Deck 14: Gas Metal Arc and Flux Cored Arc Welding of Pipe

Question 1

​What is the purpose of the filler passes?

A) ​They add the bulk of the weld metal to the groove.
B) ​They are used to push any lack of root fusion or lack of 100% penetration.
C) ​They are used to remove any small trapped pieces of slag or lack of side wall fusion.
D) ​They are used to cover up any problems in the hot pass.

Answer 1

A

Question 2

​The hot pass can be made ________________; however, it is more difficult to keep good fusion using the ____________technique.

A) ​uphill, downhill
B) ​downhill, uphill
C) ​uphill or downhill, uphill
D) ​uphill or downhill, downhill

Answer 2

D

Question 3

​What is the advantage of the fast freeze flux of some FCA welding electrodes?

A) ​It allows a larger weld bead in all positions to fill the joint faster.
B) ​The freezing effect cools the weld off faster so the weld is not as hot.
C) ​When the flux freezes fast, it is easier to remove since it is cold.
D) ​There is less flux and that is why it cools so quickly.

Answer 3

A

Question 4

​Which of the following is not something that a hot pass can do?

A) ​Burn out small pieces of trapped slag.
B) ​Reshape the root face.
C) ​Remove porosity in the root pass.
D) ​Push the root penetration a little deeper.

Question 5

​It is faster to make the root weld using the downhill technique if ______________________.

A) ​you can see all of the joint so you can follow it
B) ​the root opening is narrow so the weld has something to support it
C) ​The voltage is lowered by 5 to 10 volts
D) ​the root opening is uniform and not too wide or narrow

Question 6

​Why do you need to be careful not to gouge the pipe bevel surface?

A) ​It makes it harder to align the pipe ends.
B) ​Deep gouges can be considered defects.
C) ​They can cause the electrode to become stuck if they are too deep.
D) ​Because the tack welds are harder to make if the gouges are too close to the root face.

Question 7

​What can be used to force the ends of a pipe in alignment?

A) ​vise grips
B) ​a heating torch
C) ​a dog and wedge
D) ​a pair of pliers

Question 8

​Which tool might be used when assembling a joint for a code quality weld?

A) ​high-low gauge
B) ​micrometer
C) ​vernier caliper
D) ​outside and inside calipers

Question 9

​What is the bevel angle for the end of pipe?

A) ​15° and 45°
B) ​20° and 45°
C) ​30° and 35°
D) ​45° and 50°

Question 10

​How should the weld progress if the root opening is wider than normal?

A) ​downhill
B) ​From the 9:00 to the 6:00 o'clock downhill and from the 9:00 to the 12:00 o'clock position uphill.
C) ​uphill
D) ​From the 9:00 to the 6:00 o'clock uphill and from the 9:00 to the 12:00 o'clock position downhill.

Question 11

​Which step is critical when making a code quality weld?

A) ​cleaning
B) ​tack welding
C) ​fitting
D) ​All of the above

Question 12

​According to the API code, the maximum offset for pipes of the same nominal diameter is ____.

A) ​1/32 in.(0.8 mm)
B) ​1/16 in.(1.6 mm)
C) ​3/32 in.(2.4 mm)
D) ​1/8 in.(3 mm)

Question 13

​Arc strikes outside of the weld groove are _____________.

A) ​potential defects.
B) ​easy to grind off if needed.
C) ​usually small and are no problem.
D) ​can be left if they are less than 1 in.(25 mm) from the groove.

Question 14

​What type of grinding disk must be used to feather the edge of tack welds?

A) ​A standard grinding stone as long as the root opening has not decreased due to the tack weld shrinkage.
B) ​A thin grinding disk.
C) ​A new disk so it can reach all the way down into the groove.
D) ​A cupped disk so it is easier to work around the curve of the pipe.

Question 15

​The filler passes should be stopped when the surface is approximately ____________ below the pipe's outer surface.

A) ​1/32 in.to 3/32 in.(0.8 mm to 2.4 mm)
B) ​1/16 in.to 1/8 in.(1.6 mm to 3 mm)
C) ​1/32 in.to 3/32 in.(0.8 mm to 2.4 mm)
D) ​3/64 in.to 1/8 in.(1.2 mm to 3 mm)

Question 16

​Why should the pipe coupon being flame cut be caught with a pair of pliers?

A) ​To keep the root face from being nicked and damaged.
B) ​If the coupon hits the floor, it can be knocked out of round.
C) ​The round pipe coupon can roll under a table or welder and be hard to get out.
D) ​So you do not have to bend down and pick it up.

Question 17

​How many tack welds are needed to hold a pipe joint in alignment for welding?

A) ​4, one at the 12:00, 3:00, 6:00, and 9:00 o'clock positions.
B) ​5 to 6
C) ​It depends on the size of the tack welds.
D) ​The number will vary depending on the pipe's diameter.

Question 18

​Any part of the root face that has undercut or trapped slag or any area with more than ____ buildup can be ground down.

A) ​1/32 in.(0.8 mm)
B) ​1/16 in.(1.6 mm)
C) ​3/32 in.(2.4 mm)
D) ​1/8 in.(3 mm)

Question 19

​Why is the root pass weld started on top of a tack weld?

A) ​To eliminate the potential lack of fusion.
B) ​To prevent porosity caused by the lack of shielding gas at the instant the weld starts.
C) ​So the arc light will show the root opening and make it easier to get aligned with the root opening as the weld moves off of the tack weld.
D) ​The root pass can be started anywhere it is comfortable for the welder to begin welding.

Question 20

​What is another name for the cover pass?

A) ​top
B) ​finish
C) ​cap
D) ​fillup

Question 21

​The frequency of porosity shall not exceed one in each _________ of weld length.

A) ​4 in (100 mm)
B) ​3 in (75 mm)
C) ​2 in (50 mm)
D) ​1 in (25 mm)

Question 22

​What can be done to protect the contact tube tip from damage?

A) ​Use a high temperature insulating tape to protect the tip.
B) ​Use a slightly larger size contact tube tip for the wire size.
C) ​Spray the contact tube with WD-40 so the wire will feed smoother.
D) ​Recess it inside of the nozzle.

Question 23

​A small flat surface of 1/16-in (1.6 mm) wide, called the ______ or ______, is ground or machined on the beveled edge.

Question 24

​Which of the following is not an application for a pipe socket?

A) ​bicycle frame
B) ​power plant
C) ​industrial hydraulics
D) ​chemical plant

Question 25

​Which of the following weld joint types would not be used to join a pipe end to a plate?

A) ​bevel groove
B) ​V-groove
C) ​fillet weld
D) ​J-groove

Question 26

​Unless a backing ring is used, most root passes are made with the _____ process.

Question 27

​For a visual inspection of a pipe weld, what is the acceptable discontinuity for overlap?

A) ​1/32 in.(0.8 mm)
B) ​1/16 in.(1.6 mm)
C) ​3/32 in.(2.4 mm)
D) ​None allowed

Question 28

​The cover pass cannot be any wider than ____ wider than the groove being welded.

A) ​1/32 in.(0.8 mm)
B) ​1/16 in.(1.6 mm)
C) ​3/32 in.(2.4 mm)
D) ​1/8 in.(3 mm)

Question 29

​The inside and outside pipe surfaces must be ground clean back ________ from the joint.

Question 30

​What should be done if there is undercut along the top toe of a fillet weld when using the spray transfer method?

A) ​Decrease the work angle to direct more metal onto that side.
B) ​Change to a leading angle.
C) ​Change to a trailing angle.
D) ​Use a perpendicular travel angle to make the weld pool more fluid so it will fill the undercut.

Question 31

​For a visual inspection of a pipe weld, what is the acceptable discontinuity for cracks?

A) ​1/32 in.(0.8 mm)
B) ​1/16 in.(1.6 mm)
C) ​3/32 in.(2.4 mm)
D) ​None allowed

Question 32

​The maximum reinforcement of the cover pass is ____________.

A) ​1/32 in.(0.8 mm)
B) ​1/16 in.(1.6 mm)
C) ​3/32 in.(2.4 mm)
D) ​1/8 in.(3 mm)

Question 33

​It is important that tack welds be made _____________________________ so that they do not become weld defects in the finished weld.

Question 34

​When using the spray metal transfer method, what can happen if the tip gets too close to the work?

A) ​The wire may arc out and cause a lot of spatter to be thrown from the weld.
B) ​The shorter stickout will cause the weld to get hotter due to the reduced resistance in the shorter wire and the weld will become wider and more fluid.
C) ​The tip may be melted.
D) ​A flood of sparks as the weld pool is overheated will erupt.

Question 35

​As the 1G weld passes over the top of the pipe and starts downhill, change to a slight ________ angle that will increase to approximately a _______ angle.

A) ​forehand, 30°
B) ​backhand, 45°
C) ​perpendicular, 90°
D) ​right, 90°

Question 36

​Undercut shall not exceed the lesser of ______% of the base metal thickness or ____________.

A) ​10%, 1/32 in.(0.8 mm)
B) ​5%, 1/16 in.(1.6 mm)
C) ​8%, 3/64 in.(1.2 mm)
D) ​3%, 1/64 in.(0.4 mm)

Question 37

​For a visual inspection of a pipe weld, what is the acceptable discontinuity for incomplete fusion?

A) ​1/32 in.(0.8 mm)
B) ​1/16 in.(1.6 mm)
C) ​3/32 in.(2.4 mm)
D) ​None allowed

Question 38

​The maximum diameter of any single porosity shall not exceed ______________.

A) ​1/32 in.(0.8 mm)
B) ​1/16 in.(1.6 mm)
C) ​3/32 in.(2.4 mm)
D) ​1/8 in.(3 mm)

Question 39

​Although the welded pipe seam is ___________, it is usually easy to find by looking at the inside surface of the pipe.

Question 40

​What should the gun angle and travel direction be for making a 1G weld from the 1:30 to 10:30 positions?

A) ​A 45°forehand angle in the direction of travel.
B) ​A 14° to 20° forehand angle in the direction of travel.
C) ​A 30° to 90° backhand angle in the direction of travel.
D) ​A 60° backhand angle in the opposite direction of travel.

Question 41

​What determines the size, number, and location of tack welds on a pipe joint?

Question 42

​A small weld coupon may become too hot to allow you to make a good weld, so be sure to give the coupon time to ___________________.

Question 43

​The root pass welds must start and end on the ______________.

Question 44

​How is the root pass made on pipe?

Question 45

​Filler passes only need to have complete fusion to the previous weld and do not need to have ________.

Question 46

​Why is it important to clean the outside and inside surface of the pipe next to the groove?

Question 47

​The ends of the tack welds must be ground to a ___________.

Question 48

​Describe how the end of a pipe is to be prepared for welding.

Question 49

​Why are the ends of tack welds ground to a featheredge?

Question 50

​If the contact tube tip melts, the copper from the tip might enter the weld pool and make a _____________________ in the weld.