BTEB Welding Exam flashcards

32 cards. Read the term and the definition here. The deck at the top of this page is optional.

SMAW electrode E6013

A rutile-coated mild steel electrode with minimum tensile strength 60,000 psi, usable in all positions, and suitable for AC or DC welding.

Arc length effect

A long arc raises voltage, increases spatter, and reduces penetration; a short arc lowers voltage, gives deeper penetration, and may cause electrode sticking.

Neutral oxy-acetylene flame

A flame with equal oxygen and acetylene, producing a bright inner cone and a bluish outer envelope at about 3,200 °C, used for general steel welding.

Carburising flame zones

An excess-acetylene flame has three zones: a small inner cone, a whitish feather, and an outer envelope; used for hardfacing and aluminium.

GMAW spray transfer

A metal transfer mode using high current and argon-rich shielding gas, producing fine droplets and deep penetration, limited to flat and horizontal positions.

Weld joint types

The five basic joints are butt, lap, T-joint, corner, and edge; the joint type determines the weld type, such as groove or fillet.

Porosity cause

Porosity is gas entrapment in the weld, commonly caused by damp electrodes, dirty base metal, excessive arc length, or inadequate shielding gas flow.

Undercut defect

A groove melted into the base metal along the weld toe that is not filled by weld metal, caused by excessive current or incorrect electrode angle.

Lack of fusion

A discontinuity where weld metal does not fuse to the base metal or previous pass, often due to low current, fast travel, or poor joint preparation.

Slag inclusion

Solid non-metallic slag trapped in the weld, caused by failure to remove slag between passes or by low current that prevents slag from floating out.

Back-step welding

A distortion-control technique in which each weld pass starts ahead of the previous one and progresses backward, balancing shrinkage stresses along the joint.

Duty cycle

The percentage of a 10-minute period a welding machine can operate at a given current without overheating; for example, 60% duty at 200 A.

Electrode coating functions

The coating on a covered electrode stabilises the arc, generates shielding gas, forms slag to protect the weld, and adds alloying elements.

TIG welding principle

Gas tungsten arc welding uses a non-consumable tungsten electrode and argon shielding gas; filler metal is added separately, giving clean, precise welds.

Welding position codes

The four standard positions are flat (1), horizontal (2), vertical (3), and overhead (4); the number is appended to the weld type code.

Heat input formula

Heat input (kJ/mm) equals voltage multiplied by current multiplied by 60, divided by travel speed in mm/min and by 1000.

Welding helmet shade

The lens darkness selected for the welding current; shade 10–13 is typical for SMAW, while lower shades suit low-current TIG welding.

PPE for arc welding

A welding helmet with correct filter, leather gloves, flame-retardant apron, safety boots, and clear safety glasses for chipping slag.

Acetylene cylinder pressure limit

The working pressure of acetylene must never exceed 1.5 bar (about 15 psi), because higher pressure can cause decomposition and explosion.

Flashback arrestor

A device fitted to the regulator or torch end of each gas hose that stops a flame from travelling back into the cylinder or regulator.

Oxygen fitting rule

Never use oil or grease on oxygen fittings or threads; oxygen combined with oil can ignite spontaneously and cause a severe fire or explosion.

Cylinder storage rules

Store oxygen and acetylene cylinders upright and separately, secured with chains, with valve caps fitted when not connected to equipment.

Fire watch distance

Remove combustible materials within about 10 metres of the welding arc, or protect them with fire blankets, and keep an extinguisher nearby.

Earth clamp placement

Connect the work return cable clamp directly to the workpiece, not to the bench frame or machine casing, to ensure a low-resistance path.

Welding machine earthing

The welding machine frame must be connected to a reliable earth to prevent electric shock if a fault energises the casing.

Fume extraction

Welding fumes must be captured at source with extraction or forced ventilation; confined spaces require a standby person outside the space.

Hot work permit

A formal authorisation required before welding in areas with fire risk, specifying precautions, a fire watch, and a check after work ends.

Chipping slag eye protection

Clear safety glasses must be worn under the welding helmet so eyes are protected when the helmet is raised to chip slag.

Cable inspection

Before welding, check electrode holder insulation, cable sheathing, and earth clamp condition; replace damaged cables to prevent shock and burns.

Confined space welding

Welding inside a confined space requires gas testing, forced ventilation, a trained standby person, and a rescue plan before entry.

Hot workpiece handling

Weldments remain hot after welding; place them in a marked cooling area and use tongs or gloves before handling to prevent burns.

Workshop housekeeping

Keep walkways clear, coil cables off the floor, and store gas cylinders and hot work pieces in designated areas to prevent trips and fires.