B. Increased base metal heat.
C. Out-of-position welding.
D. Shallow penetration.
85. What piece of SMAW equipment is shown below?
A. Electrode holder
B. Lug
C. Quick disconnector
D. Workpiece clamp
86. A SMAW electrode designed for welding high sulfur, phosphorus and medium-to high-carbon steels which have a tendency to underbead cracking, would fall into the:
A. Fast-freeze electrode group.
B. Fill-freeze electrode group.
C. Fast-fill electrode group.
D. Low-hydrogen group.
87. What is the AWS specification for carbon steel electrodes?
A. A5.1
B. A5.5
C. A5.11
D. A5.24
88. When can the welding leads be wrapped around the arm, shoulder, waist, and/or the body?
A. Anytime
B. Occasionally
C. Never
D. When needed for steadiness
89. An arc welding power source rated at 250 amps, 50% duty cycle, can be used at 250 amps for:
A. About 50 hours and then cooled.
B. 2 minutes out of every 10 minutes.
C. 5 minutes out of every 10 minutes.
D. 6 minutes out of every 10 minutes.
90. What causes the heat in SMAW?
A. Dirty metal
B. Electric arc
C. High frequency current
D. Moisture in the flux
91. Which electrode is classified as a fast-freeze electrode?
A. E-6011
B. E-6013
C. E-7014
D. E-7018
92. Proper electrical grounding of the welding machine is required:
A. For an arc to be struck and stabilized continuously.
B. To prevent arc flash when the electrode is too close.
C. To prevent electrical shock or possible electrocution.
D. To prevent ultraviolet and infrared ray skin burns. Please use the following figure for this question.
93. Using the fillet weld profiles shown above, what is the problem with fillet weld "1"?
A. Excessive convexity
B. Excessive undercut
C. Insufficient leg
D. Insufficient throat
94. The heat energy developed by electric arc welding is the result of:
A. Resistance to current flow across the arc.
B. The amp setting on the power source.
C. The duty cycle of the welding machine.
D. Volts across the arc.
95. Arc blow tends to be the biggest problem when:
A. Building up thick overlapping beads.
B. Using very low hydrogen electrodes.
C. Using very high hydrogen electrodes.
D. Welding on the ends of base metal.
96. An all-position, deep penetrating SMAW electrode with a light slag coating would fall into the:
A. Fast-freeze electrode group.
B. Fill-freeze electrode group.
C. Fast-fill electrode group.
D. Low-hydrogen electrode group. Please use the following figure for this question.
97. The drawing above shows the bead sequence for a horizontal fillet weld using SMAW. What is electrode angle "C" for the sixth pass?
A. 15°
B. 20°
C. 45°
D. 70°
98. When performing SMAW you should NOT wear:
A. Coveralls.
B. Dark clothing.
C. A welding cap.
D. Low top shoes.
99. What is the term for the outside surface of a ball?
A. Concave
B. Convex
C. Convoluted
D. Refracted
100. What is the AWS specification for low-alloy electrodes?
A. A5.1
B. A5.5
C. A5.11
D. A5.24 Please use the following figure for this question.
101. Using the diagram of a SMAW setup shown above, what is the polarity?
A. AC
B. DCEN (DCSP)
C. DCEP (DCRP)
D. HFAC
102. Low hydrogen electrodes that exceed the maximum exposure time can be:
A. Dried once.
B. Dried repeatedly.
C. Used on any job.
D. Used on higher standard jobs. Please use the following figure for this question.
103. The drawing above shows the bead sequence for a horizontal fillet weld using SMAW. What is electrode angle "A" for the fifth pass?
A. 20°
B. 45°
C. 70°
D. 90°
104. What part of the fillet weld is described as convex or concave?
A. Face
B. Leg
C. Root
D. Throat
105. The traceability requirements of welding filler materials vary according to the:
A. Base metal.
B. Client requirements and specifications.
C. State and local law.
D. Welder type.
106. What does the term, traceability, mean in reference to SMAW electrodes?
A. The ability to follow a previously completed weld with the next bead
B. The ability to follow a soap stone line when producing the weld
C. The ability to follow and document the type of electrode that was used
D. The ability to reproduce a weld exactly as it was done before
107. What is the size of a welding cable based on?
A. Amount of amperage the insulation can withstand before breaking down
B. Diameter of the cable including insulation and any reinforcement cord
C. Length of the cable from the welding machine to the electrode holder
D. Number of copper strands it contains which determines the cable diameter Please use the following figure for this question.
108. The drawing above shows the bead sequence for a horizontal fillet weld using SMAW. What is electrode angle "A" for the first pass?
A. 90°
B. 70°
C. 45°
D. 20°
109. Welding machines are classified by the:
A. Maximum amperage they can produce.
B. Open circuit voltage they require.
C. Operating voltage they require.
D. Type(s) of welding current produced.
110. Work clothes worn by welders should NOT contain:
A. Synthetics.
B. Leather.
C. Cotton.
D. Wool.
111. Which code requires that low hydrogen electrodes receive special handling?
A. AWS
B. ASME
C. OSHA
D. All codes
112. Which electrode is classified as a low-hydrogen electrode?
A. E-6010
B. E-6013
C. E-7014
D. E-7018
113. A SMAW electrode with a high deposition rate, shallow penetration and a
heavy slag coating, and that is designated for flat and horizontal fillet welds would fall into the:
A. Fast-freeze electrode group.
B. Fill-freeze electrode group.
C. Fast-fill electrode group.
D. Low-hydrogen group.
114. Which electrode is used to make welds on galvanized, plated, or painted surfaces?
A. E-6010
B. E-6013
C. E-7014
D. E-7018
115. What do governors on engine driven generator and alternator welding machines control?
A. Primary power
B. Rectifier
C. Speed
D. Temperature
116. One way to compensate for arc blow is to:
A. Change the electrode angle.
B. Lengthen the arc length.
C. Use a shorter electrode.
D. Weave the weld bead.
Please use the following figure for this question.
117. The drawing above shows the bead sequence for a horizontal fillet weld using SMAW. What is electrode angle "B" for the fourth pass?
A. 90°
B. 70°
C. 45°
D. 20°
118. An all-position, shallow penetrating SMAW electrode with a medium slag coating would fall into the:
A. Fast-freeze electrode group.
B. Fill-freeze electrode group.
C. Fast-fill electrode group.
D. Low-hydrogen group.
119. Why should gas cylinders NEVER be welded on?
A. The cylinders do not conduct electricity.
B. The cylinders will explode.
C. The paint will be melted off the cylinders.
D. The welding machine will ground out.
120. When selecting welding cable size, determine the amperage load and the:
A. Distance the current will travel.
B. Type of welding machine.
C. Voltage.
D. Welding process to be used.
121. When working with electricity the abbreviation AC refers to:
A. Accurate calculations.
B. Alternate classification.
C. Alternating circuit.
D. Alternating current.
122. When restarting a bead in SMAW, the arc should be struck:
A. 1/4" behind the crater on the bead deposited.
B. 1/4" to 3/8" in front of the crater.
C. In the back center of the crater.
D. To one side of and behind the crater.
123. What is the high-voltage, low-amperage current from commercial power lines coming into the welding machine called?
A. Primary
B. Rectified
C. Secondary
D. Variable
Student Name: ______________________
Teacher: ______________________ Date: ___________
District: Buncombe County
Test: 9_12 T and I 7661 - Welding Technology I Test 1
Description: Shelded metal arc welding
Form: 505
1. What type weld is shown below?
A. Concave fillet
B. Concave groove
C. Convex fillet
D. Convex groove
2. What piece of SMAW equipment is shown below?
A. Electrode holder
B. Lug
C. Quick disconnector
D. Workpiece clamp
3. How can porosity be reduced in a SMAW weldment?
A. Weld faster and turn the welding current down
B. Weld faster and turn the welding current up
C. Weld slower and turn the welding current down
D. Weld slower and turn the welding current up Please use the following figure for this question.
4. In the chart shown above, what is the maximum length of a #1/0 welding lead that can carry 300 amps?
A. 50 Feet
B. 100 Feet
C. 150 Feet
D. 250 Feet
5. In SMAW open circuit voltage is usually between:
A. 20 and 30 volts.
B. 30 and 40 volts.
C. 50 and 100 volts.
D. 100 and 150 volts. Please use the following figure for this question.
6. Using the fillet weld profiles shown above, what is the problem with fillet weld "2"?
A. Excessive convexity
B. Inadequate penetration
C. Insufficient leg
D. Insufficient throat
7. Before plugging a welding machine into an outlet:
A. Set the amperage to zero.
B. Switch to open circuit voltage.
C. Locate the electrical disconnect.
D. Connect the ground clamp.
8. What causes the heat in SMAW?
A. Dirty metal
B. Electric arc
C. High frequency current
D. Moisture in the flux
9. What is the maximum exposure time of E-7018 electrodes to the atmosphere?
A. 1 hour
B. 2 hours
C. 4 hours
D. 6 hours
10. Welding current traveling through bearings, seals or valves:
A. Can cause an increase in the open circuit voltage.
B. Can cause severe damage.
C. Will cause no damage.
D. Will cause the amperage to vary.
11. Which electrode is used to minimize the danger of weld cracking in thick or highly restrained mild or alloy steels in any position?
A. E-6010
B. E-6013
C. E-7014
D. E-7018
12. What may happen if gloves are not worn when putting an electrode in a SMAW electrode holder?
A. Electrode may be damaged from moisture on the hands
B. Warranty on the electrode may be voided
C. Welder inserting the electrode may be shocked
D. Welding machine may be grounded out
13. Arc blow can cause:
A. Arc stability.
B. Electrodes to cool.
C. Excess penetration.
D. Spatter and porosity.
Please use the following figure for this question.
14. In the chart shown above, what size welding cable is needed to weld at 225 amps using a welding machine with 20% duty cycle and leads 90 feet long?
A. #2
B. #3
C. #1/0
D. #2/0
15. Electrode selection is very important for any welding job and is related to the type and thickness of the base metal. One rule of thumb is:
A. The electrode diameter should be no more than 1/3 of the base metal thickness.
B. The electrode diameter should be smaller in diameter than the base metal thickness.
C. The electrode diameter should be two times the base metal thickness.
D. The electrode diameter should be one half the base metal thickness.
16. A SMAW electrode designed for welding high sulfur, phosphorus and medium-to high-carbon steels which have a tendency to underbead cracking, would fall into the:
A. Fast-freeze electrode group.
B. Fill-freeze electrode group.
C. Fast-fill electrode group.
D. Low-hydrogen group.
17. Arc welding current is:
A. AC or DC.
B. AC or HF.
C. DC only.
D. AC only.
18. When can the welding leads be wrapped around the arm, shoulder, waist, and/or the body?
A. Anytime
B. Occasionally
C. Never
D. When needed for steadiness
19. What type weld bead can be made using a variety of patterns that produce a side-to-side motion of the electrode?
A. Arc
B. Key hole
C. Stringer
D. Weave
20. How is the speed of a SMAW weld bead measured?
A. Feet per hour
B. Feet per minute
C. Inches per hour
D. Inches per minute
21. The acceptance criteria for the size of an SMAW overhead fillet weld is plus or minus:
A. 1/8".
B. 3/16".
C. 5/32".
D. 1/16".
22. An all-position, deep penetrating SMAW electrode with a light slag coating would fall into the:
A. Fast-freeze electrode group.
B. Fill-freeze electrode group.
C. Fast-fill electrode group.
D. Low-hydrogen electrode group.
23. SMAW electrodes manufactured in the United States:
A. Can have either the AWS OR manufacturer? classification printed on them.
B. Must have the AWS classification number printed on them.
C. Must have the manufacturer? classification printed on them.
D. Must NOT be printed on because the ink destabilizes the arc.
24. Arc blow tends to be the biggest problem when:
A. Building up thick overlapping beads.
B. Using very low hydrogen electrodes.
C. Using very high hydrogen electrodes.
D. Welding on the ends of base metal.
25. In SMAW the crater at the end of each bead should be filled by:
A. Starting and stopping the arc several times until the crater is filled.
B. Holding a long arc over the crater until the crater is filled slightly larger than
the bead.
C. Breaking the arc and then start the arc again for several seconds holding a very short arc.
D. Reversing the electrode angle and moving 1/8 inch toward the start of the weld.
26. An all-position, shallow penetrating SMAW electrode with a medium slag coating would fall into the:
A. Fast-freeze electrode group.
B. Fill-freeze electrode group.
C. Fast-fill electrode group.
D. Low-hydrogen group.
27. Why should wet welding gloves NOT be worn when welding?
A. The operator could be shocked.
B. The skin becomes irritated
C. They shrink when exposed to heat.
D. They will contain fungus or mold.
28. Which type electrode picks up moisture faster than any other type of electrode?
A. Fast-freeze electrode
B. Fill-freeze electrode
C. Fast-fill electrode
D. Low-hydrogen
29. When working with electricity the abbreviation AC refers to:
A. Accurate calculations.
B. Alternate classification.
C. Alternating circuit.
D. Alternating current.
30. In the United States the frequency of alternating current is almost always:
A. 25 cycles per second.
B. 40 cycles per second.
C. 50 cycles per second.
D. 60 cycles per second.
31. Which electrode is classified as a low-hydrogen electrode?
A. E-6010
B. E-6013
C. E-7014
D. E-7018
32. Work clothes worn by welders should NOT contain:
A. Synthetics.
B. Leather.
C. Cotton.
D. Wool.
33. When using SMAW to weld flat beads, place the electrode at a 90° angle, then lean it:
A. 10° to 20°
B. 20° to 40°
C. 40° to 60°
D. 45° to 65°
34. Which electrode is classified as a fast-freeze electrode?
A. E-6011
B. E-6013
C. E-7014
D. E-7018
35. What are the characteristics of a SMAW weld bead, if the arc length is too short?
A. Excessive spatter
B. High and narrow
C. Undercut
D. Wide and flat
36. The conductors inside of an arc welding cable are made of fine strands of:
A. Aluminum.
B. Copper.
C. Gold.
D. Steel.
37. Voltage is the measure of:
A. Alternating current frequency.
B. Current flow rate.
C. Electromotive forces.
D. Heat energy.
38. How is the size of a workpiece clamp designated?
A. The distance in inches that the clamp jaws will spread to grasp the workpiece
B. The length in inches from the cable connection to the end of the clamp
C. The rated amperage that it can carry without overheating
D. The rated resistance it has to the current flow
39. Terminations of SMAW beads are made at:
A. Both the beginning and end of all weld passes.
B. The beginning of all welds.
C. The beginning of new weld passes only.
D. The ends of welds.
40. When selecting welding cable size, determine the amperage load and the:
A. Distance the current will travel.
B. Type of welding machine.
C. Voltage.
D. Welding process to be used.
41. An E6013 electrode is classified as a:
A. Fast-freeze electrode.
B. Fill-freeze electrode.
C. Fast-fill electrode.
D. Low-hydrogen.
42. What does the flux coating of an SMAW electrode do to the molten metal when it melts?
A. Anneals and hardens
B. Cleans and deoxidizes
C. Lubricates for ductility
D. Softens and anneals
43. When welding with DCEN, the electrons flow from the:
A. Work to the electrode.
B. Electrode to the work.
C. Electrode to the work and back to the electrode.
D. Ground to the work.
44. When Shielded Metal Arc Welding up to 200 amps, the filter lens recommended is a:
A. Number 4.
B. Number 6.
C. Number 10.
D. Number 14. Please use the following figure for this question.
45. The drawing above shows the bead sequence for a horizontal fillet weld using SMAW. What is electrode angle "C" for the sixth pass?
A. 15°
B. 20°
C. 45°
D. 70°
46. What is the size of a welding cable based on?
A. Amount of amperage the insulation can withstand before breaking down
B. Diameter of the cable including insulation and any reinforcement cord
C. Length of the cable from the welding machine to the electrode holder
D. Number of copper strands it contains which determines the cable diameter
47. To compensate for the recessed electrode core when welding with heavier flux-coated electrodes (such as E7018 or E6013), the visible arc length should be:
A. Angled.
B. Lengthened.
C. Shortened.
D. Whipped.
48. What temperature does the SMAW arc exceed?
A. 11,000°F
B. 16,000°F
C. 20,000°F
D. 30,000°F
49. One way to compensate for arc blow is to:
A. Run the weld bead in the opposite direction.
B. Shorten the arc length.
C. Use a full length electrode.
D. Whip the electrode tip.
50. Electrode storage ovens should be set at about:
A. 75°
B. 120°
C. 250°
D. 600°
51. The suffix on the end of the electrode classification E-8018-C2 indicates:
A. All position electrode.
B. Minimum tensile strength.
C. Alloy steel electrode.
D. Flux coated electrode.
52. A good electrode to use for sheet metal would be:
A. E7018.
B. E6013.
C. E7024.
D. E8018-C1. Please use the following figure for this question.
53. In the chart shown above, what size welding cable is needed to weld at 200 amps using a welding machine with 50% duty cycle and leads 225 feet long?
A. #1/0
B. #2/0
C. #3/0
D. #4/0
54. Proper electrical grounding of the welding machine is required:
A. For an arc to be struck and stabilized continuously.
B. To prevent arc flash when the electrode is too close.
C. To prevent electrical shock or possible electrocution.
D. To prevent ultraviolet and infrared ray skin burns.
55. Which electrode is classified as a fill-freeze electrode?
A. E-6010
B. E-6011
C. E-6013
D. E-7018
56. Which electrode is the largest?
A. 3/32"
B. 1/8"
C. 3/16"
D. 5/32" Please use the following figure for this question.
57. In the chart shown above, what is the maximum length of a #1/0 welding lead that can carry 200 amps?
A. Up to 50 Feet
B. 50-100 Feet
C. 150-200 Feet
D. 200-250 Feet
58. Which code requires that low hydrogen electrodes receive special handling?
A. AWS
B. ASME
C. OSHA
D. All codes
59. When restarting a bead in SMAW, the arc should be struck:
A. 1/4" behind the crater on the bead deposited.
B. 1/4" to 3/8" in front of the crater.
C. In the back center of the crater.
D. To one side of and behind the crater.
60. With DCEP welding current, the electrode is:
A. Grounded.
B. Negative.
C. Neutral.
D. Positive. Please use the following figure for this question.
61. Using the cable size chart above, determine the size welding cable needed for welding using 650 amps at 60% duty cycle 195 feet from the power source and 100 feet above ground level?
A. #1/0
B. #2/0
C. #3/0
D. #4/0
62. Which SMAW electrode is HARDEST to strike an arc with?
A. E6010
B. E6011
C. E7018
D. E7024
63. If work is to be located a good distance from the welding machine, use a larger cable to the electrode holder so that the cable:
A. Can be run over without being cut.
B. Does not overheat.
C. Is not stretched.
D. Will not be moved.
64. For SMAW, operating voltage:
A. Has no relation to open circuit voltage.
B. Is always lower than open circuit voltage.
C. Is always higher than open circuit voltage.
D. May be higher or lower than open circuit voltage.
Please use the following figure for this question.
65. Using the fillet weld profiles shown above, what is the problem with fillet weld "1"?
A. Excessive convexity
B. Excessive undercut
C. Insufficient leg
D. Insufficient throat
Please use the following figure for this question.
66. Using the cable size chart above, determine the size welding cable needed for welding using 200 amps at 60% duty cycle 80 feet from the power source?
A. #1
B. #2
C. #3
D. #4
67. Why should gas cylinders NEVER be welded on?
A. The cylinders do not conduct electricity.
B. The cylinders will explode.
C. The paint will be melted off the cylinders.
D. The welding machine will ground out.
68. Polarity refers to:
A. The distance between the electrode and work.
B. The direction AC current flows.
C. High voltage welding current.
D. The direction of DC welding current.
69. What does the acronym LASH refer to in SMAW?
A. Arc length, angle, speed, and heat
B. Leave a small hole
C. Load, amperage, and slow heat
D. Low angle and slow heat
70. Arc flash is:
A. A sudden surge of welding current caused by improper grounding.
B. Dangerous and can cause burns to the eyes and skin.
C. Flying debris caused by the arc contacting the work.
D. The high voltage necessary to initiate the arc.
71. What is the AWS specification for carbon steel electrodes?
A. A5.1
B. A5.5
C. A5.11
D. A5.24
72. The traceability requirements of welding filler materials vary according to the:
A. Base metal.
B. Client requirements and specifications.
C. State and local law.
D. Welder type. Please use the following figure for this question.
73. The drawing above shows the bead sequence for a horizontal fillet weld using SMAW. What is electrode angle "B" for the fourth pass?
A. 90°
B. 70°
C. 45°
D. 20°
74. The point in the weld where one weld bead stops and another begins is a/an:
A. Convex point.
B. Oscillation point.
C. Restart point.
D. Weld termination. Please use the following figure for this question.
75. Using the fillet weld profiles shown above, what is the problem with fillet weld "5"?
A. Excessive convexity
B. Excessive undercut
C. Inadequate penetration
D. Insufficient leg
76. An E7024 electrode is classified as a:
A. Fast-freeze electrode.
B. Fill-freeze electrode.
C. Fast-fill electrode.
D. Low-hydrogen.
77. What should the selection of the proper size electrode holder for SMAW be based on?
A. Depth of penetration and position of weld
B. Electrodes and amperage being used
C. Length and diameter of the electrodes
D. Size and strength of the welders hand
78. What part of the fillet weld is described as convex or concave?
A. Face
B. Leg
C. Root
D. Throat
79. In SMAW, DCEP is recommended for:
A. Flat position welding.
B. Increased base metal heat.
C. Out-of-position welding.
D. Shallow penetration.
80. When receiving a new shipment of low-hydrogen electrodes and one container? seal has been broken, what should be done?
A. Put the damaged container in the oven
B. Reject the damaged container
C. Use the damaged container first
D. Wrap the damaged container in plastic
81. When performing SMAW you should NOT wear:
A. Coveralls.
B. Dark clothing.
C. A welding cap.
D. Low top shoes.
82. When using E7018 electrodes, set the current to:
A. DCEN.
B. DCEP.
C. DCSP.
D. HFDC.
83. The welding electrode that is the LEAST penetrating is:
A. E6010.
B. E6011.
C. E6013.
D. E7010.
84. Proper primary electrical grounding of the welding machine is required to:
A. Prevent arc flash.
B. Prevent electrical shock.
C. Stabilize the arc.
D. Strike the arc.
85. Prior to opening, electrode containers:
A. Can be stored anywhere as long as they are covered.
B. Should be stored close to their point of use.
C. Should be stored off the floor on pallets or shelves.
D. Should be stored in an oven.
86. To change the chemical composition and strength of the deposited weld metal, some electrodes have:
A. Powdered metal in the flux.
B. Carbon in the flux.
C. Fibers in the flux.
D. Inert gas in the flux.
87. What does the term, traceability, mean in reference to SMAW electrodes?
A. The ability to follow a previously completed weld with the next bead
B. The ability to follow a soap stone line when producing the weld
C. The ability to follow and document the type of electrode that was used
D. The ability to reproduce a weld exactly as it was done before
88. What are lugs used for with SMAW equipment?
A. Connect the electrode to the electrode holder
B. Connect the workpiece clamp to the workpiece
C. Connect the welding cable to the electrode holder or ground clamp
D. Connect the welding cables to the machine current terminals
89. Electrical current is the flow along a conductor of:
A. Atoms.
B. Electrons.
C. Neutrons.
D. Protons.
90. Which electrode is used to make welds on galvanized, plated, or painted surfaces?
A. E-6010
B. E-6013
C. E-7014
D. E-7018
91. What type of current is used with an E6010?
A. AC
B. ACHF
C. DCEN
D. DCEP
92. Which electrode angle in SMAW will give the deepest penetration?
A. 5° opposite the direction of travel
B. 45° opposite the direction of travel
C. Leading angle
D. Trailing angle
93. What is the AWS specification for low-alloy electrodes?
A. A5.1
B. A5.5
C. A5.11
D. A5.24
94. Which electrode is classified as a fast-fill electrode?
A. E-6010
B. E-6013
C. E-7018
D. E-7024
95. The heat energy developed by electric arc welding is the result of:
A. Resistance to current flow across the arc.
B. The amp setting on the power source.
C. The duty cycle of the welding machine.
D. Volts across the arc.
96. What is the name for a welding bead with little or no side-to-side movement?
A. Outside
B. Stringer
C. Vertical
D. Weave
97. What is the term for the outside surface of a ball?
A. Concave
B. Convex
C. Convoluted
D. Refracted Please use the following figure for this question.
98. Using the diagram of a SMAW setup shown above, what is the polarity?
A. AC
B. DCEN (DCSP)
C. DCEP (DCRP)
D. HFAC
99. Smaller diameter electrodes require:
A. Higher amperage current.
B. Lower amperage current.
C. Shorter arc gaps.
D. Square butt gaps.
100. When using SMAW the filler metal should match the chemical composition and mechanical properties of the:
A. Base metal.
B. Flux coating.
C. Shielding gas.
D. Slag.
101. The standard length of a 1/8" SMAW electrode is:
A. 10".
B. 12".
C. 14".
D. 16".
102. When referring to electrical current, what is the number of cycles per second?
A. Amperage
B. Frequency
C. Period
D. Voltage
103. What is the high-voltage, low-amperage current from commercial power lines coming into the welding machine called?
A. Primary
B. Rectified
C. Secondary
D. Variable
104. An arc welding power source rated at 250 amps, 50% duty cycle, can be used at 250 amps for:
A. About 50 hours and then cooled.
B. 2 minutes out of every 10 minutes.
C. 5 minutes out of every 10 minutes.
D. 6 minutes out of every 10 minutes.
105. Two types of harmful rays that SMAW produces are:
A. Alpha and beta.
B. Gamma and x-ray.
C. Infrared and ultraviolet.
D. Supersonic and ultrasonic. Please use the following figure for this question.
106. The drawing above shows the bead sequence for a horizontal fillet weld using SMAW. What is electrode angle "A" for the first pass?
A. 90°
B. 70°
C. 45°
D. 20°
107. The rectifier type welding machine converts primary current from commercial power lines into:
A. AC current.
B. ACHF current.
C. DC current.
D. HF current.
108. One way to compensate for arc blow is to:
A. Change the electrode angle.
B. Lengthen the arc length.
C. Use a shorter electrode.
D. Weave the weld bead.
109. What do governors on engine driven generator and alternator welding machines control?
A. Primary power
B. Rectifier
C. Speed
D. Temperature
110. Primary current is:
A. Another name for DC current.
B. Another name for the welding current produced by a transformer.
C. Electrical current which comes from commercial power lines.
D. Not needed when using transformers.
111. Welding machines are classified by the:
A. Maximum amperage they can produce.
B. Open circuit voltage they require.
C. Operating voltage they require.
D. Type(s) of welding current produced.
Please use the following figure for this question.
112. The drawing above shows the bead sequence for a horizontal fillet weld using SMAW. What is electrode angle "A" for the fifth pass?
A. 20°
B. 45°
C. 70°
D. 90°
113. Which electrode has the highest tensile strength?
A. E9018
B. E8018
C. E7018
D. E6011
114. Which type of current CANNOT be used with E6010 and E-7010 electrodes?
A. AC
B. DCEN
C. DCEP
D. DCRP
115. What is added to the flux coatings of SMAW electrodes to change the chemical composition and strength of the deposited weld metal?
A. Alloys
B. Hydrogen
C. Nitrogen
D. Oxygen
116. In the E7014 the 4 denotes:
A. Chemical analysis of the coating.
B. Position recommended for welding.
C. Tensile strength after welding.
D. Tensile strength before heat treating.
117. The direction in which the current flows in a circuit determines:
A. Amperage.
B. Arc length.
C. Polarity.
D. Resistance.
118. Before starting an engine-driven generator:
A. Connect the ground lead.
B. Perform pre-start checks.
C. Set the amperage.
D. Add fuel.
119. Non-low-hydrogen electrodes may be used if their coatings are not damaged and they have not come in direct contact with:
A. Chipped slag.
B. Direct sunlight.
C. Oil and water.
D. The ground.
120. A SMAW electrode with a high deposition rate, shallow penetration and a heavy slag coating, and that is designated for flat and horizontal fillet welds would fall into the:
A. Fast-freeze electrode group.
B. Fill-freeze electrode group.
C. Fast-fill electrode group.
D. Low-hydrogen group. Please use the following figure for this question.
121. Using the fillet weld profiles shown above, what is the problem with fillet weld "6"?
A. Excessive convexity
B. Excessive undercut
C. Inadequate fusion
D. Overlap
122. Low hydrogen electrodes that exceed the maximum exposure time can be:
A. Dried once.
B. Dried repeatedly.
C. Used on any job.
D. Used on higher standard jobs.