Weld 120 SMAW Worksheet
Weld 110 OFW Chapter Reviews Name: _______________________________________ Date: _____________ SUMMER SCHEDULE Required Reading: Welding Principals and Applications 7th Edition Larry Jeffus Due Week 1: Review Test Chapter 30 – Oxyfuel Welding and Cutting Equipment, Setup and Operation (27 points). Due Week 2: Review Test Chapter 31 – Oxyfuel Gases and Filler Metals (18 points). Review Test Chapter 32 – Oxyacetylene Welding (20 points). Review Test Chapter 33 – Soldering, Brazing and Braze Welding (34 points). Due Week 3: Review Test Chapter 7 – Flame Cutting (32 points). Review Test Chapter 8 – Plasma Arc Cutting (26 points). Due Week 4: Review Test Chapter 2 – Safety in Welding (53 points). Review Test Chapter 9 – Related Cutting Processes (16 points). Due Week 6: Review Test Chapter 18 – Shop Math and Weld Costs (34 points). Review Test Chapter 19 – Reading Technical Drawings (17 points). Weld 110 OFW Chapter Reviews Page 1 of 36 (Revised 7-1-2014) THIS PAGE LEFT INTENTIONALLY BLANK Weld 110 OFW Chapter Reviews Page 2 of 36 (Revised 7-1-2014) Weld 110 OFW Review Test Chapter 30 Name: _______________________________________ Date: _____________ Required Reading: (Welding Principals and Applications 7th Edition Larry Jeffus Chapter 30) Review Test Chapter 30 answer all questions 1 through 27 Total Points (27) 1. What is the purpose of a pressure regulator? _____________________________________________________________________________________ 2. What may result if a pressure regulator is not used on the type of gas or pressure range for which it was designed? _____________________________________________________________________________________ 3. Describe how a single-stage regulator operates. _____________________________________________________________________________________ _____________________________________________________________________________________ 4. Is the torch pressure always the same as the working gauge pressure? Why or why not? _____________________________________________________________________________________ _____________________________________________________________________________________ 5. Why does the high-pressure gauge on a regulator not always indicate the amount of gas in the cylinder? _____________________________________________________________________________________ 6. How does the operation of a safety relief valve differ from the operation of a safety disc valve? _____________________________________________________________________________________ 7. Describe the difference between an argon cylinder valve fitting and a carbon dioxide cylinder valve fitting. _____________________________________________________________________________________ _____________________________________________________________________________________ 8. What is meant by regulator creep? _____________________________________________________________________________________ 9. Who should repair regulators? _____________________________________________________________________________________ Weld 110 OFW Chapter Reviews Page 3 of 36 (Revised 7-1-2014) Weld 110 OFW Review Test Chapter 30 Name: _______________________________________ Date: _____________ 10. Why must the pressure be released from a regulator when work is finished? _____________________________________________________________________________________ _____________________________________________________________________________________ 11. Why are combination welding and cutting torches considered to be more versatile? _____________________________________________________________________________________ 12. What is the advantage of using an injector-type mixing chamber? _____________________________________________________________________________________ 13. What should be done to the valve packing if the valve knob does not turn freely after it has been tightened to stop a leak? _____________________________________________________________________________________ 14. What may happen to a tip seat if it is incorrectly tightened? _____________________________________________________________________________________ 15. What can happen to a tip if it is excessively cleaned with a tip cleaner? _____________________________________________________________________________________ 16. What is the difference between a reverse flow valve and a flashback arrestor? _____________________________________________________________________________________ _____________________________________________________________________________________ 17. What are Siamese hoses? _____________________________________________________________________________________ 18. Why must the pressure be bled off hoses when work is complete? _____________________________________________________________________________________ 19. What is the difference between a backfire and a flashback? _____________________________________________________________________________________ _____________________________________________________________________________________ 20. Why is a neutral flame the most commonly used oxyacetylene flame used? _____________________________________________________________________________________ 21. What properties should a good leak-detecting solution have? _____________________________________________________________________________________ Weld 110 OFW Chapter Reviews Page 4 of 36 (Revised 7-1-2014) Weld 110 OFW Review Test Chapter 30 Name: _______________________________________ Date: _____________ 22. Why must the oxygen cylinder valve be opened all the way to the top? _____________________________________________________________________________________ 23. How long should hoses be purged? _____________________________________________________________________________________ 24. What should be done with cylinders that have leaking valve stems? _____________________________________________________________________________________ 25. How should the spark lighter be held to light a torch? _____________________________________________________________________________________ 26. Once the torch is lit, why must the acetylene flow be increased until the flame stops smoking before the oxygen is turned on for adjustment? _____________________________________________________________________________________ 27. What type of piping can be used for a manifold system? _____________________________________________________________________________________ Weld 110 OFW Chapter Reviews Page 5 of 36 (Revised 7-1-2014) THIS PAGE LEFT INTENTIONALLY BLANK Weld 110 OFW Chapter Reviews Page 6 of 36 (Revised 7-1-2014) Weld 110 OFW Review Test Chapter 31 Name: _______________________________________ Date: _____________ Required Reading: (Welding Principals and Applications 7th Edition Larry Jeffus Chapter 31) Review Test Chapter 31 answer all questions 1 through 18 Total Points (18) 1. What elements make up all hydrocarbons? _____________________________________________________________________________________ 2. What are the separate parts that make up an oxyacetylene flame? _____________________________________________________________________________________ _____________________________________________________________________________________ 3. Use Table 31-1 to determine which fuel gas requires the largest amount of oxygen from the torch. _____________________________________________________________________________________ 4. Approximately how long would it take a 50/50 mixture of oxygen and acetylene to flashback through a 21-foot (6.4008-m) long hose? _____________________________________________________________________________________ 5. Use Table 31-2 to determine which fuel gas has the highest burning velocity when mixed with oxygen. _____________________________________________________________________________________ 6. How is acetylene produced? _____________________________________________________________________________________ 7. Why is it not safe to use acetylene above 15 psig (100 kPag)? _____________________________________________________________________________________ 8. Use Table 31-3 to determine the largest tip orifice size (drill number) that could be used with an acetylene cylinder containing 175 cubic feet (4956 L). _____________________________________________________________________________________ 9. Where is the highest temperature and where is the greatest heat produced in a neutral oxyacetylene flame? _____________________________________________________________________________________ _____________________________________________________________________________________ 10. Use Table 31-4 to determine what would be the pressures in cylinders containing MAPP® on a 100°F (38°C) day, Propane on a 100°F (38°C) day, Ethane on a 100°F (38°C) day. _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ Weld 110 OFW Chapter Reviews Page 7 of 36 (Revised 7-1-2014) Weld 110 OFW Review Test Chapter 31 Name: _______________________________________ Date: _____________ 11. What are methylacetylene-propadiene fuel gases used for? _____________________________________________________________________________________ 12. Use Table 31-5 to determine which oxygen fuel-gas mixture produces the highest total heat. _____________________________________________________________________________________ 13. Which fuel gas has the strongest odor and is easiest to detect? _____________________________________________________________________________________ 14. What is the major advantage of using propane or natural gas? _____________________________________________________________________________________ 15. Use Table 31-6 to determine which fuel gas would be best for a. cutting material thicker than 5 in. (125 mm) _____________________ b. powdered metallizing _____________________ c. stack cutting _____________________ 16. What two major safety problems does hydrogen present? _____________________________________________________________________________________ _____________________________________________________________________________________ 17. Why should coat hangers not be used as gas welding filler metal? _____________________________________________________________________________________ _____________________________________________________________________________________ 18. Explain the significance of the AWS filler metal classification RG45. _____________________________________________________________________________________ _____________________________________________________________________________________ Weld 110 OFW Chapter Reviews Page 8 of 36 (Revised 7-1-2014) Weld 110 OFW Review Test Chapter 32 Name: _______________________________________ Date: _____________ Required Reading: (Welding Principals and Applications Larry Jeffus 7th Edition Chapter 32) Review Test Chapter 32 answer all questions 1 through 20 Total Points (20) 19. What protects the molten weld pool from oxidation during a gas weld? _____________________________________________________________________________________ 20. How does tip size affect a gas weld? _____________________________________________________________________________________ 21. How does torch angle affect a gas weld? _____________________________________________________________________________________ 22. How does welding rod size affect a gas weld? _____________________________________________________________________________________ 23. What is a good indication that the molten weld pool is not being protected from oxidation? _____________________________________________________________________________________ 24. Why should the end of the gas filler rod be bent? _____________________________________________________________________________________ 25. What is the purpose of a heat sink? _____________________________________________________________________________________ _____________________________________________________________________________________ 26. Why should the end of the welding rod be kept inside the flame envelope? _____________________________________________________________________________________ 27. Does a weld have to have 100% penetration to be strong? _____________________________________________________________________________________ 28. What technique can be used to minimize weld distortion on a flat butt joint? _____________________________________________________________________________________ 29. Why does the edge of the top plate on a lap joint tend to melt more easily? _____________________________________________________________________________________ 30. What is meant by the term out-of-position? _____________________________________________________________________________________ 31. What holds the molten weld pool in place on a vertical weld? _____________________________________________________________________________________ Weld 110 OFW Chapter Reviews Page 9 of 36 (Revised 7-1-2014) Weld 110 OFW Review Test Chapter 32 Name: _______________________________________ Date: _____________ 32. What additional personal safety protection should be used for overhead welds? _____________________________________________________________________________________ 33. What force holds the molten weld pool in place on an overhead weld? _____________________________________________________________________________________ 34. What is the welding sequence for a 1G weld? _____________________________________________________________________________________ _____________________________________________________________________________________ 35. What is the proper method for stopping a weld pool so it can be easily restarted? _____________________________________________________________________________________ 36. What welding positions are required when making a 5G weld on pipe? _____________________________________________________________________________________ 37. What welding positions are required when making a 6G weld on pipe? _____________________________________________________________________________________ 38. How can 100% penetration be ensured when making welds on thin-wall tubing? _____________________________________________________________________________________ Weld 110 OFW Chapter Reviews Page 10 of 36 (Revised 7-1-2014) Weld 110 OFW Review Test Chapter 33 Name: _______________________________________ Date: _____________ Required Reading: (Welding Principals and Applications 7th Edition Larry Jeffus Chapter 33) Review Test Chapter 33 answer all questions 1 through 34 Total Points (34) 1. Explain the difference between brazing and soldering. _____________________________________________________________________________________ _____________________________________________________________________________________ 2. How does capillary action separate brazing from braze welding? _____________________________________________________________________________________ _____________________________________________________________________________________ 3. Why can brazing be both a permanent and a temporary joining method? _____________________________________________________________________________________ _____________________________________________________________________________________ 4. Why is it less likely that a semi skilled worker would damage a part with brazing than with welding? _____________________________________________________________________________________ 5. What is the effect of joint spacing on joint tensile strength? _____________________________________________________________________________________ 6. Why are braze joints subject to fatigue failure? _____________________________________________________________________________________ 7. Do all braze joints resist corrosion? Give an example. _____________________________________________________________________________________ _____________________________________________________________________________________ 8. What are the three primary functions that a flux must perform? 1) ____________________________________________________ 2) ____________________________________________________ 3) ____________________________________________________ 9. In what forms are fluxes available? 1) _____________________ 2) _____________________ 3) _____________________ 4) _____________________ 5) _____________________ Weld 110 OFW Chapter Reviews Page 11 of 36 (Revised 7-1-2014) Weld 110 OFW Review Test Chapter 33 Name: _______________________________________ Date: _____________ 10. How can liquid fluxes be delivered to the joint through the torch? _____________________________________________________________________________________ _____________________________________________________________________________________ 11. How do fluxes react with the base metal? _____________________________________________________________________________________ 12. How are soldering and brazing methods grouped? _____________________________________________________________________________________ 13. What are the advantages of torch soldering? _____________________________________________________________________________________ 14. What are the advantages of furnace brazing? _____________________________________________________________________________________ 15. How does the induction brazing method heat the part being brazed? _____________________________________________________________________________________ 16. What soldering process can be used to join parts and provide a protective coating to the part at the same time? _____________________________________________________________________________________ 17. What soldering or brazing process uses a machine similar to a spot welder to produce the heat required to make a joint? _____________________________________________________________________________________ 18. What is a metal alloy? _____________________________________________________________________________________ 19. Why must parts not be moved as they cool through the paste range? _____________________________________________________________________________________ 20. Why must you not use tin-lead solders on water piping? _____________________________________________________________________________________ 21. Using Table 33-3, determine the approximate temperature at which a mixture of 90% tin with 10% lead would become 100% liquid. _____________________________________________________________________________________ Weld 110 OFW Chapter Reviews Page 12 of 36 (Revised 7-1-2014) Weld 110 OFW Review Test Chapter 33 Name: _______________________________________ Date: _____________ 22. What is a major use of tin-antimony solder? _____________________________________________________________________________________ 23. What solder alloy can retain its strength at elevated temperatures? _____________________________________________________________________________________ 24. Why do brazing alloys use letters such as CuZn to identify the metal? _____________________________________________________________________________________ 25. What is the white smoke that can be given off from copper-zinc brazing alloy? _____________________________________________________________________________________ 26. Which copper-zinc brazing alloy could be used to join or repair each of the following? 1) cast iron ____________ , _____________ 2) build up wear surfaces _____________ 3) malleable iron _____________ 4) naval brass _____________ 27. Why should copper-phosphorus not be used on fittings with ferrous substrates? _____________________________________________________________________________________ 28. Silver-copper alloys can be used to join which metals? _____________________________________________________________________________________ 29. Which nickel alloy would be best for joining the following? 1) poor fitting joints ____________ 2) honeycomb structures ____________ 3) jet engine parts ____________ 4) corrosive applications ____________ 30. Why does BCu-2 brazing alloy use an organic compound mixed with copper? _____________________________________________________________________________________ 31. Using Table 33-6, determine the ideal joint spacing for the following braze alloys. 1) BCuZn ___________________ 2) BAlSi ___________________ 3) BCuP ___________________ 32. What indicates that you have overheated the solder flux on copper? _____________________________________________________________________________________ Weld 110 OFW Chapter Reviews Page 13 of 36 (Revised 7-1-2014) Weld 110 OFW Review Test Chapter 33 Name: _______________________________________ Date: _____________ 33. How can the size of a braze bead be controlled? _____________________________________________________________________________________ _____________________________________________________________________________________ 34. Why is brazing a better process than welding to rebuild some surfaces? _____________________________________________________________________________________ _____________________________________________________________________________________ Weld 110 OFW Chapter Reviews Page 14 of 36 (Revised 7-1-2014) Weld 110 OFW Review Test Chapter 7 Name: _______________________________________ Date: _____________ Required Reading: (Welding Principals and Applications 7th Edition Larry Jeffus Chapter 7) Review Test Chapter 7 answer all questions 1 through 32 Total Points (32) 1. Using Table 7-1, list the six different fuel gases in rank order according to their temperature. 1) (hottest) __________________ 2) __________________ 3) __________________ 4) __________________ 5) __________________ 6) (coolest) __________________ 2. What is a combination welding-cutting torch? _____________________________________________________________________________________ 3. State one advantage of owning a combination welding-cutting torch as opposed to just having a cutting torch. _____________________________________________________________________________________ 4. State one advantage of owning a dedicated cutting torch as compared to having a combination welding-cutting torch. _____________________________________________________________________________________ _____________________________________________________________________________________ 5. What is a mixing chamber? Where is it located? _____________________________________________________________________________________ 6. Define the term equal-pressure torch. How does it work? _____________________________________________________________________________________ _____________________________________________________________________________________ 7. How does an injector-type mixing chamber work? _____________________________________________________________________________________ _____________________________________________________________________________________ 8. State the advantages of having two oxygen regulators on a machine-cutting torch. _____________________________________________________________________________________ _____________________________________________________________________________________ Weld 110 OFW Chapter Reviews Page 15 of 36 (Revised 7-1-2014) Weld 110 OFW Review Test Chapter 7 Name: _______________________________________ Date: _____________ 9. Why are some copper alloy cutting tips chrome plated? _____________________________________________________________________________________ 10. What determines the amount of preheat flame requirements of a torch? _____________________________________________________________________________________ 11. What can happen if acetylene is used on a tip designed to be used with propane or other such gas? _____________________________________________________________________________________ 12. Why are some propane and natural gas tips made with a deep, recessed center? _____________________________________________________________________________________ 13. What types of tip seals are used with cutting torch tips? _____________________________________________________________________________________ 14. If a cutting tip should stick in the cutting head, how should it be removed? _____________________________________________________________________________________ 15. How can cutting torch tip seals be repaired? _____________________________________________________________________________________ _____________________________________________________________________________________ 16. Why is the oxygen valve turned on before starting to clean a cutting tip? _____________________________________________________________________________________ 17. Why does the preheat flame become slightly oxidizing when the cutting lever is released? _____________________________________________________________________________________ 18. What causes the tiny ripples in a hand cut? _____________________________________________________________________________________ 19. Why is a slight forward torch angle helpful for cutting? _____________________________________________________________________________________ _____________________________________________________________________________________ 20. Why should cans, drums, tanks, or other sealed containers not be opened with a cutting torch? _____________________________________________________________________________________ _____________________________________________________________________________________ Weld 110 OFW Chapter Reviews Page 16 of 36 (Revised 7-1-2014) Weld 110 OFW Review Test Chapter 7 Name: _______________________________________ Date: _____________ 21. Why is the torch tip raised as the cutting lever is depressed when cutting a hole? _____________________________________________________________________________________ 22. Why are the preheat holes not aligned in the kerf when making a bevel cut? _____________________________________________________________________________________ 23. Sketch the proper end shape of a soapstone that is to be used for marking metal. See Figure 7-33 in text. 24. Using Table 7-4, answer the following: 1) Oxygen pressure for cutting 1/4-in. (6-mm)-thick metal – __________________ 2) Acetylene pressure for cutting 1-in. (25-mm)-thick metal – __________________ 3) Tip cleaner size for a tip for 2-in. (51-mm)-thick metal – __________________ 4) Drill size for a tip for 1/2-in. (13-mm)-thick metal – __________________ 25. What is the best way to set the oxygen pressure for cutting? _____________________________________________________________________________________ _____________________________________________________________________________________ 26. What metals can be cut with the oxyfuel gas process? _____________________________________________________________________________________ 27. Why is it important to have extra ventilation and/or a respirator when cutting some used metal? _____________________________________________________________________________________ 28. What factors regarding a cut can be read from the sides of the kerf after a cut? _____________________________________________________________________________________ _____________________________________________________________________________________ 29. What is hard slag? _____________________________________________________________________________________ _____________________________________________________________________________________ Weld 110 OFW Chapter Reviews Page 17 of 36 (Revised 7-1-2014) Weld 110 OFW Review Test Chapter 7 Name: _______________________________________ Date: _____________ 30. Why is it important to make good-quality cuts? _____________________________________________________________________________________ _____________________________________________________________________________________ 31. Describe the methods of controlling distortion when making cuts. _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ 32. How does cutting small diameter pipe differ from cutting large diameter pipe? _____________________________________________________________________________________ _____________________________________________________________________________________ Weld 110 OFW Chapter Reviews Page 18 of 36 (Revised 7-1-2014) Weld 110 OFW Review Test Chapter 8 Name: _______________________________________ Date: _____________ Required Reading: (Welding Principals and Applications 7th Edition Larry Jeffus Chapter 8) Review Test Chapter 8 answer all questions 1 through 26 Total Points (26) 1. What is an electrical plasma? _____________________________________________________________________________________ 2. Approximately how many times hotter is the plasma arc than an unrestricted arc? _____________________________________________________________________________________ 3. Why is the body on a manual plasma torch made from a special type of plastic? _____________________________________________________________________________________ 4. How are the torch heads of a plasma torch cooled? _____________________________________________________________________________________ 5. What three types of power switches are used on plasma torches? _____________________________________________________________________________________ 6. Why are some copper parts plated? _____________________________________________________________________________________ 7. Why have copper/tungsten tips helped the plasma torch? _____________________________________________________________________________________ 8. What provides the gap between the electrode tip and the nozzle tip? _____________________________________________________________________________________ 9. What are the advantages of a water shroud nozzle for plasma cutting? _____________________________________________________________________________________ 10. How is water used to control power cable overheating? _____________________________________________________________________________________ 11. What factors must be considered when selecting a material for plasma arc gas hoses? _____________________________________________________________________________________ 12. Why must the cooling water be turned off when the plasma cutting torch is not being used? _____________________________________________________________________________________ Weld 110 OFW Chapter Reviews Page 19 of 36 (Revised 7-1-2014) Weld 110 OFW Review Test Chapter 8 Name: _______________________________________ Date: _____________ 13. What type of voltage is required for a plasma cutting torch? _____________________________________________________________________________________ 14. A plasma arc torch that is operating with 90 volts (close circuit) and 25 amps is using how many watts of power? _____________________________________________________________________________________ 15. Why do plasma cuts have little or no distortion? _____________________________________________________________________________________ 16. What has limited the upper cutting speed limits of the plasma arc cutting process? _____________________________________________________________________________________ 17. What metals can be commonly cut using the PAC process? _____________________________________________________________________________________ 18. What happens to torches not using drag nozzle tips if the standoff distance is not maintained? _____________________________________________________________________________________ _____________________________________________________________________________________ 19. What are the two methods for establishing the plasma path to the metal being cut? _____________________________________________________________________________________ 20. List eight items that will affect the quality of a PAC kerf. 1) ____________________ 2) ____________________ 3) ____________________ 4) ____________________ 5) ____________________ 6) ____________________ 7) ____________________ 8) ____________________ 21. List seven items that are affected by the choice of PAC gas or gases on the cut. 1) ____________________ 2) ____________________ 3) ____________________ 4) ____________________ 5) ____________________ 6) ____________________ 7) ____________________ 22. Describe stack cutting. _____________________________________________________________________________________ Weld 110 OFW Chapter Reviews Page 20 of 36 (Revised 7-1-2014) Weld 110 OFW Review Test Chapter 8 Name: _______________________________________ Date: _____________ 23. How does PAC dross compare with OFC slag? _____________________________________________________________________________________ 24. Why must high-power PAC machines be used by a semiautomatic or automatic cutting system? _____________________________________________________________________________________ 25. What is the advantage of using a water table for PAC? _____________________________________________________________________________________ _____________________________________________________________________________________ 26. How is plasma arc gouging performed? _____________________________________________________________________________________ Weld 110 OFW Chapter Reviews Page 21 of 36 (Revised 7-1-2014) THIS PAGE LEFT INTENTIONALLY BLANK Weld 110 OFW Chapter Reviews Page 22 of 36 (Revised 7-1-2014) Weld 110 OFW Review Test Chapter 2 Name: _______________________________________ Date: _____________ Required Reading: (Welding Principals and Applications 7th Edition Larry Jeffus Chapter 2) Review Test Chapter 2 answer all questions 1 through 53 Total Points (53) 1. What is the key to preventing accidents in a welding shop? _____________________________________________________________________________________ 2. Who is ultimately responsible for the welder's safety? _____________________________________________________________________________________ 3. Describe the three classifications of burns. a. 1st degree: __________________________________________ b. 2nd degree: _________________________________________ c. 3rd degree: _________________________________________ 4. What emergency steps should be taken to treat burns? a. 1st degree: _________________________________________ b. 2nd degree: _________________________________________ c. 3rd degree: _________________________________________ 5. List the three types of light that may be present during welding. _____________________________________________________________________________________ 6. Which type of light is the most likely to cause burns? Why? _____________________________________________________________________________________ 7. What can be done on the job site to reduce the danger of reflected light? _____________________________________________________________________________________ _____________________________________________________________________________________ 8. In what two ways can ultraviolet light burn the eyes? _____________________________________________________________________________________ 9. What is the name of the eye burn that can occur in a fraction of a second? _____________________________________________________________________________________ 10. Why is it important to seek medical treatment for eye burns? _____________________________________________________________________________________ Weld 110 OFW Chapter Reviews Page 23 of 36 (Revised 7-1-2014) Weld 110 OFW Review Test Chapter 2 Name: _______________________________________ Date: _____________ 11. Why must eye protection be worn at all times in the welding shop? _____________________________________________________________________________________ 12. According to Table 2-1 what eye and/or face protection should be used for each of the following: a. Acetylene Welding: _______________________________ b. Chipping: _______________________________________ c. Electric Arc Welding: ______________________________ d. Spot Welding: ____________________________________ 13. What types of injuries can occur to the ears during welding? _____________________________________________________________________________________ 14. What types of protection are available to protect the ears during welding? _____________________________________________________________________________________ 15. What types of information should be covered in a respirator training program? _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ 16. Name two types of respirators and describe how they work. _____________________________________________________________________________________ _____________________________________________________________________________________ 17. List the materials that can give off dangerous fumes during welding and require forced ventilation. _____________________________________________________________________________________ 18. Why must metal that has been used before be cleaned prior to welding? _____________________________________________________________________________________ 19. Under what conditions can natural ventilation be used? _____________________________________________________________________________________ _____________________________________________________________________________________ Weld 110 OFW Chapter Reviews Page 24 of 36 (Revised 7-1-2014) Weld 110 OFW Review Test Chapter 2 Name: _______________________________________ Date: _____________ 20. When must forced ventilation be used? _____________________________________________________________________________________ 21. Who must be provided with Material Safety Data Sheets (MSDS)? _____________________________________________________________________________________ 22. Name two advantages of recycling scrap metal. _____________________________________________________________________________________ 23. What fabric(s) are the best choices to wear as general work clothing in a welding shop? _____________________________________________________________________________________ 24. Describe the ideal work shirt, pants, boots, and caps that should be worn in a welding shop. _____________________________________________________________________________________ 25. Why is it unsafe to carry butane lighters or matches in your pockets while welding? _____________________________________________________________________________________ 26. What special protective items can be worn to provide extra protection for a welder’s hands, arms, body, waist, legs, and feet? _____________________________________________________________________________________ 27. Describe an acceptable storage area for a cylinder of fuel gas. _____________________________________________________________________________________ 28. How must high-pressure gas cylinders be stored so they cannot accidentally be knocked over? _____________________________________________________________________________________ 29. What should be done with a leaking cylinder if the leak cannot be stopped? _____________________________________________________________________________________ 30. Why is it important that acetylene cylinders not be stored horizontally? _____________________________________________________________________________________ 31. How far away should highly combustible materials be from any welding or cutting? _____________________________________________________________________________________ Weld 110 OFW Chapter Reviews Page 25 of 36 (Revised 7-1-2014) Weld 110 OFW Review Test Chapter 2 Name: _______________________________________ Date: _____________ 32. List the four types of fire extinguishers and what type of material that is on fire they are used to extinguish. a. Type A: _________________________________________ b. Type B: _________________________________________ c. Type C: _________________________________________ d. Type D: _________________________________________ 33. What is hot work? _____________________________________________________________________________________ 34. When is a fire watch needed? _____________________________________________________________________________________ 35. Why is it important to have a planned maintenance program for tools and equipment? _____________________________________________________________________________________ 36. Why is it important to keep a welding area clean? _____________________________________________________________________________________ 37. What should you do if you have to leave a piece of hot metal unattended? _____________________________________________________________________________________ 38. Why must a mushroomed chisel or hammer be reground? _____________________________________________________________________________________ 39. What causes most electric shocks in the welding industry? _____________________________________________________________________________________ 40. What can happen if too much power is being carried by a cable? _____________________________________________________________________________________ 41. Why must equipment be turned off and unplugged before working on the electrical terminals? _____________________________________________________________________________________ 42. According to the Welding Safety Checklist in Figure 2-40 what are the factors necessary for a confined space hazard? a. ____________________ b. ____________________ c. ____________________ d. ____________________ e. ____________________ Weld 110 OFW Chapter Reviews Page 26 of 36 (Revised 7-1-2014) Weld 110 OFW Review Test Chapter 2 Name: _______________________________________ Date: _____________ 43. According to Table 2-2 what gauge wire size would be needed for a power tool that has a name plate amperage of 9 and a cord length of 100 feet? _____________________________________________________________________________________ 44. What is a GFCI? _____________________________________________________________________________________ 45. Why is important to not weld when everything is wet? _____________________________________________________________________________________ _____________________________________________________________________________________ 46. List five safety tips for safe extension cord use. When using extension cords, keep in mind the following safety tips: _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ 47. List 10 safety rules for the safe use of portable electric tools. Following are a few safety precautions that should be observed: _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ Weld 110 OFW Chapter Reviews Page 27 of 36 (Revised 7-1-2014) Weld 110 OFW Review Test Chapter 2 Name: _______________________________________ Date: _____________ 48. List two types of grinders used by welders. _____________________________________________________________________________________ 49. How close to the grinding stone face should the tool rest be adjusted? _____________________________________________________________________________________ 50. Name metal cutting machines used in the welding shop and what their advantages are. _____________________________________________________________________________________ _____________________________________________________________________________________ 51. Describe how a person should safely lift a heavy object. _____________________________________________________________________________________ _____________________________________________________________________________________ 52. List the things that should be inspected on a ladder. _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ 53. List and explain five ladder use safety rules. The following are general safety and usage rules for ladders: _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ Weld 110 OFW Chapter Reviews Page 28 of 36 (Revised 7-1-2014) Weld 110 OFW Review Test Chapter 9 Name: _______________________________________ Date: _____________ Required Reading: (Welding Principals and Applications 7th Edition Larry Jeffus Chapter 9) Review Test Chapter 9 answer all questions 1 through 16 Total Points (16) 1. Describe the use of the following processes: LBD, LBW, and LBC. 1) LBD: _____________________________________________________________________ 2) LBW: _____________________________________________________________________ 3) LBC: _____________________________________________________________________ 2. How is laser light formed? _____________________________________________________________________________________ 3. Other than the lasing material, what is the difference between solid state lasers and gas lasers? _____________________________________________________________________________________ 4. What effect does a material’s surface have on the laser beam? _____________________________________________________________________________________ 5. Using Table 9-1, list the assist cutting gas and the material it can be used to cut. See Table 9-1, page 207. 1) Air: ________________________________________________________________________ 2) Oxygen: ____________________________________________________________________ 3) Nitrogen: ___________________________________________________________________ 4) Argon: _____________________________________________________________________ 6. What are reactive laser assist gases called? How do they work? _____________________________________________________________________________________ 7. What type of laser beam is used for drilling? Why? _____________________________________________________________________________________ 8. What is CAC-A? _____________________________________________________________________________________ Weld 110 OFW Chapter Reviews Page 29 of 36 (Revised 7-1-2014) Weld 110 OFW Review Test Chapter 9 Name: _______________________________________ Date: _____________ 9. Using Table 9-2, give the recommended procedure for air carbon arc gouging of carbon steel, magnesium alloys, and low alloy copper. 1) Carbon steel: ______________________________________________________________ 2) Magnesium alloys:__________________________________________________________ 3) Low alloy copper: __________________________________________________________ 10. Why are some carbon arc electrodes copper-coated? _____________________________________________________________________________________ 11. What may occur if an SMA welding machine has below minimum arc voltage for air carbon arc gouging? _____________________________________________________________________________________ 12. How can carbon arc welding be used to ensure 100% weld penetration? _____________________________________________________________________________________ 13. What is washing, and how can it be used? _____________________________________________________________________________________ _____________________________________________________________________________________ 14. How are oxygen lance cuts usually started? _____________________________________________________________________________________ 15. What unusual material can be cut with an oxygen lance? _____________________________________________________________________________________ 16. What are the advantages of abrasive powder to the water jet cutting stream? _____________________________________________________________________________________ Weld 110 OFW Chapter Reviews Page 30 of 36 (Revised 7-1-2014) Weld 110 OFW Review Test Chapter 18 Name: _______________________________________ Date: _____________ Required Reading: (Welding Principals and Applications 7th Edition Larry Jeffus Chapter 18) Review Test Chapter 18 answer all questions 1 through 34 Total Points (34) 1. What are two ways math is most commonly used in the welding shop? _____________________________________________________________________________________ 2. What is the two two-letter abbreviation for the metric system? _____________________________________________________________________________________ 3. List factors that affect the cost of producing weldments. _____________________________________________________________________________________ 4. List three examples of whole numbers. _____________________________________________________________________________________ 5. List three examples of decimal fractions. _____________________________________________________________________________________ 6. List three examples of a mixed unit. _____________________________________________________________________________________ 7. List three examples of fractions. _____________________________________________________________________________________ 8. What would the labor cost be if 20 hours were worked at an hourly rate of $25? _____________________________________________________________________________________ 9. What is the first step in the sequence of mathematical operations? _____________________________________________________________________________________ 10. If you need two pieces of pipe—one must be 15 ft and the other 10 ft—what is the total amount of pipe needed? _____________________________________________________________________________________ Weld 110 OFW Chapter Reviews Page 31 of 36 (Revised 7-1-2014) Weld 110 OFW Review Test Chapter 18 Name: _______________________________________ Date: _____________ 11. How many total feet of metal stock would you need if one piece is 12 ft 5 in. long and the other is 7 ft 3 in. long? _____________________________________________________________________________________ 12. How many total feet of metal stock would you need if one piece is 11 ft 9 in. long and the other is 6 ft 5 in. long? _____________________________________________________________________________________ 13. How many feet of scrap pipe will you have left from a 9 ft 6 in. piece when 4 ft 2 in. is cut off? _____________________________________________________________________________________ 14. How much scrap pipe will you have once you cut out 5.5 ft from a 20-ft length of pipe? _____________________________________________________________________________________ 15. When the denominators of two fractions to be added or subtracted are different, what must be done before they can be added? _____________________________________________________________________________________ 16. How thick will the finished part be if two pieces of metal are welded together if one is 3/4 in. thick and the other is 5/16 in. thick? _____________________________________________________________________________________ 17. How much metal is left if 1/8 in. is ground off a 5/16-in.-thick plate? _____________________________________________________________________________________ 18. What is a dimensioning tolerance? _____________________________________________________________________________________ 19. What is the minimum and maximum length a part can be if it is shown as needing to be 5 7/8 in. ± 1/8? _____________________________________________________________________________________ 20. List examples of fixed and variable costs that must be considered when estimating a job. _____________________________________________________________________________________ Weld 110 OFW Chapter Reviews Page 32 of 36 (Revised 7-1-2014) Weld 110 OFW Review Test Chapter 18 Name: _______________________________________ Date: _____________ 21. List examples of overhead costs that a welding shop might have. _____________________________________________________________________________________ 22. When estimating weld cost, what weld joint design factors should be considered? _____________________________________________________________________________________ 23. When a weld is oversized, what joint failure problem can result? _____________________________________________________________________________________ 24. How does the bevel angle in a groove weld affect the filler metal volume? _____________________________________________________________________________________ 25. What is the cross-sectional area of a V-groove weld that is 6 mm wide and 8 mm deep on a 10-mmthick plate having a 2-mm root opening? What would the area be in square inches? _____________________________________________________________________________________ 26. What is the cross-sectional area of a fillet weld that has an equal leg of 1/2 in.? What is the SI area? _____________________________________________________________________________________ 27. What two amounts must be multiplied to determine the weight of weld metal required to fill a groove or make a fillet weld? _____________________________________________________________________________________ 28. How many pounds of steel electrode are required to make a weld that has a volume of 18 in3? _____________________________________________________________________________________ 29. Why is not every pound of electrode filler metal used converted into weld metal? _____________________________________________________________________________________ 30. What does it mean if an electrode has a 50% deposition efficiency? _____________________________________________________________________________________ 31. What is the meaning of the term deposition rate? _____________________________________________________________________________________ Weld 110 OFW Chapter Reviews Page 33 of 36 (Revised 7-1-2014) Weld 110 OFW Review Test Chapter 18 Name: _______________________________________ Date: _____________ 32. What factor is not included in the deposition efficiency of coated electrodes? _____________________________________________________________________________________ 33. Why do flux cored wires have a higher deposition efficiency than coated electrodes? _____________________________________________________________________________________ 34. If a weldment project has a 45% operating factor, what does that mean? _____________________________________________________________________________________ Weld 110 OFW Chapter Reviews Page 34 of 36 (Revised 7-1-2014) Weld 110 OFW Review Test Chapter 19 Name: _______________________________________ Date: _____________ Required Reading: (Welding Principals and Applications 7th Edition Larry Jeffus Chapter 19) Review Test Chapter 19 answer all questions 1 through 17 Total Points (17) 1. Give examples of drawing pages that might be included in a set of drawings? _____________________________________________________________________________________ 2. The title box on a drawing can contain what information? _____________________________________________________________________________________ 3. Where would a welder look in the set of drawings to find a list of the various items that would be needed to build a weldment? _____________________________________________________________________________________ 4. Sketch an object that contains all of the necessary elements so that you can use the following line types: object line, hidden line, centerline, extension line, and dimension line. Label each line type using leaders and arrows. 5. What type of lines can be used in a drawing to show that part of an object has been removed? _____________________________________________________________________________________ 6. Describe what phantom lines are in a drawing. _____________________________________________________________________________________ 7. Compare an orthographic projection (mechanical drawing) to a pictorial drawing. _____________________________________________________________________________________ 8. A mechanical drawing usually includes which three views of an object? _____________________________________________________________________________________ Weld 110 OFW Chapter Reviews Page 35 of 36 (Revised 7-1-2014) Weld 110 OFW Review Test Chapter 19 Name: _______________________________________ Date: _____________ 9. List two types of pictorial drawings that can be included with a set of mechanical drawings. _____________________________________________________________________________________ 10. What view might be used to show part of an object as if it were sawn away to reveal internal details? _____________________________________________________________________________________ 11. What kind of information does a detail view on a drawing provide? _____________________________________________________________________________________ 12. The height of an object would be found on which of the standard views in a set of drawings? _____________________________________________________________________________________ 13. What is the difference between “as drawn” and “as built” drawings? _____________________________________________________________________________________ 14. What tool can be used to draw an object so that it is smaller or larger than it really is? _____________________________________________________________________________________ 15. What is the difference between architectural scales and engineering scales? _____________________________________________________________________________________ 16. Why is knowing how to sketch a drawing a valuable skill in the welding shop? _____________________________________________________________________________________ 17. Which type of computer graphics program lines stay crisp and clean no matter how much you zoom in and out of the image? _____________________________________________________________________________________ Weld 110 OFW Chapter Reviews Page 36 of 36 (Revised 7-1-2014)
© Copyright 2024