Introduction to Welding

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1. What is welding?
A. Welding is a manufacturing process.
B. Welding is a metals fabrication trade.
C. Welding is a metal joining process by the use of heat. Welding is a job skill.
D. Welding can not be defined.
2. When was welding discovered?
A. During the Industrial Revolution.
B. In ancient times.
C. During the renaissance.
D. During the Middle Ages.
3. What is the best source of information and resources on the subject of welding
technology?
A. The American Society for Metals.
B. Any published welding text book.
C. Anywhere on the Internet.
D. The American Welding Society.
4. Where can you learn to weld?
A. Company or Union training programs.
B. The Military, Job or Peace Corps.
C. Technical School or College.
D. Any of the above.
5. What tradesman may sometimes work mainly with the skill of welding?
A. SteamFitter / PipePitter / Boilermaker.
B. Iron worker / ShipFitter / SheetMetal worker.
C. Auto / Aerospace worker.
D. All of the above.
6. How many types of welding ( welding process ) are there?
A. Over 150.
B. 25 to 50.
C. Over 50.

D. 5 to 10.
7. The skill level required for weldors may best be classified as?
A. Low - Skilled.
B. Semi - Skilled.
C. Highly - Skilled
D. Very diversified.
8. Where do Weldors usually work?
A. Indoors / Fabrication.
B. High Altitudes / OffShore.
C. Underwater / Atmospheric Chambers.
D. Anywhere.
E. Outdoors / Construction.
9. What are the major occupational hazards for the weldor?
A. IR and UV radiation.
B. Toxic fumes an Explosions.
C. Electrical Hazard and Extreem Temperatures.
D. Any or all fo the above.
10. What is the first consideration in any welding operation?
A. Quality, procedures and specifications.
B. Knowledege of safety and accident prevention.
C. Technical knowledge of the welding process.
D. Labor cost and overhead expenses
1. Weld defects are best detected by?
A. Visual inspection.
B. Destructive / Mechanical tests.
C. NonDestructive examination (NDT).
D. All of the above.
2. What defects are usually found along the toe of a weld?
A. Slag inclusion.
B. Overlap.
C. Undercut.
D. All of the above.

3. Amperage setting too high may cause what defect?

A. Excessive buildup.
B. Overlap.
C. Undercut.
D. Lack of penatration.
4. Travel speed too fast is usually associated with which defects?
A. Lack of fusion, surface cracks.
B. Undercut, underfill.
C. Porosity, underbead cracks.
D. None of the above.
5. Wrong polarity selection is usually associated with which defect?
A. Arc blow.
B. Excessive spatter.
C. Porosity.
D. Any of the above.
6. Many welding defects can be attributed to?
A. Wrong / incorrect amperage setting, polarity selection.
B. Wrong / incorrect electrode angle, arc length.
C. Wrong / incorrect travel speed, manipulation technique.
D. All of the above.
7. Which defect is not found along the toe of the weld?
A. Crater cracks.
B. Excessive spatter.
C. Lack of fusion.
D. Lack of peneteration.
8. Which part of a weld is generally considered the most critical?
A. The toe.
B. The Face
C. The throat.
D. The root.
E. The leg.
9. Who may be the least qualified to examine welding defects?
A. The Quality Control Engineer - The Welding Inspector.

B. The Facilities Engineer - The Safety Inspector.

C. The Manufacturing Engineer -The welder.
D. A and C above.
10. Sound welding can be produced by sound?
A. Specifications - Procedures - Qualifications.
B. Standards - Principles - Applications.
C. Knowledge - Techniques - Practices.
D. All of the above.

1. In which order were the above processes discovered / invented?

A. Gas Metal Arc Welding then Gas Tungsten Arc Welding.
B. Oxy-Acetylene Welding then Shielded Metal Arc Welding.
C. Shielded Metal Arc Welding then Oxy-Acetylene Welding.
2. Which processes above does not uses the same heat source?
A. Shielded Metal Arc Welding and Gas Tungsten Arc Welding.
B. Gas Tungsten Arc Welding and Gas Metal Arc Welding.
C. Shielded Metal Arc Welding and Oxy-Acetylene Welding.
3. Which process above uses consumable filler wire?
A. Gas Metal Arc Welding only.
B. Gas Metal Arc Welding and Shielded Metal Arc Welding.
C. Oxy-Acetylene Welding and Gas Tungsten Arc Welding.
D. All of the above.
4. Which two processes above do not use a consumable electrode?
A. Gas Metal Arc Welding and Gas Tungsten Arc Welding.
B. Oxy-Acetylene Welding and Gas Tungsten Arc Welding.
C. Gas Metal Arc Welding and Shielded Metal Arc Welding.
5. In which processes above is the molten puddle gas shielded?
A. Gas Metal Arc Welding and Gas Tungsten Arc Welding.
B. Gas Metal Arc Welding and Shielded Metal Arc Welding.
C. Shielded Metal Arc Welding and Oxy-Acetylene Welding.
D. All of the above.
6. Which processes basicly uses similar welding current?

A. Gas Tungsten Arc Welding and Gas Metal Arc Welding

B. Gas Metal Arc Welding and Shielded Metal Arc Welding.
C. Gas Tungsten Arc Welding and Shielded Metal Arc Welding.
7. Which processes above requires the least amount of practice to master?
A. Oxy-Acetylene Welding and Gas Tungsten Arc Welding.
B. Shielded Metal Arc Welding and Gas Metal Arc Welding.
C. Gas Tungsten Arc Welding and Gas Metal Arc Welding.
D. They all require extensive practice to master.
8. Which processes above poses the greater danger or hazard?
A. Shielded Metal Arc Welding and Oxy-Acetylene Welding.
B. Gas Tungsten Arc Welding and Gas Metal Arc Welding.
C. All of the above.
9. Which processes above produces the lowest quality welds?
A. Shielded Metal Arc Welding and Oxy-Acetylene Welding.
B. Gas Tungsten Arc Welding and Gas Metal Arc Welding.
C. Each process will produce very high quality welds.
10. Which process may be cosidered the most productive?
A. Gas Metal Arc Welding.
B. Gas Tungsten Arc Welding.
C. Shielded Metal Arc Welding.
1. Oxy-acetylene produces a flame temperture hotter than arc welding.
A. True.
B. False.
2. Acetylene fittings are always identified by the color red.
A. True.
B. False.
3. Clyinder gas bottles can be identified by.
A. the color of the bottle.
B. by the size of the bottle.
C. by the lable on the bottle.
D. all of the above.
4. When valves / fittings squeak or stick, they should be?
A. lubricated.

B. changed or repaired.
C. over tightened just a little.
D. any of the above.
5. Pure acetylene is oderless.
A. True.
B. False.
6. The quantity of gas in a cylinder is determined by.
A. the temperture of the cylinder.
B. the cylinder pressure gage reading.
C. weighing the cylinder.
D. all of the above.
7. Which flame produces the highest temperture.
A. carburized.
B. neutral.
C. oxidized.
D. reducing.
8. To weld thicker plate, you should.
A. change to a larger tip size.
B. weld slower.
C. increase the gas pressures.
D. any of the above.
9. Another term for flashback is backfire (they mean the same.)
A. True.
B. False.
10. An advantage of gas welding may be.
A. travel speed.
B. deposition rate.
C. weld ductility.
D. none of the above.

Shielded Metal Arc Welding ( SMAW )

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1. What are the three basic current outputs for shielded metal arc welding machines?
A. AC, DC, AC/DC.
B. CC, CP, CV.
2. The power source output for shielded Metal Arc Welding is.
A. Constant Voltage.
B. Constant Current.
C. Constant Potential.
D. Constant Amperage.
3. Current selection for Shielded Metal Arc Welding is usually based on.
A. the electrode coating.
B. the electrode size.
C. the base metal .
D. all of the above.
4. Match the process varaible with the welding operator Control.
A.

too fast - too slow.

B.

too short - too long.

C.

too steep - too shallow.

D.

too high - too low.

5. In question four above, the variables are based on.

A. base metal alloy and thickness.
B. the desired outcomes.

C. the weld position.

D. the weld joint and type.
6. The amperage setting is normally based on.
A. the metal alloy and thickmess.
B. the electrode diameter.
C. the weld joint and position.
D. the electrode type and length.
7. The operator technique (Drag - Whip - Oscillate ) usually depends on.
A. the weld position
B. the weld size.
C. the electrode coating type.
D. all of the above.
8. Match the Burning characteristic - manipulative technique - F number.
A. Fast Freeze =
B. Fast Fill =

=
=

C. Fill Freeze =
D. Fast Follow =

=
=

9. A change in arc length will produce a change in ______________________.

A. amperage.
B. voltage.
C. a change in both A and B.
D. the energy input.
10. The welding polarity selection is.
A. based on the burning characteristic of the electrode.
B. based on the direction you are welding.
C. based on the electrode coating type.
D. based on both A and C.

Gas Tungsten Arc Welding ( GTAW )

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1. The GTAW process was primarily developed to weld.

A. Thin metal.
B. Magnesium.
C. Aluminum, Stainless steel and pipe.
D. Both A and C above.
2. GTAW, is the same as TIG and HELI-ARC.
A. True.
B. False.
C. True and / or False
D.
3. Which is an advantage of GTAW.
A. Travel speeds.
B. Easy to operate.
C. Sound welds.
D. Operating costs.
4. Which industry was primarily responsible for developing the GTAW process.
A. Defense.
B. Commercial / Transportation
C. ShipBuilding.
D. Nuclear power plants.
5. A primary advantage of helium gas is.
A. Travel speed / penetration.
B. Penetration / better shielding
C. Better gas shielding.
D. Better shielding / travel speed.
6. A primary advantage of argon gas is.
A.Travel speed / penetration
B. Penetration / better shielding.
C. Better gas shielding.
D. Better shielding / travel speed.
7. The hazards of GTAW may be less than other welding processes.
A. True.
B. False
C.

D.
8. Match the color code with the type of tungsten.
A. Red.
B. Yellow.
C. Brown.
D. Green.
9. Select the parts of a GTAW torch.
A. Nozzle, collet, gas lens.
B. Cup, collet body, collet.
C. Contact tip, cup, collet body.
D. Gas diffuser, contact tube, Nozzle,
10. Which current polarity can not be used for GTAW.
A. Direct current reverse polarity.
B. Alternating current.
C. Direct current straight polarity.
D. None of the above.

Gas Metal Arc Welding ( GMAW )

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1. The GMAW process was originally developed by.
A.
2. Select the basic types of metal transfer.
A.

3. Slope is the relationship between.

A. Travel speed and weld position.
B. Wire speed and Current.
C. Voltage and Amperage setting.
D. Gun angle and Arc length.
4. In the term < E70S-3 > the " S " indicates.
A. Silicon.

B. Solid.
C. Semi-automatic.
D. Shielded.
5. Select the best advantage of GMAW below.
A. Welding travel speed.
B. Equipment set-up and maintenance.
C. Out of position welding.
D. Weld quality.
6. GMAW is un-reliable in producing high quality welds in all positions.
A. True.
B. False
7. Which gas / gases can be used with the GMAW process.
A. Argon
B. Argon / Carbon Dioxide.
C. Helium.
D. All of the above.
8. The terms Cast & Helix refer to.
A. The composition of the welding wire.
B. A condition in the mig gun liner.
C. The reaction of a strand of welding wire when removed from the coil.
D. Several internal parts of the wire feeder.
9. The correct reading of the float ball in a flow meter is.
A. By reading top of the float ball.
B. By reading the center of the float ball.
C. By reading the bottom of the float ball.
D. By referencing the manufactures recommendations.
10. In the term < GMAW-S > the " S " indicates.
A. Shielded transfer.
B. Short circuiting transfer.
C. Spray transfer
D. Semi-automatic transfer.