Section 1: Basics of Welding

• Question: What is the definition of welding?

Answer: Welding is a materials joining process in which two or more parts are
coalesced at their contacting surfaces by a suitable application of heat and/or
pressure.
• Question: What is the term used for the surfaces to be joined in welding?
Answer: Faying surfaces.
• Question: Name the substance used to prevent the molten pool from reacting with
air components during welding.
Answer: Flux.
• Question: What is arc shielding, and why is it important?
Answer: Arc shielding covers the molten weld pool and electrode tip with inert
gases like helium or argon to prevent reactions with oxygen, nitrogen, or
hydrogen.
• Question: What is the melting temperature of an electric arc in welding?
Answer: It can go up to 5500°C.

Section 2: Welding Processes

• Question: Name two major types of electrodes used in arc welding.
Answer: Consumable and non-consumable electrodes.
• Question: What distinguishes gas metal arc welding (GMAW) from shielded
metal arc welding (SMAW)?
Answer: In GMAW, the electrode is a consumable bare metal wire, and shielding
is provided by a gas, whereas in SMAW, the electrode is a coated filler metal rod.
• Question: What is the main application of submerged arc welding (SAW)?
Answer: It is used for joining thick steel sections with a continuous bare wire
electrode and granular flux.
• Question: What is resistance welding, and how is heat generated in this process?
Answer: Resistance welding uses heat generated by electrical resistance to
current flow at the junction to accomplish coalescence.
• Question: What are the two versions of flux-cored arc welding (FCAW)?
Answer:
• Self-shielded FCAW
• Gas-shielded FCAW

Section 3: Welding Joints

• Question: List the five basic types of weld joints.
Answer: Butt, corner, lap, tee, and edge joints.
• Question: What is the characteristic feature of a butt joint?
Answer: The two pieces are joined in the same plane, edge to edge.
• Question: Which joint is most suitable for applications requiring high strength
and minimal material usage?
Answer: Butt joint.
Section 4: Advantages and Disadvantages of Welding
• Question: What are the advantages of welding over mechanical fastening?
Answer: Welding provides a permanent joint, often stronger than the parent
materials, is economical in terms of material usage, and is not restricted to factory
environments.
• Question: Why is welding considered economical in fabrication costs?
Answer: It avoids additional alterations like drilling or fasteners, resulting in
lighter and cost-effective assemblies.
• Question: What are the disadvantages of welding?
Answer: Welding is labor-intensive, involves high energy processes, lacks
disassembly convenience, and may result in undetectable quality defects.
• Question: What makes welded joints potentially weaker than the parent material?
Answer: The presence of welding defects such as cracks or incomplete fusion.
• Question: Why is welding considered inherently dangerous?
Answer: It involves high energy, such as intense heat, electrical currents, and
hazardous gases.

Section 5: Welding Defects

• Question: What are the most common types of welding defects?
Answer: Cracks, cavities (porosity and shrinkage voids), solid inclusions, and
incomplete fusion.
• Question: How do cracks in welding affect the joint?
Answer: They cause fracture-type interruptions, reducing the joint's strength.
• Question: What causes porosity in weld metal?
Answer: Entrapped gases during the solidification process.
• Question: Define shrinkage voids.
Answer: Cavities formed during solidification due to material shrinkage.
• Question: What is a slag inclusion, and how does it form?
Answer: Nonmetallic solid materials trapped inside the weld metal, often
generated during arc welding.

Section 6: Fusion Welding Processes

• Question: What distinguishes fusion welding from solid-state welding?
Answer: Fusion welding involves melting the base metals, while solid-state
welding does not.
• Question: Name the primary types of fusion welding processes.
Answer: Arc welding, resistance welding, oxyfuel gas welding, and specialized
methods like laser-beam welding.
• Question: What is the main use of gas tungsten arc welding (GTAW)?
Answer: It uses a non-consumable tungsten electrode and inert gas for precise,
high-quality welds.
• Question: Explain the principle of plasma arc welding (PAW).
Answer: It directs a constricted plasma arc at the weld area, generating a high-
velocity, intensely hot stream for welding.
• Question: What is the purpose of granular flux in submerged arc welding?
Answer: It provides arc shielding and enhances weld quality by minimizing
atmospheric contamination.

Section 7: Solid-State Welding Processes

• Question: How does solid-state welding achieve coalescence?
Answer: Through pressure alone or a combination of heat and pressure below the
metal's melting point.
• Question: Describe roll welding (ROW).
Answer: Pressure is applied via rolls, with or without external heat, to join the
materials.
• Question: What is the main application of friction welding (FRW)?
Answer: It is used to join similar or dissimilar materials by generating frictional
heat combined with pressure.
• Question: What is unique about diffusion welding (DFW)?
Answer: It allows atomic diffusion across the joint interface in a controlled
environment, resulting in a high-quality bond.
• Question: How does ultrasonic welding (USW) achieve a bond?
Answer: By applying oscillatory shear stresses of ultrasonic frequency under
modest clamping force.

Section 8: Types of Welding Equipment

• Question: What type of electrode is used in shielded metal arc welding (SMAW)?
Answer: A consumable filler metal rod coated with flux.
• Question: What equipment is essential for gas metal arc welding (GMAW)?
Answer: A welding gun, consumable wire electrode, and shielding gas supply
system.
• Question: What distinguishes a tungsten electrode in GTAW?
Answer: It is non-consumable and provides precision in high-quality welds.
• Question: What tool is commonly used in oxyacetylene welding?
Answer: A welding torch.
• Question: Name two equipment pieces specific to resistance welding.
Answer: Spot welding electrodes and seam welding wheels.
Basics of Welding
1. What is the definition of welding?
Answer: Welding is a materials joining process in which two or more parts are
coalesced at their contacting surfaces by a suitable application of heat and/or pressure.
2. What is the term used for the surfaces to be joined in welding?
Answer: Faying surfaces.
3. Name the substance used to prevent the molten pool from reacting with air components
during welding.
Answer: Flux.
4. What is arc shielding, and why is it important?
Answer: Arc shielding covers the molten weld pool and electrode tip with inert gases
like helium or argon to prevent reactions with oxygen, nitrogen, or hydrogen.
5. What is the melting temperature of an electric arc in welding?
Answer: It can go up to 5500°C.
Section 4: Advantages and Disadvantages of Welding
1. What are the advantages of welding over mechanical fastening?
Answer: Welding provides a permanent joint, often stronger than the parent materials, is
economical in terms of material usage, and is not restricted to factory environments.
2. Why is welding considered economical in fabrication costs?
Answer: It avoids additional alterations like drilling or fasteners, resulting in lighter and
cost-effective assemblies.
3. What are the disadvantages of welding?
Answer: Welding is labor-intensive, involves high energy processes, lacks disassembly
convenience, and may result in undetectable quality defects.
4. What makes welded joints potentially weaker than the parent material?
Answer: The presence of welding defects such as cracks or incomplete fusion.
5. Why is welding considered inherently dangerous?
Answer: It involves high energy, such as intense heat, electrical currents, and hazardous
gases.
Section 5: Welding Defects
1. What are the most common types of welding defects?
Answer: Cracks, cavities (porosity and shrinkage voids), solid inclusions, and
incomplete fusion.
2. How do cracks in welding affect the joint?
Answer: They cause fracture-type interruptions, reducing the joint's strength.
3. What causes porosity in weld metal?
Answer: Entrapped gases during the solidification process.
4. Define shrinkage voids.
Answer: Cavities formed during solidification due to material shrinkage.
5. What is a slag inclusion, and how does it form?
Answer: Nonmetallic solid materials trapped inside the weld metal, often generated
during arc welding.
Section 1: Introduction to Gas Metal Arc Welding (GMAW)
• Question: What are the three main divisions of the GMAW process?
Answer: Metal Inert Gas (MIG) welding, Metal Active Gas (MAG) welding, and
Flux-Cored Arc Welding (FCAW).

• Question: Why is GMAW considered a semi-automatic welding process?

Answer: Because once the machine is correctly set up, it automatically adjusts
itself for variances during the welding process.

• Question: What is one major advantage of GMAW over conventional stick

welding?
Answer: GMAW allows for continuous welding without the need for frequently
changing electrodes.

Section 2: Equipment Used in GMAW

• Question: What is the primary function of the power source in GMAW?
Answer: To generate the welding current.

• Question: What does the wire feeder do in the GMAW process?

Answer: It draws the wire off the spool and pushes it through the welding gun.

• Question: Describe the components carried within the welding gun cable.
Answer: The electrode wire, welding current, shielding gas, and electrical signals.

• Question: What does the gas nozzle on the welding gun do?
Answer: It directs the shielding gas to form a protective envelope around the
weld pool.

Section 3: Principles of GMAW

• Question: How is the arc generated in GMAW?
Answer: By an electric arc across a gap between the electrode and the base metal,
creating enough heat for melting.

• Question: What is the role of shielding gas in GMAW?

Answer: To prevent oxygen and nitrogen in the atmosphere from contaminating
the molten metal, avoiding porosity in the weld.

• Question: List two shielding gases commonly used in MIG and MAG welding.
Answer: Argon and helium.

Section 4: Modes of Metal Transfer in GMAW

• Question: What are the three basic modes of metal transfer in GMAW?
Answer: Short circuit transfer, globular transfer, and spray transfer.

• Question: For what application is short circuit transfer particularly suitable?

Answer: Welding thin metals up to 2 mm in thickness and for out-of-position
welds.

• Question: How does spray transfer differ from globular transfer?

Answer: Spray transfer provides a more stable arc and is used for higher current
levels, producing a finer weld.

Section 5: Safety in GMAW

• Question: Why must operators wear a welding mask or hood during GMAW?
Answer: To protect against harmful eye-damaging light radiation.

• Question: What is the recommended lens shade for GMAW welding masks?
Answer: A number 12 shaded lens.

• Question: What condition is caused by looking directly at the arc without

protection?
Answer: Arc eye, a painful and potentially severe condition.

Section 6: Welding Techniques and Procedures

• Question: Why is proper cleaning of the base metal essential before welding?
Answer: To remove rust, mill scale, and other contaminants that can affect weld
quality.

• Question: What tool is recommended for cleaning the base metal?

Answer: An angle grinder.

• Question: What is the recommended gun angle for most welds in GMAW?
Answer: 20 to 25 degrees off vertical.

• Question: How can you assess whether your weld is going correctly?
Answer: By listening to the sound of the arc, which should resemble tearing
cloth.

Section 7: Maintenance and Shut-Down Procedures

• Question: What is the first step in shutting down GMAW equipment?
Answer: Close the delivery valve on the gas cylinder.

• Question: Why should the gas in the line be drained after welding?
Answer: To prevent buildup and ensure safety.

• Question: What should be done to the voltage and wire feeder controls after
shutting down the machine?
Answer: They should be set back to their minimum positions.
Section 1: Basics of Welding
1. What is the definition of welding?
Answer: Welding is a materials joining process in which two or more parts are
coalesced at their contacting surfaces by a suitable application of heat and/or pressure.
2. What is the term used for the surfaces to be joined in welding?
Answer: Faying surfaces.
3. Name the substance used to prevent the molten pool from reacting with air components
during welding.
Answer: Flux.
4. What is arc shielding, and why is it important?
Answer: Arc shielding covers the molten weld pool and electrode tip with inert gases
like helium or argon to prevent reactions with oxygen, nitrogen, or hydrogen.
5. What is the melting temperature of an electric arc in welding?
Answer: It can go up to 5500°C.
Section 4: Advantages and Disadvantages of Welding
1. What are the advantages of welding over mechanical fastening?
Answer: Welding provides a permanent joint, often stronger than the parent materials, is
economical in terms of material usage, and is not restricted to factory environments.
2. Why is welding considered economical in fabrication costs?
Answer: It avoids additional alterations like drilling or fasteners, resulting in lighter and
cost-effective assemblies.
3. What are the disadvantages of welding?
Answer: Welding is labor-intensive, involves high energy processes, lacks disassembly
convenience, and may result in undetectable quality defects.
4. What makes welded joints potentially weaker than the parent material?
Answer: The presence of welding defects such as cracks or incomplete fusion.
5. Why is welding considered inherently dangerous?
Answer: It involves high energy, such as intense heat, electrical currents, and hazardous
gases.
Section 5: Welding Defects
1. What are the most common types of welding defects?
Answer: Cracks, cavities (porosity and shrinkage voids), solid inclusions, and
incomplete fusion.
2. How do cracks in welding affect the joint?
Answer: They cause fracture-type interruptions, reducing the joint's strength.
3. What causes porosity in weld metal?
Answer: Entrapped gases during the solidification process.
4. Define shrinkage voids.
Answer: Cavities formed during solidification due to material shrinkage.
5. What is a slag inclusion, and how does it form?
Answer: Nonmetallic solid materials trapped inside the weld metal, often generated
during arc welding.
Advanced Welding Processes
1. What is electron-beam welding (EBW)?
Answer: A fusion-welding process in which the heat for welding is produced by a
highly focused, high-intensity stream of electrons impinging on the work surface.
2. How does laser-beam welding (LBW) differ from electron-beam welding?
Answer: LBW uses a concentrated, coherent light beam to achieve coalescence, while
EBW uses a focused stream of electrons.
3. What is thermit welding (TW) commonly used for?
Answer: It is often used for welding rails and other large structural components.
4. Describe the process of electroslag welding (ESW).
Answer: ESW achieves coalescence using electrically conductive molten slag that
generates heat to weld the base metal.
5. What materials are most suitable for friction stir welding?
Answer: Materials with low melting points, such as aluminum and magnesium alloys.
Safety in Welding
1. Why is PPE essential in welding?
Answer: PPE protects against hazards like burns, UV radiation, fumes, and sparks.
2. List three common pieces of PPE used in welding.
Answer: Welding helmets, gloves, and fire-resistant clothing.
3. What precautions should be taken to avoid electric shock in welding?
Answer: Ensure proper grounding, use insulated tools, and wear dry gloves.
4. Why is ventilation important in a welding environment?
Answer: To reduce exposure to harmful fumes and gases.
5. What is the purpose of a welding curtain?
Answer: To protect nearby workers from UV radiation and flying sparks.
Welding Applications
1. What is a common application of resistance welding?
Answer: It is widely used in the automotive industry for assembling vehicle bodies.
2. Which welding process is preferred for joining thin sheets of metal?
Answer: Gas tungsten arc welding (GTAW).
3. How is submerged arc welding used in industry?
Answer: It is commonly used for long, straight welds in pipelines and structural steel.
4. Why is laser welding advantageous in electronics manufacturing?
Answer: It provides precision and minimal heat-affected zones.
5. What are some applications of explosion welding?
Answer: It is used to bond dissimilar metals, such as steel and aluminum, in aerospace
and shipbuilding.
Welding Metallurgy
1. What is the heat-affected zone (HAZ) in welding?
Answer: The area of the base metal that experiences changes in microstructure due to
heat from welding.
2. How can welding impact the grain structure of a metal?
Answer: It can cause grain growth, reducing the material's strength and toughness.
3. What is stress relief in welded joints?
Answer: A heat treatment process to reduce residual stresses in the welded area.
4. Why is preheating important before welding certain materials?
Answer: It minimizes thermal gradients and reduces the risk of cracking.
5. What is the role of filler metals in influencing weld properties?
Answer: Filler metals can enhance the mechanical properties and corrosion resistance
of the weld.