Submerged Arc Welding (SAW)

1.

Q1. In Submerged Arc Welding (SAW), the arc is struck between:

A) A coated electrode and parent metal

B) A continuous bare wire and the parent plate

C) Tungsten electrode and parent plate

D) Gas-shielded electrode and base plate

2.

Q2. In SAW, the arc and molten pool are protected by:

A) CO₂ gas

B) Argon shielding

C) A granular flux

D) Vacuum chamber

3.

Q3. The main function of the flux in SAW is to:

A) Increase deposition rate only

B) Protect the weld from contamination

C) Provide filler metal

D) Reduce current requirement

4.

Q4. The wire electrode in SAW is fed by:

A) Manual hand feed

B) Motor-driven rollers

C) Magnetic field

D) Compressed gas pressure

5.

Q5. The use of flux in SAW restricts the welding to:

A) All positions

B) Overhead position only

C) Flat and horizontal-vertical positions

D) Vertical-up position

6.

Q6. In SAW, unmelted flux:

A) Must be discarded

B) Becomes electrode coating

C) Is reclaimed and reused

D) Turns into shielding gas

7.

Q7. Which current polarity in SAW provides deep penetration up to 1000A?

A) DC positive (DC+ve)

B) DC negative (DC–ve)

C) AC only

D) Pulsed current

8.

Q8. For cladding operations in SAW, which polarity is preferred?

A) AC

B) DC negative (DC–ve)

C) DC positive (DC+ve)

D) Alternating + pulsed

9.

Q9. To avoid arc blow at higher currents or multiple electrode systems, SAW often uses:

A) DC–ve

B) AC

C) Pulsed DC

D) Hybrid power source

10.

Q10. In multiple electrode SAW systems, the lead arc usually uses:

A) AC

B) DC+ve

C) DC–ve

D) Pulsed DC

11.

Q11. A typical application of SAW is:

A) Car body repair

B) Thin sheet welding

C) Fabrication of ships and pressure vessels

D) Jewelry welding

12.

Q12. Minimum thickness suitable for SAW welding is about:

A) 2 mm

B) 3 mm

C) 5 mm

D) 1 mm

13.

Q13. Which of the following is NOT a material joined by SAW?

A) Carbon steels

B) Stainless steels

C) Titanium alloys

D) Nickel alloys

14.

15.

Q14. Fluxes in SAW are generally:

A) Liquid solutions

B) Granular mineral compounds

C) Organic binders

D) Powdered aluminum

16.

Q15. Fused fluxes are produced by:

A) Chemical vapor deposition

B) Sintering powders

C) Melting constituents in a furnace and granulating

D) Spray coating

17.

Q16. A major advantage of fused fluxes is:

A) Higher porosity

B) More hygroscopic nature

C) Good chemical homogeneity

D) Difficult recycling

18.

Q17. A disadvantage of fused fluxes is:

A) Low stability

B) Limited composition range

C) Easy contamination

D) Excess alloy content

19.

20.

Q18. Agglomerated fluxes are bonded by:

A) Heat fusion

B) Potassium or sodium silicate

C) Resin coating

D) Metal oxides

21.

Q19. One advantage of agglomerated fluxes is:

A) Difficult to alloy

B) Poor flux layer

C) Deoxidisers and alloying can be added easily

D) No recycling possible

22.

Q20. One disadvantage of agglomerated fluxes is:

A) High chemical homogeneity

B) More hygroscopic nature

C) Easier storage

D) Stronger arc control

23.

Q21. Increasing welding current in SAW results in:

A) Reduced penetration

B) Increased penetration and wire melt-off

C) Lower deposition

D) No effect

24.

Q22. Excessively high welding current may cause:

A) Wide flat bead

B) Lack of fusion

C) Burn-through and undercut

D) Uniform bead

25.

Q23. Arc voltage mainly controls:

A) Travel speed

B) Bead shape and appearance

C) Heat input only

D) Filler wire type

26.

Q24. Excessively high arc voltage in SAW may result in:

A) Deeper penetration

B) Wide bead prone to cracking

C) Narrow bead with lack of fusion

D) Stable arc

27.

Q25. Increasing travel speed in SAW generally:

A) Increases heat input

B) Increases penetration

C) Decreases penetration and bead size

D) No effect

28.

Q26. Excessively low welding current in SAW may cause:

A) Wide bead with porosity

B) Unstable arc and lack of penetration

C) Smooth and defect-free weld

D) Deep penetration

29.

Q27. Increasing arc voltage with constant current in SAW will:

A) Narrow the bead

B) Reduce flux consumption

C) Produce a flatter, wider bead

D) Reduce bead width

30.

Q28. Excessively low arc voltage produces:

A) Wide flat bead

B) High narrow bead

C) Bead prone to cracking

D) Uniform wide bead

31.

Q29. Increasing travel speed in SAW decreases

A) Weld bead depth

B) Heat input per unit length

C) Arc length

D) Flux coverage

32.

Q30. High travel speed leads to:

A) More filler metal per unit length

B) Wider bead

C) Deeper penetration

D) Smaller bead size

33.

Q31. Electrode size affects:

A) Only flux consumption

B) Only voltage

C) Bead shape and depth of penetration

D) Power supply

34.

Q32. A smaller diameter electrode at same current produces:

A) Lower current density

B) Lower deposition rate

C) Higher current density and deposition rate

D) No effect

35.

Q33. A larger diameter electrode can:

A) Carry less current

B) Reduce deposition at high amperage

C) Carry more current and give higher deposition at high amperage

D) Cause porosity only

36.

Q34. Electrode extension refers to:

A) Distance between arc and base metal

B) Electrode protrusion beyond contact tip

C) Arc length

D) Flux thickness

37.

Q35. Increasing electrode extension in SAW:

A) Reduces melting rate

B) Increases melting rate but decreases penetration

C) Decreases electrode heating

D) Improves penetration

38.

Q36. In SAW, stainless steel electrodes:

A) Melt slower than carbon steel

B) Have less resistance heating

C) Melt faster due to higher resistance heating

Need no extension

39.

Q37. Excessively deep flux layer causes:

A) Stable bead

B) Confinement of arc and rope-like weld

C) Smooth weld with wide bead

D) Full arc exposure

40.

Q38. If flux layer is too shallow:

A) Smooth weld without defects

B) High penetration

C) Arc not fully submerged, spatter and porosity

D) Strong bead with uniform finish

41.

Q39. Fluxes should be stored carefully because

A) They lose color

B) They become magnetic

C) They absorb moisture and cause porosity

D) They melt during storage

42.

Q40. SAW wire electrodes are often copper-coated to:

A) Reduce melting rate

B) Increase hardness

C) Improve corrosion resistance and feeding

D) Reduce penetration

43.

Q41. Rust on SAW electrodes is harmful because:

A) Improves arc stability

B) Enhances penetration

C) May cause hydrogen-induced cracking

D) Reduces bead size only

44.

Q42. Oil, grease or paint contamination in SAW electrodes may:

A) Improve finish

B) Increase weld strength

C) Cause no major problem

D) Lead to hydrogen absorption and property changes

45.

Q43. Carbon pick-up from contaminants in SAW may:

A) Improve corrosion resistance

B) Cause undesirable property changes

C) Increase ductility

D) Reduce hydrogen content

46.

Q44. Manufacturers recommend drying fluxes before use to:

A) Increase bead width

B) Change bead color

C) Prevent porosity and cracking

D) Reduce deposition rate

47.

Q45. In SAW, power sources usually provide:

A) Constant current only

B) Constant voltage (flat characteristic)

C) Pulsed high frequency only

d) Alternating square wave only

48.

46. Power sources for SAW can supply current in excess of:

a) 500 A

B) 700 A

C) 900 A

D) 1000 A

49.

Q47. Arc length in SAW is mainly controlled by

A) Wire feed rollers

B) Flux depth

C) Arc voltage

D) Polarity

50.

Q48. Excessively high arc voltage may lead to:

A) Smooth finish

B) Stronger weld

C) Solidification cracking and slag problems

D) Deep penetration

51.

Q49. Excessively long electrode extension causes:

A) Deep penetration

B) Narrow bead

C) Reduced penetration and bead width

D) Stable bead shape

52.

Q50. SAW is widely applied in industries because

A) It produces high spatter

B) It allows overhead welding easily

C) It gives high deposition rates and deep penetration

D) It requires no flux

53.

Q51. The shielding in SAW is provided by:

A) Carbon dioxide gas

B) Granular flux covering the arc

C) Argon atmosphere

D) Water-cooled chamber

54.

Q52. One reason SAW produces no spatter is:

A) Low current density

B) Flux composition

C) Arc is fully submerged in flux

D) Low voltage

55.

Q53. Which welding positions are NOT suitable for SAW?

A) Flat

B) Horizontal-vertical

C) Overhead and vertical-up

D) Circumferential

56.

Q54. Which current type helps reduce penetration and dilution in SAW cladding?

A) AC

B) DC+ve

C) DC–ve

D) Pulsed DC

57.

Q55. A major limitation of SAW is:

A) Slow deposition rate

B) Lack of shielding gas

C) Restricted to certain positions due to flux use

D) Poor weld strength

58.

Q56. Fused fluxes are identified by:

A) Moisture absorption

B) Uniform glass-like particles

C) Metallic appearance

D) Brown powder color

59.

Q57. A major disadvantage of fused fluxes is:

a) Easy segregation

B) Limited composition (cannot include carbonates)

C) Easy porosity control

D) Very hygroscopic

60.

Q58. Agglomerated fluxes can be easily identified because:

A) They always look metallic

B) They dissolve in water

C) They differ in color and shape

D) They have no particle variation

61.

Q59. Agglomerated fluxes allow addition of:

A) Paint coatings

B) Alloying and deoxidising elements

C) Lubricants

D) Cooling agents

62.

Q60. A problem with agglomerated fluxes is:

A) High cost

B) Limited particle size

C) Hygroscopic nature causing moisture absorption

D) Strong arc control

63.

Q61. Increasing welding current in SAW causes:

A) Narrow bead, no penetration

B) More spatter

C) Greater penetration and faster melt-of

D) No change

64.

62. Excessively high welding current may result in:

A) Concave bead

B) Burn-through and solidification cracking

C) Porosity-free weld

D) Smooth uniform bead

65.

Q63. Excessively low welding current results in:

A) Wide bead prone to cracking

B) Good fusion

C) Unstable arc and lack of penetration

D) High deposition

66.

Q64. Arc voltage increase generally produces:

A) Narrow, deep bead

B) Less flux consumption

C) Flatter, wider bead

D) Narrow penetration

67.

Q65. Excessive arc voltage in SAW can cause:

A) Strong fillet welds

B) Easy slag removal

C) Concave fillet welds prone to cracking

D) Narrow weld bead

68.

Q66. Reducing arc voltage produces:

A) Wide bead with cracking

B) More porosity

C) A stiffer arc with better penetration

D) Easy slag removal

69.

Q67. If travel speed is increased too much:

A) Heat input increases

B) More filler per unit length

C) Penetration decreases and bead becomes smaller

D) Arc length increases

70.

Q68. Electrode size increase at constant current:

A) Lowers deposition

B) Improves porosity

C) Produces wider bead with less penetration

D) Reduces flux consumption

71.

Q69. A small electrode at constant current density gives:

A) Less deposition

B) Lower arc stiffness

C) Higher deposition rate

D) Lower penetration

72.

Q70. Electrode extension heating can raise melting rate by:

A) 10–20%

B) 15–30%

C) 25–50%

D) Over 80%

73.

Q71. Too long an electrode extension results in:

A) Higher penetration

B) No change in deposition

C) Reduced penetration and narrow bead

D) Stronger bead

74.

Q72. In SAW, stainless steel electrodes compared to carbon steel electrodes:

A) Melt slower

B) Have equal resistance

C) Melt faster due to higher resistance

D) Have no effect

75.

Q73. If flux layer is excessively deep, weld appearance becomes:

A) Smooth

B) Concave

D) Fine and uniform

76.

Q74. If flux layer is too shallow:

A) Weld becomes perfect

B) High penetration without defects

C) Arc flashing, spatter, porosity

D) Strong uniform bead

77.

Q75. The main purpose of drying fluxes before use is:

A) Change flux color

B) Increase weld hardness

C) Avoid porosity and cracking

D) Reduce arc length

78.

Q76. Copper coating on SAW electrodes helps in:

A) Increasing melting rate

B) Corrosion resistance and smooth feeding

C) Reducing bead size

D) Increasing slag thickness

79.

Q77. Rust on SAW electrode wires can:

A) Increase strength

B) Lead to hydrogen cracking

C) Improve penetration

D) Help bead shape

80.

Q78. Oil or grease contamination on electrodes causes:

A) Better arc stability

B) Stronger weld metal

D) Smooth finish

81.

Q79. Carbon pick-up from contaminants generally:

A) Improves ductility

B) Increases corrosion resistance

C) Causes undesirable property changes

D) No effect

82.

Q80. Fluxes should be stored as per:

A) Welder’s personal method

B) Manufacturer’s recommendations

C) Any storage condition

D) Flux drying avoided

83.

Q81. Porosity in SAW may result from:

A) Low current

B) Moisture in flux

C) Proper arc length

D) Correct polarity

84.

Q82. Hydrogen absorption in SAW is mainly caused by:

A) High travel speed

B) AC supply

C) Moisture and contamination

D) Wide bead

85.

Q83. A power source with flat characteristic in SAW means:

A) Constant current

B) Pulsed current

C) Constant voltage

D) Low frequency

86.

Q84. Typical SAW voltage range is approximately:

A) 5–15 V

B) 10–25 V

C) 14–50 V

D) 60–100 V

87.

Q85. In SAW, arc length increases when:

A) Current decreases

B) Voltage increases

C) Flux depth decreases

D) Travel speed increases

88.

Q86. In multi-electrode SAW, the trailing arc often uses:

A) DC–ve

B) Pulsed DC

C) AC

D) Square wave

89.

Q87. A common industrial application of SAW is:

A) Thin sheet welding

B) Car repairs

C) Linepipe and ship fabrication

D) Jewelry welding

90.

Q88. Minimum material thickness recommended for SAW is:

A) 1 mm

B) 2 mm

C) 3 mm

D) 5 mm

91.

Q89. In cladding with SAW, which polarity reduces dilution?

A) AC

B) DC–ve

C) DC+ve

D) Pulsed DC

92.

Q90. One main reason for preferring AC in high-current SAW is:

A) To reduce slag

B) To avoid arc blow

C) To improve bead width

D) To prevent porosity

93.

Q91. Flux fines (very fine powder) are removed because:

A) They increase bead strength

B) They cause instability without changing composition

C) They are expensive

D) They reduce voltage

94.

Q92. Agglomerated fluxes may produce gas evolution during welding, leading to:

A) Smooth finish

B) Better penetration

C) Porosity

D) Thicker slag

95.

Q93. Excessively high current density in small electrode produces:

A) Soft arc

B) Stiff arc with deep penetration

C) Poor fusion

D) Shallow bead

96.

Q94. Too low current density in an electrode results in:

A) Stiff penetrating arc

B) Soft arc with less penetration

C) Burn-through

D) Higher deposition

97.

Q95. High arc voltage helps in:

A) Increasing slag viscosity

B) Narrow bead

C) Bridging excessive root opening

D) Reducing deposition

98.

Q96. A concave fillet weld formed in SAW due to high voltage is prone to:

A) Corrosion resistance

B) Deep penetration

C) Cracking

D) Smooth slag removal

99.

Q97. Rust on SAW flux is dangerous because it:

A) Improves arc stability

B) Is hygroscopic and introduces hydrogen

C) Makes slag easier to remove

D) Improves weld appearance

100.

Q98. The most common power source for SAW is:

A) Constant current rectifier

B) High-frequency AC generator

C) Transformer/rectifier with flat characteristic

D) Battery supply

101.

Q99. The weld bead in SAW becomes rope-like when:

A) Flux is too shallow

B) Current is too high

C) Flux layer is too deep

D) Voltage is too low

102.

Q100. SAW is preferred for long welds because:

A) It requires manual feeding

B) It uses short arc

C) It achieves high deposition rates with efficiency

D) It avoids flux altogether

103.

Q101. In SAW, the main role of flux is to:

A) Act as a filler metal

B) Only cover the bead

C) Protect, refine, and stabilize the arc

D) Reduce power requirement

104.

Q102. The molten slag in SAW primarily:

A) Weakens the weld

B) Cools the metal instantly

C) Shields weld metal and shapes bead

D) Produces porosity

105.

Q103. Which factor mainly controls penetration depth in SAW?

A) Flux type only

B) Arc length

C) Welding current

D) Storage condition

106.

Q104. To increase deposition rate in SAW, one should:

A) Lower current

B) Use larger wire diameter and high current

C) Reduce voltage

D) Reduce flux coverage

107.

Q105. In deep groove welds, multiple electrodes are used mainly to:

A) Reduce filler use

B) Increase penetration and deposition

C) Prevent slag formation

D) Reduce porosity

108.

Q106. Porosity in SAW welds can often be reduced by:

A) Using rusted wire

B) Higher travel speed

C) Drying flux properly

D) Shallow penetration

109.

Q107. The maximum thickness welded in one pass by SAW is usually around:

A) 10 mm

B) 15 mm

C) 20 mm

D) 40–50 mm with proper preparation

110.

Q108. The typical current range for industrial SAW is:

A) 50–150 A

B) 150–300 A

C) 300–600 A

D) 500–2000 A

111.

Q109. In SAW, flux depth is usually kept at:

A) 1–2 mm

B) 5–10 mm

C) 25–50 mm

D) 100 mm

112.

Q110. Excessive flux depth may cause:

A) Higher efficiency

B) Arc instability and poor bead

C) Better fusion

D) Lower risk of porosity

113.

Q111. For welding thick plates in SAW, the groove angle is generally:

A) 10–20°

B) 30–45°

C) 60–70°

D) 80–90°

114.

Q112. The flux recovery system in SAW is important because:

A) It increases arc voltage

B) It removes weld spatter

C) It saves flux and reduces waste

D) It prevents slag cracking

115.

Q113. In SAW, if the arc is not buried properly under flux, it may cause:

A) Higher penetration

B) Lower slag

C) Arc flash exposure to operator

D) Less hydrogen

116.

Q114. A convex fillet weld in SAW indicates:

A) Proper voltage

B) Too low voltage

C) Correct current

D) High speed

117.

Q115. DC–ve polarity in SAW is mainly used for:

A) Deep penetration

B) Cladding to reduce dilution

C) Thin sheet welding

D) Fillet welds

118.

Q116. High travel speed in SAW often leads to:

A) Smooth wide bead

B) Undercut and lack of fusion

C) High deposition

D) No effect

119.

Q117. The solidified slag in SAW is usually:

A) Non-removable

B) Metallic

C) Brittle and easily detachable

D) Flexible

120.

Q118. The wire feed rate in SAW is directly linked to:

A) Voltage

B) Welding current

C) Flux depth

D) Arc length

121.

Q119. When welding vertical joints with SAW, special equipment is used because:

A) Flux cannot flow upward naturally

B) Slag is too heavy

C) Process is mainly suited for flat and horizontal welding

D) Wire breaks frequently

122.

Q120. The maximum efficiency of SAW in terms of filler utilization is about:

A) 40%

B) 60%

C) 99% (near 100%)

D) 70%

123.

Q121. In SAW, excessive spatter is usually a sign of:

A) Low flux coverage

B) Incorrect voltage or polarity

C) Clean surface

D) Good bead profile

124.

Q122. The deposition efficiency of SAW compared to SMAW is:

A) Lower

B) About the same

C) Much higher

D) Negligible difference

125.

Q123. Hydrogen-induced cracking in SAW is rare because:

A) It uses thin wires

B) It is done manually

C) Flux is baked/dry, and arc is covered

D) Voltage is low

126.

Q124. Which type of joint is least suitable for SAW?

A) Butt joint

B) Fillet joint

C) Thin sheet lap joint

D) Groove weld

127.

Q125. The main limitation of SAW in field work is:

A) It requires constant current

B) Lack of filler control

C) Bulky equipment and flux handling

D) High efficiency

128.

Q126. The SAW process is most effective in:

A) Overhead welding

B) Vertical welding

C) Flat and horizontal welding

D) All positions equally

129.

Q127. Which parameter primarily affects bead width in SAW?

A) Current

B) Voltage

C) Electrode diameter

D) Flux baking

130.

Q128. Deep penetration in SAW is favored by:

A) AC supply

B) DC+ve polarity

C) DC–ve polarity

D) Low current

131.

Q129. The submerged arc remains invisible because:

A) Current is too low

B) Light intensity is weak

C) It is completely covered by flux

D) Arc is pulsed

132.

Q130. Which joint preparation is most common for thick plate SAW?

A) Square butt

B) Double V or U groove

C) Edge joint

D) Spot weld

133.

Q131. The flux composition in SAW can alter:

A) Only bead shape

B) Mechanical properties of weld metal

C) Electrode diameter

D) Arc length

134.

Q132. To avoid hydrogen cracking in SAW, flux should be:

A) Stored in open air

B) Baked and kept dry

C) Mixed with grease

D) Sprayed with oil

135.

Q133. The highest deposition rates in welding are usually achieved by:

A) SMAW

B) TIG

C) SAW

D) Oxy-fuel

136.

Q134. In multiple wire SAW, deposition is increased without:

D) Using larger electrode diameter

B) Flux

C) Increasing travel speed

D) Using larger electrode diameter

137.

Q135. AC is often used for tandem SAW electrodes because:

A) It reduces spatter

B) It minimizes arc blow

C) It lowers current

D) It increases slag

138.

Q136. Which flux type produces minimal slag removal problems?

A) Neutral flux

B) Basic flux

C) Acid flux

D) Ceramic flux

139.

Q137. A too shallow flux bed can result in:

A) Deep penetration

B) High efficiency

C) Arc exposure and spatter

D) Smooth bead

140.

Q138. Slag entrapment in SAW often occurs due to:

A) High current

B) Correct travel speed

C) Improper groove angle or low speed

D) Good flux baking

141.

Q139. The efficiency of SAW compared to SMAW is higher mainly because:

A) Wires are cheaper

B) Equipment is portable

C) Continuous wire feed and minimal spatter

D) Uses less flux

142.

Q140. When welding stainless steels with SAW, flux must:

A) Contain moisture

B) Be designed for stainless applications

C) Be reused without baking

D) Contain rust

143.

Q141. The weld bead appearance in SAW is usually:

A) Irregular B) Porous

B) Porous

C) Smooth and uniform

D) Rough and uneven

144.

Q142. Lack of fusion in SAW may be corrected by:

A) Reducing current

B) Lowering groove angle

C) Reducing travel speed or increasing current

D) Increasing flux depth

145.

Q143. The heat input in SAW is generally:

A) Low compared to SMAW

B) Very high

C) Negligible

D) Same as TIG

146.

Q144. In SAW, bead reinforcement is controlled by:

A) Baking flux

B) Travel speed and current

C) Voltage only

D) Wire storage

147.

Q145. Which feature makes SAW unsuitable for repair welding in confined spaces?

A) Current source

B) Arc length

C) Bulky equipment and flux handling

148.

Q146. Multi-wire SAW systems can use up to:

A) 2 wires maximum

B) 3 wires maximum

C) 4 or more wires

D) 1 wire only

149.

Q147. Dilution in SAW cladding can be reduced by:

A) High heat input

B) DC+ve

C) DC–ve polarity and lower heat input

D) Deep penetration

150.

Q148. The first commercial use of SAW was in:

A) Aircraft industry

B) Automobile repairs

C) Shipbuilding during World War II

D) Pipeline repairs

151.

Q149. The main economic advantage of SAW is:

A) It uses cheap flux

B) High deposition rates and efficiency

C) Small power sources

D) Less operator skill

152.

Q150. SAW is considered an automatic/semi-automatic process because:

A) Operator controls everything manually

B) Flux is placed by hand only

C) Wire feed and arc length are self-regulated

D) Power is constant

153.

Q151. Why is there no ultraviolet radiation exposure during SAW process?

A. Due to flux chemical reaction

B. Because arc is completely covered under flux

C. Special shielding gas is used

D. Due to copper coating

154.

Q152. Major source of welding fumes in SAW is?

A. Parent metal

B. Flux decomposition

C. Power source

D. Wire insulation

155.

Q153. Main advantage of narrow gap SAW process is?

A. Less flux consumption

B. Higher current efficiency

C. Reduced weld metal volume and heat input

D. Lower undercut risk

156.

Q154. Spiral pipe welding is commonly done by?

A. GMAW

B. GTAW

C. Submerged Arc Welding

D. SMAW

157.

Q155. Major use of strip cladding SAW is?

A. Crack prevention

B. Corrosion-resistant surfacing

C. Porosity removal

D. Undercut control

158.

Q156. Benefit of tandem SAW system is?

A. Current drop

B. Thin slag layer

C. Significantly increased deposition rate

D. Automatic voltage control

159.

Q157. Difference between twin-wire SAW and tandem SAW?

A. Twin-wire uses one power source for both wires, tandem uses separate power sources

B. Twin-wire gives higher deposition

C. Tandem works only on DC

D. Twin-wire is only for stainless

160.

Q158. Biggest industrial safety hazard of SAW is?

A. Arc flash

B. Welding fume and dust inhalation

C. Electric shock

D. Infrared rays

161.

Q159. Greatest risk in confined space SAW welding?

A. Arc radiation

B. Fume accumulation and suffocation

C. Electrode overheating

D. Flux solidification

162.

Q160. Most common NDT method after SAW?

A. Radiographic Testing (RT)

B. Ultrasonic Testing (UT)

C. Magnetic Particle Testing (MT)

D. Dye Penetrant Testing (PT)

163.

Q161. Why is Radiographic Testing difficult for SAW?

A. Current is high

B. Weld thickness is high

C. Flux is hard

D. No porosity forms

164.

Q162. Main cause of hydrogen cracking in SAW HAZ?

A. High arc voltage

B. Low travel speed

C. Moisture-contaminated flux

D. Narrow bead size

165.

Q163. Which polarity controls dilution in SAW?

A. AC

B. DC-ve

C. DC+ve

D. Pulsed DC

166.

Q164. Alloy recovery from flux increases when?

A. High arc voltage

B. Low travel speed

C. Flux is basic in nature

D. Small electrode diameter

167.

Q165. Drawback of high-basic flux is?

A. Difficult slag removal

B. Difficult flux recycling

C. High hygroscopicity

D. Low deposition

168.

Q166. Easy identification method of agglomerated fluxes?

A. Current consumption

B. Shape and color

C. Bead profile

D. Electrode size

169.

Q167. Advantage of fused flux recycling?

A. Low hygroscopicity

B. Thin slag formation

C. No change in composition

D. Automatic dilution control

170.

Q168. Difference between Electroslag Welding (ESW) and SAW?

A. No flux used

B. Heat source is resistance heating, not arc

C. No multi-wire system

D. Only runs on AC

171.

Q169. Why is SAW preferred for large plate fabrication (ships)?

A. Low heat input

B. Produces long continuous welds efficiently

C. Easy in vertical position

D. Better manual control

172.

Q170. Limitation of SAW process?

A. Poor weld quality

B. High cost

C. Position limitation (flat and H-V only)

D. Limited electrodes

173.

Q171. High manganese pick-up in weld metal occurs due to?

A. Stainless electrode

B. Agglomerated flux additives

C. High current

D. AC supply

174.

Q172. Optimum storage condition for SAW flux?

A. Dry open air

B. Sealed container with low humidity

C. Oil coating on flux

D. Sunlight exposure

175.

Q173. If flux layer is too thin, defect risk is?

A. Undercut

B. Hydrogen cracking

C. Porosity and spatter

D. Lack of penetration

176.

Q174. Biggest benefit of SAW automation?

A. Easy flux storage

B. Consistent weld quality and speed

C. Easy manual adjustment

D. Low current loss

177.

Q175. Width of HAZ increases when?

A. High travel speed

B. Low current

C. High heat input (low speed, high current)

D. Small electrode

178.

Q176. Current type for trailing arc in multi-wire SAW?

A. DC-ve

B. DC+ve

C. AC

D. Pulsed

179.

Q177. Best precaution to avoid porosity in SAW?

A. Increase arc length

B. Reduce current

C. Dry flux and clean base surface

D. Increase wire feed speed

180.

Q178. Major cause of poor bead appearance in SAW?

A. Low travel speed

B. Incorrect flux depth

C. Flat power source

D. Short electrode extension

181.

Q179. Usual polarity for lead arc in tandem SAW?

A. AC

B. DC+ve

C. DC-ve

D. Pulsed

182.

Q180. Benefit of reduced dilution in surfacing (cladding)?

A. Thin weld thickness

B. Higher corrosion resistance

C. Porosity prevention

D. Uniform bead

183.

Q181. Main purpose of copper coating on SAW electrode?

A. Alloy addition

B. Corrosion resistance and smooth feeding

C. Arc stability

D. Hydrogen control

184.

Q182. Method to avoid arc blow in SAW?

A. Increase flux depth

B. Increase current

C. Use AC power

D. Lower voltage

185.

Q183. Why is it difficult to add deoxidizers in fused fluxes?

A. Flux porosity

B. High losses during melting process

C. Moisture absorption

D. Color change

186.

Q184. Productivity advantage of SAW comes from?

A. Manual control

B. Multi-pass required

C. High deposition rate and continuous welding

D. Low flux consumption

187.

Q185. Drawback of agglomerated fluxes?

A. No alloying possible

B. High hygroscopicity

C. No recycling possible

D. Poor arc stability

188.

Q186. Cause of slag inclusion in SAW?

A. High travel speed

B. Low current

C. Improper flux handling and poor cleaning

D. Small electrode size

189.

Q187. Essential PPE for confined space SAW welding?

A. Safety glasses only

B. Respiratory protection

C. Welding curtains

D. Ear plugs

190.

Q188. Most useful electrode type for narrow gap SAW?

A. Large diameter electrode

B. Small diameter electrode

C. Strip electrode

D. Hollow electrode

191.

Q189. Metallurgical dilution mainly depends on?

A. Flux storage

B. Polarity and current setting

C. Electrode angle

D. Voltage fluctuation

192.

Q190. Minimum material thickness for SAW welding is?

A. 2 mm

B. 3 mm

C. 5 mm

D. 10 mm

193.

Q191. Most important factor for root pass in narrow gap SAW?

A. High voltage

B. Precise alignment and guidance

C. Deep flux layer

D. Strip cladding

194.

Q192. Advantage of agglomerated fluxes?

A. High moisture resistance

B. Easy addition of deoxidizers

C. Perfect recyclability

D. Low flux porosity

195.

Q193. Best measure to avoid weld solidification cracking?

A. Increase current

B. Proper bead shape and controlled voltage

C. Larger electrode diameter

D. Allow flux moisture

196.

Q194. Unique safety feature of SAW compared to SMAW?

A. UV shield

B. Spatter control

C. Arc invisibility under flux cover

D. Hydrogen-free welding

197.

Q195. Electrode type used in strip cladding?

A. Tubular wire

B. Flat strip electrode

C. Twisted wire

D. Copper strip

198.

Q196. Major application sector of SAW?

A. Aerospace

B. Shipbuilding and pressure vessels

C. Electronics

D. Automotive repair

199.

Q197. Main role of trailing arc in tandem SAW?

A. Root penetration

B. Cleaning

C. Filling and bead shaping

D. Voltage balancing

200.

Q198. Preferred power source output for SAW?

A. Rising current

B. Constant voltage

C. Drooping current

D. Pulsed voltage

201.

Q199. Unique property of agglomerated fluxes?

A. High moisture resistance

B. Cannot be alloyed

C. Easily identified by color/shape coding

D. Only for stainless steel

202.

Q200. Best practice to avoid hydrogen cracking after SAW?

A. Increase travel speed

B. Dry flux and clean base metal

C. Reduce voltage

D. Use small electrode

Leave a Reply Cancel reply