UNIT MEM 5.

18AB
PERFORM ADVANCED
GMAW

ASSESSMENT
QUESTIONS.

Student Name

Unit MEM 5.18 Revised June 2005 1

Unit MEM 5.18 Revised June 2005 2
QUESTION 1:

How can you prevent an arc flash while welding or near welding?
What can an arc flash result in if severe enough.

QUESTION 2:

What types of rays are given off by welding and the type of injury you receive

QUESTION 3:

Why should you never weld while standing in water?

QUESTION 4:

If welding in hot and humid conditions, what rule should you follow to avoid possible
electric shock?

QUESTION 5:

Describe, “metal fume fever”

Name a few metals known to give off fumes

If welding in a confined space what precautions should you follow to prevent metal fume
fever?

QUESTION 6:

What is the minimum distance between combustible materials and welding?

If these cannot be removed, what must be done?

Unit MEM 5.18 Revised June 2005 3

QUESTION 7:

What is the main purpose of preheating metals prior to welding?

Where is the information regarding what temperature to apply?

QUESTION 8:

When heat is applied to metals, distortion occurs.

Describe three methods minimizing distortion during and after welding?

QUESTION 9:

Name four metal transfers used for the GMAW process?

QUESTION 10:

Briefly describe the weld positions each transfer is capable of

QUESTION 11:

What hazards can occur to the welding cable or handpiece resulting as problems in wire
feed when welding?

QUESTION 12:

What type of power source is used for GMAW?

Unit MEM 5.18 Revised June 2005 4

QUESTION 13:

What is arc voltage?

What happens to arc voltage when you increase or decrease the stickout length of the wire?

QUESTION 14:

Name three common shielding gas mixtures used for the GMAW process?

What type of materials can be welded with each of these shielding gas mixtures?

QUESTION 15:

Describe the term deposition rate?

What factors govern deposition rate?

QUESTION 16:

When welding carbon steels, what are the two common types of shielding gases used?

They each have typical characteristics; name three for each type of shielding gas?

QUESTION 17:

What type of shielding mixture is used for the spray-arc metal transfer welding of stainless
steel?

Unit MEM 5.18 Revised June 2005 5

QUESTION 18:

What type of shielding gas is used for welding stainless steel with the pulse-arc transfer
method?

QUESTION 19:

What are four main types of stainless steel used in industry?

QUESTION 20:

Name 5techniques used in welding stainless steel?

QUESTION21:

To weld 304N grade stainless steel, what are three choices of welding consumables?

QUESTION 22:

Name the 3 principal factors for consideration in welding aluminium?

Unit MEM 5.18 Revised June 2005 6

QUESTION 23:

When welding aluminum using GMAW there are associated problems that can occur with
the feed of the wire.

What are they and describe how you can overcome these during welding?

QUESTION 24:

From the following electrode classifications for GMAW wires,

 ES4 – GM – W503H
 ES6 - GI - W602
 ES2 - GC – W 705H

1) Describe the type of shielding gas used:

2) The tensile strength of the weld metal:

3) The impact energy of the weld metal:

4) Whether it is hydrogen controlled:

5) The chemical composition of the electrode:

Unit MEM 5.18 Revised June 2005 7

QUESTION 25:

Find the preheat temperature to weld bisalloy 80 material 25mm thick from the following
information and using the following equations.

The chemical composition of the material is as follows,

C = 0.23%, P = 0.025%, Mn = 1.5%, Si = 0.3%, Cr = 1.2%, Ni = 0.35%, S = 0.008%, Al =

0.007%.

Determine the minimum preheat requirements from the above information and the
following welding parameters.

Arc voltage = 21 volts.

Welding current = 220 amps.
Welding speed = 150mm/min.

Find the following information,

a) What is the carbon equivalent of the steel?

b) What is the material weldability group number?

c) What is the joint weldability index?

d) What is the arc energy input?

e) What is the minimum preheat required?

CE = C + Mn + Cr + Mo + V + Ni + Cu
6 5 15

Heat Input = 60 EL
1000V

V = Travel speed.

Unit MEM 5.18 Revised June 2005 8

E = voltage
L = welding current
Working Sheet

Unit MEM 5.18 Revised June 2005 9

QUESTION 26:

From the following diagram of weld joints work out the joint thickness required for
working out the preheat of materials as described in chapter 4 – welding of steels.

You must show all working out to pass each section.

A)

B)

Unit MEM 5.18 Revised June 2005 10

Working Sheet

Unit MEM 5.18 Revised June 2005 11

C)

Unit MEM 5.18 Revised June 2005 12

Working Sheet

Unit MEM 5.18 Revised June 2005 13

QUESTION 27:

From the following chemical compositions of steels, work out the carbon equilivant for
welding purposes.

Using the formulae attached to the sheet – chapter 4 – welding of steels.

If the steel does not contain a chemical element that is in the formulae, disregard it and
only use what is in the steel.

For example if it does not contain chrome do not use it in the formulae, and if it contains
chemical elements that are not in the formulae do not use them.

A) C = 0.3%
Mn = 1.2%
Cr = 0.5%
Mo = 0.25%

B) C = 0.15%
Mn = 1.5%
Cr = 0.4%
V = 0.3%
Ni = 0.3%

C) C = 0.25%
Mn = 1.25%
Cr = 0.5%
Cu = 0.05%

D) C = 0.20%
Mn = 1.3%
Cr = 0.55%
Mo = 0.35%
V = 0.15%
Ni = 0.15%
Cu = 0.12%

Show all working out to pass this learning outcome.

Unit MEM 5.18 Revised June 2005 14

Working Sheet

Unit MEM 5.18 Revised June 2005 15

Unit MEM 5.18 Revised June 2005 16
 JSA Safety Analysis

Date Student Name

Metal Fabrication

Description of Task Potential Hazards Identified Hazards controlled by

Machine or tool used

List of all PPE Required

Unit MEM 5.18 Revised June 2005 17

Student Name:

Assessor's Name: George Homsany

Assessment Date:

Unit MEM 5.18 Revised June 2005 18

Units/Elements of Competency

Unit MEM 5.18 – Perform Advanced Welding Using GMAW

Unit Code(s) and Title(s):

Assessment Decision
 Satisfactory  Not Yet Satisfactory

Feedback and Future Action

Gaps in Performance:

(where further evidence is

required)

Candidate's Feedback on Assessment Process:

_______________________________________________________________________________

_______________________________________________________________________________

_______________________________________________________________________________

_______________________________________________________________________________

Future Strategies Agreed as a Result of the Decision:

_______________________________________________________________________________

_______________________________________________________________________________

_______________________________________________________________________________

_______________________________________________________________________________

Date Candidate's Signature Assessor's Signature

___________________ ___________________ ___________________

ASSESSMENT FEEDBACK FORM

Unit MEM 5.18 Revised June 2005 19

RECORD OF ASSESSMENT BY
OBSERVATION/DEMONSTRATION
Unit MEM 5.18 Revised June 2005 20
Name of Student:

Unit(s):

Place of Assessment: Curtin University - Kalgoorlie Campus

Name of Assessor(s)/Observer(s) George Homsany

Observation Of:
Unit MEM 5.18A – Perform advanced gas metal arc welding process
During __________________, did the candidates: YES NO

 Select welding settings and consumables  

 Assemble welding equipment  

 Weld materials to meet Australian Standard 1554 Special Purpose  

 Inspect weld and correct faults  

 Maintain weld records  

 Satisfactory  Not Yet Satisfactory

Signed by Assessor ___________________ Date: ____________

Signed by Second Assessor (If Applicable) ___________________ Date: ____________

Unit MEM 5.18 Revised June 2005 21

Unit MEM 5.18 Revised June 2005 22