Question 1

Describe the approach employed by small shops to estimate the costs of welding.

Accepted Answer

The approach to estimating costs used by smaller shops is to get a price for the materials and then estimate the production time. Process and filler metal costs are considered, but little thought is given to the hidden costs of equipment depreciation, joint efficiency, power, and so on. With the majority of the welding jobs in these shops taking from a few hours to a few days and with costs ranging from a few hundred dollars to a few thousand dollars, extensive cost analysis cannot be justified. Extensive estimating may take more time than the job itself. To remain profitable and competitive, some cost estimation is required, however.

Question 2

How many cubic yards of concrete would be needed to fill a foundation hole that is 3 ft wide, 6 ft long and 3 ft deep?

Accepted Answer

A)  1 
B)  2 
C)  3 
D)  6 
A)  1 
B)  2 
C)  3 
D)  6 B

Question 3

The ____________________ tells us how many pounds of weld metal can be produced from a given weight of the electrode of welding wire.

Accepted Answer

deposition efficiency

Question 4

What are some of the applications of angles in welding?

Accepted Answer

A)  To lay out parts for cutting. 
B)  To locate the spot for drilling. 
C)  To align parts for welding. 
D)  All of the above 
A)  To lay out parts for cutting. 
B)  To locate the spot for drilling. 
C)  To align parts for welding. 
D)  All of the above

Question 5

The ____ of a welding process refers to the percentage of the welding filler material that actually becomes part of the weld deposit.

Accepted Answer

A)  deposition rate 
B)  deposition efficiency 
C)  productivity rate 
D)  productivity efficiency 
A)  deposition rate 
B)  deposition efficiency 
C)  productivity rate 
D)  productivity efficiency

Question 6

Most weldments use a tolerance of ± ____ inch or ± ____ inch.

Accepted Answer

A)  1/32, 1/16 
B)  1/16, 1/8 
C)  1/8, 1/4 
D)  1/4, 1/2 
A)  1/32, 1/16 
B)  1/16, 1/8 
C)  1/8, 1/4 
D)  1/4, 1/2

Question 7

The cross-sectional area of the weld groove is equal to ____.

Accepted Answer

A)  the root opening times the bevel depth 
B)  the plate thickness times the root gap 
C)  one-half of the root opening times the bevel depth 
D)  the groove volume times the weld length 
A)  the root opening times the bevel depth 
B)  the plate thickness times the root gap 
C)  one-half of the root opening times the bevel depth 
D)  the groove volume times the weld length

Question 8

Which of the following is not part of the labor cost?

Accepted Answer

A)  Benefits 
B)  Overtime 
C)  Tool rental 
D)  Hourly rate of pay 
A)  Benefits 
B)  Overtime 
C)  Tool rental 
D)  Hourly rate of pay

Question 9

Total ____________________ cost includes wages and benefits.

Accepted Answer

The answer of Total ____________________ cost includes wages and benefits....

Question 10

The formula for efficiency including stub loss must always be used when estimating the cost of depositing weld metal by the ____ method.

Accepted Answer

A)  SMAW 
B)  SAW 
C)  GMAW 
D)  FCAW 
A)  SMAW 
B)  SAW 
C)  GMAW 
D)  FCAW

Question 11

Why is it that small job shops often continue using the SMAW process even though it has a relatively low operating factor?

Accepted Answer

A)  The setup time for some more efficient processes can be lengthy and that can cause the operating factor to drop. 
B)  Most small shops would not have the necessary skills to operate a GMA or FCA welding system. 
C)  More productive welding processes are not available to small shops. 
D)  Most welders would rather stick weld anyway. 
A)  The setup time for some more efficient processes can be lengthy and that can cause the operating factor to drop. 
B)  Most small shops would not have the necessary skills to operate a GMA or FCA welding system. 
C)  More productive welding processes are not available to small shops. 
D)  Most welders would rather stick weld anyway.

Question 12

____ are measurements containing numbers that are expressed in two or more different units.

Accepted Answer

A)  Fractions 
B)  Decimal fractions 
C)  Whole numbers 
D)  Mixed units 
A)  Fractions 
B)  Decimal fractions 
C)  Whole numbers 
D)  Mixed units

Question 13

How does the flux in a FCAW wire compare to a SMAW electrode, and what does it affect?

Accepted Answer

A)  FCAW has less flux, but the wire is fed into the weld faster so there is more slag on a weld as compared to a SMA weld. 
B)  Both processes' filler metals have the same amount of flux, but only the FCAW flux gets pushed deeper into the molten weld pool. 
C)  FCAW wire has a lower flux-to-metal ratio so it is more efficient than SMAW. 
D)  SMAW filler rods are a lot bigger than FCAW wire, but there is more flux-to-filler metal in the FCAW filler wire. 
A)  FCAW has less flux, but the wire is fed into the weld faster so there is more slag on a weld as compared to a SMA weld. 
B)  Both processes' filler metals have the same amount of flux, but only the FCAW flux gets pushed deeper into the molten weld pool. 
C)  FCAW wire has a lower flux-to-metal ratio so it is more efficient than SMAW. 
D)  SMAW filler rods are a lot bigger than FCAW wire, but there is more flux-to-filler metal in the FCAW filler wire.

Question 14

A(n) ____________________ is a mathematical statement of the relationship of items.

Accepted Answer

The answer of A(n) ____________________ is a mathematical statement of...

Question 15

What is the area of a rectangle that is 21.5 ft by 10 ft?

Accepted Answer

A)  250 ft2 
B)  215 ft2 
C)  430 ft2 
D)  2.15 ft2 
A)  250 ft2 
B)  215 ft2 
C)  430 ft2 
D)  2.15 ft2

Question 16

A ____ is a number that uses a decimal point to denote a unit that is smaller than 1.

Accepted Answer

A)  fraction 
B)  mixed unit 
C)  decimal fraction 
D)  whole number 
A)  fraction 
B)  mixed unit 
C)  decimal fraction 
D)  whole number

Question 17

____ are numbers used to express units in increments of 1, so they can be divided evenly by the number 1.

Accepted Answer

A)  Decimal fractions 
B)  Whole numbers 
C)  Mixed units 
D)  Fractions 
A)  Decimal fractions 
B)  Whole numbers 
C)  Mixed units 
D)  Fractions

Question 18

Describe the efficiency of solid wires for SAW.

Accepted Answer

In submerged arc welding there is no spa

Question 19

In the ____ process, when the loss due to flux handling and flux recovery systems is considered, the average ratio of flux to wire is approximately 1.4 pounds of flux for each pound of wire consumed.

Accepted Answer

A)  FCAW 
B)  SMAW 
C)  GMAW 
D)  SAW 
A)  FCAW 
B)  SMAW 
C)  GMAW 
D)  SAW

Question 20

The deposition efficiency of the argon-shielded GMA process is about ____%.

Accepted Answer

A)  85 
B)  90 
C)  95 
D)  100 
A)  85 
B)  90 
C)  95 
D)  100

Exam 20: Shop Math and Weld Cost

Describe the approach employed by small shops to estimate the costs of welding.

How many cubic yards of concrete would be needed to fill a foundation hole that is 3 ft wide, 6 ft long and 3 ft deep?

The ____________________ tells us how many pounds of weld metal can be produced from a given weight of the electrode of welding wire.

What are some of the applications of angles in welding?

The ____ of a welding process refers to the percentage of the welding filler material that actually becomes part of the weld deposit.

Most weldments use a tolerance of ± ____ inch or ± ____ inch.

The cross-sectional area of the weld groove is equal to ____.

Which of the following is not part of the labor cost?

Total ____________________ cost includes wages and benefits.

The formula for efficiency including stub loss must always be used when estimating the cost of depositing weld metal by the ____ method.

Why is it that small job shops often continue using the SMAW process even though it has a relatively low operating factor?

____ are measurements containing numbers that are expressed in two or more different units.

How does the flux in a FCAW wire compare to a SMAW electrode, and what does it affect?

A(n) ____________________ is a mathematical statement of the relationship of items.

What is the area of a rectangle that is 21.5 ft by 10 ft?

A ____ is a number that uses a decimal point to denote a unit that is smaller than 1.

____ are numbers used to express units in increments of 1, so they can be divided evenly by the number 1.

Describe the efficiency of solid wires for SAW.

In the ____ process, when the loss due to flux handling and flux recovery systems is considered, the average ratio of flux to wire is approximately 1.4 pounds of flux for each pound of wire consumed.

The deposition efficiency of the argon-shielded GMA process is about ____%.

Introduction to Welding

Safety in Welding

Shielded Metal Arc Equipment, Setup, and Operation

Shielded Metal Arc Welding of Plate

Shielded Metal Arc Welding of Pipe

Shielded Metal Arc Welding Aws Sense Certification

Flame Cutting Equipment, Setup, and Operation

Plasma Arc Cutting Equipment, Setup, and Operation

Related Cutting Processes

Gas Metal Arc Welding Equipment, Setup, and Operation

Gas Metal Arc Welding

Flux Cored Arc Welding Equipment, Setup, and Operation

Flux Cored Arc Welding

Gas Metal Arc and Flux Cored Arc Welding of Pipe

Gas Metal Arc and Flux Cored Arc Welding Aws Sense Certification

Gas Tungsten Arc Welding Equipment, Setup, and Operation

Gas Tungsten Arc Welding of Plate

Gas Tungsten Arc Welding of Pipe

Gas Tungsten Arc Welding Plate and Pipe Aws Sense Certification

Reading Technical Drawings

Welding Joint Design and Welding Symbols

Fabricating Techniques and Practices

Welding Codes and Standards

Testing and Inspection

Welding Metallurgy

Weldability of Metals

Filler Metal Selection

Welding Automation and Robotics

Other Welding Processes

Oxyfuel Welding Equipment, Setup, and Operation

Oxyacetylene Welding and Brazing, Braze Welding, and Soldering

Filters

Most weldments use a tolerance of ± inch or ± inch.