SMAW (Stick Welding) — Welder (456A) Practice Questions

Free SMAW (Stick Welding) practice questions

1. 1.E7018 electrode designation: what does '70' mean?

   • A.70% efficiency
   • B.Minimum tensile strength of 70,000 PSI (70 ksi)✓
   • C.70 amps
   • D.70mm length

   Why: E = electrode. 70 = 70 ksi minimum UTS. 1 = all positions. 8 = low-hydrogen iron powder coating, AC or DCEP. Most common structural electrode.

2. 2.DCEP (DC Electrode Positive) provides:

   • A.Less penetration
   • B.Deeper penetration and more heat at the workpiece (2/3 of heat at the work)✓
   • C.Wider bead only
   • D.No arc

   Why: DCEP: electron flow from work to electrode. 2/3 heat at work = deeper penetration. DCEN: 2/3 heat at electrode = faster deposition, less penetration. Most SMAW uses DCEP.

3. 3.Porosity in a SMAW weld is most commonly caused by:

   • A.Too much penetration
   • B.Moisture in the electrode coating, contaminated base metal, or excessive arc length✓
   • C.Perfect technique
   • D.Slow travel speed

   Why: Porosity: gas trapped in solidifying weld. Causes: wet electrodes (hydrogen), oil/paint/rust on base metal, long arc (loss of shielding), wind. Use dry rods and clean metal.

4. 4.Electrode storage: E6010 vs E7018 requirements:

   • A.Same for both
   • B.E7018 needs heated oven storage; E6010 needs only dry storage (not moisture-sensitive)✓
   • C.Both need ovens
   • D.Neither needs storage care

   Why: E6010 (cellulosic) actually needs some moisture to function — dry ambient storage is fine. E7018 (low-hydrogen) is extremely moisture-sensitive — heated oven mandatory.

5. 5.Incomplete fusion (lack of fusion) means:

   • A.Full penetration
   • B.The weld metal did not properly fuse to the base metal or previous pass✓
   • C.Too much fusion
   • D.Normal condition

   Why: LOF: cold lap, weld metal laid on top without melting into the base. Causes: insufficient heat, wrong angle, too fast, dirty joint, wrong technique. Serious defect.

6. 6.Arc blow causes the arc to wander and is caused by:

   • A.Wind only
   • B.Magnetic fields from DC welding, ground clamp position, or joint magnetism✓
   • C.AC welding
   • D.Low amperage

   Why: DC creates magnetic fields around the conductor. These fields deflect the arc. Solutions: move ground clamp, weld toward/away from heavy tack welds, switch to AC, use shorter arc.

7. 7.E7018 electrode should be used on DCEP or AC. Running it on DCEN causes:

   • A.Better results
   • B.Unstable arc, excessive spatter, poor bead shape, and flux coating issues✓
   • C.No difference
   • D.Deeper penetration

   Why: E7018 is designed for DCEP (reverse) or AC. DCEN (straight) gives poor arc characteristics with this coating type. Always check the electrode specification for polarity.

8. 8.The third digit in an AWS electrode designation (E70X8) indicates:

   • A.Tensile strength
   • B.Welding position capability: 1=all positions, 2=flat and horizontal only✓
   • C.Coating type
   • D.Current type

   Why: Third digit positions: 1 = all positions (F, V, OH, H). 2 = flat and horizontal only. This is critical for selecting electrodes for out-of-position work.

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