Welding Principles and Applications 7th Edition Jeffus Test Bank

Welding Principles and Applications
7th Edition Jeffus Test Bank

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Welding Principles and Applications 7th Edition Jeffus Test Bank
Chapter 3 Shielded Metal Arc Equipment, Setup, and Operation
TRUE/FALSE
1. SMAW is a rarely used welding process because of its cost and lack of flexibility.
ANS: F PTS: 1 REF: 55
2. The temperature of a welding arc does not exceed 1,100 degrees Fahrenheit.
3. The maximum safe open circuit voltage for welders is 80 volts.
ANS: T PTS: 1 REF: 59
4. Alternators can be smaller in size and lighter in weight than generators and still produce the same
amount of power.
5. Rectifiers must be connected to a heat sink and cool air blown over them.
6. Shielded metal arc welding often continues for long periods of time.
7. Large welding lead sizes make electrode manipulation easier.
8. If an electrode holder becomes hot, you should never dip it in water to cool it off.
9. A properly sized electrode holder can overheat if its jaws are dirty or loose.
10. Arc welding machines may be stacked to save space as long as there is enough room between them
for air to circulate.
MULTIPLE CHOICE
1. Which of the following is true of shielded metal arc welding?

a. The machine and the electrodes are expensive.
b. Metal as thin as 1/16 inch to several feet thick can be welded using the same machine.
c. There is a lot of equipment required, and it is difficult to move.
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d. The process is not suitable for cast iron, aluminum, stainless steel or nickel.
ANS: B PTS: 1 REF: 55
2. Electrons flow through a conductor ____.

a. from negative to positive c. from negative to negative
b. from positive to negative d. from positive to positive
ANS: A PTS: 1 REF: 55
3. Resistance to the flow of electrons produces ____.

a. electricity c. light
b. voltage d. heat
ANS: D PTS: 1 REF: 55-56
4. The three units used to measure an electrical current are ____.

a. voltage, ohms, and arc length c. arc length, amps, and watts
b. ohms, arc length, and amps d. amps, watts, and volts
ANS: D PTS: 1 REF: 56
5. ____ controls the maximum gap the electrons can jump to form the arc.
a. Voltage c. Heat
b. Amperage d. Wattage
6. ____ controls the size of the arc.

a. Voltage c. Heat
7. ____ is a measurement of the amount of electrical energy or power in the arc.

a. Voltage c. Heat
8. The temperature of a welding arc is dependent on the ____, arc length, and atmosphere.
a. wattage c. amperage
b. capacitance d. voltage
9. The amount of heat produced by a welding arc is determined by the ____.

a. amperage c. voltage
b. wattage d. capacitance
10. The shielded metal arc welding machine’s voltage output ____ as its current ____.
a. decreases, decreases c. increases, decreases
b. increases, increases d. decreases, increases
11. Open circuit voltage ____.
a. is the voltage at the arc during welding
b. is the voltage at the electrode before striking an arc
c. varies with arc length, type of electrode, type of current, and polarity
d. is usually between 10 V and 45 V
12. ____ can cause an arc to move during a weld.

a. Alternating current c. Uneven flux lines
b. Air currents d. Imperfections in the welding material
ANS: C PTS: 1 REF: 59
13. A transformer with more turns of wire in the primary winding than in the secondary winding is
known as a ____.
a. welding transformer c. step-down transformer
b. low-amperage transformer d. high-voltage transformer
14. The major classifications of welding machines are ____.

a. multiple core, inversion, transformer
b. multiple inversion, transformer core, and step-down
c. multiple coil, movable coil, movable core, and inverter
d. magnetic core, movable coil, and transformer
15. The ____ machine allows the selection of different current settings by tapping into the secondary
coil at a different turn value.
a. inverter c. multiple-coil
b. transformer d. movable-coil
16. ____ machines are adjusted by turning a handwheel that moves the internal parts closer together or
farther apart.
a. Movable coil c. Inverter
b. Tap type d. Transformer
17. In a standard welding transformer, the size of the iron core is determined by ____.
a. the distance between the coils
b. the length of time it takes for the magnetic field to build up and collapse
c. the desired thickness of the weld bead
d. the speed of the rotor
18. A(n) ____ produces AC, and a(n) ____ produces DC.
a. alternator, generator c. diode, alternator
b. generator, alternator d. generator, diode
ANS: A PTS: 1 REF: 63-64
19. In alternators the welding current is produced on the ____.

a. brushes c. armature
b. diode d. stator
20. In generators the welding current is produced on the ____.

a. brushes c. armature
b. diode d. stator
21. The heat produced by a rectifier ____.

a. leads to a higher amperage in DC than AC
b. reduces the power efficiency of the welding machine
c. increases the power efficiency of the welding machine
d. can be recycled in a heat sink to provide power to other machines
22. A 60% duty cycle means that the machine can be used a total of ____ minutes out of every ten
minutes at the maximum rated current.
a. two c. eight
b. six d. ten
23. Welding cables made of aluminum wire must be ____ would be required for copper.
a. one size smaller than c. one size larger than
b. the same size as d. two sizes larger than
24. A work clamp ____.

a. may have power losses that should be ignored
b. reduces welding efficiency
c. must not clamp too tightly to the material
d. should be carefully touched occasionally to determine if it is hot
25. Welding cables should ____.

a. be wrapped around the body to distribute the weight
b. be sufficiently long to reach the work station
c. never be installed overhead
d. be placed on the floor in aisles and walkways
COMPLETION
1. An electric current is the flow of ____________________.

ANS: electrons
PTS: 1 REF: 55
2. ____________________ is a measure of electric pressure.
ANS:
Voltage
Volts
V
PTS: 1 REF: 56
3. ____________________ is the measurement of the total number of electrons flowing.
ANS:
Amperage
Amperes
Amps
A
PTS: 1 REF: 56
4. ____________________ is the measurement of the amount of electrical energy or power in the

arc.
ANS:
Wattage
Watts
W
PTS: 1 REF: 56
5. The positive side of an electrode arc is called a(n) ____________________.
ANS: anode
PTS: 1 REF: 57
6. The negative side of an electrode arc is called a(n) ____________________.
ANS: cathode
PTS: 1 REF: 57
7. In a(n) ____________________ welding machine the incoming power is changed from 60 cycles
per second to several thousand cycles per second.
ANS: inverter
PTS: 1 REF: 63
8. A(n) ____________________ allows a current to flow in one direction only.

ANS: rectifier
PTS: 1 REF: 65
9. The ______________________________ is the percentage of time a welding machine can be used

continuously.
ANS: duty cycle
PTS: 1 REF: 66
10. The terms welding cables and ____________________ mean the same thing.
ANS: welding leads
PTS: 1 REF: 66
SHORT ANSWER
1. Give an overview of the process of shielded metal arc welding.
ANS:
Shielded metal arc welding (SMAW) is a welding process that uses a flux-covered metal electrode
to carry an electrical current. The current forms an arc across the gap between the end of the
electrode and the work. The electric arc creates sufficient heat to melt both the electrode and the
work. Molten metal from the electrode travels across the arc to the molten pool on the base metal,
where they mix together. The end of the electrode and molten pool of metal is surrounded,
purified, and protected by a gaseous cloud and a covering of molten flux produced as the flux
coating of the electrode burns or vaporizes. As the arc moves away, the mixture of molten
electrode and base metal solidifies and becomes one piece. At the same time, the molten flux
solidifies forming a solid slag. Some electrode types produce heavier slag coverings than others.
PTS: 1 REF: 55
2. Explain what magnetic flux lines are and how they may cause a wire to move when welding with
very high amperages.
ANS:
When electrons flow they create lines of magnetic force that circle around the line of flow. Lines
of magnetic force are referred to as magnetic flux lines. These lines space themselves evenly along
a current-carrying wire. If the wire is bent, the flux lines on one side are compressed together, and
those on the other side are stretched out. The unevenly spaced flux lines try to straighten the wire
so that the lines can be evenly spaced once again. The force that they place on the wire is usually
small. However, when welding with very high amperages, 600 amperes or more, the force may
cause the wire to move.
PTS: 1 REF: 59
3. Explain how a welding transformer works.
ANS:
Welding Principles and Applications 7th Edition Jeffus Test Bank
A welding transformer uses the alternating current (AC) supplied to the welding shop at a high
voltage to produce the low-voltage welding power. As electrons flow through a wire they produce
a magnetic field around the wire. If the wire is wound into a coil the weak magnetic field of each
wire is concentrated to produce a much stronger central magnetic force. Because the current being
used is alternating or reversing each 1/120 of a second, the magnetic field is constantly being built
and allowed to collapse. By placing a second or secondary winding of wire in the magnetic field
produced by the first or primary winding, a current will be induced in the secondary winding. The
placing of an iron core in the center of these coils will increase the concentration of the magnetic
field.
PTS: 1 REF: 60
4. Explain how generators and alternators work, and the similarities and differences between them.
ANS:
Generators and alternators both produce welding electricity from a mechanical power source. Both
devices have an armature that rotates and a stator that is stationary. As a wire moves through a
magnetic force field, electrons in the wire are made to move, producing electricity.
In an alternator, magnetic lines of force rotate inside a coil of wire. An alternator can produce AC
only. In a generator, a coil of wire rotates inside a magnetic field. A generator produces DC. It is
possible for alternators to use diodes to change the AC to DC for welding. In generators, the
welding current is produced on the armature and is picked up with brushes. In alternators, the
welding current is produced on the stator, and only the small current for the electromagnetic force
field goes across the brushes. Therefore, the brushes in an alternator are smaller and last longer.
Alternators can be smaller in size and lighter in weight than generators and still produce the same
amount of power.
PTS: 1 REF: 63-64
5. Explain how an alternating welding current can be converted to a direct current.
ANS:
Alternating welding current can be converted to direct current by using a series of rectifiers. A
rectifier allows current to flow in one direction only. If one rectifier is added, it would be difficult
to weld. A series of rectifiers, known as a bridge rectifier, can modify the alternating current.
Rectifiers become hot as they change AC to DC. They must be attached to a heat sink and cooled
by having air blown over them. The heat produced by a rectifier reduces the power efficiency of
the welding machine. At the same dial settings for AC and DC, the DC is at a lower amperage. The
difference in amperage (power) is due to heat lost in the rectifiers. The loss in power makes
operation with AC more efficient and less expensive compared to DC.
PTS: 1 REF: 65
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Welding Principles and Applications

7th Edition Jeffus Test Bank

Chapter 3 Shielded Metal Arc Equipment, Setup, and Operation

ANS: F PTS: 1 REF: 55

ANS: F PTS: 1 REF: 56

3. The maximum safe open circuit voltage for welders is 80 volts.

ANS: T PTS: 1 REF: 59

ANS: T PTS: 1 REF: 64

ANS: T PTS: 1 REF: 65

ANS: F PTS: 1 REF: 66

7. Large welding lead sizes make electrode manipulation easier.

ANS: F PTS: 1 REF: 66

ANS: T PTS: 1 REF: 67

ANS: T PTS: 1 REF: 67

ANS: T PTS: 1 REF: 68

1. Which of the following is true of shielded metal arc welding?

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2. Electrons flow through a conductor ____.

3. Resistance to the flow of electrons produces ____.

4. The three units used to measure an electrical current are ____.

6. ____ controls the size of the arc.

7. ____ is a measurement of the amount of electrical energy or power in the arc.

9. The amount of heat produced by a welding arc is determined by the ____.

12. ____ can cause an arc to move during a weld.

14. The major classifications of welding machines are ____.

19. In alternators the welding current is produced on the ____.

20. In generators the welding current is produced on the ____.

21. The heat produced by a rectifier ____.

24. A work clamp ____.

25. Welding cables should ____.

1. An electric current is the flow of ____________________.

2. ____________________ is a measure of electric pressure.

3. ____________________ is the measurement of the total number of electrons flowing.

4. ____________________ is the measurement of the amount of electrical energy or power in the

5. The positive side of an electrode arc is called a(n) ____________________.

6. The negative side of an electrode arc is called a(n) ____________________.

8. A(n) ____________________ allows a current to flow in one direction only.

9. The ______________________________ is the percentage of time a welding machine can be used

ANS: duty cycle

ANS: welding leads

1. Give an overview of the process of shielded metal arc welding.

3. Explain how a welding transformer works.

PTS: 1 REF: 63-64

5. Explain how an alternating welding current can be converted to a direct current.

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