Welding Interview Preparation Guide
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Welding Interview Questions and Answers will guide us now that welding is a fabrication or sculptural process that joins materials, usually metals or thermoplastics, by causing coalescence. This is often done by melting the workpieces and adding a filler material to form a pool of molten material the weld pool that cools to become a strong joint, with pressure sometimes used in conjunction with heat, or by itself, to produce the weld. So learn Welding by Welding Interview Questions with Answers

25 Welding Questions and Answers:

1 :: What is prototype tooling?

Prototype tooling as basic part fixturing, as well as the use of manual clamping and rigid steel framing that is fabricated from a customer's parts.

Prototype tooling provides a concept of what the production tooling is meant to be. It is not meant for production tooling. When the prototype tooling is tried out, final tooling could be quoted to you and provided.

Prototype tooling does not include: part presence sensors, tooling design drawings or pneumatic clamping and isn't subjected to a customer's specifications or original design. Prototype tooling demonstrates the correct way to weld the part and also shows how tooling can be instituted at low cost to the customer.
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2 :: What is the meaning of ROI, and when does it apply to customers?

ROI stands for "Return on Investment". This is the amount your company will save by incorporating robots. A robotic system typically produces the same output as 4 welders. The annual savings (ROI) can be calculated as follows:

ROI = [(x + y) * 4 - z] * t

x = Hourly Rate of Welder
y = Equipment Cost Per Hour
z = Robotic System Cost Per Hour
t = 2080 Hours Per Year
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3 :: What is GMAW?

Gas Metal Arc Welding is a welding method more commonly referred to as GMAW or MIG welding.

Typically used in the automotive and sheet metal industries, GMAW can be an automatic or semi-automatic process. GMAW provides high quality welds at a low cost to the manufacturer.

This arc welding application feeds a GMAW metal consumable electrode and shielding gas through the welding gun. An electrical current travels down the electrode and strikes the arc between the metal being welded and the wire electrode.

The advantages of GMAW include:

Speed - GMAW is a fast welding application

User-friendly - This welding approach is easy to set up and implement.

Cheap - GMAW equipment tends to be more affordable and more available than other welding equipment.

GMAW is used on these materials:
Steel, Aluminum, Copper, Nickel, Magnesium and other non-ferrous materials.
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4 :: What is a robot work envelope?

A robot can only work in the area in which it can move. This area is called the work envelope. The work envelope is determined by how far the robot's arm can reach and how flexible the robot is. The more reach and flexibility a robot has, the larger the work envelope will be.

Axes - The number of axes a robot has define its flexibility level. The typical industrial robot has six axes of movement.

Length of arm segments - The robot's axes link arm segments which each vary in length. The length of the arms combined with the capabilities of each axis determine a robot's reach.

Placement - Robots have different mounting options. Their work envelopes vary in scope depending on whether they are shelf, ceiling, wall, or floor mounted. Some robots can be mounted to tracks or gantry systems, which further expands their work envelopes.

Construction - A robot's strength effects its work space. Robots have different payload capacities which in turn determine the type of EOAT that can be attached.
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5 :: What is a welding crater?

Unless welding is performed with a very low current, a concave dip, called a crater occurs at the end of a weldment.

This crater results from the force of the arc and the contraction of melted metal when it cools and solidifies. The size of each crater relates directly to the welding current. Craters are not desirable because they cause a welding defect due to slag wrapping.

Crater welding is one method used to fill craters. It requires regular welding current. There are control sequences that allow you to switch to a crater filler current.
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6 :: What is turnkey integration?

Turnkey integration gets its name from being all-inclusive and production-ready.

Robot workcells are turnkey integration systems because they require little installation and have every necessary element: robot, safety, tooling, etc. Turn a key or flip a switch, and presto - you're automated!

Interested in a robotic turnkey integration system for your facility? RobotWorx is a turnkey integration expert. We build custom turnkey workcells to answer specific application needs. Avoid delays and costly mistakes when you buy a turnkey integration system.
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7 :: What is the difference between MIG and TIG Welding?

While Metal Inert Gas (MIG) and Tungsten Inert Gas (TIG) are both shielded arc welding applications, they are very different from one another. MIG welds are created with a consumable electrode, while TIG welds are created with a non-consumable electrode. TIG welding typically includes filler metal as well.

TIG and MIG arc welding can both be automated. However, TIG is a more complicated process so the equipment is more expensive and difficult to set-up. Find out more about the pros and cons of MIG vs. TIG.
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8 :: What does RobotWorx consider a refurbished robot?

Robot welding systems are considered refurbished once they have passed through RobotWorx' comprehensive 168-point reconditioning process.

Each used robot welding system is thoroughly cleaned, reworked, tested, and given a fresh coat of paint. Our robot service department pays close attention to every aspect of robot welding systems by performing the following:

* Harmonic drive and belt assembly inspection/cleaning/lubrication and replacement as needed.
* Battery replacement
* Wire harness inspection
* Bearing check and lubrication
* Repeatability and performance testing
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9 :: ANSI? CE? RIA? Can I design against one standard that will include all requirements?

Simply stated, no.

CE refers to European conformity and has nothing to do with suitability for use in the United States. ANSI is the accrediting agency that approves the standards sponsored and written by the RIA, a Standards Developing Organization.

The R15.06 is performance requirements for personnel safety.

A design standard is ANSI/UL 1740 that actually states hardware requirements and specifications. The UL 1740 and R15.06 are harmonized so that if you build the hardware in compliance with UL 1740, you should be able to meet the safeguarding requirements in R15.06.
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10 :: Are welding robots safe to use?

Welding robots are equipped with internal and external safety features. Light curtains, safety stops, walls, weight-sensitive mats, and shielding protect the robot and the robot operator. Other safety features are programmed into the robot. Vision peripherals can also work as safety devices.

Furthermore, welding robots provide a safe alternative to manual welding. Unlike their human counterparts, welding robots don't run the risk of electric shock, severe burns, eye damage, etc.

Instead, they remove workers from the danger zone to the safety of operator's positions. They are oblivious to the bright light, sparks, chemical fumes, and extreme heat caused by welding applications.
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