Welding and General Safety Test



Welding and General Safety Test

Pleasant Valley High School

***YOU MUST GET 100% OF THIS TEST CORRECT BEFORE YOU WILL USE ANY SHOP EQUIPMENT. ADDITIONALLY, YOU MUST WRITE OUT THE QUESTIONS AND CORRECT ANSWERS TO THE QUESTIONS YOU MISSED ON THE BACK OF THIS TEST AFTER IT IS CORRECTED to ensure you can be 100% safe in the shop. Your safety and the safety of those working around you depend upon the knowledge of safe metal shop practices.

Directions: Choose the best answer to each question (multiple choice)

GENERAL SAFETY:

1. Making unapproved projects of any type (including but not limited to weapons, toys and any other unapproved items) is against department policy and is ___________

a) unacceptable and will carry disciplinary action

b) alright to do only if you want to

c) is ok with permission from a friend

d) is ok anytime

2. In this shop there are:

a) SMAW welders

b) Oxy-Fuel welders

c) GMAW welders

d) All of the above

3. Safety glasses are to be worn in the shop…

a) Always

b) When you feel like it

c) When sparks fly

d) Only if they are in style

4. Any dangerous condition or injury to a person in the shop should be reported…

a) When convenient

b) At once

c) At the end of class

d) After school

5. Horseplay in the shop..

a) Is ok if both people want to participate

b) Is ok for certain individuals

c) Is permitted between classes

d) Is never acceptable and will not be tolerated

6. If a piece of equipment is not working properly, or you accidentally broke it…

a) Don’t tell anyone

b) Inform the custodian

c) Tell the principal

d) Tell Mr. Joiner

7. It is alright to work in the shop while under the influence of prescription, non-prescription or illegal drugs or alcohol.

a) True

b) False

8. It is not a good idea to operate electrical equipment including welders when you have wet or sweaty hands because of the risk of________. To help avoid this you should wear gloves.

a) Looking foolish

b) Backlash

c) Heat stroke

d) Electrical shock

9. It is NEVER acceptable to use any listening device (IPOD, MP3, etc) while in the welding lab because:

a) The teacher does not like music

b) The cord could get caught in moving machine with you attached

c) Both B and D

d) It is a distraction to you as you cant hear potential danger in the lab

10. It is a bad idea to have a fuel lighter in your pocket when welding because…

a) smoking is illegal

b) you might loose your lighter

c) it could explode from a welding spark landing on it

d) it could vaporize

11. The most important thing to consider when working with these machines in this or any other shop is…

a) safety

b) getting the job done fast

c) cutting corners to save time

d) when is lunch break

12. What does AWS stand for?

a) Associated Welders System

b) Associated Welders Society

c) American Welding Society

d) American Welding System

13. When using sharp-edged tools, you should always cut :

a) to the left of yourself

b) toward yourself

c) away from yourself

d) to the right of yourself

MACHINES:

14. When operating the band saw, you should not push down on the machine during a cut because…

a) It will break the teeth off the blade and possibly bend it

b) It will mess up the calibration

c) Your best friend said not to

d) The wheels will melt

15. Before drilling a hole in metal with the drill press, you should secure your work to the drill press table with…

a) Your hands

b) Your friends hands

c) A clamp or vise

d) Nothing, it’s not necessary

16. The tool rest on a bench grinder should be set how far from the wheel?

a) 1 inch

b) As far from the wheel as possible without touching it

c) ½ inch

d) As close to the wheel as possible without touching it

17. Aside from using the tool rest on the machine, what else must you use for protection when using any grinder?

a) Safety Glasses

b) Leathers or leather apron

c) Football helmet

d) Welding helmet

18. When grinding very small pieces of metal on the bench grinder, the metal should be held with...

a) Your thumb and fore finger

b) Your bare hands always

c) Vise grips or pliers

d) all the strength in your left hand

19. What type of power is used to make the cut with a band saw?

a) By pushing down lightly

b) By pushing down hard

c) With the weight of the machine

d) Any of the above

20. Make sure the grinder comes to a stop before __________.

a) Grinding again

b) Leaving

c) Putting on your safety mask

d) Welding

21. On any machine in the shop, it is all right to remove a guard or safety devise only if…

a) It is in your way

b) You can complete the job faster

c) Mr. Joiner gives you permission

d) That particular machine you have at home has that guard missing

22. A grinding wheel that is cracked or fractures should be used…

a) Very carefully

b) If you are an expert

c) Never

d) Only on days that end with “Y”

OXYGEN-ACETYLENE WELDING:

23. Oxygen Acetylene welding produces heat to ________ degrees Fahrenheit

a) 630

b) 1,500

c) 6,300

d) 3,600

24. Oxyacetylene welders can join

a) Dissimilar metals

b) Similar welders

c) Similar and dissimilar metals

d) Only mild steel

25. Maximum pressure that acetylene can be compressed to inside the cylinder is 300 PSI, it can be compressed this much because of the liner inside the bottle that is made up of…

a) acetylene

b) acetyl alcohol

c) acetone

d) oxygen

26. Maximum pressure for acetylene outside the bottle is_________ PSI, because there is no acetone liner to help stabilize it

a) 15

b) 25

c) 10

d) 5

27. The most desirable flame to weld with is a…

a) Carburizing flame

b) Neutral flame

c) Negative flame

d) Oxidizing flame

28. Name the two types of flames that you do not want to weld with:

a) Hot and Cold

b) Carburizing and Neutral

c) Neutral and Oxidizing

d) Carburizing and Oxidizing

29. The most common reasons for tip popping are…

a) A dirty tip and putting the tip in the molten puddle

b) A new tip and a dirty tip

c) Dropping the torch and stepping on it

d) A dirty tip and a too big of a tip

30. What are the first two steps in setting up an oxygen acetylene welder from scratch?

a) Turn in the T screws and light the torch

b) Attach the regulators and light the torch

c) Check for leaks and pressurize the system

d) Inspect the bottles and remove the caps

31. What must you do before lighting the torch, after you just put the system together?

a) Back out T-screws before opening bottles

b) Check for leaks with a lighter or striker

c) Hold your breath

d) Hold your breath and watch

32. When you are oxyacetylene welding, it is important to do what just after you shut off the oxygen and acetylene at the torch handle?

a) Put the torch away

b) Put the caps on the cylinders

c) Purge with acetylene

d) Purge with oxygen

33. The gas pressure in the regulator is adjusted with the…

a) G screw

b) B screw

c) Screwdriver

d) T screw

34. When setting an oxygen regulator for welding, it should be at about____ PSI and an acetylene regulator should be set at about ____ PSI.

a) 15, 5

b) 10,20

c) 15,15

d) wherever, whatever

35. You open the oxygen cylinder how far?

a) One full turn

b) Not at all

c) all the way

d) you don’t open it

36. You open the acetylene cylinder how far?

a) About one turn

b) Half way

c) all the way

d) you don’t open it

37. Acetylene cylinders are usually red and have____ handed threads.

a) left

b) right

c) front

d) back

38. You can tell by looking at the ____ to see if it is notched on a regulator to determine if it belongs to the oxygen cylinder or the acetylene cylinder.

a) regulator

b) bottle

c) nut

d) bolt

39. The nut on an acetylene regulator has a _____ on it, telling you the threads are left handed.

a) nock

b) notch

c) x

d) special coating

40. Regular sunglasses are adequate to wear for OFW welding

a) True

b) False

41. The two gauges on the regulator indicate:

a) atmospheric pressure

b) cylinder pressure

c) working pressure

d) both B and C

S.M.A.W.

42. The proper arc length for arc welding is about…

a) 1/8 of an inch

b) one inch

c) one foot

d) ½ of an inch

43. What does S.M.A.W. stand for?

a) Should Make A Waterbed

b) Shield Metal Arc Welding

c) Slag Metal Arc Welding

d) Superior Metal Arc Welding

44. Arc flash is…

a) removing your shirt

b) hitting hammers together

c) looking at the arc light without eye protection

d) looking at the arc light through protective lenses

45. What should you do before striking an arc?

a) yell ARC or COVER

b) yell like a cat

c) make sure your gloves match

d) get a good nights sleep

46. Symptoms of arc flash include…

a) burning feet and blistering arms

b) feeling sick to your stomach

c) like a sunburn or hot burning sand in your eyes

d) there is no such thing as arc flash

47. On a E6013 arc rod, the E stands for…

a) electric

b) electrode

c) eclectic

d) arc

48. On a E6013 arc rod, the 60 stands for…

a) 60 lbs of tinsel strength

b) 60,000 lbs of tinsel strength

c) 60,000 lbs of kinetic strength

d) 60 lbs of kinetic strength

49. We will usually set our arc welders on which setting for this class?

a) Direct Current Electrode Positive (DCEP)

b) Direct Current Electrode Negative (DCEN)

c) AC- alternating current

d) ACDC

50. What effect on spatter does a longer arc length have?

a) more spatter

b) less spatter

c) same amount of spatter

d) no spatter

51. What can happen to the arc if the arc length becomes too long?

a) the arc will go out

b) the arc will get hotter

c) the arc will get cooler

d) the arc will melt the electrode to the work piece

52. What can happen to the arc is the arc length becomes too short?

a) the arc will go out

b) the arc will get hotter

c) the arc will get cooler

d) the arc will melt the electrode to the work piece

G.M.A.W.

53. A MIG welder would use the following shield gas

a) Argon or C02

b) Oxygen

c) Acetylene

d) Acetone

54. The distance the wire sticks out from the contact tube on a MIG gun is called:

a) Stick out

b) Stick up

c) Wire Speed

d) Voltage

55. The consumable part in a MIG gun is called the ……….

a) Wire

b) Diffuser

c) Contact tube

d) Nozzle

56. The wire diameter on a 220 Volt Short-Circuit MIG welder in our shop is……….

a) .030

b) .305

c) .503

d) .035

PLASMA CUTTING:

57. Containers such as 55 gallon drums can be cut with a plasma cutter only:

a) if the contents of the drum were not flammable

b) if the contents of the drum were flammable

c) if it is unknown what the contents of the drum were (may be flammable)

d) all of the above

58.What is the minimum shade lens required to plasma cut?

a) # 3

b) # 5

c) # 7

d) # 10

59. Full leathers should be worn to protect from heat and sparks when plasma cutting

a) True

b) False

60. The Consumable part (s) of the plasma cutter is the:

a) tip

b) electrode

c) tip and electrode

d) swirl ring

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