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Stuff Every Welder Should Know

Welding and metal fabrication basics: processes, safety, metals and joints.

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  1. What polarity does MIG welding of mild steel use?
    Show the answer

    DC electrode positive (reverse polarity). MIG welding runs on direct current with the wire on the positive side. That setup is called DCEP, or reverse polarity.

  2. Self-shielded flux-cored wires like E71T-11 run on which polarity?
    Show the answer

    DC electrode negative (straight polarity). Hobart says T-8 and T-11 self-shielded wires should run on DCEN. Wrong polarity can add spatter. Solid MIG wire is the opposite and uses DCEP.

  3. What is the most common shielding gas mix for MIG welding mild steel?
    Show the answer

    75% argon, 25% carbon dioxide. The 75/25 argon and CO2 blend is the all-purpose choice for carbon steel. It runs smooth with little spatter.

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  1. What polarity does MIG welding of mild steel use?
  2. Self-shielded flux-cored wires like E71T-11 run on which polarity?
  3. What is the most common shielding gas mix for MIG welding mild steel?
  4. Compared with 75/25 argon and CO2, what does 100% CO2 shielding gas tend to give?
  5. What shielding gas is most common for MIG welding aluminum?
  6. Which shielding gas works for all TIG applications, all metals and thicknesses?
  7. When TIG welding steel, which polarity setting does Miller recommend?
  8. What current type is used for TIG welding aluminum?
  9. Which welding wire needs no external shielding gas?
  10. Should you push or drag a flux-cored gun?
  11. A typical MIG stickout is about how long?
  12. On a MIG welder, wire feed speed mainly affects which two things?
  13. Miller's rule: about how many amps for 1/8 inch steel with MIG?
  14. In the stick electrode E7018, what does the 70 mean?
  15. In an AWS stick electrode code like E7018, the third digit tells you what?
  16. Miller says to store opened low hydrogen E7018 electrodes at what temperature?
  17. Which stick electrode digs through rust, oil and paint but runs only on DC?
  18. What can E6011 do that E6010 cannot?
  19. Miller says E6013 electrodes should only be used on what?
  20. Which stick electrode has a lot of iron powder to boost deposition rates?
  21. Stick electrodes with AWS codes ending in which digits are low hydrogen?
  22. TIG welding's official name, GTAW, stands for what?
  23. A ground tungsten point should be how long compared with its diameter?
  24. Miller says to allow how much post-flow gas time after the TIG arc stops?
  25. Miller suggests holding the TIG torch at about what angle?
  26. Which joint design is the most common in all applications, per Miller?
  27. In a butt joint, how do the two pieces meet?
  28. What defines a lap joint?
  29. Two pieces joined at 90 degrees to form an L make which joint?
  30. Why is the flat welding position generally the easiest?
  31. What does the weld puddle naturally tend to do when welding vertically?
  32. Why is overhead welding often necessary?
  33. On a weld symbol, what is the arrow side?
  34. An open circle where the arrow meets the reference line means what?
  35. A flag at the arrow and reference line junction means the weld is made where?
  36. What does a plasma cutter use to cut metal?
  37. Oxy-fuel cutting is mainly used on which kind of metal?
  38. What gas does a typical plasma cutter run on?
  39. For steel thicker than 1 inch, which cutting tool is capable of greater speeds?
  40. Which of these is one of the four basic fuel gases used with oxygen for cutting?
  41. OSHA says an acetylene cylinder valve must not be opened more than how far?
  42. Which flux-cored type needs external gas and has easy-to-remove slag?
  43. Which wire is ideal for welding outdoors in windy conditions?
  44. ER70S-6 solid MIG wire is the usual pick for welding what?
  45. Which argon and CO2 mix does Miller say works well for MIG welding stainless steel?
  46. What feeder setup does Miller recommend for MIG welding soft aluminum wire?
  47. Hobart suggests what drag angle for E71T-11 self-shielded wire?
  48. What does the -1 in an electrode code like 7018-1 mean?
  49. What gun angle does Miller suggest for a MIG fillet weld?
  50. Under OSHA's general industry rule, how long must a fire watch continue after welding or cutting stops?
  51. Where practicable, how far from the work site should combustibles be moved before welding?
  52. Which gas must never be used to ventilate a confined space where welding is done?
  53. A welder crawls into a tank through a small opening. Who must be stationed outside?
  54. OSHA requires helmets or hand shields for arc welding, except for which process?
  55. How should other workers near an arc welding area be shielded from the arc rays?
  56. Besides the welder, who else must be provided with proper eye protection at the job?
  57. Per OSHA's guide, which shade number suits stick welding with 1/16 to 5/32 inch electrodes?
  58. OSHA's guide lists which shade for gas-shielded arc welding on ferrous metals with 1/16 to 5/32 inch electrodes?
  59. OSHA's guide lists which shade for stick welding with 5/16 and 3/8 inch electrodes?
  60. Gas welding light work up to 1/8 inch uses which shade in OSHA's guide?
  61. Indoors, OSHA says welding galvanized (zinc-coated) steel must be done with what?
  62. Indoors or in a confined space, welding cadmium-coated metal must be done with what?
  63. OSHA's minimum mechanical ventilation rate per welder is how many cubic feet per minute?
  64. Mechanical ventilation is required in a space with less than how many cubic feet per welder?
  65. In a confined space where ventilation is impossible, which agency must approve the airline respirators OSHA requires?
  66. Stored oxygen cylinders must be kept how far from fuel-gas cylinders, unless a fire barrier is used?
  67. When a gas cylinder is not in use, how should its valve protection cap be fitted?
  68. OSHA says acetylene must not be used at a pressure in excess of how many psig?
  69. How should acetylene cylinders be stored?
  70. Why must oxygen cylinders never be handled with oily hands or gloves?
  71. What words are marked on the gauges of oxygen regulators?
  72. What must be done to cylinder valves before moving the cylinders?
  73. How should compressed gas cylinders be kept relative to radiators and heat sources?
  74. Where must a gas cylinder NOT be placed, according to OSHA?
  75. A fuel-gas cylinder's valve leaks, and closing the valve will not stop it. Where should it go?
  76. What must be done with oxy-fuel hose that shows leaks, burns or worn places?
  77. Which welding machines are excepted from the rule that the frame or case must be grounded?
  78. Why should coiled welding cable be spread out before use?
  79. OSHA says welding cables with splices within what distance of the electrode holder shall not be used?
  80. When an electrode holder is not in use, how must it be placed?
  81. Which items must not be used to carry welding current?
  82. What must happen to a welding machine that has become wet before it is used again?
  83. Where must the work lead be firmly attached?
  84. What should be done with a welding cable that has damaged insulation or exposed bare conductors?
  85. What is the most common cause of porosity when MIG welding?
  86. Which base metal condition can lead to porosity in a weld?
  87. Which is a common cause of undercut in a MIG weld?
  88. Welder's flash, or arc eye, usually causes symptoms how long after the UV exposure?
  89. Which should never be used to treat welder's flash because it can delay healing?
  90. According to Miller, what does preheating the metal do for a weld?
  91. Aluminum's surface oxide melts at about 3,700 F. At what temperature does the aluminum underneath melt?
  92. Why is the magnet test not a perfect way to identify stainless steel?
  93. On a bench grinder, the work rest may be how far from the wheel at most?
  94. What is the 'ring test' done on a grinding wheel before mounting it?
  95. How should you hold metal that you are drilling on a drill press?
  96. As the drill bit gets larger, what should happen to drill press spindle speed?
  97. Why does a tight-fitting seam help limit warping on thin metal?
  98. What is layout dye used for before scribing lines on metal?
  99. OSHA says gloves for welding, cutting or burning must be leather (or equivalent) and free of what?
  100. When bandsawing, how many teeth should be in contact with the thickness of the material?