Gas Metal Arc Welding

and Flux-Cored Arc Welding

Instructional/Task Analysis
Related Information: What Application: What the
the Student Should Know Student Should Be Able to Do

Unit 1: GMAW Orientation and Safety

1. Terms and definitions 17. Solve problems concerning GMAW safety

2. Advantages of the GMAW process
3. Limitations of the GMAW process
4. Principles of GMAW
5. GMAW applications
6. Benefits from learning GMAW
7. Electrical safety requirements for GMAW
8. Guidelines for duty cycle safety
9. Rules for handling cables and gas and
coolant hoses
10. Rules for handling hollow castings or
containers
11. Hazards associated with arc rays
12. Types of welding hoods
13. Guidelines for selecting a safe lens shade for
GMAW
14. Protective clothing required for GMAW
15. Environmental safety requirements
16. Safety guidelines for working with electrode
wire

Unit 2: GMAW Equipment, Applications, and Techniques

1. Terms and definitions

2. Characteristics of short-circuit transfer
3. Characteristics of globular transfer
4. Characteristics of spray transfer
5. Characteristics of pulsed spray transfer
6. Characteristics of surface tension transfer
7. GMAW machine controls and their functions

MAVCC—Gas Metal Arc Welding and Flux-Cored Arc Welding xxxv

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Unit 2: GMAW Equipment, Applications, and Techniques (continued)

8. GMAW electrical controls and their functions
9. Wire feeder controls and their functions
10. Roll adjustment requirements for wire feeders
11. Preventive maintenance requirements for
wire feeders
12. AWS classifications for electrode wires
13. Basic short-circuit electrode wires and their
characteristics
14. Rules of thumb for GMAW, STT, and GMAW-
P electrode wire selection
15. Guidelines for storing spools and coils of
electrode wire
16. Types of GMAW guns and their
characteristics
17. Parts of a GMAW gun tip and their functions
18. Steps in assembling contact tips, gas
diffusers, nozzles, and insulators
19. Maintenance requirements for GMAW guns
20. Electrode extension and its function in
GMAW
21. GMAW shielding gases and their applications
22. GMAW welding techniques and their
characteristics
23. Techniques for properly ending a GMAW
weld
24. Techniques for position welding with GMAW
25. Conditions that require special attention with
GMAW
26. Possible causes and corrective actions for
undercutting
27. Possible causes and corrective actions for
porosity
28. Possible causes and corrective actions for
incomplete fusion

xxxvi MAVCC—Gas Metal Arc Welding and Flux-Cored Arc Welding

 Instructional/Task Analysis
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Unit 2: GMAW Equipment, Applications, and Techniques (continued)

29. Possible causes and corrective actions for 34. Set up wire on a GMAW wire feeder
incomplete joint penetration
35. Set up a flow meter and regulator for a
30. Possible causes and corrective actions for GMAW shielding gas
excessive melt-through
36. Set up GMAW equipment for short-circuit
31. Flow meters and their use in GMAW transfer on mild steel
32. Flow rates for GMAW shielding gases 37. Prepare mild steel for GMAW
33. Guidelines for troubleshooting GMAW 38. Use short-circuit transfer to lay stringer
problems beads and build a pad on mild steel in the
flat position
39. Use short-circuit transfer to weld to
specifications a fillet weld lap joint on mild
steel in the flat position
40. Use short-circuit transfer to weld to
specifications a fillet weld T-joint on mild
steel in the flat position
41. Use short-circuit transfer to weld to
specifications a V-groove butt joint on mild
steel in the flat position
42. Perform a guided-bend test on a welded V-
groove butt joint
43. Use short-circuit transfer to weld to
specifications a fillet weld lap joint on mild
steel in the horizontal position
44. Use short-circuit transfer to weld to
specifications a fillet weld T-joint on mild
steel in the horizontal position
45. Use short-circuit transfer to weld to
specifications a V-groove butt joint on mild
steel in the horizontal position
46. Use short-circuit transfer to weld to
specifications a fillet weld lap joint on mild
steel in the vertical position
47. Use short-circuit transfer to weld to
specifications a fillet weld T-joint on mild
steel in the vertical position

MAVCC—Gas Metal Arc Welding and Flux-Cored Arc Welding xxxvii

Instructional/Task Analysis
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Unit 2: GMAW Equipment, Applications, and Techniques (continued)

48. Use short-circuit transfer to weld to
specifications a V-groove butt joint on mild
steel in the vertical position
49. Use short-circuit transfer to weld to
specifications a fillet weld lap joint on mild
steel in the overhead position
50. Use short-circuit transfer to weld to
specifications a fillet weld T-joint on mild steel
in the overhead position
51. Use short-circuit transfer to weld to
specifications a V-groove butt joint on mild
steel in the overhead position
52. Set up GMAW equipment for spray transfer
on mild steel
53. Use spray transfer to weld to specifications a
fillet weld lap joint on mild steel in the flat
position
54. Use spray transfer to weld to specifications a
fillet weld T-joint on mild steel in the flat
position
55. Use spray transfer to weld to specifications a
fillet weld lap joint on mild steel in the
horizontal position
56. Use spray transfer to weld to specifications a
fillet weld T-joint on mild steel in the horizontal
position
57. Use spray transfer to weld to specifications a V-
groove butt joint on mild steel in the flat position
58. Set up GMAW equipment for spray transfer on
aluminum
59. Prepare aluminum for GMAW
60. Use spray transfer to weld to specifications a
fillet weld lap joint on aluminum in the flat
position
61. Use spray transfer to weld to specifications a
fillet weld T-joint on aluminum in the flat
position
62. Use spray transfer to weld to specifications a
fillet weld lap joint on aluminum in the
horizontal position
63. Use spray transfer to weld to specifications a
fillet weld T-joint on aluminum in the horizontal
position

xxxviii MAVCC—Gas Metal Arc Welding and Flux-Cored Arc Welding

 Instructional/Task Analysis
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the Student Should Know Student Should Be Able to Do

Unit 2: GMAW Equipment, Applications, and Techniques (continued)

64. Use spray transfer to weld to specifications a

fillet weld lap joint on aluminum in the vertical
up position
65. Use spray transfer to weld to specifications a
fillet weld T-joint on aluminum in the vertical
up position
66. Use spray transfer to weld to specifications a
fillet weld lap joint on aluminum in the vertical
down position
67. Use spray transfer to weld to specifications a
fillet weld T-joint on aluminum in the vertical
down position
68. Use spray transfer to weld to specifications a
fillet weld lap joint on aluminum in the
overhead position
69. Use spray transfer to weld to specifications a
fillet weld T-joint on aluminum in the overhead
position
70. Set up GMAW-P equipment for pulsed-spray
transfer on mild steel
71. Use pulsed-spray transfer to weld to
specifications a V-groove butt joint on mild
steel in the flat position
72. Use pulsed-spray transfer to weld to
specifications a V-groove butt joint on mild
steel in the horizontal position
73. Use pulsed-spray transfer to weld to
specifications a V-groove butt joint on mild
steel in the vertical position
74. Set up STT equipment for surface tension
transfer on mild steel
75. Use surface tension transfer to weld to
specifications a V-groove butt joint on mild
steel in the flat position
76. Use surface tension transfer to weld to
specifications a V-groove butt joint on mild
steel in the horizontal position
77. Use surface tension transfer to weld to
specifications a V-groove butt joint on mild
steel in the vertical position

MAVCC—Gas Metal Arc Welding and Flux-Cored Arc Welding xxxix

Instructional/Task Analysis
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the Student Should Know Student Should Be Able to Do

Unit 3: Flux-Cored Arc Welding

1. Terms and definitions 18. Set up or replace wire on a flux-cored wire

feeder
2. Advantages of FCAW
19. Set up FCAW equipment for
3. Limitations of FCAW
semiautomatic flux-cored welding
4. How students benefit from learning FCAW
20. Prepare mild steel for FCAW
5. Equipment required for semiautomatic self-
21. Weld to specifications a fillet weld lap joint
shielded FCAW
on mild steel in the flat position
6. Types of flux-cored arc welding processes
22. Weld to specifications a fillet weld T-joint
7. Types of FCAW guns and their uses on mild steel in the flat position
8. Classifications for FCAW electrode wires 23. Weld to specifications a fillet weld lap joint
9. Electrode extension and visible electrode on mild steel in the horizontal position
extension 24. Weld to specifications a fillet weld T-joint
10. Basic types of flux-cored wire feeders on mild steel in the horizontal position

11. Guidelines for using drive rolls and guide 25. Weld to specifications a fillet weld lap joint
tubes on mild steel in the vertical position

12. Steps for starting an arc with the 26. Weld to specifications a fillet weld T-joint
semiautomatic process on mild steel in the vertical position

13. Operating variables with flux-cored electrode 27. Weld to specifications a fillet weld lap joint
wires on mild steel in the overhead position

14. Guidelines for preparing FCAW applications 28. Weld to specifications a fillet weld T-joint
on mild steel in the overhead position
15. Guidelines for semiautomatic FCAW
29. Weld to specifications a v-groove butt joint
16. Safety requirements for FCAW on mild steel in the flat position
17. Guidelines for troubleshooting FCAW 30. Weld to specifications a v-groove butt joint
problems on mild steel in the horizontal position
31. Weld to specifications a V-groove butt joint
on mild steel in the vertical position
32. Weld to specifications a V-groove butt joint
on mild steel in the overhead position

xl MAVCC—Gas Metal Arc Welding and Flux-Cored Arc Welding