Casting & Welding Theory & Questions Altogethre 2013

MetalCasting MetalCasting
BySKMondal BySKMondal
Sandcasting
S d i di d h i Sand casting uses ordinary sand as the primary
mould material.
The sand grains are mixed with small amounts of
other materials such as clay and water to improve other materials, such as clay and water, to improve
mouldability and cohesive strength, and are then
packed around a pattern that has the shape of the packed around a pattern that has the shape of the
desired casting.
The pattern must be removed before pouring, the
mold is usually made in two or more pieces. mold is usually made in two or more pieces.
An opening called a sprue hole is cut from the top of
th ld th h th d d t d t the mold through the sand and connected to a
system of channels called runners.
Contd.
The molten metal is poured into the sprue hole, flows p p
through the runners, and enters the mold cavity
through an opening called a gate. through an opening called a gate.
Gravity flow is the most common means of
i t d i th t l i t th ld introducing the metal into the mold.
After solidification, the mold is broken and the
finished casting is removed.
The casting is then fettled by cutting off the ingate The casting is then fettled by cutting off the ingate
and the feeder head.
Because the mold is destroyed, a new mold must be
made for each casting. g
Contd
Sequentialstepsinmakingasandcasting
Apatternboardisplacedbetweenthebottom(drag)
andtop(cope)halvesofaflask,withthebottomsideup. p ( p ) , p
S di h k di h d h lf f h ld Sandisthenpackedintothedraghalfofthemold.
Abottomboardispositionedontopofthepackedsand,
andthemoldisturnedover showingthetop(cope)half andthemoldisturnedover,showingthetop(cope)half
ofpatternwithsprue andriserpinsinplace.
Thecopehalfofthemoldisthenpackedwithsand Thecopehalfofthemoldisthenpackedwithsand.
Contd
The mold is opened, the pattern board is drawn
(removed), and the runner and gate are cut into the
surface of the sand.
Th ld i bl d ith th tt b d The mold is reassembled with the pattern board
removed, and molten metal is poured through the
sprue.
The contents are shaken from the flask and the metal
i d f h d d f f h segment is separated from the sand, ready for further
processing.
CastingTerms
Flask: A moulding flask is one which holds the sand
mould intact. It is made up of wood for temporary
applications or metal for longterm use.
Drag: Lower moulding flask.
Cope: Upper moulding flask.
h k d ld fl k d h Cheek: Intermediate moulding flask used in three
piece moulding piece moulding.
Contd
For-2013 (IES, GATE & PSUs) Page 1
Pattern: Pattern is a replica of the final object to be Pattern: Pattern is a replica of the final object to be
made with some modifications. made with some modifications.
Parting line: This is the dividing line between the two g g
moulding flasks that makes up the sand mould.
Bottom board: This is a board normally made of wood,
which is used at the start of the mould making.
Contd
Moulding sand: The freshly prepared refractory
material used for making the mould cavity. It is a
mixture of silica, clay and moisture in appropriate
i proportions.
B ki d Thi i d f d d b t Backing sand: This is made up of used and burnt
sand sand.
Core: Used for making hollowcavities in castings Core: Used for making hollowcavities in castings.
Pouring basin: A small funnel shaped cavity at the top Pouring basin: A small funnelshaped cavity at the top
of the mould into which the molten metal is poured. p
Sprue: The passage through which the molten metal
from the pouring basin reaches the mould cavity.
Runner: The passage ways in the parting plane through
hi h l l fl i l d b f h h which molten metal flow is regulated before they reach
the mould cavity the mould cavity.
Gate: The actual entry point through which molten y p g
metal enters the mould cavity in a controlled rate.
Contd
Chaplet: Chaplets are used to support cores inside the
mould cavity mould cavity.
Chill: Chills are metallic objects, which are placed in Chill: Chills are metallic objects, which are placed in
the mould to increase the cooling rate of castings.
Riser: It is a reservoir of molten metal provided in the
casting so that hot metal can flow back into the mould
i h h i d i i l f l d cavity when there is a reduction in volume of metal due
to solidification to solidification
Contd
Padding
Tapering of thinner section towards thicker section
is known as 'padding' is known as padding .
This will require extra material.
If padding is not provided, centre line shrinkage or
porosity will result in the thinner section. p y
IES2001
Th i f h l t i The main purpose of chaplets is
(a) To ensure directional solidification (a) To ensure directional solidification
(b) To provide efficient venting (b) To provide efficient venting
(c) For aligning the mold boxes (c) For aligning the mold boxes
(d) To support the cores (d) To support the cores
IES1996
Which of the following methods are used for
obtaining directional solidification for riser design
1. Suitable placement of chills
2. Suitable placement of chaplets
l dd 3. Employing padding
S l t th t Select the correct answer.
(a) 1 and 2 (b) 1 and 3 (c) 2 and 3 (d) 1 2 and 3 (a) 1 and 2 (b) 1 and 3 (c) 2 and 3 (d) 1, 2 and 3
IES2007
Which one of the following is the correct Which one of the following is the correct
statement?
G i id d i ld Gate is provided in moulds to
(a) Feed the casting at a constant rate ( ) g
(b) Give passage to gases
( ) C f h i k (c) Compensate for shrinkage
(d) Avoid cavities ( )
GATE2009
MatchtheitemsinColumnIandColumnII.
ColumnIColumnII ColumnIColumnII
P.MetallicChills1.Supportforthecore
QM t lli Ch l t R i fth lt t l Q.MetallicChaplets2.Reservoirofthemoltenmetal
R.Riser3.Controlcoolingofcritical
i sections
S.ExothermicPadding4.Progressivesolidification
(a) P1,Q3,R2,S4 (b) P1,Q4,R2,S3
(c) P3,Q4,R2,S1 (d) P4,Q1,R2,S3 ( ) 3, Q 4, , ( ) 4, Q , , 3
GATE1992
Inagreensandmouldingprocess,uniform
rammingleadsto rammingleadsto
(a) Lesschanceofgasporosity
(b) Uniformflowofmoltenmetalintothemould
cavity cavity
(c) Greaterdimensionalstabilityofthecasting
(d) Lesssandexpansiontypeofcastingdefect
GATE2011
Green sand mould indicates that
(a) polymeric mould has been cured (a) polymeric mould has been cured
(b) mould has been totally dried
(c) mould is green in colour
(d) mould contains moisture (d) mould contains moisture
Pattern
A pattern is a replica of the object to be made by the
casting process, with some modifications.
The main modifications are The main modifications are
The addition of pattern allowances,
The provision of core prints, and
Elimination of fine details, which cannot be obtained Elimination of fine details, which cannot be obtained
by casting and hence are to be obtained by further
processing processing
PatternAllowances
1. Shrinkageorcontractionallowance g
2. Draftortaperallowance
3. Machiningorfinishallowance
4. Distortionorcamberallowance
5. Rappingallowance
Shrinkageallowance
All metals shrink when cooling except perhaps
bismuth.
This is because of the interatomic vibrations which
l f d b are amplified by an increase in temperature.
Th h i k ll i l b dd d h The shrinkage allowance is always to be added to the
linear dimensions Even in case of internal dimensions linear dimensions. Even in case of internal dimensions.
Contd
Liquidshrinkageandsolidshrinkage
Liquid shrinkage refers to the reduction in
volume when the metal changes from liquid to volume when the metal changes from liquid to
solid state at the solidus temperature. To account
f hi i id d i h ld for this, risers are provided in the moulds.
Solid shrinkage is the reduction in volume
caused when a metal loses temperature in the caused, when a metal loses temperature in the
solid state. The shrinkage allowance is provided to
k f hi d i take care of this reduction.
Pattern Allowances
Cast Iron 10 mm/m
Brass, Copper, Aluminium 15 mm/m Brass, Copper, Aluminium 15 mm/m
Steel 20 mm/m
Zinc, Lead 25 mm/m
In grey cast iron and spheroidal graphite iron, the
f hi i i l h l amount of graphitization controls the actual
shrinkage. When graphitization is more, the
shrinkage would be less and vice versa.
IES1995
Which one of the following materials will require
the largest size of riser for the same size of casting?
(a) Aluminium
(b) Cast iron
(c) Steel
(d) (d) Copper.
GATE1999
Which of the following materials requires the Which of the following materials requires the
largest shrinkage allowance, while making a
pattern for casting? pattern for casting?
(a) Aluminium
(b) Brass
(c) Cast Iron (c) Cast Iron
(d) Plain Carbon Steel
IES1999
In solidification of metal during casting,
f l d compensation for solid contraction is
( ) P id d b h i (a) Provided by the oversize pattern
(b) A hi d b l l d i (b) Achieved by properly placed risers
(c) Obtained by promoting directional (c) Obtained by promoting directional
solidification solidification
(d) Made by providing chills ( ) y p g
ISRO2007 ISRO2007
Shrinkage allowance is made by Shrinkage allowance is made by
(a) Adding to external and internal dimensions
(b) Subtracting from external and internal
dimensions
(c) Subtracting from external dimensions and
adding to internal dimensions adding to internal dimensions
(d) Adding to external dimensions and subtracting
from internal dimensions
GATE2001
Shrinkage allowance on pattern is provided to
compensate for shrinkage when
(a) The temperature of liquid metal drops from (a) The temperature of liquid metal drops from
pouring to freezing temperature
(b) Th t l h f li id t lid t t t (b) The metal changes from liquid to solid state at
freezing temperature
(c) The temperature of solid phase drops from
freezing to room temperature freezing to room temperature
(d) The temperature of metal drops from pouring
to room temperature
GATE2004
Gray cast iron blocks 200 x 100 x 10 mm are to be Gray cast iron blocks 200 x 100 x 10 mm are to be
cast in sand moulds. Shrinkage allowance for
pattern making is 1% The ratio of the volume of pattern making is 1%. The ratio of the volume of
pattern to that of the casting will be
(a) 0 97 (b) 0 99 (c) 1 01 (d) 1 03 (a) 0.97 (b) 0.99 (c) 1.01 (d) 1.03
GATE2008
Whil li bi l ti f id While cooling, a cubical casting of side 40 mm
undergoes 3% 4% and 5% volume shrinkage undergoes 3%, 4% and 5% volume shrinkage
during the liquid state, phase transition and solid g q p
state, respectively. The volume of metal
compensated from the riser is
(a) 2% (b) 7% (c) 8% (d) 9%
GATE2011
A cubic casting of 50 mm side undergoes volumetric
solidification shrinkage and volumetric solid g
contraction of 4% and 6% respectively. No riser is
used Assume uniform cooling in all directions The used. Assume uniform cooling in all directions. The
side of the cube after solidification and contraction is
( ) 8 (a) 48.32 mm
(b) 49.90 mm ( ) 49 9
(c) 49.94 mm
(d) (d) 49.96 mm
IAS1995
Assertion (A): A pattern is made exactly similar to
the part to be cast. the part to be cast.
Reason (R): Pattern is used to make the mould
cavity for pouring in molten for casting cavity for pouring in molten for casting.
(a) Both A and R are individually true and R is the
l i f A correct explanation of A
(b) Both A and R are individually true but R is not the y
correct explanation of A
(c) A is true but R is false (c) A is true but R is false
(d) A is false but R is true
IAS2003
Match List I (Material to be cast) with List II
(Shrinkage Allowance in mm/m) and select the ( g / )
correct answer using the codes given belowthe lists:
ListI ListII List I List II
(MaterialtoCast)(ShrinkageAllowanceinmm/m)
(A) Greycastiron 1 7 10 (A) Greycastiron 1. 7 10
(B) Brass 2. 15
( ) l (C) Steel 3. 20
(D) Zinc 4. 24
Codes:A B C D A B C D
(a) 1 2 3 4 (b) 3 4 1 2 (a) 1 2 3 4 (b) 3 4 1 2
(c) 1 4 3 2 (d) 3 2 1 4
Draft
To reduce the chances of the damage of the mould
h f l h l f cavity at the time of pattern removal, the vertical faces
of the pattern are always tapered from the parting line of the pattern are always tapered from the parting line.
This provision is called draft allowance. This provision is called draft allowance.
Inner surfaces of the pattern require higher draft than p q g
outer surfaces.
Draft is always provided as an extra metal.
DRAFTALLOWANCE
ShakeAllowance
At the time of pattern removal, the pattern is rapped p , p pp
all around the vertical faces to enlarge the mould
cavity slightly to facilitates its removal.
It is a negative allowance and is to be applied only to
those dimensions, which are parallel to the parting
l plane.
DistortionAllowance
A metal when it has just solidified is very weak and
therefore is likely to be distortion prone.
This is particularly so for weaker sections such as long
fl t ti V U ti i li t d ti flat portions, V, U sections or in a complicated casting
which may have thin and long sections which are
connected to thick sections.
The foundry practice should be to make extra
i l i i f d i h di i material provision for reducing the distortion.
PatternMaterials
Wood patterns are relatively easy to make. Wood is not
very dimensionally stable. Commonly used teak, white y y y ,
pine and mahogany wood.
Metal patterns are more expensive but are more Metal patterns are more expensive but are more
dimensionally stable and more durable. Commonly used
CI Brass aluminiumand white metal CI, Brass, aluminiumand white metal.
Hard plastics, such as urethanes, and are often preferred
h h ll b d d d with processes that use strong, organically bonded sands
that tend to stick to other pattern materials.
In the fullmold process, expanded polystyrene (EPS) is
used.
Investment casting uses wax patterns.
Thepatternmaterialshouldbe
Easilyworked,shapedandjoined
Lightinweight
Strong,hardanddurable
R i t tt d b i Resistanttowearandabrasion
Resistanttocorrosion,andtochemicalreactions Resistanttocorrosion,andtochemicalreactions
Dimensionallystableandunaffectedbyvariationsin
temperatureandhumidity.
Availableatlowcost.
IES1994
Which of the following materials can be used for
making patterns?
1. Aluminium 2. Wax 3. Mercury 4. Lead
Select the correct answer using the codes given below:
Codes:
( ) d (b) d ( ) d (d) d (a) 1,3 and 4 (b) 2,3 and 4 (c) 1, 2 and 4 (d) 1, 2 and 3
GATE2000
Di bl tt d f Disposablepatternsaremadeof
(a) Wood (a) Wood
(b) Rubber (b) Rubber
(c) Metal (c) Metal
(d) Polystyrene (d) Polystyrene
TypesofPattern
Single Piece Pattern
These are inexpensive and the simplest type of These are inexpensive and the simplest type of
patterns. As the name indicates, they are made of a
single piece single piece.
Gated Pattern
Gating and runner system are integral with the Gating and runner system are integral with the
pattern. This would eliminate the hand cutting of
the runners and gates and help in improving the the runners and gates and help in improving the
productivity of a moulding.
TypesofPattern
Split Pattern or Two Piece Pattern
This is the most widely used type of pattern for intricate y yp p
castings. When the contour of the casting makes its
withdrawal from the mould difficult, or when the depth withdrawal from the mould difficult, or when the depth
of the casting is too high, then the pattern is split into two
parts so that one part is in the drag and the other in the parts so that one part is in the drag and the other in the
cope.
TypesofPattern
Cope and Drag Pattern
These are similar to split patterns. In addition to
splitting the pattern, the cope and drag halves of p g p , p g
the pattern along with the gating and riser systems
are attached separately to the metal or wooden are attached separately to the metal or wooden
plates along with the alignment pins. They are
called the cope and drag patterns called the cope and drag patterns.
TypesofPattern
Match Plate Pattern Match Plate Pattern
The cope and drag patterns along with the
i d h i i d i l gating and the risering are mounted on a single
matching metal or wooden plate on either side. g p
TypesofPattern
Loose Piece Pattern
This type of pattern is also used when the
contour of the part is such that withdrawing the contour of the part is such that withdrawing the
pattern from the mould is not possible.
TypesofPattern
F ll B d P Follow Board Pattern
This type of pattern is adopted for those yp p p
castings where there are some portions, which
are structurally weak and if not supported are structurally weak and if not supported
properly are likely to break under the force of
ramming ramming.
IES2008
The pattern adopted for those castings where there The pattern adopted for those castings where there
are some portions which are structurally weak and
are likely to break by the force of ramming are are likely to break by the force of ramming are
called:
(a) Loose piece pattern
(b) Follow board pattern (b) Follow board pattern
(c) Skelton pattern
(d) Single piece pattern
TypesofPattern
Sweep Pattern
It is used to sweep the complete casting by means It is used to sweep the complete casting by means
of a plane sweep. These are used for generating
large shapes which are axi symmetrical or large shapes, which are axisymmetrical or
prismatic in nature such as bellshaped or
li d i l cylindrical.
TypesofPattern
Sk l P Skeleton Pattern
A skeleton of the pattern made of strips of wood p p
is used for building the final pattern by packing
sand around the skeleton After packing the sand around the skeleton. After packing the
sand, the desired form is obtained with the help
of a strickle This t pe of pattern is useful of a strickle. This type of pattern is useful
generally for very large castings, required in
ll h l small quantities where large expense on
complete wooden pattern is not justified. p p j
CoolingCurve g
Fluidity
The ability of a metal to flow and fill a mold is known
as fluidity.
Pouring Temperature
The most important controlling factor of fluidity is the The most important controlling factor of fluidity is the
pouring temperature or the amount of superheat.
Higher the pouring temperature the higher the fluidity Higher the pouring temperature, the higher the fluidity.
Excessive temperatures should be avoided, however. At
high pouring temperatures metalmold reactions are high pouring temperatures, metalmold reactions are
accelerated and the fluidity may be so great as to permit
penetration. penetration.
Penetration is a defect where the metal not only fills the
mold cavity but also fills the small voids between the sand mold cavity but also fills the small voids between the sand
particles in a sand mold.
GATE 2012 (PI) GATE2012(PI)
In sand casting, fluidity of the molten metal In sand casting, fluidity of the molten metal
increases with
(A) i i d f h (A) increase in degree of superheat
(B) decrease in pouring rate ( ) p g
(C) increase in thermal conductivity of the mould
(D) i i d i i (D) increase in sand grain size
ISRO2011
Fluidity in casting (CI) operation is greatly
influenced by
a) Melting temperature of molten metal
b) Pouring temperature of molten metal
c) Finish of the mould
d) Carbon content of molten metal
Core
Used for making cavities and hollow projections.
All sides of core are surrounded by the molten metal All sides of core are surrounded by the molten metal
and are therefore subjected to much more severe
thermal and mechanical conditions and as a result the thermal and mechanical conditions and as a result the
core sand should be of higher strength than the
ldi d moulding sand.
Desiredcharacteristicsofacore
Green Strength: A core made of green sand should Green Strength: A core made of green sand should
be strong enough to retain the shape till it goes for
baking baking.
Dry Strength: It should have adequate dry strength
so that when the core is placed in the mould, it
should be able to resist the metal pressure acting on p g
it.
Refractoriness: Since in most cases the core is Refractoriness: Since in most cases, the core is
surrounded all around it is desirable that the core
i l h ld h hi h f i material should have higher refractoriness.
Contd
Permeability: Gases evolving from the molten metal y g
and generated from the mould may have to go
through the core to escape out of the mould. Hence through the core to escape out of the mould. Hence
cores are required to have higher permeability.
P bilit N b Th t f fl f i i Permeability Number: The rate of flow of air passing
through a standard specimen under a standard pressure is
d bili b termed as permeability number.
The standard permeability test is to measure time p y
taken by a 2000 cu cm of air at a pressure typically of
980 Pa (10 g/cm
2
), to pass through a standard sand 980 Pa (10 g/cm ), to pass through a standard sand
specimen confined in a specimen tube. The standard
specimen size is 50 8 mm in diameter and a length of specimen size is 50.8 mm in diameter and a length of
50.8 mm.
Then the permeability number R is obtained by Then, the permeability number, R is obtained by
VH
R
AT
=
WhereV=volumeofair=2000cm
3
pAT
WhereV=volumeofair=2000cm
3
H=heightofthesandspecimen=5.08cm
p=airpressure,g/cm
2
A=crosssectionalareaofsandspecimen=20 268cm
2
A=crosssectionalareaofsandspecimen=20.268cm
T=timeinminutesforthecompleteairtopassthrough
Insertingtheabovestandardvaluesintothe
i expression,weget
501.28
R =
.
R
pT
Calculatethepermeabilitynumberofsandifittakes1min
25stopass2000cm
3
ofairatapressureof5g/cm
2
through 25stopass2000cm
3
ofairatapressureof5g/cm through
thestandardsample.
2
5.0 / p g cm =
1min25 1.417min
501 28
T s = =
501.28
70.75
5 1.417
R = =
IES 2007 IES2007

Whatispermeability?Permeabilityismoreimportant Whatispermeability?Permeabilityismoreimportant
inthebasicprocessofsandcastingthanporosity.Give p g p y
oneimportantreasonforthisfeature.
[2marks]
Collapsibility:Atthetimeofcooling,castingshrinks,and p y g, g ,
unlessthecorehasgoodcollapsibility(abilitytodecrease
insize)itislikelytoprovideresistanceagainstshrinkage ) y p g g
andthuscancausehottears.
Friability: The ability to crumble should be a very Friability: The ability to crumble should be a very
important consideration at the time of removal. p
Smoothness: Surface of the core should be smooth
for good finish to the casting.
LowGas Emission
CoreSands
Used clay free silica sand.
Binders used are linseed oil, core oil, resins, dextrin,
molasses, etc.
l f l d f h d Core oils are mixtures of linseed, soy, fish and
petroleumoils and coal tar petroleumoils and coal tar.
The general composition of a core sand mixture could The general composition of a core sand mixture could
be core oil (1%) and water (2.5 to 6%). ( ) ( 5 )
CarbonDioxideMoulding
S di ili ( l SiO N O) i d bi d Sodium silicate (water glass, SiO
2
:Na
2
O) is used as a binder.
This is essentially a quick process of core or mould
preparation.
The mould is prepared with a mixture of sodium silicate and p p
sand and then treated with carbon dioxide for two to three
minutes such that a dry compressive strength of over 1.4 y p g 4
MPa is arrived.
The carbon dioxide is expected to form a weak acid which The carbon dioxide is expected to form a weak acid, which
hydrolyses the sodium silicate resulting in amorphous silica,
which forms the bond which forms the bond.
The introduction of CO
2
gas starts the reaction by forming
h d d d b ( O O) hydrated sodiumcarbonate (Na
2
CO
3
+ H
2
O).
Contd
The compressive strength of the bond increases with The compressive strength of the bond increases with
standing time due to dehydration.
Because of the high strength of the bond, the core need not
be provided with any other reinforcements.
It does not involve any distortions due to baking and also
better dimensional accuracies are achieved better dimensional accuracies are achieved.
The sand mixture does not have good shelf life and The sand mixture does not have good shelf life and
therefore should be used immediately after preparation.
IES2002
Assertion (A): In CO
2
casting process, the mould or
core attains maximum strength.
Reason (R): The optimum gassing time of CO
2
through the mould or core forms Silica Gel which through the mould or core forms Silica Gel which
imparts sufficient strength to the mould or core.
(a) Both A and R are individually true and R is the (a) Both A and R are individually true and R is the
( ) (b) Both A and R are individually true but R is not the
(c) A is true but R is false
(d) A is false but R is true (d) A is false but R is true
G 2008 ( ) GATE 2008(PI)
In sand casting of a hollow part of lead a cylindrical core In sand casting of a hollow part of lead, a cylindrical core
of diameter 120 mm and height 180 mm is placed inside of diameter 120 mm and height 180 mm is placed inside
the mould cavity. The densities of core material and lead
are 1600 kg/m
3
and 11,300 kg/m
3
respectively. The net
force (in N) that tends to lift the core during pouring of
molten metal will be
( ) ( ) ( ) ( ) (a) 19.7 (b) 64.5 (c) 193.7 (d) 257.6
MouldingSandComposition
Sand: Ordinary silica Sand (SiO
2
), zircon, or olivine
d sands.
Cl A bi di i d h ldi Clay: Acts as binding agents mixed to the moulding
sands sands
Kaolinite or fire clay (Al O 2SiO 2H O) and Kaolinite or fire clay (Al
2
O
3
2SiO
2
2H
2
O), and
Bentonite (Al O 4SiO H O nH O). Bentonite (Al
2
O
3
4SiO
2
H
2
O nH
2
O).
Water: Clay is activated by water. y y
OtherAdditives
Cereal binder up to 2% increases the strength.
Pitch if used up to 3% would improve the hot
strength.
Saw dust up to 2% may improve the collapsibility by
l l b i d i h bili slowly burning, and increase the permeability.
Oth t i l l h lt f l il hit Other materials: sea coal, asphalt, fuel oil, graphite,
molasses iron oxide etc molasses, iron oxide, etc.
MouldingSandProperties
Porosity or Permeability: Permeability or porosity of
the moulding sand is the measure of its ability to g y
permit air to flow through it.
Strength: It is defined as the property of holding Strength: It is defined as the property of holding
together of sand grains. A moulding sand should have
l h h h ld d ll ample strength so that the mould does not collapse or
get partially destroyed during conveying, turning over
or closing.
Refractoriness: It is the ability of the moulding sand Refractoriness: It is the ability of the moulding sand
mixture to withstand the heat of melt without showing
i f ft i f i any signs of softening or fusion.
Contd
Plasticity: Itisthemeasureofthemouldingsandtoflow
d d d i i d if l aroundandoverapatternduringrammingandtouniformly
filltheflask.
Collapsibility:Thisistheabilityofthemouldingsandto
decreaseinvolumetosomeextentunderthecompressive p
forcesdevelopedbytheshrinkageofmetalduringfreezing
andsubsequentcooling. q g
Adhesiveness:Thisisthepropertyofsandmixtureto
adheretoanotherbody(here themouldingflasks) The adheretoanotherbody(here,themouldingflasks).The
mouldingsandshouldclingtothesidesofthemoulding
boxessothatitdoesnotfalloutwhentheflasksarelifted boxessothatitdoesnotfalloutwhentheflasksarelifted
andturnedover.Thispropertydependsonthetypeand
t fbi d di th d i amountofbinderusedinthesandmix.
OtherSands
Facing sand: The small amount of carbonaceous Facing sand: The small amount of carbonaceous
material sprinkled on the inner surface of the mold
i i b f fi i h h i cavity to give a better surface finish to the castings.
Backing sand: It is what constitutes most of the g
refractory material found in the mould. This is made
up of used and burnt sand up of used and burnt sand.
Green Sand: The molding sand that contains
moisture is termed as green sand. The green sand
should have enough strength so that the constructed g g
mould retains its shape.
Dry sand: When the moisture in the moulding sand is Dry sand: When the moisture in the moulding sand is
completely expelled, it is called dry sand.
IES2008
S ll t f b t i l i kl d Small amount of carbonaceous material sprinkled
on the inner surface of mould cavity is called on the inner surface of mould cavity is called
(a) Backing sand (a) Backing sand
(b) Facing sand ( ) g
(c) Green sand ( )
(d) Dry sand
Grainsizenumber
ASTM (American Society for Testing and Materials)
grain size number defined as grain size number, defined as
N
- n1
2
Where N is the number of grains per square inch
visible in a prepared specimen at 100X and n is the visible in a prepared specimen at 100X and n is the
ASTM grainsize number.
L ASTM b f i i hi h Low ASTM numbers mean a few massive grains; high
numbers refer to many small grains.
IES2002
In the grain size determination using standard
charts, the relation between the given size
b d th b f i 'N' number n and the average number of grains N
per square inch at a magnification of 100 X is p q g
(a) N = 2
n
(b) N = 2
nl
(c) N = 2
n + 1
(d) N = 2
n
+ 1
CastingYield
Thecastingyieldistheproportionoftheactual
castingmass,w,tothemassofmetalpouredintothe
mould,W,expressedasapercentage. p p g
= Casting yield 100
w
WW
G i S GatingSystem
Contd
G ti S t GatingSystem
P i b i A ll f l h d i h Pouring basin: A small funnel shaped cavity at the
top of the mould into which the molten metal is
poured.
Sprue: The passage through which the molten metal,
f h b h h ld from the pouring basin, reaches the mould cavity. In
many cases it controls the flow of metal into the
mould.
Runner: The channel through which the molten
metal is carried from the sprue to the gate.
Contd
Ingate: Achannelthroughwhichthemoltenmetal Ingate: Achannelthroughwhichthemoltenmetal
entersthemouldcavity.
V S ll i i h ld f ili Vent: Smallopeninginthemouldtofacilitateescape
ofairandgases.
TypesofGateorIngate
Top gate: Causes turbulence in the mould cavity, it is prone
f d f bl d d h to form dross, favourable temperature gradient towards the
gate only for ferrous alloys gate, only for ferrous alloys.
Bottom gate: No mould erosion, used for very deep moulds, g , y p ,
higher pouring time, Causes unfavourable temperature
gradients.
Parting Gate: most widely used gate easiest and most Parting Gate: most widely used gate, easiest and most
economical in preparation.
d f h d l f Step Gate: Used for heavy and large castings, size of ingates
are normally increased from top to bottom.
IES2011
In light metal casting, runner should be so designed
that:
1. It avoids aspiration
I id b l 2. It avoids turbulence
3. The path of runner is reduced in area so that 3 p
unequal volume of flow through each gate
takes place takes place
(a) 1 and 2 only (b) 1 and 3 only
(c) 2 and 3 only (d) 1, 2 and 3
GATE 2010(PI)
During the filling process of a given sand mould cavity by
lt t l th h h i t l f i l molten metal through a horizontal runner of circular cross
section the frictional head loss of the molten metal in the
runner will increase with the
(a) increase in runner diameter
(b) decrease in internal surface roughness of runner
(c) decrease in length of runner (c) decrease in length of runner
(d) increase in average velocity of molten metal (d) increase in average velocity of molten metal
IES 2011 IES2011
Match List I with List II and select the correct answer using g
the code given below the lists :
A.Topgate 1.Heavyandlargecastings
B.Bottomgate 2.Mostwidelyusedandeconomical
C.Partinggate 3.Turbulence
DSt t U f bl t t di t
Codes
D.Stepgate 4.Unfavourable temperaturegradient
A B C D A B C D
(a) 3 4 2 1 (b) 1 4 2 3 (a) 3 4 2 1 (b) 1 4 2 3
(c) 3 2 4 1 (d) 1 2 4 3
IES1998
A d i ld A sand casting mould
assembly is shown in
the above figure. The
elements marked A
and B are respectively
(a) Sprue and riser (a) Sprue and riser
(b) Ingate and riser
(c) Drag and runner
(d) Ri d (d) Riser and runner
GATE2002
The primary purpose of a sprue in a casting
mould is to
(a)Feed the casting at a rate consistent with the rate (a)Feed the casting at a rate consistent with the rate
of solidification
(b)A i f l l (b)Act as a reservoir for molten metal
(c)Feed molten metal from the pouring basin to the ( ) p g
gate
(d)Help feed the casting until all solidification takes (d)Help feed the casting until all solidification takes
place
Thegoalsforthegatingsystem
To minimize turbulence to avoid trapping gasses into
the mold the mold
To get enough metal into the mold cavity before the
l lidif metal starts to solidify
To avoid shrinkage g
Establish the best possible temperature gradient in the
solidifying casting so that the shrinkage if occurs must solidifying casting so that the shrinkage if occurs must
be in the gating system not in the required cast part.
Incorporates a system for trapping the nonmetallic
inclusions.
IES1998
Whichofthefollowingaretherequirementsofanideal
gatingsystem?
1. Themoltenmetalshouldenterthemouldcavitywithas
highavelocityaspossible. highavelocityaspossible.
2. Itshouldfacilitatecompletefillingofthemouldcavity.
I h ldb bl h b i f i 3. Itshouldbeabletopreventtheabsorptionofairorgases
fromthesurroundingsonthemoltenmetalwhile
flowingthroughit.
Selectthecorrectanswerusingthecodesgivenbelow: g g
(a)1,2and3 (b)1and2 (c)2and3 (d)1and3
IES2009
Considerthefollowingstatements:
1 Theactualentrypointthroughwhichthemolten 1.Theactualentrypointthroughwhichthemolten
metalentersthemouldcavityiscalledingate.
2.Bottomgateincaseofamouldcreatesunfavourable
temperaturegradient. p g
3.Sprueincaseofamouldismadetaperedtoavoidair
inclusion inclusion.
Whichoftheabovestatementsis/arecorrect?
(a)1only (b)1and2 (c)2and3 (d)1and3
TypesofGatingSystems
Thegatingsystemsareoftwotypes: Thegatingsystemsareoftwotypes:
Pressurizedgatingsystem
Unpressurizedgatingsystem p g g y
PressurizedGatingSystem
The total cross sectional area decreases towards the
ld it mold cavity
Back pressure is maintained by the restrictions in the p y
metal flow
Flowof liquid (volume) is almost equal fromall gates Flowof liquid (volume) is almost equal fromall gates
Back pressure helps in reducing the aspiration as the
sprue always runs full
Because of the restrictions the metal flows at high Because of the restrictions the metal flows at high
velocity leading to more turbulence and chances of
mold erosion mold erosion.
UnPressurizedGatingSystem
The total cross sectional area increases towards the
mold cavity
Restriction only at the bottomof sprue
Flowof liquid (volume) is different fromall gates
Aspiration in the gating system as the system never
f ll runs full
Less turbulence Less turbulence.
S D i Sprue Design
h h l h h h h h l Sprue: Sprue is the channel through which the molten
metal is brought into the parting plane where it enters the
runners and gates to ultimately reach the mould cavity.
The molten metal when moving from the top of the cope to g p p
the parting plane gains in velocity and some lowpressure
area would be created around the metal in the sprue. area would be created around the metal in the sprue.
Since the sand mould is permeable, atmospheric air would
be breathed into this low pressure area which would then be breathed into this lowpressure area which would then
be carried to the mould cavity.
l h bl f h To eliminate this problem of air aspiration, the sprue is
tapered to gradually reduce the cross section as it moves
away from the top of the cope as shown in Figure below (b).
Contd
Theexacttaperingcanbeobtainedbytheequationof
continuity DenotingthetopandchokesectionsofThesprue by continuity.DenotingthetopandchokesectionsofThesprue by
thesubscriptstand'c'respectively,weget
A V A V = =
c
V
A A
t t c c
A V A V
t c
t
A A
V
Contd
Sincethevelocitiesareproportionaltothesquareof
thepotentialheads ascanbederivedfrom thepotentialheads,ascanbederivedfrom
Bernoulli'sequation,
=
c
t c
h
A A
h
t c
t
h
WhereH=actual WhereH actual
sprue height
andh
t
=h+H andh
t
h+H
GATE2001
The height of the downsprue is 175 mm and its The height of the down sprue is 175 mm and its
crosssectional area at the base is 200 mm
2
. The
cross sectional area of the horizontal runner is crosssectional area of the horizontal runner is
also 200 mm
2
. Assuming no losses, indicate the
h i f h i (i d ) i d correct choice for the time (in seconds) required to
fill a mould cavity of volume 10
6
mm
3
. (Use g = 10
m/s
2
).
(a)2 67 (b)8 45 (c)26 72 (d)84 50 (a)2.67 (b)8.45 (c)26.72 (d)84.50
GATE2007
A 200 mm long down sprue has an area of cross A 200 mm long down sprue has an area of cross
section of 650 mm
2
where the pouring basin meets the
d (i h b i i f h d ) down sprue (i.e. at the beginning of the down sprue).
A constant head of molten metal is maintained by the
pouring basin. The Molten metal flow rate is 6.5 10
5
mm
3
/s. Considering the end of down sprue to be open mm /s. Considering the end of down sprue to be open
to atmosphere and an acceleration due to gravity of
10
4
mm/s
2
the area of the down sprue in mm
2
at its end 10
4
mm/s , the area of the down sprue in mm at its end
(avoiding aspiration effect) should be
( ) ( ) ( ) ( ) (a)650.0 (b)350.0 (c)290.7 (d)190.0
Contd
Gatingratio
Gatingratioisdefinedas:Sprue area:Runnerarea:
Ingate area.
Forhighqualitysteelcastings,agatingratioof1:2:2or
1:2:1 5willproducecastingsnearlyfreefromerosion 1:2:1.5willproducecastingsnearlyfreefromerosion,
willminimizeoxidation,andwillproduceuniform , p
flow.
Agatingratioof1:4:4mightfavour theformationof
oxidationdefects.
IES2003
A gating ratio of 1: 2: 4 is used to design the gating
system for magnesium alloy casting. This gating ratio y g y g g g
refers to the cross section areas of the various gating
elements as given below: elements as given below:
1. Down sprue 2. Runner bar 3. Ingates
Th f h b l i h The correct sequence of the above elements in the
ratio 1: 2: 4 is
(a) 1, 2 and 3
(b) 1,3 and 2 (b) 1,3 and 2
(c) 2, 3 and 1
(d) (d) 3, 1 an 2
IES2005
The gating ratio 2: 8: 1 for copper in gating system The gating ratio 2: 8: 1 for copper in gating system
design refers to the ratio of areas of:
( ) S R I (a) Sprue: Runner: Ingate
(b) Runner: Ingate: Sprue ( ) g p
(c) Runner: Sprue: Ingate
(d) I R S (d) Ingate: Runner: Sprue
GATE2010
I ti t th ti t Inagatingsystem,theratio1:2:4represents
(a) Sprue basearea:runnerarea:ingate area (a) Sprue basearea:runnerarea:ingate area
(b) Pouringbasinarea:ingate area:runnerarea (b) Pouringbasinarea:ingate area:runnerarea
(c) Sprue basearea:ingate area:castingarea (c) Sprue basearea:ingate area:castingarea
(d) Runnerarea:ingate area:castingarea (d) Runnerarea:ingate area:castingarea
IAS1999
Assertion (A): The rate of flow of metal through sprue
is NOT a function of the crosssectional areas of
sprue, runner and gate.
Reason (R): If respective crosssectional areas of Reason (R): If respective cross sectional areas of
sprue, runner and gate are in the ratio of 1: 2: 2, the
system is known as unpressurised gating system. y p g g y
(a) Both A and R are individually true and R is the correct
explanation of A explanation of A
(b) Both A and R are individually true but R is not the
correct explanation of A correct explanation of A
RisersandRiserDesign
Ri dd d i d i d f d li id Risers are added reservoirs designed to feed liquid
metal to the solidifying casting as a means of
compensating for solidification shrinkage.
To perform this function the risers must solidify after To perform this function, the risers must solidify after
the casting.
d Ch ' l d h f According to Chvorinov's rule, a good shape for a riser
would be one that has a long freezing time (i.e., a small
surface area per unit volume).
Live risers (also known as hot risers) receive the last Live risers (also known as hot risers) receive the last
hot metal that enters the mold and generally do so at a
ti h th t l i th ld it h l d time when the metal in the mold cavity has already
begun to cool and solidify.
IES1994
A i (A) I ld i i d i d d l d Assertion (A): In a mould, a riser is designed and placed
so that the riser will solidify after the casting has solidified.
Reason (R): A riser is a reservoir of molten metal which
will supply molten metal where a shrinkage cavity would pp y g y
have occurred.
(a) Both A and R are individually true and R is the correct (a) Both A and R are individually true and R is the correct
explanation of A
(b) B th A d R i di id ll t b t R i t th (b) Both A and R are individually true but R is not the
(d) A is false but R is true ( )
Chvorinovs rule
l l d f ( ) ( ) Totalsolidificationtime(t
s
)=B(V/A)
n
wheren=1.5to2.0 wheren 1.5to2.0
[Where,B=mouldconstantandisafunctionof(mould
t i l ti t i l d diti f ti ] material,castingmaterial,andconditionofcasting]
n=2 andt
riser
=1.25t
casting riser
5
casting

2 2
V V
1 25 or =

riser casting
1.25
A A
or
( )
=
2
2
V D H/ 4
D
Forcylinder
ofdiameterD
( )
= +
2
D
A DH 2
4
ofdiameterD
andheightH
IES2011
h l h b l f The relationship between total freezing time t,
volume of the casting V and its surface area A,
according to Chvorinovs rule is :
V
( )
V
a t k
A
A

=

2
( )
A
b t k
V

=

2
( )
A
c t k
V

=

Wh K i
2
( )
V
d t k
A

=

Where K is a constant

IES1998
A spherical drop of molten metal of radius 2 mm p p
was found to solidify in 10 seconds. A similar drop
of radius 4 mmwould solidify in
(a) 14.14 seconds
(b) 20 seconds
(c) 28.30 seconds
(d) 40 seconds
GATE2003
With lidifi ti f t f
6
/
2
th With a solidification factor of 0.97 x 10
6
s/m
2
, the
solidification time (in seconds) for a spherical solidification time (in seconds) for a spherical
casting of 200 mmdiameter is g
(a) 539 (b) 1078 (c) 4311 (d) 3233
IES2006
According to Chvorinov's equation, the
solidification time of a casting is proportional to:
(a) v
2
(b) v
(c) 1/v
(d) 1/v
2
Where, v = volume of casting
GATE 2010(PI)
Solidification time of a metallic alloy casting is
(a) Directly proportional to its surface area
(b) Directly proportional to the specific heat of the
t t i l cast material
(c) Directly proportional to the thermal diffusivity of (c) Directly proportional to the thermal diffusivity of
the molten metal the molten metal
(d)Inversely proportional to the pouring ( ) y p p p g
temperature.
GATE2007
Volume of a cube of side 'l' and volume of a sphere of Volume of a cube of side l and volume of a sphere of
radius r are equal. Both the cube and the sphere are solid q p
and of same material. They are being cast. The ratio of the
solidification time of the cube to the same of the sphere is:
( ) ( ) ( ) ( )
3 6 2 2 3 2 4
4 r 4 r 4 r 4 r
a b c d
6 l 6 l 6 l 6 l

In a sand casting process, a sphere and a cylinder g p , p y
of equal volumes are separately cast from the same
molten metal under identical conditions. The
height and diameter of the cylinder are equal. The
ratio of the solidification time of the sphere to that ratio of the solidification time of the sphere to that
of the cylinder is
(a) 1 14 (a) 1.14
(b) 0.87
( ) (c) 1.31
(d) 0.76 ( ) 7
GATE2009(PI) ( )
A solid cylinder of diameter D and height equal to D, and a solid
cube of side L are being sand cast by using the same material cube of side L are being sand cast by using the same material.
Assuming there is no superheat in both the cases, the ratio of
solidification time of the cylinder to the solidification time of the
cube is cube is
(a) (L/D)
2
(b) (2L/D)
2
( ) ( D/L)
2
(c) (2D/L)
2
(d) (D/L)
2
IES 2012
Theratioofsurfaceareaofvolumeforaunitvolumeof
f riserisminimumincaseof
( )C li d i l i (a)Cylindricalriser
(b)S h i l i (b)Sphericalriser
(c)Hemisphericalriser (c)Hemisphericalriser
(d)Cuboidsriser (d)Cuboidsriser
IES 2011 C ti l IES2011Conventional
A round casting is 20 mm in diameter and 50 mm in g 5
length. Another casting of the same metal is elliptical in
cross section, with a major to minor axis ratio of 2, and
has the same length and crosssectional area as the
round casting. Both pieces are cast under the same
conditions What is the difference in the solidification conditions. What is the difference in the solidification
times of the two castings ? [10 Marks] times of the two castings ? [10 Marks]
( ) ( )( )
Areaof ellipse
Circumference 3 3 3
ab
a b a b a b
=

= + + +

( ) ( )( )
( )
2 2
Circumference 3 3 3
2 / 2 (approx.)
a b a b a b
a b

= + + +

= +
ConventionalQuestionESE2003
Compare the solidification time of two optimum side
f h l h h l d l h risers of the same volume with one has cylindrical shape
and other is parallopiped [30 Marks] and other is parallopiped. [30 Marks]
ModulusMethod
It has been empirically established that if the modulus
f h i d h d l f h i b of the riser exceeds the modulus of the casting by a
factor of 1 2 the feeding during solidification would be factor of 1.2, the feeding during solidification would be
satisfactory.
M
R
= 1.2 Mc
Modulus = volume/Surface area
In steel castings, it is generally preferable to choose a
i i h h i h di i f riser with a heighttodiameter ratio of 1.
Contd
2
2
D
D
+
2
4
D +
Conventional Question IES2008 ConventionalQuestionIES2008
Calculate the size of a cylindrical riser (height and diameter Calculate the size of a cylindrical riser (height and diameter
equal) necessary to feed a steel slab casting of dimensions
30 x 30 x 6 cm with a side riser, casting poured horizontally
into the mould.
[Use Modulus Method] [Use Modulus Method]
[10 Marks] [ ]
Caines Method
Freezingratio=ratio ofcoolingcharacteristicsofcastingto
theriser.
( )
A
( )
( )
Casting
A
V
X
A
V
=
Therisershouldsolidifylastsox>1
( )
Riser
V
AccordingtoCaine X=
a
c
Y b
+
AccordingtoCaine X
Y d b
Y b
riser
V
Y=anda,b,careconstant.
riser
casting
V
Table:ConstantsinCaines Method
Conventional Question IES2007 Conventional QuestionIES2007
Calculate the size of a cylindrical riser (height and y g
diameter equal) necessary to feed a steel slab
casting of dimensions 25 x 25 x 5 cm with a side
riser, casting poured horizontally into the mould.
[Use Caines Method]
[ F l b d ] [ For steel a = 0.10, b = 0.03 and c = 1.00 ]
Chills
E l hill f hi h h i hi h h l External chills are masses of highheatcapacity, highthermal
conductivity material that are placed in the mould (adjacent to
th ti ) t l t th li f i i the casting) to accelerate the cooling of various regions.
Chills can effectively promote directional solidification or
i h ff i f di di f i Th f increase the effective feeding distance of a riser. They can often
be used to reduce the number of risers required for a casting.
Internal chills are pieces of metal that are placed within the
mould cavity to absorb heat and promote more rapid
lidifi i Si f hi l ill l d i h solidification. Since some of this metal will melt during the
operation, it will absorb not only the heatcapacity energy, but
l h t f f i Si th lti t l b t f also some heat of fusion. Since they ultimately become part of
the final casting, internal chills must be made from the same
ll th t b i t alloy as that being cast.
IES1995
Di ti l lidifi ti i ti b Directional solidification in castings can be
improved by using improved by using
(a) Chills and chaplets (a) Chills and chaplets
(b) Chills and padding ( ) p g
(c) Chaplets and padding ( ) p p g
(d) Chills, chaplets and padding.
GATE1998,2007
Chill d i ld t Chills are used in moulds to
(a) Achieve directional solidification (a) Achieve directional solidification
(b) Reduce the possibility of blowholes (b) Reduce the possibility of blowholes
(c) Reduce freezing time (c) Reduce freezing time
(d) Smoothen metal flow for reducing splatter. (d) Smoothen metal flow for reducing splatter.
IAS1994
Chillsareusedincastingmouldsto
( ) A hi di i l lidifi i (a) Achievedirectionalsolidification
(b) Reducepossibilityofblowholes ( ) p y
(c) Reducethefreezingtime
(d) I h h f f (d) Increasethesmoothnessofcastsurface
Cupola Cupola
Cupola has been the most widely used furnace for
melting cast iron.
In hot blast cupola, the flue gases are used to preheat the In hot blast cupola, the flue gases are used to preheat the
air blast to the cupola so that the temperature in the
furnace is considerably higher than that in a furnace is considerably higher than that in a
conventional cupola. Coke is fuel and Lime stone
(C CO ) i l d fl (CaCO
3
) is mostly used flux.
Cost of melting low. g
Main disadvantages of cupola is that it is not possible to
produce iron below 2 8% carbon produce iron below 2.8% carbon.
Steel can be also prepared in cupola by employing
duplexing and triplexing operations.
IES1997
Assertion (A): Steel can be melted in hot blast cupola.
Reason (R): In hot blast cupola the flue gases are used to Reason (R): In hot blast cupola, the flue gases are used to
preheat the air blast to the cupola so that the temperature in
th f i id bl hi h th th t i the furnace is considerably higher than that in a
conventional cupola.
explanation of A p
(d) A i f l b R i (d) A is false but R is true
IES 2012
St t t (I) C l f i t l d f Statement (I): Cupola furnace is not employed for
melting steel in foundry
Statement (II): The temperatures generated within a
cupola are not adequate for melting Steel
(a) Both Statement (I) and Statement (II) are
individually true and Statement (II) is the correct y ( )
explanation of Statement (I)
(b) Both Statement (I) and Statement (II) are (b) Both Statement (I) and Statement (II) are
individually true but Statement (II) is not the correct
explanation of Statement (I) explanation of Statement (I)
(c) Statement (I) is true but Statement (II) is false
( ) ( ) ( ) (d) Statement (I) is false but Statement (II) is true
El i A F ElectricArcFurnace
For heavy steel castings, the openhearth type of
f h l l f d ld b ll furnaces with electric arc or oil fired would be generally
suitable in viewof the large heat required for melting suitable in viewof the large heat required for melting.
Electric arc furnaces are more suitable for ferrous Electric arc furnaces are more suitable for ferrous
materials and are larger in capacity. g p y
Crucible Furnace Crucible Furnace
Smaller foundries generally prefer the crucible furnace.
The crucible is generally heated by electric resistance
or gas flame. or gas flame.
Induction Furnace
The induction furnaces are used for all types of The induction furnaces are used for all types of
materials, the chief advantage being that the heat
source is isolated from the charge and the slag and flux source is isolated from the charge and the slag and flux
get the necessary heat directly from the charge instead
f th h t of the heat source.
Ladles
Twotypesofladlesusedinthepouringofcastings.
CastingCleaning(fettling)
Impuritiesinthemoltenmetalarepreventedfrom
reachingthemouldcavitybyprovidinga g y y p g
(i) Strainer
(ii) B tt ll (ii) Bottomwell
(iii) Skimbob
GATE1996
Light impurities in the molten metal are prevented Light impurities in the molten metal are prevented
from reaching the mould cavity by providing a
( ) S i (a) Strainer
(b) Button well ( )
(c) Skim bob
(d) All f h b (d) All of the above
P i i Pouringtime
Timetakentofillthemouldwithtopgate
Where A=Areaofmould
A H
H=Heightofmould
A A fG t
A
g m
A.H
t
A 2gh
=
A
g
=AreaofGate
H
m
=Gateheight
g m
g
Timetakentofillthemouldwithbottomgate Timetakentofillthemouldwithbottomgate
( )
2A
( ) B m m
g
2A
t h h H
A 2g
=
GATE2005
A mould has a downsprue whose length is 20 cm A mould has a downsprue whose length is 20 cm
and the cross sectional area at the base of the
downsprue is 1cm
2
The downsprue feeds a downsprue is 1cm
2
. The downsprue feeds a
horizontal runner leading into the mould cavity of
l
3
Th i i d fill h volume 1000 cm
3
. The time required to fill the
mould cavity will be
(a)4.05 s (b)5.05 s (c)6.05 s (d)7.25 s
GATE2006
In a sand casting operation, the total liquid head is a sa d cast g ope at o , t e tota qu d ead s
maintained constant such that it is equal to the mould
height The time taken to fill the mould with a top gate height. The time taken to fill the mould with a top gate
is t
A.
If the same mould is filled with a bottom gate,
th th ti t k i t I th ti i d t then the time taken is t
B
. Ignore the time required to
fill the runner and frictional effects. Assume
atmospheric pressure at the top molten metal surfaces.
The relation between t
A
and t
B
is
A B
(A) 2
(B) 2
B A
B A
t t
t t
=
= ( )
(C)
2
B A
A
B
t
t =
2
(D) 2 2
B A
t t =
( ) k d GATE 2007(PI)LinkedS1
I d ti f b In a sand casting process, a sprue of 10 mm base
diameter and 250 mm height leads to a runner 5 g
which fills a cubical mould cavity of 100 mm size
Th l fl (i
3
/ ) i The volume flowrate (in mm
3
/s) is
(a) 0 8 x 10
5
(b) 1 1 x 10
5
(a) 0.8 x 10 (b) 1.1 x 10
(c) 1.7 x 10
5
(d) 2.3 x 10
5
( ) k d GATE 2007(PI)LinkedS2
I d ti f b In a sand casting process, a sprue of 10 mm base
diameter and 250 mm height leads to a runner 5 g
which fills a cubical mould cavity of 100 mm size
Th ld filli i (i d ) i The mould filling time (in seconds) is
(a) 2 8 (b) 5 78 (a) 2.8 (b) 5.78
(c) 7.54 (d) 8.41
Expressionforchokearea
=
2
m
CA mm
ct 2gH ct 2gH
Wherem=massofthecasting,kg
=Densityofmetal,kg/m
3
y , g /
t=pouringtime
Effi i f t di th f ti f t
c=Efficiencyfactorandisthefunctionofgate
systemused
H=Effectiveheadofliquidmetal
=hfortopgate p g
Contd
h
H=h forbottomgate
m
h
2
=h forpartinglinegate
2
c
h
2h
m
2h
h
m
h
C
h
h
topgatepartinglinegatebottomgate
m
h
P i li
m
h
topgatepartinglinegatebottomgate
IES 2009 IES2009
2marks 2marks
IAS2011 Main IAS2011Main
Sk t h ld f t h ll t t b Sketch a mould for two hollow components to be
cast On the diagram indicate runner gate riser cast. On the diagram, indicate runner, gate, riser,
core, cope, sprue, pouring basin, sprue well, drag, p p p g p g
parting line.
[10Marks]
CastingDefects
Thefollowingarethemajordefects,whicharelikelyto
d occurinsandcastings:
G d f Gasdefects
Sh i k iti Shrinkagecavities
Moldingmaterialdefects Moldingmaterialdefects
Pouringmetaldefects Pouringmetaldefects
Moldshift Moldshift.
GasDefects
A condition existing in a casting caused by the
trapping of gas in the molten metal or by mold gases trapping of gas in the molten metal or by mold gases
evolved during the pouring of the casting.
The defects in this category can be classified into
blowholes and pinhole porosity. p p y
Blowholes are spherical or elongated cavities present
in the casting on the surface or inside the casting in the casting on the surface or inside the casting.
Pinhole porosity occurs due to the dissolution of
hydrogen gas, which gets entrapped during heating of
molten metal.
Sh i k C i i ShrinkageCavities
These are caused by liquid shrinkage occurring during the These are caused by liquid shrinkage occurring during the
solidification of the casting.
T f hi f di f li id l i To compensate for this, proper feeding of liquid metal is
required. For this reason risers are placed at the
i l i h ld appropriate places in the mold.
Sprues may be too thin, too long or not attached in the p y g
proper location, causing shrinkage cavities.
It is recommended to use thick sprues to avoid shrinkage It is recommended to use thick sprues to avoid shrinkage
cavities.
MoldingMaterialDefects g
Cutsandwashes Cutsandwashes,
Scab Scab
Metalpenetration Metalpenetration,
Fusion,and Fusion,and
Swell Swell
Cutandwashes
These appear as rough spots and areas of excess metal, and
are caused by erosion of molding sand by the flowing y g y g
metal.
This is caused by the molding sand not having enough This is caused by the molding sand not having enough
strength and the molten metal flowing at high velocity.
Th f b k f b h h i f The former can be taken care of by the proper choice of
molding sand and the latter can be overcome by the
d f h proper design of the gating system.
S b Scab
This defect occurs when a portion of the face of a mould This defect occurs when a portion of the face of a mould
lifts or breaks down and the recess thus made is filled by
metal metal.
When the metal is poured into the cavity, gas may be
di d i h h i l b k h d disengaged with such violence as to break up the sand,
which is then washed away and the resulting cavity filled
i h l with metal.
The reasons can be: too fine sand, low permeability of p y
sand, high moisture content of sand and uneven mould
ramming. g
Metalpenetration
h l l h b d When molten metal enters into the gaps between sand
grains, the result is a rough casting surface.
This occurs because the sand is coarse or no mold wash was
applied on the surface of the mold. The coarser the sand pp
grains more the metal penetration.
Fusion
This is caused by the fusion of the sand grains with
the molten metal, giving a brittle, glassy appearance
on the casting surface.
The main reason for this is that the clay or the sand
ti l f l f t i th t th particles are of lower refractoriness or that the
pouring temperature is too high pouring temperature is too high.
Swell Swe
Under the influence of metallostatic forces, the mold
wall may move back causing a swell in the dimension wall may move back causing a swell in the dimension
of the casting. A proper ramming of the mold will
correct this defect correct this defect.
Inclusions
Particles of slag refractory materials sand or Particles of slag, refractory materials sand or
deoxidation products are trapped in the casting during
pouring solidification The provision of choke in the pouring solidification. The provision of choke in the
gating system and the pouring basin at the top of the
mold can prevent this defect mold can prevent this defect
PouringMetalDefects
The likely defects in this category are
Misruns and Mis runs and
Cold shuts
A misrun is caused when the metal is unable to fill A mis run is caused when the metal is unable to fill
the mold cavity completely and thus leaves unfilled
cavities cavities.
A cold shut is caused when two streams while meeting
in the mold cavity, do not fuse together properly thus
forming a discontinuity in the casting. forming a discontinuity in the casting.
Contd
The misrun and cold shut defects are caused either by y
a lower fluidity of the mold or when the section
thickness of the casting is very small. Fluidity can be thickness of the casting is very small. Fluidity can be
improved by changing the composition of the metal
and by increasing the pouring temperature of the and by increasing the pouring temperature of the
metal.
GATE2004
Mi i ti d f t hi h d t Misrun is a casting defect which occurs due to
(a) Very high pouring temperature of the metal (a) Very high pouring temperature of the metal
(b) Insufficient fluidity of the molten metal (b) Insufficient fluidity of the molten metal
(c) Absorption of gases by the liquid metal (c) Absorption of gases by the liquid metal
(d) Improper alignment of the mould flasks (d) Improper alignment of the mould flasks
GATE2009
Two streams of liquid metal which are not hot
enough to fuse properly result into a casting defect
known as
(a) Cold shut
(b) Swell
( ) d h (c) Sand wash
(d) S b (d) Scab
MoldShift
The mold shift defect occurs when cope and drag
or molding boxes have not been properly aligned.
IES2001
S bi Scabisa
(a) Sandcastingdefect (a) Sandcastingdefect
(b) Machiningdefect (b) Machiningdefect
(c) Weldingdefect (c) Weldingdefect
(d) Forgingdefect (d) Forgingdefect
IAS2004
MatchListI(CastingDefects)withListII(Explanation)andselectthecorrect
answerusingthecodesgivenbelowthelists:
(CastingDefects) (Explanation)
A.Metallicprojections 1.Consistofroundedorroughinternalorexposedcavities
includingblowholesandpinholes includingblowholesandpinholes
B.Cavities 2.Formedduringmelting,solidificationandmoulding.
C.Inclusions 3.Includessinglefolds,laps,scarsadheringsandlayersand
oxidescale oxidescale
D.Discontinuities 4.Includecracks,coldorhottearingandcoldshuts
5.Consistoffins,flashormassiveprojectionsandrough
surfaces surfaces
(a) 1 5 3 2 (b) 1 5 2 4
(c) 5 1 2 4 (d) 5 1 3 2 (c) 5 1 2 4 (d) 5 1 3 2
GATE2003
Hardnessofgreensandmouldincreaseswith
( ) I i i b d6 (a) Increaseinmoisturecontentbeyond6percent
(b) Increaseinpermeability ( ) p y
(c) Decreaseinpermeability
(d) I i b h i d (d) Increaseinbothmoisturecontentand
permeability
IES1998
Assertion(A):Stiffeningmembers,suchaswebs
andribs,usedonacastingshouldbeliberally andribs,usedonacastingshouldbeliberally
provided.
Reason(R):Theywillprovideadditionalstrength Reason(R):Theywillprovideadditionalstrength
toacastmember.
( ) B hA dR i di id ll dRi h (a) BothAandRareindividuallytrueandRisthe
correctexplanationofA
(b) BothAandRareindividuallytruebutRisnot the
correctexplanationofA p
(c) AistruebutRisfalse
(d) AisfalsebutRistrue (d) AisfalsebutRistrue
IES2005
In gating system design, which one of the
following is the correct sequence in which choke following is the correct sequence in which choke
area, pouring time, pouring basin and sprue sizes
l l d? are calculated?
(a) Chokearea Pouringtime Pouringbasin Sprue ( ) g g p
(b) Pouringbasin Sprue Chokearea Pouringtime
( ) Ch k S P i b i P i i (c) Chokearea Sprue Pouringbasin Pouringtime
(d) Pouringbasin Pouringtime Chokearea Sprue ( ) g g p
IES1997
Ifthemeltingratioofacupolais10:1,thenthe
cokerequirementforonetonmeltwillbe cokerequirementforonetonmeltwillbe
(a) 0.1ton
(b) 10tons
(c) 1ton (c) 1ton
(d) 11tons
IES2009
Inwhichoneofthefollowingfurnacesmostofthe
non ferrousalloysaremelted? nonferrousalloysaremelted?
(a) Reverberatory furnace
(b) Inductionfurnace
(c) Cruciblefurnace (c) Cruciblefurnace
(d) Potfurnace
IAS2001
Whichofthefollowingpatternmaterialsareused
inPrecisionCasting? inPrecisionCasting?
1. PlasterofParis
2. Plastics
3 AnodizedAluminium Alloy 3. AnodizedAluminium Alloy
4. FrozenMercury
Selectthecorrectanswerusingthecodesgivenbelow:
(a)1and2(b) 2and4(c)3and4(d)1and3 (a)1and2(b) 2and4(c)3and4(d)1and3
IAS2004
Whichoneofthefollowinggatingsystemsisbest
suitedtoobtaindirectionalsolidification? suitedtoobtaindirectionalsolidification?
(a) Topgrating
(b) Partlinegrating
(c) Bottomgrating (c) Bottomgrating
(d) Steppedgrating
C t Al i i C d CastAluminiumCode
Fourdigitidentificationsystem ou d g t de t cat o syste
Firstdigitindicatesalloygroup
l 1 Aluminium,99%ormore
2 copper 2 copper
3 Silicon,withcopperand/ormagnesium
4 silicon
5 magnesium 5 magnesium
6 notused
7 zinc
8 tin 8 tin
9 otherelements
CastAluminiumCodeContd..
S d di i id if h l i i ll Second two digits identify the aluminium alloy or
indicate the aluminium purity.
The last digit is separating from the other three by a
decimal point and indicates the product form; that is decimal point and indicates the product form; that is,
castings or ingots
d f f h l ll d d b A modification of the original alloy is indicated by a
serial letter before the numerical designation.
Alloy A514.0 indicates an aluminium alloy casting with
magnesium as the principal alloy One modification to magnesium as the principal alloy. One modification to
the original alloy has made, as indicated by the letter A.
IES2011
In the designation of Aluminium casting A514.0
indicates :
(a) Aluminium purity
(b) Al i i (b) Aluminiumcontent
(c) Percentage of alloy element ( ) g y
(d) Magnesium Content
Ans. (d) s (d)
S i lC ti SpecialCasting p g
BySKMondal BySKMondal
ShellMoulding g
The sand is mixed with a thermosetting resin is e sa d s ed w t a t e osett g es s
allowed to come in contact with a heated metal pattern
(200
0
C) (200 C).
A skin (shell) of about 3.5 mm of sand and plastic
mixture adhere to the pattern.
Then the shell is removed from the pattern. Then the shell is removed from the pattern.
The cope and drag shells are kept in a flask with
b k t i l d th lt t l i necessary backup material and the molten metal is
poured into the mold.
Can produce complex parts.
A good surface finish and good size tolerance
reduce the need for machining.
Materials can be cast: CI, Al and Cu alloys.
Shellmouldingprocess Shellmouldingprocess
Molding Sand in Shell Molding MoldingSandinShellMolding
The molding sand is a mixture of fine grained quartz sand
and powdered bakelite.
Cold coating and Hot coating methods are used for
i h d i i h b k li coating the sand grains with bakelite.
Cold coating: quartz sand is poured into the mixer and Cold coating: quartz sand is poured into the mixer and
then the solution of powdered bakelite in acetone and p
ethyl aldehyde are added. (mixture is 92% quartz sand,
5% bakelite, 3% ethylaldehyde )
Contd
Hot coating: the mixture is heated to 150
o
C 180
o
C prior g 5 p
to loading the sand. In the course of sand mixing, the
soluble phenol formaldehyde resin is added. The mixer is
ll d l 8 C H i i b allowed to cool up to 80 90
o
C. Hot coting gives better
properties to the mixtures than cold method properties to the mixtures than cold method.
Advantages
Dimensional accuracy.
Smoother surface finish. (Due to finer size grain used)
Very thin sections can be cast.
Very small amount of sand is needed.
Limitations
Expensive pattern
Small size casting only.
Hi hl li d h b b i d Highly complicated shapes cannot be obtained.
M hi ti t d i t i d d f h dli More sophisticated equipment is needed for handling
the shell moldings the shell moldings.
Applications Applications
C li d d li d h d f i l d IC Cylinders and cylinder heads for air cooled IC
engines engines
Automobile transmission parts. Automobile transmission parts.
Piston rings g
IES2010
C id th f ll i d t f h ll Considerthefollowingadvantagesofshell
mouldcasting: g
1.Closedimensionaltolerance.
2.Goodsurfacefinish.
3 Lowcost 3.Lowcost.
4.Easier. 4
Whichofthesearecorrect?
(a)1,2and3only (b)2,3and4only
( ) d l (d) d (c)1,2and4only (d)1,2,3and4
IES1996
Consider the following ingredients used in
moulding: moulding:
1. Dry silica sand
2.Clay
3 Phenol formaldehyde 3.Phenol formaldehyde
4.Sodiumsilicate
Those used for shell mould casting include
(a) 1 2 and 4 (b) 2 3 and 4 (a) 1, 2 and 4 (b) 2, 3 and 4
(c) 1and 3 (d) 1, 2, 3 and 4
IES2005
Inshellmoulding,howcantheshellthickness
beaccuratelymaintained? beaccuratelymaintained?
(a)Bycontrollingthetimeduringwhichthepattern
i i i h ld isincontactwithmould
(b)Bycontrollingthetimeduringwhichthepattern ( ) y g g p
isheated
(c)Bymaintainingthetemperatureofthepatternin (c)Bymaintainingthetemperatureofthepatternin
therangeof175
o
C 380
o
C
(d)Bythetypeofbinderused
IES2006
Shellmouldingcanbeusedfor:
( ) P d i illi (a) Producingmillingcutters
(b) Makinggoldornaments ( ) g g
(c) Producingheavyandthickwalledcasting
(d) P d i hi i (d) Producingthincasting
IES2007
Which of the following are employed in shell Which of the following are employed in shell
moulding?
R i bi d M l H i il 1. Resin binder 2. Metal pattern 3. Heating coils
Select the correct answer using the code given g g
below:
(a) 1 and 2 only (b) 1 and 3 only (a) 1 and 2 only (b) 1 and 3 only
(c) 2 and 3 only (d) 1, 2 and 3
IAS2007
The mould in shell moulding process is made up
of which of the following?
(a) Gypsum + setting agents
(b) Green sand + clay
(c) Sodiumsilicate + dried sand
(d) Dried silica + phenolic resin
IAS1999
Match List I (Moulding Process) with List II (Binding
Agent) and select the correct answer using the codes
b l h l given belowthe lists:
List I List II
A. Green sand 1. Silicate
B. Core sand 2. Organic
C. Shell moulding 3. Clay
D. CO2 process 4. Plaster of Paris p
5. Plastic
(a) 3 2 5 1 (b) 3 2 4 1
(c) 2 3 5 4 (d) 2 3 4 5 ( ) 3 5 4 ( ) 3 4 5
InvestmentCasting
Investment casting process or lost wax process
Basic steps: p
1. Produce expendable wax, plastic, or polystyrene patterns.
2 Assemble these patterns onto a gating system 2. Assemble these patterns onto a gating system
3. Investing or covering the pattern assembly with refractory
slurry slurry
4. Melting the pattern assembly to remove the pattern material
i i h ld h l f h 5. Firing the mould to remove the last traces of the pattern
material
6. Pouring molten metal
7. Knockout, cutoff and finishing. g
Fig.Investmentflaskcastingprocedure
CeramicShellInvestmentCasting
In ceramic shell investment casting a ceramic shell is g
built around a tree assembly by repeatedly dipping a
pattern into a slurry (refractory material such as
zircon with binder).
After each dipping and stuccoing is completed, the
assembly is allowed to thoroughly dry before the next assembly is allowed to thoroughly dry before the next
coating is applied. coating is applied.
IES 2009 IES2009
2marks 2marks
Advantages
Tight dimensional tolerances
Excellent surface finish (1.2 to 3.0 m )
Machining can be reduced or completely
li i t d eliminated
High melting point alloy can be cast almost any High melting point alloy can be cast, almost any
metal can be cast
Almost unlimited intricacy
Limitations
C tl tt d ld Costly patterns and moulds
Labour costs can be high Labour costs can be high
Limited size Limited size
Applications
A d k t t Aerospace and rocket components.
Vanes and blades for gas turbines Vanes and blades for gas turbines.
Surgical instruments Surgical instruments
IES2011
The proper sequence of investment casting steps is :
(a) Slurry coating pattern melt outShakeout Stucco (a) Slurry coating pattern melt out Shakeout Stucco
coating
(b) S i Sl i Sh k P (b) Stucco coating Slurry coating Shakeout Pattern
melt out
(c) Slurry coating Stucco coating Pattern melt out
Shakeout Shakeout
(d) Stucco coating Shakeout Slurry coating Pattern
l melt out
GATE2006
An expendable pattern is used in An expendable pattern is used in
(a) Slush casting
(b) Squeeze casting
(c) Centrifugal casting (c) Centrifugal casting
(d) Investment casting
GATE2011(PI)
Whi h f th f ll i ti Which of the following casting processes uses
expendable pattern and expendable mould? expendable pattern and expendable mould?
(a) Shell mould casting (a) Shell mould casting
(b) Investment casting ( ) g
(c) Pressure die casting ( ) g
(d) Centrifugal casting
ISRO2010 ISRO2010
Investment casting is used for Investment casting is used for
(a) Shapes which are made by difficulty using complex ( ) p y y g p
patterns in sand casting
(b) Mass production
(c) Shapes which are very complex and intricate and
can't be cast by any other method can t be cast by any other method
(d) There is nothing like investment casting ( ) g g
IES1992
Themostpreferredprocessforcastinggasturbine
bladesis: bladesis:
(a) Diemoulding
(b) Shellmoulding
(c) Investmentmoulding (c) Investmentmoulding
(d) Sandcasting
JWM2010
Considerthefollowingmaterials: Considerthefollowingmaterials:
1.Wax
2.Wood
3 Plastic 3.Plastic
Whichofthesematerialscanbeusedaspatternin
investmentcastingprocess?
(a)1 2and3 (b)1and2only (a)1,2and3 (b)1and2only
(c)2and3only (d)1and3only
IES2010
Assertion (A): The investment casting is used for Assertion (A): The investment casting is used for
precision parts such as turbine plates, sewing
hi machines etc.
Reason (R): The investment castings have a good ( ) g g
surface finish and are exact reproductions of the
master pattern master pattern.
(b) Both A and R are individually true but R is NOT the (b) Both A and R are individually true but R is NOT the
( ) A i t b t R i f l (c) A is true but R is false
IES 2007 IES2007
Consider the following statements in respect of Consider the following statements in respect of
investment castings:
Th tt tt i / t j i d t t lk 1. The pattern or patterns is/are not joined to a stalk or
sprue also of wax to forma tree of patterns.
2.The prepared moulds are placed in an oven and heated
gently to dry off the invest and melt out the bulk of wax.
3.The moulds are usually poured by placing the moulds in
a vacuum chamber. Which of the statements given above a vacuum chamber. Which of the statements given above
are correct?
(a) 1 and 2 only (b) 1 and 3 only (a) 1 and 2 only (b) 1 and 3 only
(c)2 and 3 only (d) 1, 2 and 3
IES2006
Which of the following materials are used for
making patterns in investment casting method? making patterns in investment casting method?
1. Wax 2. Rubber 3. Wood 4. Plastic
Select the correct answer using the codes given below:
(a) Only 1 and 3 (b) Only 2 and 3 (a) Only 1 and 3 (b) Only 2 and 3
(c) Only 1, 2 and 4 (d) Only 2, 3 and 4
IAS1996
Light and intricate parts with close dimensional
tolerances of the order of 0 005 mm are tolerances of the order of 0.005 mm are
produced by
(a) Investment casting
(b) Die casting (b) Die casting
(c) Centrifugal casting
(d) Shell mould casting
PermanentMouldCasting
The process in which we use a die to make the p
castings is called permanent mold casting or gravity
die casting, since the metal enters the mold under die casting, since the metal enters the mold under
gravity.
S ti i di ti i j t th lt t l Some time in diecasting we inject the molten metal
with a high pressure. When we apply pressure in
injecting the metal it is called pressure die casting
process. p
Grey cast iron is used for mould material.
Advantages
Good surface finish and dimensional accuracy Good su ace s a d d e s o a accu acy
Metal mold gives rapid cooling and finegrain
t t structure
Multipleuse molds. p
Disadvantages
High initial mold cost g
Shape, size, and complexity are limited
Mold life is very limited with highmeltingpoint Mold life is very limited with highmeltingpoint
metals such as steel.
Low melting point metals can be cast Low melting point metals can be cast
Aluminum
Zi Zinc
Magnesiumalloys
Brass
Cast iron Cast iron
Applications
Pi t / li d / d Pistons/cylinders/rods
Gears Gears
Kitchenware Kitchenware
DieCasting
Molten metal is injected into closed metal dies under j
pressures ranging from 100 to 150 MPa.
Pressure is maintained during solidification
After which the dies separate and the casting is ejected
along with its attached sprues and runners.
Cores must be simple and retractable and take the
f f i l formof moving metal segments
Diecastingmachinescanbe
Hotchamber
Coldchamber
Hot chamber machines are Hotchambermachinesare
Good for low temperature (approx. 400C) Good for low temperature (approx. 400 C)
Faster than cold chamber machines
Cycle times must be short to minimize metal
contamination
Metal starts in a heated cylinder
A i f l i h di A piston forces metal into the die
The piston retracts, and draws metal in p ,
Metal: Lead, Tin, Zinc
HotChamber
Coldchambermachines
Castshighmeltingpointmetals(>600C) Castshighmeltingpointmetals(>600 C)
Highpressuresused g p
Metalisheatedinaseparatecrucible
Metalisladledintoacoldchamber
Themetalisrapidlyforcedintothemoldbeforeit
l cools
Copper,BrassandAluminiumcancast. Copper,BrassandAluminiumcancast.
Ad t Advantages
E l h f ( ) Extremelysmoothsurfaces(1m)
E ll tdi i l Excellentdimensionalaccuracy
Rapidproductionrate Rapidproductionrate
Bettermechanicalpropertiescomparedtosand Bettermechanicalpropertiescomparedtosand
castingg
Intricatepartspossible p p
Minimumfinishingoperations g p
Thinsectionspossible
Limitations Limitations
Highinitialdiecost Highinitialdiecost
Limitedtohighfluiditynonferrousmetals Limitedtohigh fluiditynonferrousmetals
Partsizeislimited
Porositymaybeaproblem
Somescrapinsprues,runners,andflash,butthiscan
bedirectlyrecycled
A li i Applications
Carburettors
Automotive parts
B h fi Bathroom fixtures
Toys y
l Common metals
Alloys of aluminum, zinc, magnesium, and lead Alloys of aluminum, zinc, magnesium, and lead
Also possible with alloys of copper and tin
IES2011
d h f ll d f d Consider the following advantages of die casting over
sand casting :
1. Rapidity of the process
2 Smooth surface 2. Smooth surface
3. Strong dense metal structure
Whi h f h d ? Which of these advantages are correct ?
(a) 1, 2 and 3 ( ) , 3
(b) 1 and 2 only
(c) 2 and 3 only (c) 2 and 3 only
(d) 1 and 3 only
IES2009
Which of the following are the most suitable
materials for die casting? materials for die casting?
(a) Zinc and its alloys
(b) Copper and its alloys
(c) Aluminiumand its alloys (c) Aluminiumand its alloys
(d) Lead and its alloys
JWM2010
Assertion (A) : In die casting method small Assertion (A) : In die casting method, small
thickness can be filled with liquid metal.
Reason (R) : The air in die cavity trapped inside the
casting causes problems. g p
(a) BothAandRareindividuallytrueandRisthe
t l ti fA correctexplanationofA
(b) BothAandRareindividuallytruebutRisnot the y
(c) AistruebutRisfalse (c) AistruebutRisfalse
(d) AisfalsebutRistrue
IES2005
Which one of the following processes produces a
casting when pressure forces the molten metal casting when pressure forces the molten metal
into the mould cavity?
(a) Shell moulding (b) Investment casting
(c) Die casting (d) Continuous casting (c) Die casting (d) Continuous casting
IES2006
In which of the following are metal moulds used?
( ) G d ld (a) Greensand mould
(b) Dry sand mould ( ) y
(c) Die casting process
(d) L ldi (d) Loam moulding
IES1995
Assertion (A): An aluminium alloy with 11 % silicon is
used for making engine pistons by die casting g g p y g
technique.
Reason (R): Aluminium has low density and addition Reason (R): Aluminium has low density and addition
of silicon improves its fluidity and therefore its
castability. y
IES1995
MatchListIwithListIIandselectthecorrectanswertakingthehelp
ofcodesgivenbelowthelists:
ListI ListII ListI ListII
(Products) (Processofmanufacture)
A. Automobilepistoninaluminium alloy 1.Pressurediecasting p y g
B. Enginecrankshaftinspheroidal
graphiteiron 2.Gravitydiecasting
C Carburettor housinginaluminiumalloy 3 Sandcasting C. Carburettor housinginaluminiumalloy 3.Sandcasting
D. Casttitaniumblades 4.Precisioninvestment
casting
h ll ld 5.Shellmoulding
Code: A B C D A B C D
(a) 2 3 1 5 (b) 3 2 1 5 (a) 2 3 1 5 (b) 3 2 1 5
(c) 2 1 3 4 (d) 4 1 2 3
IAS2007
Zi di i h l h 1. Zincdiecastingshavelowstrength.
2. Inthediecastingprocess,verythinsectionsor g p , y
complexshapescanbeobtainedeasily.
Whichofthestatementsgivenaboveis/arecorrect? Whichofthestatementsgivenaboveis/arecorrect?
(a) 1only
(b) 2only
(c) Both1and2 (c) Both1and2
(d) Neither1nor2
IAS1996
Assertion (A): Die casting yields a product of good
accuracy and finish. accuracy and finish.
Reason (R): Low melting alloys used in die
casting casting.
l i f A correct explanation of A
(b) Both A and R are individually true but R is not the y
IES2011
Consider the following statements :
1 Hot chamber machine is used for casting zinc tin and 1. Hot chamber machine is used for casting zinc, tin and
other low melting alloys.
C ld h b hi i d f di i f 2. Cold chamber machine is used for die casting of
ferrous alloys
3. Rapid cooling rate in die casting produces high
strength and quality in many alloys strength and quality in many alloys.
Which of these statements are correct?
(a) 1, 2 and 3 (b) 1 and 2 only
(c) 2 and 3 only (d) 1 and 3 only (c) 2 and 3 only (d) 1 and 3 only
GATE2007
Which of the following engineering materials is Which of the following engineering materials is
the most suitable candidate for hot chamber die
casting? casting?
(a) Lowcarbon steel
(b) Titanium
(c) Copper (c) Copper
(d) Tin
IES1995
Assertion (A): Aluminium alloys are cast in hot
chamber die casting machine. g
Reason (R): Aluminium alloys require high melting
when compared to zinc alloys. when compared to zinc alloys.
Hot chamber die casting process is NOT suited for Hot chamber die casting process is NOT suited for
(a) Lead and its alloy (a) Lead and its alloy
(b) Zinc and its alloy ( ) y
(c) Tin and its alloy
(d) Aluminumand its alloy
C if l C i CentrifugalCasting
Process: Molten metal is introduced into a rotating sand Process: Molten metal is introduced into a rotating sand,
metal, or graphite mould, and held against the mould g p g
wall by centrifugal force until it is solidified
A mold is set up and rotated along a vertical (rpm is
reasonable), or horizontal (2001000 rpm is reasonable)
axis axis.
The mold is coated with a refractory coating. The mold is coated with a refractory coating.
During cooling lower density impurities will tend to rise g g y p
towards the center of rotation.
Fig Truecentrifugalcasting Fig.Truecentrifugalcasting
Properties
The mechanical properties of centrifugally cast jobs are
better compared to other processes, because the inclusions
such as slag and oxides get segregated towards the centre
and can be easily removed by machining. Also, the y y g
pressure acting on the metal throughout the solidification
causes the porosity to be eliminated giving rise to dense p y g g
metal.
No cores are required for making concentric holes in the No cores are required for making concentric holes in the
case of true centrifugal casting.
Advantages
Fine grained structure at the outer surface of the
casting free of gas and shrinkage cavities and casting free of gas and shrinkage cavities and
porosity
F i f h ll i i i li d i h Formation of hollow interiors in cylinders without
cores
Can produce a wide range of cylindrical parts,
including ones of large size including ones of large size.
Good dimensional accuracy, soundness, and
l li cleanliness
There is no need for gates and runners, which g ,
increases the casting yield, reaching almost 100 %.
Limitations
More segregation of alloy component during pouring under
the forces of rotation the forces of rotation
Contamination of internal surface of castings with non Contamination of internal surface of castings with non
metallic inclusions
Inaccurate internal diameter
Shape is limited.
Spinning equipment can be expensive
Poor machinability
Commonmetals
Iron
steel
stainlesssteel
ll f l i i d i k l alloysofaluminium,copper,andnickel
GATE2002
In centrifugal casting, the impurities are In centrifugal casting, the impurities are
(a) Uniformly distributed
(b) Forced towards the outer surface
(c) Trapped near the mean radius of the casting (c) Trapped near the mean radius of the casting
(d) Collected at the centre of the casting
GATE1993
Centrifugally cast products have
( ) L i i h hi h i (a) Large grain structure with high porosity
(b) Fine grain structure with high density ( ) g g y
(c) Fine grain structure with lowdensity
(d) S i f l d h ki f h (d) Segregation of slug towards the outer skin of the
casting
In hollow cylindrical parts, made by centrifugal casting, y p , y g g,
the density of the part is
(a) maximum at the outer region
(b) maximum at the inner region
(c) maximum at the midpoint between outer and inner
surfaces
(d) uniform throughout
IES2008
h h f h f ll d Which of the following casting processes does not
/do not require central core for producing pipe?
1. Sand casting process
2 Die casting process 2. Die casting process
3. Centrifugal casting process
S l h i h d i b l Select the correct answer using the code given below:
(a) 1 and 2 ( )
(b) 2 only
(c) 2 and 3 (c) 2 and 3
(d) 3 only
IES2009
Which one of the following casting processes is
best suited to make bigger size hollow
symmetrical pipes?
(a) Die casting
(b) Investment casting
( ) h ll ld (c) Shell moulding
(d) C if l i (d) Centrifugal casting
IES2007
Which one of the following is the correct
statement? statement?
In a centrifugal casting method
(a) No core is used
(b) Core may be made of any metal (b) Core may be made of any metal
(c) Core is made of sand
(d) Core is made of ferrous metal
IES1998
Poormachinability ofcentrifugallycastironpipe
isdueto isdueto
(a) Chilling
(b) Segregation
(c) Densestructure (c) Densestructure
(d) Highmouldrotationspeed
IES2009
Which of the following are the most likely
characteristics in centrifugal casting? characteristics in centrifugal casting?
(a) Fine grain size and high porosity
(b) Coarse grain size and high porosity
(c) Fine grain size and high density (c) Fine grain size and high density
(d) Coarse grain size and high density
IES2007
MatchListIwithListIIandselectthecorrectanswerusingthecodegiven
belowtheLists:
ListI ListII ListI ListII
(CastingProcess) (Principle)
A. Diecasting 1.Themetalsolidifiesinarotatingmould
B Investmentcasting 2 Thepatternclusterisrepeatedlydipped B. Investmentcasting 2.Thepatternclusterisrepeatedlydipped
intoaceramicslurryanddustedwith
refractory
C Shellmoulding 3 Moltenmetalisforcedbypressureinto C. Shellmoulding 3.Moltenmetalisforcedbypressureinto
ametallicmould
D. Centrifugalcasting 4.Aftercooling,theinvestisremoved
fromthe Castingbypressurejettingor g y p j g
vibratorycleaning
(a) 2 1 3 4 (b) 3 4 2 1 ( ) 3 4 ( ) 3 4
(c) 2 4 3 1 (c) 3 1 2 4
IES2000
MatchListI(Process)withListII(Products/materials)
andselectthecorrectanswerusingthecodesgiven
b l h belowtheLists:
ListI ListII
A. Diecasting 1.Phenolformaldehyde
B. Shellmolding 2.C.I.pipes
C. CO
2
molding 3.Nonferrousalloys
D. Centrifugalcasting 4.Sodiumsilicate g g
(a) 1 3 4 2 (b) 3 1 4 2 ( ) 3 4 ( ) 3 4
(c) 3 1 2 4 (d) 1 3 2 4
IAS2004
MatchListI(NameoftheProcess)withListII(Advantage)andselectthecorrect
answerusingthecodesgivenbelowthelists: answerusingthecodesgivenbelowthelists:
ListI ListII
(NameoftheProcess) (Advantage)
A. SandCasting 1.Largecylindricalpartswithgoodquality
B. Ceramicmoldcasting 2.Excellentdimensionalaccuracyandsurface
finish finish
C. Diecasting 3.Intricateshapesandclosetoleranceparts
D. Centrifugalcasting 4.Almostanymetaliscastandthereifnolimitto
h d h size,shapeandweight
5.Gooddimensionalaccuracy,finishandlow
porosity p y
(a) 2 3 5 1 (b) 4 1 2 3
(c) 2 1 5 3 (d) 4 3 2 1
SemicentrifugalCasting
Centrifugal force assists the flow of metal from a
central reservoir to the extremities of a rotating
symmetrical mold, which may be either expendable or
l i l multipleuse
R t ti l d l th f t t if l Rotational speeds are lower than for true centrifugal
casting casting
Cores can be used to increase the complexity of the Cores can be used to increase the complexity of the
product.
Fig. Semicentrifugalcasting
IAS2003
Assertion (A): Semicentrifugal casting process is
similar to true centrifugal casting except that the g g p
central core is used in it to form inner surface.
Reason (R): In semicentrifugal casting process the Reason (R): In semi centrifugal casting process the
axis of spin is always vertical
explanation of A
(b) Both A and R are individually true but R is not the (b) Both A and R are individually true but R is not the
Centrifuging
Uses centrifuging action to force the metal from a central
pouring reservoir into separate mold cavities that are
ff t f th i f t ti offset from the axis of rotation.
Lowspeed Lowspeed
May used to assist in the pouring of investment casting y p g g
trees.
Fig.Methodofcastingbythecentrifugingprocess
IES2000
MatchListI(Typeofcasting)withListII(Workingprinciples)
andselectthecorrectanswerusingthecodesgivenbelowthe
Lists: Lists:
ListI ListII
A. Diecasting 1.Moltenmetalisforcedintothedie A. Diecasting 1.Moltenmetalisforcedintothedie
underpressure
B. Centrifugalcasting 2.Axisofrotationdoesnotcoincidewith
axisofmould axisofmould
C. Centrifuging 3.Metalsolidifieswhenmouldisrotating
D. Continuouscasting 4.Continuouslypouringmoltenmetal D. Continuouscasting 4.Continuouslypouringmoltenmetal
intomould
Codes: A B C D A B C D
( ) (b) (a) 1 3 2 4 (b) 4 3 2 1
(c) 1 2 3 4 (d) 4 2 3 1
DrySandMolding
To reduce gas forming materials air dried mould used.
Types:
1.Skin drying and
2.Complete mold drying
SlushCasting
Slush casting is a variation of the permanent mold process
in which the metal is permitted to remain in the mold only in which the metal is permitted to remain in the mold only
until a shell of the desired thickness has formed.
The mold is then inverted and the remaining liquid is
poured out.
When the mold halves are separated, the resulting casting
is a hollow shape with good surface detail but variable wall s a o o s ape t good su ace deta but va ab e a
thickness.
Frequently used to cast low melting temperature metals Frequently used to cast lowmeltingtemperature metals
into ornamental objects such as candlesticks, lamp bases,
and statuary and statuary.
IAS2004
Which of the following are produced by slush
casting? casting?
(a) Hollowcastings with thick walls
(b) Hollowcastings with thin walls
(c) Thin castings (c) Thin castings
(d) Thick castings
IES2011
The method of casting for producing ornamental pieces
are:
(a) Slush and gravity casting
(b) P d d l h i (b) Pressed and slush casting
(c) Gravity and semi permanent mould casting ( ) y p g
(d) Semi permanent mould and pressed casting
IES 2012
Th f ki h ll i f i l The process of making hollow castings of noncircular
shape and desired thickness by permanent mould
without the use of cores is known as
(a) Die casting (b) Slush casting (a) Die casting (b) Slush casting
(c) Pressed casting (d) Centrifugal casting
SqueezeCasting
Process:
M l l i d i f di 1. Molten metal is poured into an open face die.
2. A punch is advanced into the die, and to the metal. p ,
3.Pressure (less than forging) is applied to the punch
and die while the part solidifies and die while the part solidifies.
4.The punch is retracted, and the part is knocked out
with an ejector pin.
Overcomes problems with feeding the die and Overcomes problems with feeding the die, and
produces near net, highly detailed parts.
IAS2002
MatchListI(CastingProcess)withListII
(Applications)andselectthecorrectanswerusingthe
d b l h codesgivenbelowtheLists:
ListI ListII
(CastingProcess) (Applications)
A. Centrifugalcasting 1. Carburetor
B. Squeezecasting 2. Pipes
C. DieCasting 3. Wheelsfor g 3
automobiles
4. Gearhousings
Codes:A B C A B C
(a) 2 3 1 (b) 4 1 3
(c) 2 1 3 (d) 4 3 1
SingleCrystalCasting
Th i ff i l Theprocessiseffectively:
1. Prepareamoldsothatoneendisaheatedoven,and p ,
theotherendchilled.Thepartshouldbeorientedso
thatthecoolinghappensoverthelongestdistance thatthecoolinghappensoverthelongestdistance.
2. Castmetalintothemold
3. Solidificationwillbeginatthechillplate.These
dendriteswillgrowtowardstheheatedendofthe de d tes g o to a ds t e eated e d o t e
partaslongdendritic crystals.Thepartisslowly
pulledoutoftheoven pastthechillplate pulledoutoftheoven,pastthechillplate.
4. Removethesolidifiedpart.
Creepandthermalshockresistanceproperties. Creepandthermalshockresistanceproperties.
IES2009
2marks
PlasterCasting
Process: A slurry of plaster, water, and various additives is
additives is pouted over a pattern and allowed to set. The
pattern is removed and the mould is baked to remove
excess water. After pouring and solidification, the mould is p g
broken and the casting is removed.
Advantage: High dimensional accuracy and smooth Advantage: High dimensional accuracy and smooth
surface finish, thin sections and intricate detail can
produce produce.
Limitations: Lowertemperature nonferrous metals only:
Common metals: Primarily aluminiumand copper
PitMoulding
This method is used for very large castings and is done on
the foundry floor the foundry floor.
IES1996
Whichofthefollowingpairsarecorrectlymatched?
Pi ldi F l j b 1. Pitmoulding ..................Forlargejobs.
2. Investmentmoulding ...Lostwaxprocess. g p
3. Plastermoulding Mouldpreparedin
gypsum gypsum.
(a) 1,2and3 (b) 1and2
(c) 1and3 (d) 2and3
LoamMoulding
M ldi l i ll ifi i ll d f Moulding loam is generally artificially composed of
common brick clay and sharp sand common brickclay, and sharp sand.
Loam means mud Loam means mud.
Loam Moulding is restricted to forms which cannot be Loam Moulding is restricted to forms which cannot be
cast conveniently in any other process.
It is costly.
IES1997
Which one of the following pairs is not correctly
matched? matched?
(a) Aluminiumalloy piston Pressure die casting
(b) Jewellery.. Lost wax process
(c) Large pipes Centrifugal casting (c) Large pipes ..Centrifugal casting
(d) Large bells Loam moulding
GATE1998
ListI ListII
(A) Sandcasting (1) Symmetricaland ( ) Sa d cas g ( ) Sy e ca a d
circularshapesonly
(B) Plastermouldcasting (2) Partshavehardened ( ) g ( )
skinsandsoftinterior
(C) Shellmouldcasting (3) Minimumpost
i i castingprocessing
(D) Investmentcasting (4) Partshaveatendency
t towarp
(5) Partshavesoftskin
andhardinterior andhardinterior
(6) Suitableonlyfornon
ferrousmetals ferrousmetals
GATE1992
Matchthefollowingmoulding/castingprocesseswith
theproduct: p
Moulding/Castingprocesses Product
(A) Slushcasting (P)Turbineblade (A) Slushcasting (P)Turbineblade
(B) Shellmoulding (Q)Machinetoolbed
(C) D d ldi (R)C li d bl k (C) Drysandmoulding (R)Cylinderblock
(D) Centrifugalcasting (S)Hollowcastings
l k l h d likelampshades
(T)Rainwaterpipe
(U)Castironshoe
brake
GATE1996
ListI ListII
(A) Ri f i f b d F i (A) Rivetsforaircraftbody 1. Forging
(B) Carburettor body 2. Coldheading ( ) y g
(C) Crankshafts 3. Aluminiumbased
alloy alloy
(D) Nails 4. Pressurediecasting
5. Investmentcasting
IES2003
MatchListI(Products)withListII(CastingProcess)andselect
thecorrectanswerusingthecodesgivenbelowtheLists:
Li I Li II ListI ListII
(Products) (CastingProcess)
A Hollowstatues 1 CentrifugalCasting A. Hollowstatues 1. CentrifugalCasting
B. Dentures 2. InvestmentCasting
C. Aluminiumalloypistons 3. SlushCasting y p 3 g
D. Rockerarms 4. ShellMoulding
5. GravityDieCasting
Codes: A B C D A B C D
(a) 3 2 4 5 (b) 1 3 4 5
( ) (d) (c) 1 2 3 4 (d) 3 2 5 4
IES1993
MatchtheitemsofListI(Equipment)withtheitems
ofListII(Process)andselectthecorrectanswerusing ( ) g
thegivencodes.
ListI(Equipment) ListII(Process) ListI(Equipment) ListII(Process)
P HotChamberMachine 1. Cleaning
Q Muller 2 Coremaking Q Muller 2. Coremaking
R DielectricBaker 3. Diecasting
d l l S SandBlaster 4. Annealing
5. Sandmixing
(a) P2,Q1,R4,S5 (b) P4,Q2,R3,S5
(c) P4,Q5,R1,S2 (d) P3,Q5,R2,S1 (c) P 4,Q 5,R 1,S 2 (d) P 3,Q 5,R 2,S 1
IAS2004
MatchListI(NameoftheCastingProcess)withListII(ProcessDefinition)andselect
thecorrectanswerusingthecodesgivenbelowthelists:
List I List II ListI ListII
(NameoftheCastingProcess) (ProcessDefinition)
A. Diecasting 1.Thisprocessinvolvesuseofamouldmadeof
Driedsilicasandandphenolic resinmixture
B. Electroslag casting 2.Inthisprocess,moltenmetalisforcedby
Pressureintoametalmould Pressureintoametalmould
C. Centrifugalcasting 3.Thisprocessemploysaconsumableelectrode
D. Precisioncasting 4.Thisprocessinvolvesrotatingamouldwhilethe
l l d f metalsolidifies
5.Thisprocessproducesverysmooth,highly
Accuratecastingsfrombothferrousandnon g
ferrousalloys
(a) 5 4 1 2 (b) 2 3 4 5 (a) 5 4 1 2 (b) 2 3 4 5
(c) 5 3 4 2 (d) 2 4 1 5
( ) GATE 2007(PI)
Match the lists Match the lists
Group1 Group2 Group 1 Group 2
P.SandCasting 1.Turbineblades
Q.CentrifugalCasting 2.ICEnginePistons
R I C i L b ll R.InvestmentCasting 3.Largebells
S DieCasting 4 Pulleys
(a) P 4 Q 1 R 3 S 2 (b) P 2 Q 4 R 3 S 1
S.DieCasting 4.Pulleys
(a) P 4, Q 1, R 3, S 2 (b) P 2, Q 4, R 3, S 1
(c) P 3, Q 4, R 1, S 2 (d) P 3, Q 2, R 1, S 4
BySKMondal y
WeldingDefinition
Welding is a process by which two materials, usually
metals are permanently joined together by metals, are permanently joined together by
coalescence, which is induced by a combination of
d ll i l di i temperature, pressure, and metallurgical conditions.
The particular combination of these variables can p
range from high temperature with no pressure to high
pressure with no increase in temperature pressure with no increase in temperature.
Welding (positive process)
Machining (negative process)
F i i ( ) Forming, casting (zero process)
Requirementforahighqualitywelding
1. A source of satisfactory heat and/or pressure,
2. A means of protecting or cleaning the metal, and
3. Caution to avoid, or compensate for, harmful
metallurgical effects.
l ifi i f ldi Classificationofweldingprocesses
Oxy fuel gas welding (OFW) y g g ( )
Arc welding (Aw)
Resistance welding Resistance welding
Solid state welding (friction welding, ultrasonic welding,
forge welding etc ) forge welding etc.)
Unique process q p
Thermit welding
Laser beamwelding Laser beamwelding
Electroslag welding
Flash welding
Induction welding
Electron beamwelding
IES 2012
Th d h ldi i The advantage o the welding process is
(a) It relieves the joint from residual stresses ( ) j
(b) It helps in checking of distortion of work piece
( ) L b f l d ll b h i il d/ (c) Large number of metals and alloys, both similar and/or
dissimilar can be joined.
(d) Heat produced during the welding does not produce
metallurgical changes metallurgical changes.
Weldability /FabricationProcesses
The weldability of a material will depend on the
specific welding or joining process being considered specific welding or joining process being considered.
For resistance welding of consistent quality, it is
ll h id i di l usually necessary to remove the oxide immediately
before welding.
Fabrication weldability test is used to determine
mechanical properties required for satisfactory mechanical properties required for satisfactory
performance of welded joint.
Th f h i i l i The correct sequence of the given materials in
ascending order of their weldability is
Aluminum < copper < cast iron < MS
Contd
CaseofAluminium
The oxide coating on aluminum alloys causes some
difficulty in relation to its weldability. y y
It also has high thermal conductivity and a very short
temperature range between liquidus and solidus and when temperature range between liquidus and solidus and when
liquid its viscosity is very low.
Al i i i b b f l li h Aluminium is poor absorber of laser light.
During fusion welding, the aluminum would oxidize so g g
readily that special fluxes or protective inertgas
atmospheres must be employed. p p y
Friction welding and TIG welding is good for aluminium.
For aluminium AC current plus high frequency is must For aluminium AC current plus high frequency is must.
CaseofCastIron
Cast iron is more difficult to weld because of its high
carbon content and brittleness (poor ductility) (p y)
Massive carbon deposits have a tendency to form in
the areas adjacent to the weld and highcarbon the areas adjacent to the weld, and high carbon
martensite tends to form in the heataffected zones.
These microstructures are very brittle and may crack These microstructures are very brittle and may crack
spontaneously while welding is in progress or later
when load is applied to the workpiece when load is applied to the workpiece.
Cast iron can be joined by the oxyacetylene brazing
process and shielded metal arc welding (stick) process and shielded metalarc welding (stick)
process.
h d h d Some cases preheating and/or post heating is required.
CaseofStainlessSteel
Stainless steel is a difficult metal to weld because it
contains both nickel and chromium.
The best method for welding stainless steel is TIG
welding welding.
The electric arc is also preferred for welding stainless
steels A heavily coated welding rod which produce a steels. A heavily coated welding rod, which produce a
shielded arc, is employed.
Y d b j b f l i You must do a better job of precleaning.
Using a low arc current setting with faster travel g g
speeds is important when welding stainless steel,
because some stainless steels are subject to carbide j
precipitation.
Contd..
CaseofStainlessSteel
The ferritic stainless steels are generally less weldable
than the austenitic stainless steel and require both q
preheating and postweld heat treatments.
Welds of ferritic stainless steel can be by Welds of ferritic stainless steel can be by
(i) autogenously (i.e. without the addition of filler
metal) metal)
(ii) with an austenitic stainless steel
(iii) i hi h i k l fill ll (iii) using a high nickel filler alloy.
(iv) Type 405 filler (low 11% Cr, low carbon and small
% l) 0.2% Al)
Welding process: TIG, MIG, Shieldedmetal arc g p
welding and Plasma arc welding
IES2010
Assertion (A): It is generally difficult to weld Assertion (A): It is generally difficult to weld
Aluminumparts by normal arc welding process.
Reason (R): Hard and brittle Aluminumoxide film
is formed at the welded joints. j
t l ti f A correct explanation of A
(b) Both A and R are individually true but R is NOT the y
IES2006
Assertion(A):Aluminium haspoorweldability.
R (R) Al i i h hi h h l Reason(R):Aluminium hashighthermal
conductivityandhighaffinitytooxygen.
(a) BothAandRareindividuallytrueandRisthe
correctexplanationofA correctexplanationofA
(b) BothAandRareindividuallytruebutRisnot the
l i fA correctexplanationofA
(c) AistruebutRisfalse ( )
IES2011
During plasma arc welding of aluminium, improved
removal of the surface oxide from the base metal is
obtained with typical polarity of :
(a) DC Straight (a) DC Straight
(b) DC reverse
(c) AC potential
(d) Reverse polarity of phase of AC potential (d) Reverse polarity of phase of AC potential
IES2011
d h f ll Considerthefollowingstatements.
Castironisdifficulttoweld,becauseof ,
1.Lowductility
P f i 2.Poorfusion
3.Tendencytocrackoncooling 3 y g
Whichofthesestatementsarecorrect?
(a)1 2and3 (a)1,2and3
(b)1and2only
(c)2and3only
(d)1and3only (d)1and3only
IES2006
Fabricationweldability testisusedtodetermine
(a) Mechanicalpropertiesrequiredforsatisfactory
performanceofweldedjoint p j
(b) Susceptibilityofweldedjointforcracking
( ) S i bili f j i d i (c) Suitabilityforjointdesign
(d) Appropriatemachiningprocess ( ) pp p g p
IES1999
Thecorrectsequenceofthegivenmaterialsin
di d fth i ld bilit i ascendingorderoftheirweldability is
(a) MS,copper,castiron,aluminium ( ) , pp , ,
(b) Castiron,MS,aluminiumcopper
( ) C i MS l i i (c) Copper,castiron,MS,aluminium
(d) Aluminium,copper,castiron,MS ( ) , pp , ,
IES2010
W ld bilit f f iti t i l t l d i Weldability of ferritic stainless steel used in
automotive exhaust system is improved by y p y
selecting stainless steel electrode having low
content of content of
(a) Carbon (b) Nitrogen ( ) ( ) g
(c) Chromium (d) Carbon and Nitrogen
IES2010
Consider the following statements regarding Consider the following statements regarding
welded joints:
1. It is a permanent type of joint.
2 It is reliable and economical for pressure vessel 2. It is reliable and economical for pressure vessel
construction.
f f f b l d l 3. It is free from fabricational residual stresses.
4. Such joints are suitable for static loading only. 4. Such joints are suitable for static loading only.
5. Welding is a versatile and flexible metal joining process.
Which of the above statements are correct?
(a) 1, 2 and 3 only (b) 2, 3 and 4 only (a) 1, 2 and 3 only (b) 2, 3 and 4 only
(c) 1, 2, 3, 4 and 5 (d) 1, 2 and 5 only
IES 2012
Whi h f h f ll i f i ld bili f Whichofthefollowingfactorsimproveweldabilityof
steel?
1.Lowcarboncontent
2 Highcarboncontent 2.Highcarboncontent
3.Goodaffinitycontent
4.Pooraffinitytooxygen
( ) d (b) d (a)1and3 (b)2and3
(c)1and4 (d)2and4
GasFlameProcesses:
W ldi C i d S i h i Welding,CuttingandStraightening
Oxyfuel gas Welding (OFW): Heat source is the Oxyfuel gas Welding (OFW): Heat source is the
flame produced by the combustion of a fuel gas and
oxygen.
OFW has largely been replaced by other processes but
it is still popular because of its portability and the low it is still popular because of its portability and the low
capital investment.
Acetylene is the principal fuel gas employed. Acetylene is the principal fuel gas employed.
Combustionofoxygenandacetylene(C
2
H
2
)ina
ldi t h d t i t t ti weldingtorchproducesatemp.inatwostagereaction.
Inthefirststage g
+Heat
Thi i h i f h h
C H O CO H + +
2 2 2 2
2
Thisreactionoccursnearthetipofthetorch.
InthesecondstagecombustionoftheCOandH
2
and g
2
occursjustbeyondthefirstcombustionzone.
2CO+O 2CO +Heat 2CO+O
2
2CO
2
+Heat
H
2
+O
2
H
2
O+Heat
1
2
Oxygenforsecondaryreactionsisobtainedfromthe
atmosphere atmosphere.
Three types of flames can be obtained by varying
th / t l ( /f l ) ti the oxygen/acetylene (or oxygen/fuel gas) ratio.
If the ratio is about 1 : 1 to 1.15 : 1, all reactions are 5 ,
carried to completion and a neutral flame is produced.
Most welding is done with a neutral flame It is Most welding is done with a neutral flame. It is
chemically neutral and neither oxidizes or carburizes
h l b i ld d the metal being welded.
Oxyacetylenegasweldingneutralflame
A higher ratio, such as 1.5 : 1, produces an oxidizing
flame, hotter than the neutral flame (about 3300
o
C)
but similar in appearance. pp
Used when welding copper and copper alloys but
harmful when welding steel because the excess oxygen harmful when welding steel because the excess oxygen
reacts with the carbon, decarburizing the region
d h ld around the weld.
OxyacetylenegasweldingOxidisingflame
Excess fuel, on the other hand, produces a carburizing
flame Carburizing flame can carburize metal also flame. Carburizing flame can carburize metal also.
The excess fuel decomposes to carbon and hydrogen,
d h fl i ( b and the flame temperature is not as great (about
3000
o
C).
Flames of this type are used in welding Monel (a
nickelcopper alloy) highcarbon steels and some nickel copper alloy), high carbon steels, and some
alloy steels, and for applying some types of hardfacing
material material.
OxyacetylenegasweldingCarburizingflame
Metal Flame
MS N
High carbon steel R
Grey cast iron N, slightly oxidizing
Alloy steel N
Aluminium Slightly carburizing
Brass Slightly oxidizing
C B N li h l idi i Copper, Bronze N, slightly oxidizing
Nickel alloys Slightly carburizing
L d N Lead N
IES2009Conventional
Explain the three types of oxyacetylene flames.
Indicate with the help of sketches the various
zones, respective temperature ranges and
applications of each t pe of flame applications of each type of flame.
[20 Marks] [20 Marks]
Di Diagram g
d d i i i Uses,Advantages,andLimitations
OFW i f i ldi OFW is fusion welding.
No pressure is involved. p
Filler metal can be added in the formof a wire or rod.
Fl b d l h f d Fluxes may be used to clean the surfaces and remove
contaminating oxide. The gaseous shield produced by
vaporizing flux can prevent oxidation during welding,
and the slag produced by solidifying flux can protect a d t e s ag p oduced by so d y g u ca p otect
the weld pool. Flux can be added as a powder, the
welding rod can be dipped in a flux paste or the rods welding rod can be dipped in a flux paste, or the rods
can be precoated.
Contd
Exposer of the heated and molten metal to the various p
gases in the flame and atmosphere makes it difficult to
prevent contamination.
Heat source is not concentrated, a large area of the
metal is heated and distortion is likely to occur.
Fl ldi i ill i i fi ld k i Flame welding is still quite common in field work, in
maintenance and repairs and in fabricating small maintenance and repairs, and in fabricating small
quantities of specialized products. qua t t es o spec a ed p oducts.
Oxyacetyleneweldingequipment
Oxygen is stored in a cylinder at a pressure ranging
from 13 8 MPa to 18 2 MPa from 13.8 MPa to 18.2 MPa .
Due to high explosiveness of free acetylene it is stored
in a cylinder with 8085% porous calcium silicate and
then filled with acetone which absorb upto 420 times p 4
by its volume at a pressure 1.75 MPa .
At the time of acetylene release if acetone comes with At the time of acetylene release if acetone comes with
acetylene the flame would give a purple colour.
Another option is acetylene generator.
2 2 2 2 2
2 ( ) CaC H O C H Ca OH + +
Pressure Gas Welding PressureGasWelding
Pressure gas welding (PGW) or Oxyacetylene g g ( ) y y
Pressure Welding is a process used to make butt
joints between the ends of objects such as pipe j j p p
andrailroad rail.
The ends are heated with a gas flame to a The ends are heated with a gas flame to a
temperature below the melting point, and the soft
metal is then forced together under considerable metal is then forced together under considerable
pressure.
Thi th f i t ll 'f f lid This process, therefore, is actually a 'form of solid
state welding.
IES2010
Th ti b t O d A t l The ratio between Oxygen and Acetylene
gases for neutral flame in gas welding is g g g
(a) 2 : 1 (b) 1 : 2
(c) 1 : 1 (d) 4 : 1
GATE1994
The ratio of acetylene to oxygen is e at o o acety e e to o yge s
approximately. for a neutral flames used in
gas welding gas welding.
(a) 1 : 1
(b) 1 : 2
(c) 1 : 3 (c) 1 : 3
(d) 1.5 : 1
GATE2003
InOxyacetylenegaswelding,temperatureatthe
innerconeoftheflameisaround innerconeoftheflameisaround
(a) 3500C
(b) 3200C
(c) 2900C (c) 2900 C
(d) 2550C
IES2010
Assertion (A): Oxidizing flame is used in gas Assertion (A): Oxidizing flame is used in gas
welding to join medium carbon steels having high
l i i melting point.
Reason (R): In gas welding, oxidizing flame ( ) g g, g
produces the maximum temperature compared to
neutral and reducing flame neutral and reducing flame.
(b) Both A and R are individually true but R is NOT the (b) Both A and R are individually true but R is NOT the
GATE2002
The temperature of a carburising flame in gas
welding is that of a neutral or an oxidising flame welding is that of a neutral or an oxidising flame.
(a) Lowerthan
(b) Higherthan
(c) Equalto (c) Equalto
(d) Unrelatedto
IES2009
By which one of the following methods gray cast
i i ll ld d? iron is usually welded?
(a) TIGwelding (b) MIGwelding ( ) g ( ) g
(c) Gaswelding (d) Arcwelding
IES1998
In oxyacetylene gas welding, for complete
b ti th l f i d combustion, the volume of oxygen required per
unit of acetylene is
(a) 1
(b) 1 5 (b) 1.5
(c) 2
(d) 2.5
IAS1994
In gas welding of mild steel using an oxy
t l fl th t t l t f t l acetylene flame. the total amount of acetylene
consumed was 10 litre. The oxygen consumption
fromthe cylinder is
(a) 5litre (a) 5litre
(b) 10litre
(c) 15litre
(d) 20litre (d) 20litre
IAS1995
Assertion (A): If neutral flame is used in oxy
acetylene welding, both oxygen and acetylene y g, yg y
cylinders of same capacity will be emptied at the same
time.
Reason (R): Neutral flame uses equal amounts of
oxygen and acetylene.
( ) B hA dR i di id ll dRi h (a) BothAandRareindividuallytrueandRisthecorrect
explanationofA
(b) B thA dR i di id ll t b tRi t th (b) BothAandRareindividuallytruebutRisnot the
(c) AistruebutRisfalse (c) AistruebutRisfalse
IES 2012
St t t (I) I ldi th t l t b j i d t Statement (I): In gas welding the metal to be joined gets
oxidized or carburized
Statement (II): The neutral flame affects no chemical
change on the molten metal.
OxygenTorchCutting(GasCutting)
Iron and steel oxidize (burn) when heated to a
temperature between 800
0
C to 1000
0
C temperature between 800
0
C to 1000
0
C.
Highpressure oxygen jet (300 KPa) is directed against
a heated steel plate, the oxygen jet burns the metal and
blows it away causing the cut (kerf ). y g ( )
For cutting metallic plates shears are used. These are
useful for straight line cuts and also for cuts up to 40 useful for straightline cuts and also for cuts up to 40
mm thickness.
Contd
For thicker plates with specified contour, shearing
cannot be used and oxyfuel gas cutting (OFC) is
useful.
Gascutting is similar to gas welding except torch tip.
Fig differencesintorchtipsforgasweldingandgascutting
Contd
Larger size orifice produces kerf width wider and larger
d oxygen consumed.
At kindling temperature (about 870
o
C), iron form iron g p
oxide.
Reaction: Reaction:
3Fe + 2O
2
Fe
3
O
4
+6.67 MJ/kg of iron
h h The other reactions:
2Fe + O
2
2FeO + 3.18 MJ/kg of iron
2
3 J g
4Fe + 3O
2
2Fe
2
O
3
+ 4.9 MJ/kg of iron
All exothermic reactions preheat the steel All exothermic reactions preheat the steel.
Contd
For complete oxidation 0.287 m
3
oxygen/kg of iron is o co p ete o dat o 0. 87 o yge / g o o s
required
D t idi d t l bl th t l Due to unoxidized metal blown away the actual
requirement is much less.
Torch tip held vertically or slightly inclined in the
direction of travel. direction of travel.
Torch position is about 1.5 to 3 mmvertical from plate.
Contd
The drag lines shows the characteristics of the movement
f h of the oxygen stream.
Fi iti i f tti t hi f l tti
Drag is the amount by which the lower edge of the drag
line trails from the top edge
Fig positioningofcuttingtorchinoxy fuelgascutting
line trails from the top edge.
Good cut means negligible drag.
Contd
If torch moved too rapidly, the bottom does not get
ffi i t h t d d l d h sufficient heat and produces large drag so very rough
and irregularshapedcut edges.
If torch moved slowly a large amount of slag is
generated and produces irregular cut generated and produces irregular cut.
Contd
Gas cutting is more useful with thick plates. g p
F thi h t (l th thi k) ti i h ld For thin sheets (less than 3 mm thick) tip size should
be small. If small tips are not available then the tip is
inclined at an angle of 15 to 20 degrees.
Fig.Recommendedtorchpositionforcuttingthinsteel
IAS2011 Main IAS2011Main
D lf l t k t h f t l Draw a self explanatory sketch of oxyacetylene gas
cutting torch Briefly explain how cutting is cutting torch. Briefly explain how cutting is
effected.
[20Marks]
Application
Useful only for materials which readily get oxidized
and the oxides have lower melting points than the
metals.
Widely used for ferrous materials.
Cannot be used for aluminum, bronze, stainless steel
d lik t l i th i t id ti and like metals since they resist oxidation.
Difficulties
Metal temperature goes beyond lower critical
temperature and structural transformations occur temperature and structural transformations occur.
Final microstructure depends on cooling rate.
Steels with less than 0.3 % carbon cause no problem.
Contd
For high carbon steel material around the cut should g
be preheated (about 250 to 300
o
C) and may post heat
also necessary.
Cutting CI is difficult, since its melting temp. is lower
than iron oxide.
If h i d i k l i f If chromium and nickel etc are present in ferrous
alloys oxidation and cutting is difficult alloys oxidation and cutting is difficult.
IES1992
The edge of a steel plate cut by oxygen cutting will
t h d d h th b t t i get hardened when the carbon content is
(a) Less than 0.1 percent ( ) p
(b) Less than 0.3 percent
( ) M h (c) More than 0.3 percent
(d) Anywhere between 0.1 to 1.0 percent ( ) y p
IES2007
Considerthefollowingstatementsinrespectofoxy
acetylenewelding: y g
1. Thejointisnotheatedtoastateoffusion.
2. Nopressureisused. 2. Nopressureisused.
3. Oxygenisstoredinsteelcylinderatapressureof14
MPa.
4. Whenthereisanexcessofacetyleneused,thereisa
decidedchangeintheappearance g pp
offlame.
Whichofthestatementsgivenabovearecorrect? g
(a)1,2and3 (b) 2,3and4
(c) 1,3and4 (d) 1,2and4 ( ) , 3 4 ( ) , 4
IES2001
Oxyacetylenereducingflameisusedwhile
i tth ldi carryingouttheweldingon
(a) Mildsteel (b) Highcarbonsteel ( ) ( ) g
(c) Greycastiron (d) Alloysteels
IES1992
Thick steel plate cut with oxygen normally shows
i f ki Thi t d f ki signs of cracking. This tendency for cracking can
be minimised by
(a) Slowspeed cutting
(b) Cutting in two or more stages (b) Cutting in two or more stages
(c) Preheating the plate
(d) Using oxyacetylene flame
IES2005
I ldi th t h h ldb h ld t l f 1. Ingaswelding,thetorchshouldbeheldatanangleof
30 to45 fromthehorizontalplane.
I ldi h Si f h hd d h 2. Ingaswelding,theSizeofthetorchdependsuponthe
thicknessofmetaltobeformed.
h d ff b 3. Dragingascuttingisthetimedifferencebetween
heatingoftheplateandstartingtheoxygengasfor
tti cutting.
Whichofthestatementsgivenabovearecorrect?
(a) 1,2and3 (b) 1and2
(c) 2and3 (d) 1and3 (c) 2and3 (d) 1and3
PowderCutting
Cast iron stainless steel and others high alloy steels are Cast iron, stainless steel, and others high alloy steels are
difficult to cut by oxyfuel cutting and we can use powder
i cutting.
By injecting a finely divided 200mesh iron powder into y j g y p
the flame, a lower melting point eutectic oxide is formed
at the cutting interface where additional ironoxygen at the cutting interface, where additional ironoxygen
reaction is generated and cutting proceeds in a similar
f f l tti way of oxyfuel cutting.
The heat and the fluxing action of the burning iron g g
powder enable the cutting oxygen stream to oxidize the
base metal continuously, just as in cutting carbon steel. base metal continuously, just as in cutting carbon steel.
GATE2009 (PI) GATE2009(PI)
Whi h f th f ll i d h ld b f d f Which of the following powders should be fed for
effective oxyfuel cutting of stainless steel? effective oxy fuel cutting of stainless steel?
(a) Steel (a) Steel
(b) Aluminum ( )
(c) Copper ( ) pp
(d) Ceramic
l PlasmaCutting
Uses ionized gas jet (plasma) to cut materials resistant to Uses ionized gas jet (plasma) to cut materials resistant to
oxyfuel cutting,
h l l d b h High velocity electrons generated by the arc impact gas
molecules, and ionize them.
The ionized gas is forced through nozzle (upto 500 m/s), and
the jet heats the metal, and blasts the molten metal away. j , y
More economical, more versatile and much faster (5 to 8
times) than oxyfuel cutting produces narrow kerfs and times) than oxyfuel cutting, produces narrow kerfs and
smooth surfaces.
HAZ i / h h f l i HAZ is 1/3 to th than oxyfuel cutting.
Maximum plate thickness = 200 mm
l i ldi ElectricArcWelding
l i ldi ElectricArcWelding
Fig Basiccircuitforarcwelding Fig.Basiccircuitforarcwelding
PrincipleofArc
An arc is generated between cathode and anode when
they are touched to establish the flow of current and
then separated by a small distance.
65% to 75% heat is generated at the anode.
If DC is used and the work is positive (the anode of the
i it) th diti i k t i ht l it circuit), the condition is known as straight polarity
(SPDC) (SPDC).
Contd
Work is negative and electrode is positive is reverse g p
polarity (RPDC).
SPDC conditions are preferred.
DC arcwelding maintain a stable arc and preferred for
difficult tasks such as overhead welding.
For a stable arc, the gap should be maintained.
Contd
ISRO2011 ISRO2011
I ldi t ti i i i f Inarcwelding,penetrationisminimumfor
( )DCSP (a)DCSP
(b)DCRP (b)DCRP
( )AC (c)AC
(d) (d)DCEN
Manual arc welding is done with shielded (covered)
electrodes
Baremetal wire used in automatic or semiautomatic Bare metal wire used in automatic or semiautomatic
machines.
N bl l t d ( t t ) i t Non consumable electrodes (e.g tungsten) is not
consumed by the arc and a separate metal wire is used
as filler.
There are three modes of metal transfer (globular There are three modes of metal transfer (globular,
spray and shortcircuit).
Threemodesofmetaltransferduringarcwelding MajorForcestakepartinMetalTransfer
(i)gravityforce
(ii)Surfacetension
(iii)electromagneticinteraction
( ) (iv)hydrodynamicactionofplasma
JWM2010
Assertion (A) : Bead is the metal added during
single pass of welding. single pass of welding.
Reason (R) : Bead material is same as base metal.
correct explanation of A p
(b) Both A and R are individually true but R is NOT the
GATE1993
Ind.c.welding,thestraightpolarity(electrode
negative)resultsin negative)resultsin
(a) Lowerpenetration
(b) Lowerdepositionrate
(c) Lessheatingofworkpiece (c) Lessheatingofworkpiece
(d) Smallerweldpool
Arcweldingequipments
1. Droopers: Constant current welding machines
G d f l ldi Good for manual welding
2. Constant voltage machines g
Good for automatic welding
Contd
Fig.Machinewithdifferentsettings
Fig.Characteristiccurveofaconstantvoltagearcweldingmachine
Formula Formula
V I
1
V I
OCV SCC
+ =
OCV SCC
Requires a large current (150 to 1000 A) voltage is Requires a large current (150 to 1000 A), voltage is
between 30 and 40 V, actual voltage across the arc between 30 and 40 V, actual voltage across the arc
varying from 12 to 30 V.
To initiate a weld, the operator strike the electrode and
start arc.
IES2010
I ldi th l th h ld b l t In arc welding, the arc length should be equal to
(a) 4.5 times the rod diameter ( ) 4 5
(b) 3 times the rod diameter
( ) i h d di (c) 1.5 times the rod diameter
(d) Rod diameter ( )
IES2005
Considerthefollowingstatements: Considerthefollowingstatements:
1. Inarcwelding,65%to75%heatisgeneratedatthe
d anode.
2. Dutycycleincaseofarcweldingisthecycleof y y g y
completeweldingofworkpiecefromthe
beginning beginning.
3. ArcblowismorecommonwithDCwelding.
Whichofthestatementsgivenaboveare
correct? correct?
(a) 1,2and3 (b) 1and2 ( ) , 3 ( )
(c) 2and3 (d) 1and3
IES2001
Inmanualarcwelding,theequipmentshould g q p
havedroopingcharacteristicsinordertomaintain
(a) Voltageconstantwhenarclengthchanges
(b) Currentconstantwhenarclengthchanges
(c) Temperatureintheareconstant
(d) Weldpoolredhot
IES2001
Inarcwelding,d.c.reversepolarityisusedtobear
t d t i greateradvantagein
(a) Overheadwelding ( ) g
(b) Flatweldingoflapjoints
( ) Ed ldi (c) Edgewelding
(d) Flatweldingofbuttjoints ( ) g j
IES1998
The voltagecurrent characteristics of a dc
t f ldi i t i ht li generator for arc welding is a straight line
between an opencircuit voltage of 80 V and short
circuit current of 300 A. The generator settings for
maximumarc power will be p
(a) 0 V and 150 A (b) 40 V and 300 A
( ) V d A (d) 8 V d A (c) 40 V and 150 A (d) 80 V and 300 A
IAS1999
Opencircuit voltage of 60 V and current of 160A
th ldi diti f ldi f were the welding conditions for arc welding of a
certain class of steel strip of thickness 10 mm. For
arc welding of 5mm thick strip of the same steel,
the welding voltage and current would be g g
(a) 60 V and 80 A
(b) V d 6 A (b) 120 V and 160 A
(c) 60 V and 40 A ( ) 4
(d) 120 V and 40 A
IAS1998
AssumingastraightlineVIcharacteristicsfora
d ldi t h t i it t A dcweldinggenerator,shortcircuitcurrentas400A
andopencircuitvoltageas400whichoneofthe
followingisthecorrectvoltageandcurrentsetting
formaximumarcpower? p
(a) 400Aand100V (b) 200Aand200V
( ) A d V (d) A d V (c) 400Aand50V (d) 200Aand50V
GATE2012SameQinGATE2012(PI)
In a DC arc welding operation, the voltagearc
length characteristic was obtained as V = 20 + 5L length characteristic was obtained as V
arc
= 20 + 5L
where the arc length L was varied between 5 mm
and 7 mm Here V denotes the arc voltage in Volts and 7 mm. Here V
arc
denotes the arc voltage in Volts.
The arc current was varied from 400 A to 500 A.
A i li h i i h Assuming linear power source characteristic, the
open circuit voltage and the short circuit current for
the welding operation are
(a) 45 V 450 A (b) 75 V 750 A (a) 45 V, 450 A (b) 75 V, 750 A
(c) 95 V, 950 A (d) 150 V, 1500 A
( ) GATE 2007(PI)
Th DC f ldi h th The DC power source for arc welding has the
characteristic 3V + I = 240, where V = Voltage and 3 4 g
I = Current in amp. For maximum arc power at
the electrode voltage should be set at the electrode, voltage should be set at
(a) 20 V (b) 40 V (c) 60 V (d) 80 V ( ) ( ) 4 ( ) ( )
GATE1992
A low carbon steel plate is to be welded by the manual
metal arc welding process using a linear V I metal arc welding process using a linear V I
characteristic DC Power source. The following data are
il bl available :
OCV of Power source = 62 V
Short circuit current = 130 A
A l h L Arc length, L = 4 mm
Traverse speed of welding = 15 cm/s p g 5 /
Efficiency of heat input = 85%
V l i i V L Voltage is given as V = 20 + 1.5 L
Calculate the heat input into the workprice
DutyCycle
The percentage of time in a 5 min period that a
welding machine can be used at its rated output welding machine can be used at its rated output
without overloading.
Time is spent in setting up, metal chipping, cleaning
and inspection. p
For manual welding a 60% duty cycle is suggested and
for automatic welding 100% duty cycle for automatic welding 100% duty cycle.
Contd
Requireddutycycle

=

2
I
T T Requireddutycycle, =

a
a
T T
I
Where,T=rateddutycycle
I=ratedcurrentattherateddutycycle I=ratedcurrentattherateddutycycle
I
o
=Maximumcurrentattherateddutycycle
IFS2011 IFS2011
What is the maximum output current that can be What is the maximum output current that can be
drawn at 100% duty cycle from a welding power source
rated at 600A at 60% duty cycle rated at 600A at 60% duty cycle.
[3Marks]
Electrode
1. NonconsumableElectrodes
C bl El d 2. ConsumableElectrodes
NonconsumableElectrodes
M d f b G hi T Madeofcarbon,GraphiteorTungsten.
CarbonandGraphiteareusedforD.C. p
Electrodeisnotconsumed,thearclengthremains
constant arcisstableandeasytomaintain constant,arcisstableandeasytomaintain.
Contd
ConsumableElectrodes
Provides filler materials.
Same composition Same composition.
This requires that the electrode be moved toward or
away from the work to maintain the arc and
satisfactory welding conditions. y g
Contd
Consumable electrodes are three kinds:
(a) Bare
(b) Fl d li htl t d (b) Fluxed or lightly coated
(c) Coated or extruded / shielded ( )
For automatic welding, bare electrode is in the form of
continuous wire (coil) continuous wire (coil).
Electrodecoatingcharacteristic
1. Provide a protective atmosphere.
S bili h 2. Stabilize the arc.
3. Provide a protective slag coating to accumulate 3 p g g
impurities, prevent oxidation, and slow the cooling of
the weld metal the weld metal.
4. Reduce spatter.
5. Add alloying elements.
6 Affect arc penetration 6. Affect arc penetration
7. Influence the shape of the weld bead.
8. Add additional filler metal.
GATE1994
Theelectrodesusedinarcweldingarecoated.
Thiscoatingisnotexpectedto Thiscoatingisnotexpectedto
(a) Provideprotectiveatmospheretoweld
(b) Stabilizetheare
(c) Addalloyingelements (c) Addalloyingelements
(d) Preventselectrodefromcontamination
Electrodecoatings
l. Slag Forming Ingredients. asbestos, mica, silica,
fluorspar titanium dioxide Iron oxide magnesium fluorspar, titanium dioxide, Iron oxide, magnesium
carbonate, Calciumcarbonate and aluminiumoxide.
2. Arc Stabilizing Ingredients. or ionizing agents: 2. Arc Stabilizing Ingredients. or ionizing agents:
potassium silicate, TiO
2
+ ZrO
2
(Rutile), Mica,
Calcium oxide sodium oxide magnesium oxide Calcium oxide, sodium oxide, magnesium oxide,
feldspar (KAI Si
3
O
8
)
Contd
3.DeoxidizingIngredients. Cellulose,Calcium
b d l i h d i dfl carbonate,dolo mite,starch,dextrin,woodflour,
graphite,aluminium,ferromanganese.
4.BindingMaterials Sodiumsilicate,potassiumsilicate, g
asbestos.
5.AlloyingConstituentstoImproveStrengthofWeld
6.TiO
2
andpotassiumcompoundsincreasethemelting
rateofthebasemetalforbetterpenetration rateofthebasemetalforbetterpenetration.
I d id hi h d i i 7.Ironpowderprovideshigherdepositionrate.
Contd Contd
The slag is then easily chipped.
Coatings are designed to melt more slowly than the Coatings are designed to melt more slowly than the
filler wire.
Binders
AC arc welding used potassium silicate binders.
DC arc welding used sodium silicate binders.
Potassium has a lower ionization potential as compared
h d with sodium.
IES2007
The coating material of an arc welding electrode
t i hi h f th f ll i ? contains which of the following?
1. Deoxidising agent g g
2. Arc stabilizing agent
Sl f i 3. Slag forming agent
Select the correct answer using the code given below: g g
(a) 1, 2 and 3 (b) 1 and 2 only
( ) d l (d) d l (c) 2 and 3 only (d) 1 and 3 only
IES1997
Assertion (A): The electrodes of ac arc welding are
coated with sodium silicate, whereas electrodes used ,
for dc arc welding are coated with potassium silicate
binders.
Reason (R): Potassium has a lower ionization
potential than sodium.
( ) B h A d R i di id ll d R i h (a) Both A and R are individually true and R is the correct
explanation of A
IES2002
MatchListIwithListIIandselectthecorrectanswer:
ListI(Ingredients) ListII(Welding ListI(Ingredients) ListII(Welding
functions)
A Sili A t bili A. Silica 1. Arc stabilizer
B. Potassiumoxalate 2. Deoxidizer
C. Ferrosilicon 3. Fluxingagent
D. Cellulose 4. Gasformingmaterial 4 g
(a) 3 4 2 1 (b) 2 1 3 4 (a) 3 4 2 1 (b) 2 1 3 4
(c) 3 1 2 4 (d) 2 4 3 1
WeldingFlux
Availableinthreeforms
Granular
Electrodewirecoating Electrodewirecoating
Electrodecore
Low Hydrogen Electrode LowHydrogenElectrode
The basic coatings contain large amount of The basic coatings contain large amount of
calcium carbonate (limestone) and calcium
fluoride (fluorspar) and produce low hydrogen fluoride (fluorspar) and produce low hydrogen.
But it can absorb moisture therefore coated low
hydrogen electrodes are backed before use to a
temperature of 200
o
C to 300
0
C and stored in an p 3
oven at 110
o
C to 150
o
C
Other types of electrode release large amount of Other types of electrode release large amount of
hydrogen, which can dissolve in the weld metal
d l d b i l ki and lead to embrittlement or cracking.
IFS2011 IFS2011
Whatismeantbylowhydrogenelectrode? Whatismeantbylow hydrogenelectrode?
[2marks]
W ldi P iti WeldingPositions
Fig.Thepositionofelectrodeforhorizontalwelding
Fig.Positioningofelectrodeforweldinginverticallyupwardposition
ldi WeldingCurrent
Weldingcurrentdependsupon:thethicknessofthe
weldedmetal typeofjoint weldingspeed positionof weldedmetal,typeofjoint,weldingspeed,positionof
theweld,thethicknessandtypeofthecoatingonthe
l d di ki l h electrodeanditsworkinglength.
Weldingcurrent,I=k.d,amperes;disdia.(mm) g , , p ; ( )
WeldingVoltage
Thearcvoltagedependsonlyuponthearclength
V=k
1
+k
2
l Volts
1 2
Wh li h l hi dk dk Wherelisthearclengthinmmandk
1
andk
2
are
constants,
k
1
=10to12;andk
2
=2to3
TheminimumArcvoltageisgivenby
V
min
=(20+0.04l)Volt
ArcLength
For good welds, a short arc length is necessary,
because: because:
1. Heat is concentrated.
2. More stable
3 More protective atmosphere 3. More protective atmosphere.
Contd
A long arc results in g
Large heat loss into atmosphere.
U t bl Unstable arc.
Weld pool is not protected. p p
Weld has low strength, less ductility, poor fusion and
excessive spatter excessive spatter.
Fig.ArcPowerVsArcLength
Arclengthshouldbeequaltothediameteroftheelectrodesize
Beadwidthshouldbeequaltothreediameteroftheelectrodesize q
GATE2002,Conventional
The arc lengthvoltage characteristic of a DC arc is given
by the equation: V = 24 + 4L, where V is voltage in volts
d L i l h i Th i l and L is arc length in mm. The static voltampere
characteristic of the power source is approximated by a characteristic of the power source is approximated by a
straight line with a no load voltage of 80 V and a short g g
circuit current of 600A. Determine the optimum arc
length for maximum power.
GATE2010(PI)
D i t d t l ldi ith di t During a steady gas metal arc welding with direct
current electrode positive polarity, the welding current,
lt d ld d A V d 6 / i voltage and weld speed are 150 A, 30 V and 6 m/min,
respectively. A metallic wire electrode of diameter 1.2
i b i f d t t t t f / i Th mm is being fed at a constant rate of 12 m/min. The
density, specific heat and melting temperature of the
i l t d k /
3
J/k
o
C d
o
C wire electrode are 7000 kg/m
3
, 500 J/kg
o
C and 1530
o
C,
respectively. Assume the ambient temperature to be 30
o
C
d l h l h f l i F h id and neglect the latent heat of melting. Further, consider
that twothird of the total electrical power is available for
l i f h i l d Th l i ffi i (i melting of the wire electrode. The melting efficiency (in
percentage) of the wire electrode is
(a) 39.58 (b) 45.25 (c) 49.38 (d) 54.98
GATE2008
In arc welding of a butt joint, the welding speed is
to be selected such that highest cooling rate is to be selected such that highest cooling rate is
achieved. Melting efficiency and heat transfer
ffi i d i l Th f efficiency are 0.5 and 0.7, respectively. The area of
the weld cross section is 5 mm
2
and the unit
energy required to melt the metal is 10 J/mm
3
. If
the welding power is 2 kW, the welding speed in g p , g p
mm/s is closest to
(a) 4 (b) 14 (c) 24 (d) 34 (a) 4 (b) 14 (c) 24 (d) 34
GATE2006
In an arc welding process, the voltage and current
are 25 V and 300 A respectively The arc heat are 25 V and 300 A respectively. The arc heat
transfer efficiency is 0.85 and welding speed is 8
/ Th h i (i J/ ) i mm/sec. The net heat input (in J/mm) is
(a) 64 ( ) 4
(b) 797
( ) (c) 1103
(d) 79700 ( ) 797
GATE2009 (PI) GATE2009(PI)
A t t t ldi f t l Autogenous gas tungsten arc welding of a steel
plate is carried out with welding current of 500 A plate is carried out with welding current of 500 A,
voltage of 20 V, and weld speed of 20 mm/sec. g p
Consider the heat transfer efficiency from the arc
to the weld pool as 90%. The heat input per unit
length (in KJ/mm) is
(a) 0.25 (b) 0.35 (c) 0.45 (d) 0.55
Example
Calculate the melting efficiency in the case of
ldi f t l ith t ti l f V d arcwelding of steel with a potential of 20 V and
a current of 200 A. The travel speed is 5 mm/s p 5 /
and .the crosssectional area of the joint is 20
mm
2
Heat required to melt steel may be taken mm
2
. Heat required to melt steel may be taken
as 10 J/mm
3
and the heat transfer efficiency as
0.85.
ArcblowinDCarcwelding
Contd
A bl d i th ldi f ti Arc blow occurs during the welding of magnetic
materials with DC.
The effect of arc blow is maximum when welding
corners where magnetic field concentration is
maximum.
The effect is particularly noticeable when welding with p y g
bare electrodes or when using currents belowor above
Again the problem of arc blow gets magnified when Again the problem of arc blow gets magnified when
welding highly magnetic materials such as Ni alloys,
because of the strong magnetic fields set up by these because of the strong magnetic fields set up by these
metals.
C U b l d ti f Cause: Unbalanced magnetic forces.
Contd
Effectofarcblow
Low heat penetration.
E i ld Excessive weld spatter.
Pinch effect in welding is the result of electromagnetic g g
forces
Weld spatter occurs due to Weld spatter occurs due to
High welding current
Too small an electrode arc
Contd
The effects of arc blowcan be minimized with D.C.
ldi b welding by
Shortening the arc. g
Reduce current
R d i ld d Reducing weld speed.
Balance magnetic field by placing one ground lead at g y p g g
each end of the work piece.
Wrapping the electrode cable a few turns around the Wrapping the electrode cable a few turns around the
work piece.
IES2001
Arcblowismorecommonin
(a) A.C.welding
(b) D.C.weldingwithstraightpolarity (b) D.C.weldingwithstraightpolarity
(c) D.C.weldingwithbareelectrodes
(d) A.C.weldingwithbareelectrodes
IES2001
Pincheffectinweldingistheresultof
(a) Expansionofgasesinthearc
(b) Electromagneticforces (b) Electromagneticforces
(c) Electricforce
(d) Surfacetensionofthemoltenmetal
ISRO2006
Too high welding current in arc welding would result in
(a) Excessive spatter under cutting along edges irregular (a) Excessive spatter, under cutting along edges, irregular
deposits, wasted electrodes
(b) Excessive piling up of weld metal, poor penetration,
wasted electrodes
(c) Too small bead, weak weld and wasted electrodes
(d) E i ili f ld l l i (d) Excessive piling up of weld metal, overlapping
without penetration of edges, wasted electrodes
Gasshields
An inert gas is blown into the weld zone to drive away
other atmospheric gases.
Gases are argon, helium, nitrogen, carbon dioxide and
a mixture of the above gases.
Argon ionizes easily requiring smaller arc voltages.It is
d f ldi thi h t good for welding thin sheets.
Contd
Helium, most expensive, has a better thermal
conductivity, is useful for thicker sheets, copper and
aluminiumwelding, higher deposition rate.
The arc in carbon dioxide shielding gas is unstable,
l t i d idi d d least expensive, deoxidizers needed.
It i h d th f th ld It is a heavy gas and therefore covers the weld zone
very well very well.
CarbonArcwelding
Arc is produced between a carbon electrode and the
work.
Shielding is not used.
No pressure
With or without filler metal
May be used in "twin arc method", that is, between
b ( hi ) l d two carbon (graphite) electrodes.
IES2010
Assertion (A): Straight polarity is always Assertion (A): Straight polarity is always
recommended for Carbonelectrode welding.
Reason (R): Carbon arc is stable in straight polarity.
(b) h d d d ll b h (b) Both A and R are individually true but R is NOT the
(d) A i f l b t R i t (d) A is false but R is true
TungstenInertGaswelding(TIG)
Arc is established between a nonconsumable
tungsten electrode and the workpiece tungsten electrode and the workpiece.
Tungsten is alloyed with thorium or zirconium for
better currentcarrying and electronemission
characteristics.
Arc length is constant, arc is stable and easy to
maintain maintain.
With or without filler.
Contd
Very clean welds.
All metals and alloys can be welded. (Al, Mg also)
Straight polarity is used.
Weld voltage 20 to 40 V and weld current 125 A for
RPDC to 1000 A for SPDC RPDC to 1000 A for SPDC.
Shielded Gas: Argon Shielded Gas: Argon
Torch is water or air cooled Torch is water or air cooled.
Fig.TIG
GATE2011
Whichoneamongthefollowingweldingprocesses
usednon consumableelectrode?
(a)Gasmetalarcwelding
(b)S b d ldi (b)Submergedarcwelding
(c)Gastungstenarcwelding ( ) g g
(d)Fluxcoatedarcwelding
IES2010
In an inert gas welding process the commonly used In an inert gas welding process, the commonly used
gas is
(a) Hydrogen
(b) Oxygen (b) Oxygen
(c) Heliumor Argon
(d) Krypton
ISRO2009 ISRO2009
Following gases are used in tungsten inert Following gases are used in tungsten inert
gas welding
(a) CO
2
and H
2
(b) A d (b) Argon and neon
(c) Argon and helium (c) Argon and helium
(d) Heliumand neon
GATE2002
Whichofthefollowingarcweldingprocessesdoes
notuseconsumableelectrodes? notuseconsumableelectrodes?
(a) GMAW
(b) GTAW
(c) SubmergedArcWelding (c) SubmergedArcWelding
(d) Noneofthese
IES1994
Whichoneofthefollowingweldingprocesses
bl l t d ? usesnon consumableelectrodes?
(a) TIGwelding ( ) g
(b) MIGwelding
( ) M l ldi (c) Manualarcwelding
(d) Submergedarcwelding. ( ) g g
IES2000
Whichoneofthefollowingstatementsiscorrect?
(a) Nofluxisusedingasweldingofmildsteel
(b) Boraxisthecommonlyusedfluxcoatingon (b) Boraxisthecommonlyusedfluxcoatingon
weldingelectrodes
( ) L b ldi l h b (c) Laserbeamweldingemploysavacuumchamber
andthusavoidsuseofashieldingmethod
(d) ACcanbeusedforGTAWprocess
GasMetalArcWelding(GMAW)orMIG
A consumable electrode in a gas shield.
A i b k i d i ll f d Arc is between workpiece and an automatically fed
barewire electrode.
Argon, helium, and mixtures of the two can be used.
Any metal can be welded but are used primarily with Any metal can be welded but are used primarily with
the nonferrous metals.
When welding steel, some O
2
or CO
2
is usually added
to improve the arc stability and reduce weld spatter. p y p
Contd
Fast and economical. Fast and economical.
A reversepolarity dc arc is generally used because
f i d i f d bili of its deep penetration, spray transfer, and ability
to produce smooth welds with good profile.
Fig.MIG
IES2007
InMIGwelding,themetalistransferredintothe
f f hi h fth f ll i ? formofwhichoneofthefollowing?
(a) Afinesprayofmetal ( ) p y
(b) Moltendrops
( ) W ld l (c) Weldpool
(d) Molecules ( )
IES1997
MIG ldi MIGweldingprocessuses
1.Consumableelectrode2. nonconsumableelectrode
3.D.C.powersupply 4.A.C.powersupply
Ofthesestatements Ofthesestatements
(a) 2and4arecorrect
(b) 2and3arecorrect
(c) 1and4arecorrect (c) 1and4arecorrect
(d) 1and3arecorrect
IES2010
Assertion(A):Inertgasandbareelectrodeinstead Assertion(A):Inertgasandbareelectrodeinstead
offluxcoatedelectrodeisusedinthecaseof
i TIG dMIG ldi automaticTIGandMIGweldingprocesses.
Reason(R):Betterprotectionisprovidedbyacloud ( ) p p y
ofinertgasthanthecovercreatedbytheflux.
( ) B th A d R i di id ll t d R i th (a) Both A and R are individually true and R is the
(b) Both A and R are individually true but R is NOT the
IES 2012
St t t(I) DC ith l it i di MIG Statement(I):DCwithreversepolarityisusedinMIG
welding
Statement(II):UseofDCwithreversepolarityenables
deeperpenetrationandacleanSurface
SubmergedArcwelding(SAW)
A thick layer of granular flux is deposited just ahead of
a bare wire consumable electrode, and an arc is
maintained beneath the blanket of flux with only a few
ll fl b i i ibl small flames being visible.
A ti f th fl lt M lt fl d fl A portion of the flux melts. Molten flux and flux
provides thermal insulation slows cooling rate and provides thermal insulation, slows cooling rate and
produce soft, ductile welds. p ,
Contd
Most suitable for flat butt or fillet welds in low
carbon steel (< 0.3%carbon).
The process is not recommended for highcarbon
t l t l t l l i i steels, tool steels, aluminum, magnesium,
titanium, lead, or zinc titanium, lead, or zinc.
Characteristicofsubmergedarcwelding
Highspeeds,
Highdepositionrates,
Deeppenetration,
Highcleanliness(duetothefluxaction).
Advantages
Wireelectrodesareinexpensive.
Noweldspatter.
Nearly100%depositionefficiency.
Lesserelectrodeconsumption.
Limitations
Extensive flux handling,
Contamination of the flux by moisture.
Largegrainsize structures.
Welding is restricted to the horizontal position.
Chemical control is important
IES2011
The welding process in which bare wire is used as
electrode, granular flux is used and the process is , g p
characterized by its high speed welding, is known as:
(a) Shielded arc welding (a) Shielded arc welding
(b) Plasma arc welding
(c) Submerged arc welding
(d) Gas metal arc welding (d) Gas metal arc welding
IES2006
Inwhichofthefollowingweldingprocesses,flux
i di th f f l ? isusedintheformofgranules?
(a) ACarcwelding ( ) g
(b) Submergedarcwelding
( ) A ldi (c) Argonarcwelding
(d) DCarcwelding ( ) g
IES2005
Whichofthefollowingarethemajor
characteristicsofsubmergedarcwelding? characteristicsofsubmergedarcwelding?
1. Highweldingspeeds.
2. Highdepositionrates.
3. Lowpenetration. 3. o pe et at o .
4. Lowcleanliness.
S l tth t i th d i b l Selectthecorrectanswerusingthecodegivenbelow:
(a) 2and3 (b) 1,2and3
(c) 3and4 (d) 1and2
IES2008
Assertion (A): Submerged arc welding is not
recommended for high carbon steels, tool steels, g , ,
aluminium, magnesiumetc.
Reason (R): This is because of unavailability of ( ) y
suitable fluxes, reactivity at high temperatures and
lowsublimation temperatures.
( ) B h A d R d R i h l i (a) Both A and R are true and R is the correct explanation
of A
(b) B th A d R t b t R i NOT th t (b) Both A and R are true but R is NOT the correct
explanation of A
GATE1999
For butt welding 40 mm thick steel plates, when
the expected quantity of such jobs is 5000 per the expected quantity of such jobs is 5000 per
month over a period of 10 year, choose the best
i bl ldi f h f ll i suitable welding process out of the following
available alternatives.
(a) Submerged arc welding
(b) Oxy acetylene welding (b) Oxyacetylene welding
(c) Electron beamwelding
(d) MIG welding
AtomicHydrogenwelding(AHW)
An a.c. arc is formed between two tungsten electrodes
along which streams of hydrogen are fed to the along which streams of hydrogen are fed to the
welding zone. The molecules of hydrogen are
dissociated by the high heat of the arc in the gap dissociated by the high heat of the arc in the gap
between the electrodes. The formation of atomic
hydrogen proceeds with the absorption of heat: hydrogen proceeds with the absorption of heat:
H
2
= 2H 421.2 k J / mol
Thi i h d bi f l l This atomic hydrogen recombines to form molecular
hydrogen outside the arc, particularly on the relatively
ld f f h k b i ld d l i h cold surface of the work being welded, releasing the
heat gained previously:
2H = + 421.2 k J / mol. H
2
Contd
Temperature of about 3700
o
C Temperature of about 3700
o
C.
Hydrogen acts as shielding also Hydrogen acts as shielding also.
Used for very thin sheets or small diameter wires Used for very thin sheets or small diameter wires.
Lower thermal efficiency than Arc welding Lower thermal efficiency than Arc welding.
Ceramics may be arc welded. Ceramics may be arc welded.
AC used.
IES2005
Inatomichydrogenwelding,hydrogenactsas
(a) Aheatingagent
(b) Oneofthegasestogeneratetheflame (b) Oneofthegasestogeneratetheflame
(c) Aneffectiveshieldinggasprotectingtheweld
(d) Alubricanttoincreasetheflowcharacteristicsof
weldmetal
R i t W ldi ResistanceWelding
BySKMondal
ResistanceWelding
Principle
Both heat and pressure are used Both heat and pressure are used.
Heat is generated by the electrical resistance of the
k i d h i f b h work pieces and the interface between them.
Pressure is supplied externally and is varied pp y
throughout the weld cycle.
Due to pressure a lower temperature needed than Due to pressure, a lower temperature needed than
oxyfuel or arc welding.
Contd
They are not officially classified as solidstate welding They are not officially classified as solid state welding
by the American Welding Society. y g y
Very rapid and economical.
Extremely well suited to automated manufacturing.
No filler metal, no flux, no shielding gases.
Contd
Overall resistance very low.
Very highcurrent (up to 100,000 A)
Very lowvoltage (0.5 to 10 V) is used.
FIG.Thefundamentalresistanceweldingcircuit
Fig. The desired temperature
di t ib ti th
Fig. Typical current and
pressure cycle for resistance
distribution across the
electrodes and the work
pieces in lap resistance
pressure cycle for resistance
welding. The cycle includes
forging and post heating
p p
welding.
operations.
Fig. The arrangement of the electrodes and the work in spot
welding, showing design for replaceable electrode tips.
IES 2007 IES2007
Wh t i th i i l f i t ldi ? What is the principle of resistance welding?
Indicate where the resistance is maximum in spot Indicate where the resistance is maximum in spot
welding operation. g p
[2marks]
Advantages
1. Very rapid.
2. Fully automation possible.
3. Conserve material; no filler metal, shielding gases, or
flux is required.
4. Skilled operators are not required.
5.Dissimilar metals can be easily joined.
6. High reliability and High reproducibility.
Limitations
1. High initial cost.
2. Limitations to the type of joints (mostly lap joints).
3. Skilled maintenance personne1 are required:
4. special surface treatment needed.
Application
The resistance welding processes are among the
most common technique for high volume
joining joining.
Differenttypes
1. Resistance spot welding
2. Resistance seamwelding
3. Projection welding
4. Upset welding
5. Flash welding
6. Percussion welding
Resistancespotwelding
The process description given so far is called resistance
spot welding (RSW) or simply spot welding spot welding (RSW) or simply spot welding.
This is essentially done to join two sheetmetal jobs in
a lap joint, forming a small nugget at the interface of
the two plates. p
HeatinputandEfficiencyCalculations
Contd
Electric Resistance Welding ect c Res sta ce We d g
l l l bl Joules lawapplicable
Q = I
2
Rt, Joules Q I Rt, Joules
IES2003
Inresistancewelding,heatisgeneratedduetothe
i t b t resistancebetween
(a) Electrodeandworkpiece ( ) p
(b) Asperitiesbetweentouchingplates
( ) T di i il l b i i (c) Twodissimilarmetalsbeingincontact
(d) Interatomicforces ( )
IES2001
Themaximumheatinresistanceweldingisatthe
(a) Tipofthepositiveelectrode
(b) Tipofthenegativeelectrode (b) Tipofthenegativeelectrode
(c) Topsurfaceoftheplateatthetimeofelectric
i h h l d contactwiththeelectrode
(d) InterfacebetweenthetwoplatesbeingJoined ( ) p g J
GATE2007
T lli h h f hi k ld d i l j i Two metallic sheets, each of 2.0 mm thickness, are welded in a lap joint
configuration by resistance spot welding at a welding current of 10 kA
and welding time of 10 millisecond. A spherical fusion zone extending
t th f ll thi k f h h t i f d Th ti f th up to the full thickness of each sheet is formed. The properties of the
metallic sheets are given as:
ambient temperature = 293 K
melting temperature = 1793 K
latent heat of fusion = 300 kJ/kg
density = 7000 kg/m
3
density = 7000 kg/m
3
specific heat = 800 J/kg K
Assume:
(i) Contact resistance along sheetsheet interface is 500 microohm and
along electrodesheet interface is zero;
(ii) No conductive heat loss through the bulk sheet materials; and (ii) No conductive heat loss through the bulk sheet materials; and
(iii) The complete weld fusion zone is at the melting temperature.
The melting efficiency (in %) of the process is
( ) (b) 6 ( ) (d) 8 (a) 50.37 (b) 60.37 (c) 70.37 (d) 80.37
GATE2009(PI)LinkedS1
R i ldi f l h i i d i Resistance spot welding of two steel sheets is carried out in
lap joint configuration by using a welding current of 3 kA and
ld f l ld f l a weld time of 0.2 S. A molten weld nugget of volume 20 mm
3
is obtained. The effective contact resistance is 200
(microohms). The material properties of steel are given as:
(i) latent heat of melting: 1400 kJ/kg, (ii) density: 8000
kg/m
3
, (iii) melting temperature: 1520
o
C, (iv) specific heat:
0.5 kJ/kg
o
C. The ambient temperature is 20
o
C. 5 g p
Heat (in Joules) used for producing weld nugget will be
(assuming 100% heat transfer efficiency) (assuming 100% heat transfer efficiency)
(a) 324 (b) 334 (c) 344 (d) 354
GATE2009(PI)LinkedS2
R i ldi f l h i i d i Resistance spot welding of two steel sheets is carried out in
lap joint configuration by using a welding current of 3 kA and
ld f l ld f l a weld time of 0.2 S. A molten weld nugget of volume 20 mm
3
is obtained. The effective contact resistance is 200
(microohms). The material properties of steel are given as:
(i) latent heat of melting: 1400 kJ/kg, (ii) density: 8000
kg/m
3
, (iii) melting temperature: 1520
o
C, (iv) specific heat:
0.5 kJ/kg
o
C. The ambient temperature is 20
o
C. 5 g p
Heat (in Joules) dissipated to the base metal will be
(neglecting all other heat losses) (neglecting all other heat losses)
(a) 10 (b) 16 (c) 22 (d) 32
GATE2005
Spot welding of two 1 mm thick sheets of steel
(density = 8000 kg/m
3
) is carried out successfully (density = 8000 kg/m
3
) is carried out successfully
by passing a certain amount of current for 0.1
d h h h l d Th l ld second through the electrodes. The resultant weld
nugget formed is 5 mm in diameter and 1.5 mm
thick. If the latent heat of fusion of steel is 1400
kJ/kg and the effective resistance in the welding J/ g g
operation in 200 , the current passing through the
electrodes is approximately electrodes is approximately
(a) 1480A (b) 3300 A
(c) 4060 A (d) 9400 A
GATE2001
Resistance spot welding is performed on two
plates of 1 5 mm thickness with 6 mm diameter plates of 1.5 mm thickness with 6 mm diameter
electrode, using 15000 A current for a time
d i f d A i h i f duration of 0.25 seconds. Assuming the interface
resistance to be 0.0001 , the heat generated to
formthe weld is
(a) 5625 Wsec (b) 8437 Wsec (a) 5625 W sec (b) 8437 W sec
(c) 22500 Wsec (d) 33750 Wsec
GATE2004
Two 1 mm thick steel sheets are to be spot welded
at a current of 5000 A Assuming effective at a current of 5000 A. Assuming effective
resistance to be 200 microohms and current flow
i f d h d d i h time of 0.2 second, heat generated during the
process will be
(a) 0.2 Joule (b) 1 Joule
(c) 5 Joule (d) 1000 Joules (c) 5 Joule (d) 1000 Joules
GATE1992
For resistance spot welding of 1.5 mm thick steel
sheets the current required is of the order of sheets, the current required is of the order of
(a) 10 A
(b) 100 A
(c) 1000 A (c) 1000 A
(d) 10,000 A
GATE2010
Two pipes of inner diameter 100 mm and outer
diameter 110 mm each joined by flash butt diameter 110 mm each joined by flash butt
welding using 30 V power supply. At the interface,
f i l l f h i hi h h 1 mm of material melts from each pipe which has
a resistance of 42.4 . If the unit melt energy is
64.4 MJm
3
, then time required for welding in
seconds is
(a) 1 (b) 5 (c) 10 (d) 20
IAS2003
Assertion (A): Spot welding is adopted to weld two
overlapped metal pieces between two electrode pp p
points.
Reason (R): In this process when current is switched ( ) p
on, the lapped pieces of metal are heated in a
restricted area.
( ) B h A d R i di id ll d R i h (a) Both A and R are individually true and R is the correct
explanation of A
l IES2007Conventional
Two steel sheets of thickness one mm are welded Two steel sheets of thickness one mm are welded
by resistance projection welding technique. A
t f A f d i d t current of 30,000 A for 0005 second is made to
flow. The effective resistance of joint can be taken
h h b d d as 100 micro ohms. The joint can be considered as
a cylinder of diameter 5 mm and height 15 mm. y 5 g 5
The density of steel is 000786 gm/mm
3
. The heat
needed for welding steel is 10 J/mm
3
. Calculate the needed for welding steel is 10 J/mm . Calculate the
efficiency of welding. [20]
GATE 2008(PI)
Aluminum strips of 2 mm thickness are joined together
by resistance spot welding process by applying an by resistance spot welding process by applying an
electric current of 6000 A for 0.15 sec. The heat required
for melting aluminum is 2.9 J/mm
3
. The diameter and
the thickness of weld nugget are found to be 5 mm and the thickness of weld nugget are found to be 5 mm and
2.5 mm, respectively. Assuming the electrical resistance
to be 75 (micro ohms), the percentage of total
energy utilized in forming the weld nugget is energy utilized in forming the weld nugget is
(a) 28 (b) 35 (c) 65 (d) 72 ( ) ( ) 35 ( ) 5 ( ) 7
Resistanceseamwelding
Weld is made between overlapping sheets of metal.
The seam is a series of overlapping spot welds.
The basic equipment is the same as for spot welding.
except that the electrodes are now in the form of
t ti di k rotating disks.
Ti d l f t t f th l i Timed pulses of current pass to form the overlapping
welds welds.
Contd
Welding current is a bit higher than spot welding, to
t h t i it f th dj t ld compensate short circuit of the adjacent weld.
In other process a continuous seam is produced by p p y
passing a continuous current through the rotating
electrodes with a speed of 1 5 m/min for thin sheet electrodes with a speed of 1.5 m/min for thin sheet.
Contd
Fig.Resistanceseamwelding
GATE 2012 (PI) GATE 2012(PI)
In resistance seam welding, the electrode is in the In resistance seam welding, the electrode is in the
formof a
( ) li d (a) cylinder
(b) flat plate ( ) p
(c) coil of wire
(d) i l di (d) circular disc
Projectionwelding
Limitations of spot welding.
El d di i b i i d 1. Electrode condition must be maintained
continually, and only one spot weld at a time.
2. For additional strength multiple welds needed.
Projection welding (RPW) overcomes above Projection welding (RPW) overcomes above
limitations.
Contd
Dimples are embossed on work pieces at the weld
locations and then placed between large area locations and then placed between largearea
electrodes, and pressure and current applied like spot
ldi welding.
Current flows through the dimples and heats them g p
and pressure causes the dimples to flatten and form a
weld weld.
Fig.Principleof
projectionwelding, p j g
(a)priortoapplicationof
currentandpressure
(b)andafterformationof (b)andafterformationof
welds
Contd
Projections are pressformed in any shape. j p y p
Multiple welds at a time. p
No indentation mark on the surface.
Bolts and nuts can be attached to other metal parts.
Upsetwelding
Made butt joint compared to lap joint.
Pieces are held tightly and current is applied.
Due to pressure joints get slightly upset and hence its
name.
Useful for joining rods or similar pieces.
Contd
Contd
This is the process used for making electric resistance
ld d (ERW) i i f l l f i bl welded (ERW) pipes starting from a metal plate of suitable
thickness.
The plate is first formed into the shape of the pipe with the
help of the three roll set as shown in Fig. above. The ends p g
of the plate would then be forming the butt joint.
The two rotating copper disc electrodes are made to The two rotating copper disc electrodes are made to
contact the two ends of the plate through which the
current is passed The ends get heated and then forge current is passed. The ends get heated and then forge
welded under the pressure of the rolls.
Th d f h i b ld d b f l The ends of the pieces to be upset welded must be perfectly
parallel. Any high spots if present on the ends would get
melted first before the two ends are completely joined.
FlashWelding
It is similar to upset welding except the arc rather than
resistance heating.
One pieces is clamped with cam controlled movable
platen and other with is fixed platen.
Contd
Two pieces are brought together and the power supply is
switched on Momentarily the two pieces are separated switched on. Momentarily the two pieces are separated
to create the arc to melt the ends of the two pieces.
Th i h i b h h d h Then again the pieces are brought together and the
power switched off while the two ends are fused under
force. Most of the metal melted would flash out
through the joint and forms like a fin around the joint. g j j
Faster than upset welding.
PercussionWelding
Similar to flash welding except arc power by a rapid
discharge of stored electrical energy.
The arc duration is only 1 to 10 ms, heat is intense and
highly concentrated highly concentrated.
Small weld metal is produced little or no upsetting and Small weld metal is produced, little or no upsetting, and
low HAZ.
Application: Butt welding of bar or tube where heat
damage is a major concern.
Contd
OtherWelding g
Technique Technique
Thermit Welding
Heating and coalescence is by superheated molten
metal obtained from a chemical reaction between a
metal oxide and a metallic reducing agent.
Used mixture one part aluminum and three parts iron
id d i it d b i f ( C) oxide and ignited by a magnesium fuse. (1150C).
8Al F O F Al O h t 8Al+3Fe
3
O
4
9Fe+4Al
2
O
3
+heat
Contd
Temp. 2750C produced in 30 seconds, superheating p p p g
the molten iron which provide both heat and filler
metal.
Runners and risers are provided like casting.
Copper, brass, and bronze can be welded using a
diff i i different starting mixture.
U d j i hi k i i l i Used to joint thick sections, in remote locations.
IES2000
Considerthefollowingprocesses:
G ldi 1. Gaswelding
2. Thermit welding
3. Arcwelding
4 Resistancewelding 4. Resistancewelding
Thecorrectsequenceoftheseprocessesinincreasing
d fth i ldi t t i orderoftheirweldingtemperaturesis
(a) 1,3,4,2 (b) 1,2,3,4
(c) 4,3,1,2 (d)4,1,3,2
ElectroSlagWelding
Very effective for welding thick sections.
Heat is derived from the passage of electrical current
through a liquid slag and temp. 1760C
Contd
A 65mm deep layer of molten slag, protect and p y g p
cleanse the molten metal.
Watercooled copper molding plates confined the
liquid and moved upward.
Multiple electrodes are used to provide an adequate
l f fill supply of filler.
Contd
Applications: Shipbuilding, machine manufacture,
heavy pressure vessels, and the joining of large
castings and forgings.
Slowcooling produces a coarse grain structure.
Large HAZ.
Contd
IAS2003
Whichoneofthefollowingisnotanelectric
i t th d f ldi ? resistancemethodofwelding?
(a) Electroslagwelding ( ) g g
(b) Percussionwelding
( ) S ldi (c) Seamwelding
(d) Flashwelding ( ) g
IAS2000
Considerthefollowingweldingprocesses:
1. TIGwelding 2. Submergedarcwelding
3. Electroslagwelding4. Thermit welding 3. Electro slagwelding4. Thermit welding
Whichoftheseweldingprocessesareusedforwelding
hi k i f l ? thickpiecesofmetals?
(a) 1,2and3 (b) 1,2and4 ( ) , 3 ( ) , 4
(c) 1,3and4 (d) 2,3and4
ElectronBeamWelding
A beam of electrons is magnetically focused on the
work piece in a vacuum chamber.
Heat of fusion is produced by electrons decelerate.
Allows precise beam control and deep weld
penetration.
h ld ( h b d) No shield gas (vacuum chamber used)
IES2004
Assertion (A): In electron beam welding process,
vacuum is an essential process parameter vacuum is an essential process parameter
Reason (R): Vacuum provides a highly efficient
hi ld ld shield on weld zone
(b) Both A and R are individually true but R is not the (b) Both A and R are individually true but R is not the
IES2002
Inwhichoneofthefollowingweldingtechniques
i i t i d? isvacuumenvironmentrequired?
(a) Ultrasonicwelding ( ) g
(b) Laserbeamwelding
( ) Pl ldi (c) Plasmaarcwelding
(d) Electronbeamwelding ( ) g
IES1993
Electronbeamweldingcanbecarriedoutin
(a) Openair
(b) Ashieldinggasenvironment (b) Ashieldinggasenvironment
(c) Apressurizedinertgaschamber
(d) Vacuum
IAS2004
i t f ll H tAff t dZ (HAZ)? consistsofsmallerHeatAffectedZone(HAZ)?
(a) Arcwelding (b) Electronbeamwelding ( ) g ( ) g
(c) MIGwelding (d) Thermit welding
LaserBeamWelding
Used a focused laser beam provides power intensities
in excess of 10kW/cm
2
The highintensity beam produces a very thin column
of vaporized metal with a surrounding liquid pool.
Depthtowidth ratio greater than 4: 1.
Contd
Very thin HAZ and little thermal distortion. y
Filler metal and inert gas shield may or may not used.
Deep penetration.
No vacuum needed.
No direct contact needed.
Contd
Heat input is very low, often in the range 0.1 to 10 J. p y g
Adopted by the electronics industry.
Possible to weld wires without removing the
polyurethane insulation.
Contd
IES2007
Considerthefollowingstatementsinrespectofthe
laserbeamwelding: laserbeamwelding:
1. Itcanbeusedforweldinganymetalortheir
combinationsbecauseofveryhightemperatureofthe combinationsbecauseofveryhightemperatureofthe
focalpoints.
2 Heataffectedzoneisverylargebecauseofquick 2. Heataffectedzoneisverylargebecauseofquick
heating.
Hi h i i dt th 3. Highvacuumisrequiredtocarrytheprocess.
Whichofthestatementsgivenaboveis/arecorrect?
(a) 1and2only (b) 2and3only
(c) 1only (d) 1,2and3 ( ) y ( ) 3
IES2006
i t f i i h t ff t d (HAZ)? consistsofminimumheataffectedzone(HAZ)?
(a) ShieldedMetalArcWelding(SMAW) ( ) g ( )
(b) LaserBeamWelding(LBW)
( ) Ul i W ldi (USW) (c) UltrasonicWelding(USW)
(d) MetalInertGasWelding(MIG) ( ) g ( )
GATE2012(PI)
Which of the following welding processes results in
th ll t h t ff t d ? the smallest heat affected zone?
(a) Shielded metal arc welding ( ) g
(b) Gas welding
( ) L b ldi (c) Laser beamwelding
(d) Thermit welding ( ) g
IAS2007
Consider the following welding processes:
1. Arc welding 2. MIG welding
3. Laser beamwelding 4. Submerged arc 3. Laser beamwelding 4. Submerged arc
welding
S l h i i i d f H Select the correct sequence in increasing order of Heat
affected zone (HAZ) using the code
given below:
(a) 1 2 3 4 (b) 1 4 2 3 (a) 1 2 3 4 (b) 1 4 2 3
(c) 3 2 4 1 (d) 4 3 2 1
IAS1999
Match List I (Shielding method) with List II (Welding
process) and select the correct answer using the codes p ) g
given belowthe lists:
List I List II
l l ld A. Flux coating 1. Gas metal arc welding
B. Flux granules 2. Submerged arc welding
C CO Shi ld d l ldi C. CO
2
3. Shielded metal arc welding
D. Vacuum 4. Laser beamwelding
El t b ldi 5. Electron beamwelding
(a) 1 2 5 3 (b) 1 4 2 5 (a) 1 2 5 3 (b) 1 4 2 5
(c) 3 5 1 4 (d) 3 2 1 5
ForgeWelding
Blacksmith do this.
Borax is used as a flux.
The ends to be joined were then overlapped on the
anvil and hammered to the degree necessary to
produce an acceptable weld.
l d d h k ll f h k d Quality depends on the skill of the worker and not
used by industry used by industry.
FrictionWelding
Heat is obtained by the friction between the ends of
the two parts to be joined.
One part is rotated at a high speed and other part is
axially aligned and pressed tightly against it.
Friction raises the temperature of both the ends. Then
t ti i t d b tl d th i rotation is stopped abruptly and the pressure is
increased to join increased to join.
Contd
Machine is similar to a centre lathe.
Power requirements 25 kVA to 175 kVA.
Th i l d d th t th d The axial pressure depends on the strength and
hardness of the metals being joined.
Pressure 40 MPa for lowcarbon steels to as high as 450
MPa for alloy steels. MPa for alloy steels.
Contd
Very efficient Very efficient.
Wide variety of metals or combinations of metals can
b d h l l be joined such as aluminium to steel.
Grain size is refined Grain size is refined
Strength is same as base metal.
Only round bars or tubes of the same size, or
connecting bars or tubes to flat surfaces can join. g j
One of the components must be ductile.
F i ti ldi i lid t t ldi Friction welding is a solid state welding.
Contd
Fig frictionweldingprocess
GATE2007
Whichoneofthefollowingisasolidstatejoining
process? process?
(a) Gastungstenarcwelding
(b) Resistancespotwelding
(c) Frictionwelding (c) Frictionwelding
(d) submergedarcwelding
GATE2010(PI)
Two steel bars, each of diameter 10 mm, are coaxially
friction welded, end to end, at an axial pressure of 200
MP d i l d f Th MPa and at a rotational speed of 4000 rpm. The
coefficient of friction between the mating faces of the coefficient of friction between the mating faces of the
rotating bars is 0.50. The torque is assumed to act at the g 5 q
3/4
th
radius of the rotating bar. The power (in KW)
consumed at the interface for welding is
(a) 12.33 (b) 16.44 (c) 18.50 (d) 24.66
IFS2011 IFS2011
Di ithfi th i t i df Discusswithfigurethevariousstepsrequiredfor
frictionwelding mentioningatleasttwomethods frictionwelding,mentioningatleasttwomethods
ofcontrol.
[5marks]
UltrasonicWelding(USW)
USW is a solidstate welding.
Hi h f ( KH ) i li d Highfrequency (10 to 200, KHz) is applied.
Surfaces are held together under light normal g g
pressure.
Temp do not exceed one half of the melting point Temp. do not exceed onehalf of the melting point.
The ultrasonic transducer is same as ultrasonic
machining.
Contd
Restricted to the lap joint
W ld hi i l h f il d i h Weld thin materialssheet, foil, and wireor the
attaching thin sheets to heavier structural members.
Maximum thickness 2.5 mm for aluminum and 1.0
mm for harder metals mm for harder metals.
Number of metals and dissimilar metal combinations
d l b j i d h l i and non metals can be joined such as aluminum to
ceramics or glass.
Equipment is simple and reliable.
Less surface preparation and less energy is needed Less surface preparation and less energy is needed.
Contd
Applications Applications
Joiningthedissimilarmetalsinbimetallics Joiningthedissimilarmetalsinbimetallics
Makingmicrocircuitelectricalcontacts. g
Weldingrefractoryorreactivemetals
Bondingultrathinmetal.
ExplosionWelding
Done at room temperature in air, water or vacuum.
Surface contaminants tend to be blown off the surface.
Typical impact pressures are millions of psi.
Well suited to metals that is prone to brittle joints
when heat welded, such as,
Aluminumon steel
Ti i l Titaniumon steel
Contd
Important factors are,
C i i l l i Critical velocity
Critical angle g
The cladding plate can be supported with tack welded
supports at the edges or the metal inserts supports at the edges, or the metal inserts.
Contd
Typically the detonation velocity should not exceed
% f th i l it i th t l 120% of the sonic velocity in the metal.
Contd
High velocity explosives, 45727620 m/s.
TNT TNT
RDX
PETN PETN
Composition B
Composition C4 Composition C4
Datasheet
Primacord Primacord
Mediumvelocity explosives, 15244572 m/s
Ammonium nitrate
Ammoniumperchlorate
Amatol
Nitroguonidine
Dynamites
diluted PETN
Contd
Advantages Advantages,
Can bond many dissimilar, normally unweldable
metals
The lack of heating preserves metal treatment The lack of heating preserves metal treatment
The process is compact, portable, and easy to contain
Inexpensive
No need for surface preparation No need for surface preparation
Contd
Disadvantages Disadvantages,
The metals must have high enough impact resistance,
d d l ( l %) and ductility (at least 5%)
The cladding plate cannot be too large. The cladding plate cannot be too large.
Noise and blast can require worker protection, vacuum
h b b i d i d/ t chambers, buried in sand/water.
Contd
Typicalapplications: Typicalapplications:
Verylargeplatescanbecladded Verylargeplatescanbecladded.
Joinsdissimilarmetals Joinsdissimilarmetals.
(titaniumtosteel,Altosteel,AltoCuetc ) (titaniumtosteel,Altosteel,AltoCuetc.)
Jointubetotubesheetsoflargeheatexchangers. Jointubetotubesheetsoflargeheatexchangers.
Contd
GATE1992
Inanexplosiveweldingprocess,the..
(maximum/minimum)velocityofimpactisfixed (maximum/minimum)velocityofimpactisfixed
bythevelocityofsoundinthe
(fl / ) l i l (flyer/target)platematerial
(a) Maximum;target ( ) ; g
(b) Minimum;target
( ) M i fl (c) Maximum;flyer
(d) Minimum;flyer ( ) ; y
IES2011S1Contd
MatchListIwithListIIandselectthecorrectanswer
usingthecodegivenbelowthelists: usingthecodegivenbelowthelists:
ListI ListII
A L b C b li df ldi f l A.Laserbeam
welding
1.Canbeappliedforweldingorrefractorymetals
likeniobium,tantalum,molybdenumandtungsten.
B.Electron
beamwelding
2.Asoundandcleanweldedjointiscreateddueto
rubbingoftwopartsagainsteachotherwith
d d d d h adequatespeedandpressureproducingintenseheat
raisingtemperatureabovemeltingpoint.
C.Ultrasonic
welding
3.Cleanheatsourcecreatedmuchawayfromjob,a
narrowspotisheated,workchamberoperatesina
highvacuum.
D.Friction 4.Cleanheatsourceveryquickheating,verysmall
welding
4 y q g y
focalspot,novacuumchamberisrequired.
IES2011FromS1
Codes:
A B C D A B C D A B C D A B C D
(a) 4 3 1 2 (b) 2 3 1 4
(c) 4 1 3 4 (d) 2 1 3 4
IES2009
MatchListIwithListIIandselectthecorrectanswerusingthecodegiven
belowtheLists:
List I List II ListI ListII
(WeldingProcess) (Application)
A. Laserwelding 1. Unitinglargeareasheets
i i ldi i i l B. Frictionwelding 2. Repairinglargeparts
C. Ultrasonicwelding 3. Weldingarodtoaflatsurface
D. Explosivewelding 4. Fabricationofnuclearreactor g
components
5. Weldingverythinmaterials
Code:
(a) A B C D (b) A B C D
5 4 3 2 1 4 2 5
(c) A B C D (d) A B C D
1 3 4 2 5 3 4 1
IAS2002
MatchListI,(Welding)withListII(Application)andselectthecorrect
answerusingthecodesgivenbelowtheLists:
Li I Li II ListI ListII
(Welding) (Application)
A. Explosive 1. Joiningthicksheets A. Explosive 1. Joiningthicksheets
B. Ultrasonic 2. Manufactureofheatexchanges
C. Thermit 3. Joiningthinsheetsorwiresof
similar/dissimilar metals similar/dissimilar metals
D. Projection 4. Joininghydraulicpistonrodsfor
agricultural machinery
5. Joiningrails,pipesandthicksteel
sections
(a) 2 5 1 3 (b) 4 5 1 3
(c) 2 3 5 1 (d) 4 3 5 1
IFS 2009 IFS 2009
T l t f l i i d t i l t l t Two plates of aluminium and stainless steel are to
be welded back to back to create a single plate of be welded back to back to create a single plate of
thickness equal to the sum of the thicknesses of q
the two plates. Suggest the suitable process and
explain it in brief.
[10 marks]
Autogeneous Welding
Autogeneous welding or fusion of the parent
t i l i i t hi ld ith t th material in an inert gas shield without the use
of filler metals.
MicroPlasmaArcWeld(PAW)
Similar to GTAW except the plasma caused by the arc
is constricted by a watercooled orifice
Capable of high welding speeds where size permits
Argon is used as the shielding gas.
DiffusionWelding
It i lid t t ldi hi h d It is a solid state welding process which produces
coalescence of the faying surfaces by the application of
d l t d t t ( b t t 8 % pressure and elevated temperatures (about 50 to 80%
of absolute melting point of the parent materials) for a
ti i f l f i t t f h time ranging froma couple of minutes to a few hours.
Produces high quality bonds with good strength with
little or no distortion.
Can join very dissimilar materials. Ca jo ve y d ss a ate a s.
A solid filler metal may or may not be inserted.
M t i l ld d f i ft d k t i d t Materials welded for aircraft and rocket industry:
Boron, Titanium, Aluminium, Ceramic, Composite,
G hit M i t Graphite, Magnesium etc.
GATE 2008(PI)
Which pair among the following solid state welding
processes uses heat froman external source?
P Diffusion welding; Q Friction welding
l ld ld R Ultrasonic welding S Forge welding
( ) P d R (b) R d S (a) P and R (b) R and S
( ) Q d S (d) P d S (c) Q and S (d) P and S
IAS2001
MatchListI(Weldingprocesses)withListII(Features)and
selectthecorrectanswerusingthecodesgivenbelowtheLists:
ListI ListII
A Ultrasonicwelding 1 Gasheatedtoionizedcondition A. Ultrasonicwelding 1. Gasheatedtoionizedcondition
forconductionofelectriccurrent
B. Electronbeamwelding2. Highfrequencyandhigh
b intensityvibrations
C. Plasmaarcwelding 3. Concentratedstreamofhigh
energyelectrons energyelectrons
4. Exothermalchemicalreaction
Codes:A B C A B C
(a) 1 2 4 (b) 4 3 1
(c) 2 1 4 (d) 2 3 1
JWM2010
MatchListIwithListIIandselectthecorrectanswer
usingthecodegivenbelowthelists: g g
ListI ListII
A Atomic 1 Twopiecesarebroughttogetherand A.Atomic
hydrogenwelding
1.Twopiecesarebroughttogetherand
powersupplyisswitchedon
B.Plasmaarc
welding
2.Nuggetisformedattheinterfaceof
twoplates welding twoplates
C.Spotwelding 3.Gasisionized
d
D.Flashwelding 4.Inertgasshieldedarcwelding
(a) 4 3 2 1 (b) 1 3 2 4 (a) 4 3 2 1 (b) 1 3 2 4
(c) 4 2 3 1 (d) 1 2 3 4
IES 2011 C ti l IES2011Conventional
Discuss the process capabilities and applications of Gas
M t l A W ldi G t t A W ldi d Metal Arc Welding, Gas tungsten Arc Welding, and
Diffusion Bonding processes Diffusion Bonding processes.
[15Marks] [15Marks]
BrazingandSoldering BrazingandSoldering
BrazingandSoldering
Brazing is the joining of metals through the use of heat
and a filler metal whose melting temperature is above
b b l h l f h l b 450C; but below the melting point of the metals being
joined.
C i ith ldi d th b i Comparison with welding and the brazing process
1. The composition of the brazing alloy is significantly
different from that of the base metal different from that of the base metal.
2. The strength of the brazing alloy is substantially lower
than that of the base metal than that of the base metal.
3. The melting point of the brazing alloy is lower than that
of the base metal so the base metal is not melted of the base metal, so the base metal is not melted.
4. Capillary action or capillary attraction draws the
molten filler metal into the joint, even against the flow of j , g
gravity.
B i h l di i Brazingprocesshasseveraldistinct
advantages: advantages:
1 All metals can be joined 1. All metals can be joined.
2. Suited for dissimilar metals. 2. Suited for dissimilar metals.
3. Quick and economical. 3. Qu c a d eco o ca .
4. Less defects. 4
Contd
Corrosion prone
Brazingmetalsaretypicallyalloyssuchas,
B i b (6 %C %Z ) Brazingbrass(60%Cu,40%Zn)
Manganesebronze g
Nickelsilver
C ili Coppersilicon
Silveralloys(with/withoutphosphorous) y ( / p p )
Copperphosphorous
Contd
Extremely clean surface needed.
Fluxes used are combinations of borax, boric acid,
chlorides, fluorides, tetraborates and other wetting
agents.
Contd
A popular composition is 75% borax and 25% boric p p p
acid.
Sodiumcyanide is used in brazing tungsten to copper.
Base materials not melted.
GATE2005
Thestrengthofabrazedjoint
( ) D i hi i b h (a) Decreaseswithincreaseingapbetweenthetwo
joiningsurfaces
(b) Increaseswithincreaseingapbetweenthetwo
joiningsurfaces joiningsurfaces
(c) Decreasesuptocertaingapbetweenthetwo
j i i f b d hi hi i joiningsurfacesbeyondwhichitincreases
(d) Increasesuptocertaingapbetweenthetwo ( ) p g p
joiningsurfacesbeyondwhichitdecreases
IES2006
Whichoneofthefollowingisnotafusionwelding
? process?
(a) Gaswelding ( ) g
(b) Arcwelding
( ) B i (c) Brazing
(d) Resistancewelding ( ) g
ISRO2010
Which is not correct statement about the function of Which is not correct statement about the function of
flux in brazing
(a) To avoid thermal distortion and cracking
(b) To dissolve surface oxide coatings which have formed (b) To dissolve surface oxide coatings which have formed
prior to brazing
( ) d f f d h b (c) To prevent oxides from forming during the brazing
operation on both the base metal and the brazing p g
material
(d) To facilitate the wetting process by reducing the (d) To facilitate the wetting process by reducing the
viscosity of the melt
BrazeWelding
Capillary action is not required.
Edge preparation needed.
Can join cast iron.
Contd
Done with an oxyacetylene torch.
Fig.BrazeWelding
Soldering
By definition, soldering is a brazing type of operation
where the filler metal has a melting temperature
below450C.
Strength of the filler metal is low.
Soldering is used for a neat leakproof joint or a low
i t l t i l j i t resistance electrical joint.
Not suitable for high temp application Not suitable for hightemp. application.
Contd
Effective soldering generally involves six important
steps:
(1) Design of an acceptable solder joint, (1) Design of an acceptable solder joint,
(2) Selection of the correct solder for the job,
(3) Selection of the proper type of flux,
(4) Cleaning the surfaces to be joined, (4) Cleaning the surfaces to be joined,
(5) Application of flux, solder, and sufficient heat to
ll h l ld fill h j i b ill allow the molten solder to fill the joint by capillary
action and solidify, and
(6) Removal of the flux residue, if necessary.
ld l SolderMetals
Most solders are alloys of lead and tin.
Three commonly used alloys contain 60, 50, and 40%
tin and all melt below 240C.
Contd
SolderFlux
Ammoniumchloride or rosin for soldering tin
Hydrochloric acid and zinc chloride for soldering
l i d i galvanized iron
S fl i d h ld b d ft Some fluxes are corrosive and should be removed after
use use
Silver solders uses for higher temperature service Silver solders uses for highertemperature service,
Electrical and Electronic purpose.
Difficulties with Grey Cast Iron DifficultieswithGreyCastIron
S ld i d b i diffi lt f t I d Soldering and brazing are difficult of grey cast Iron due
to surface contamination with graphite having a very low to surface contamination with graphite having a very low
surface energy. gy
IES1994
MatchList IwithList IIandselectthecorrect
answerusingthecodesgivenbelowtheLists: g g
List I(Filler) List II(Joiningprocess)
A. Cu,Zn,Agalloy 1. Brazewelding. A. Cu,Zn,Agalloy 1. Brazewelding.
B. Cu,Sn,alloy 2. Brazing
C Pb Sb alloy 3 Soldering C. Pb,Sb,alloy 3. Soldering
D.Iron oxideandaluminium powder4. TIGweldingof
aluminium aluminium
(a) 2 1 3 (b) 1 2 4 (a) 2 1 3 (b) 1 2 4
(c) 2 1 3 4 (d) 2 3 4
IAS1996
MatchListIwithListIIandselectthecorrectanswerusing
thecodesgivenbelowthelists g
ListI ListII
(Fillerrodmaterial) (Joiningprocess)
A. Mildsteel 1. MIGwelding
B. Bronze 2. Soldering
C. Brass 3. Brazing
D. Leadandtinalloy 4. Thermit welding
B ldi 5. Brazewelding
(a) 1 5 3 2 (b) 4 3 2 5 (a) 1 5 3 2 (b) 4 3 2 5
(c) 4 3 5 2 (d) 1 3 5 4
Weldingdesignanddefect
Welding Problem Causes
Cracking of weld metal High joint rigidity Cracking of weld metal High joint rigidity
Cracking of base metal Excessive stresses
Spatter Arc blow Spatter Arc blow
Distortion Poor joint selection
Slag inclusion Improper cleaning in multi- Slag inclusion Improper cleaning in multi
pass welding
Porosity Excessive H O N in the Porosity Excessive H
2
, O
2
, N
2
, in the
welding atmosphere or Damp
electrodes electrodes
LamellarTearing inclusionssuchasMn FeandS
inthebasemetaland/or inthebasemetaland/or
residualstress
IES2004
MatchListI(Weldingproblems)withListII(Causes)andselect
thecorrectanswerusingthecodesgivenbelowtheLists:
ListI ListII
A. Crackingofweldmetal 1. Excessivestresses
B C ki fb t l Hi hj i t i idit B. Crackingofbasemetal 2. Highjointrigidity
C. Porosity 3. Failuretoremoveslag
frompreviousdeposit p p
D. Inclusions 4. Oxidation
5. ExcessiveH
2
,O
2
,N
2
,in
h ldi h theweldingatmosphere
(a) 2 1 5 3 (b) 3 4 2 1 (a) 2 1 5 3 (b) 3 4 2 1
(c) 2 4 5 3 (d) 3 1 4 2
IES2003,ISRO2011
MatchListI(WeldingDefects)withListII(Causes)and
selectthecorrectanswerusingthecodesgivenbelowthe g g
Lists:
ListI ListII
( ldi f ) ( ) (WeldingDefects) (Causes)
A. Spatter 1. Dampelectrodes
B Di i A bl B. Distortion 2. Arcblow
C. Slaginclusion 3. Impropercleaningin
multipasswelding multipasswelding
D. Porosity 4. Poorjointselection
Codes:A B C D A B C D Codes:A B C D A B C D
(a) 4 2 3 1 (b) 4 2 1 3
(c) 2 4 1 3 (d) 2 4 3 1 (c) 2 4 1 3 (d) 2 4 3 1
Cracks
Cracks may be of micro or macro size and may appear in Cracks may be of micro or macro size and may appear in
the weld metal or base metal or base metal and weld
t l b d metal boundary.
Different categories of cracks are longitudinal cracks, g g
transverse cracks or radiating/star cracks and cracks in
the weld crater. the weld crater.
Cracks occur when localized stresses exceed the ultimate
t il t th f t i l tensile strength of material.
These stresses are developed due to shrinkage during p g g
solidification of weld metal.
Cracks may be developed due to poor ductility of base
metal, high sulphur and carbon contents, high arc travel
speeds i.e. fast cooling rates, too concave or convex weld p g
bead and high hydrogen contents in the weld metal.
Fig VariousTypesofCracksinWelds Fig.VariousTypesofCracksinWelds
HAZ Cracking HAZCracking
Crackinginheataffectedzonemaybecausedby: Crackinginheataffectedzonemaybecausedby:
(i)Hydrogeninweldingatmosphere (i)Hydrogeninweldingatmosphere
(ii)hotcracking (ii)hotcracking
(iii)lowductility (iii)lowductility
(iv)highresidualstresses (iv)highresidualstresses
(v)brittlephaseinthemicrostructure ( ) p
Hydrogen Induced Cracking HydrogenInducedCracking
Duetothepresenceofmoisture,grease,rustetc., ue to t e p ese ce o o stu e, g ease, ust etc.,
hydrogenmayentertheweldpoolandgetdissolvedin
theweldmetal theweldmetal.
DuringcoolinghydrogendiffusestotheHAZ.
Crackingmaydevelopduetoresidualstressesassistedby
hydrogencoalesence. hydrogencoalesence.
Thefactorsthatdeterminetheprobabilityofhydrogen
i d d b ittl t d ki f ld inducedembrittlementandcrackingofweldare:
(a)Hydrogencontent ( ) y g
(b)fracturetoughnessofweldandHAZ
( ) hi h h j i i d l f (c)stresstowhichthejointisexposedasaresultof
theweldthermalcycle.
Residualstress
The residual stresses result from the restrained expansion
and contraction that occur during localized heating and
cooling in the region of weld deposit.
The magnitude of residual stresses depends on the weldment The magnitude of residual stresses depends on the weldment
design, support and clamping of the components being
welded their materials welding process used part welded, their materials, welding process used, part
dimensions, welding sequence, post weld treatment, size of
the deposited weld beads etc the deposited weld beads, etc.
Residual stresses should not have a harmful effect on the
h f f ld d f i strength performance of weldments, reduces fatigue
strength, May cause distortion. This residual stress may
l h k f b l l d result in the cracking of a brittle material and is not
important as far as a ductile material.
Porosity
P i l h h d i h Porosity results when the gases are entrapped in the
solidifying weld metal.
These gases are generated from the flux or coating
constituents of the electrode or shielding gases used constituents of the electrode or shielding gases used
during welding or from absorbed moisture in the
coating coating.
Porosity can also be controlled if excessively high
welding currents, faster welding speeds and long arc
lengths are avoided flux and coated electrodes are lengths are avoided flux and coated electrodes are
properly baked.
Fig.DifferentFormsofPorosities Fig.DifferentFormsofPorosities
Solid Inclusion SolidInclusion
Solid inclusions may be in the form of slag or any other
nonmetallic material entrapped in the weld metal as
these may not able to float on the surface of the y
solidifying weld metal.
During arc welding flux either in the form of granules or During arc welding flux either in the form of granules or
coating after melting, reacts with the molten weld metal
i id d h i i i i h f f l removing oxides and other impurities in the form of slag
and it floats on the surface of weld metal due to its low
density.
Slag inclusion can be prevented if proper groove is Slag inclusion can be prevented if proper groove is
selected, all the slag from the previously deposited bead
is removed too high or too low welding currents and is removed, too high or too low welding currents and
long arcs are avoided.
Fig SlagInclusioninWeldments Fig.SlagInclusioninWeldments
Lack of Fusion LackofFusion
Lack of fusion is the failure to fuse together either the ac o us o s t e a u e to use toget e e t e t e
base metal and weld metal or subsequent beads in
multipass welding because of failure to raise the multipass welding because of failure to raise the
temperature of base metal or previously deposited weld
l t lti i t d i ldi layer to melting point during welding.
Lack of fusion can be avoided by properly cleaning of y p p y g
surfaces to be welded, selecting proper current, proper
welding technique and correct size of electrode. welding technique and correct size of electrode.
IncompletePenetration
I l i h h ld d h i Incomplete penetration means that the weld depth is not
upto the desired level or root faces have not reached to
melting point in a groove joint.
If either low currents or larger arc lengths or large root If either low currents or larger arc lengths or large root
face or small root gap or too narrow groove angles are
used then it results into poor penetration used then it results into poor penetration.
ImperfectShape,Distortions p p ,
Imperfect shape means the variation from the desired shape and
size of the weld bead. size of the weld bead.
During undercutting a notch is formed either on one side of the
weld bead or both sides in which stresses tend to concentrate and
it can result in the early failure of the joint. Main reasons for
undercutting are the excessive welding currents, long arc lengths
d f l d and fast travel speeds.
Underfilling may be due to low currents, fast travel speeds and
ll i f l d O l d l small size of electrodes. Overlap may occur due to low currents,
longer arc lengths and slower welding speeds.
E i i f t i f d if hi h t l lt Excessive reinforcement is formed if high currents, low voltages,
slow travel speeds and large size electrodes are used. Excessive
root penetration and sag occur if excessive high currents and slow root penetration and sag occur if excessive high currents and slow
travel speeds are used for relatively thinner members.
Distortion is caused because of shrinkage occurring due to large Distortion is caused because of shrinkage occurring due to large
heat input during welding.
l IES2011Conventional
E f d f dd id l i Enumeratefourdefectscausedduetoresidualstressesin
weldedjoints.
[2Marks]
Ans.
1. Distortion
2. Crackinginthebasemetal
3. LamellarTearing
4. Reductionoffatiguestrength
IES2004
Consider the following statements:
The magnitude of residual stresses in welding The magnitude of residual stresses in welding
depends upon
D i f ld t 1. Designofweldment
2. Supportandclampingofcomponents
3. weldingprocessused
4. Amountofmetalmelted/deposited 4 p
(a) 1 2and4 (b)1 2and3 (a) 1,2and4 (b)1,2and3
(c) 1and3 (d)2and3
GATE2003
Matchthefollowing
Workmaterial Typeofjoining yp j g
P.Aluminium 1. SubmergedArcWelding
Q.DieSteel 2. Soldering
R.CopperWire 3. Thermit Welding
S.Titaniumsheet 4. AtomicHydrogenWelding
5. GasTungstenArcWelding
6. LaserBeamWelding
7. Brazing
(a)P 2 Q 5 R 1 S 3
(b)P 6 Q 3 R 4 S 4
(c)P 4 Q 1 R 6 S 2
(d) (d)P 5 Q 4 R 2 S 6
IES2004
Th i f h h ff d (HAZ) illi i h Thesizeoftheheataffectedzone(HAZ)willincreasewith
1. Increasedstartingtemperature g p
2. Increasedweldingspeed
3 Increasedthermalconductivityofthebasemetal 3. Increasedthermalconductivityofthebasemetal
4. Increaseinbasemetalthickness
(a) 1,2and3 (b) 1and3 (a) 1,2and3 (b) 1and3
(c) 1and4 (d) 2and3
IES1992
Weldspatteroccursduetoanyofthefollowing
t except
(a) Highweldingcurrent ( ) g g
(b) Toosmallanelectrode
( ) A (c) Arc
(d) Wrongpolarity ( ) g p y
JWM2010
Assertion (A) : Spatter is one of the welding defects Assertion (A) : Spatter is one of the welding defects.
Reason (R) : In submerged arc welding process,
there is no spatter of molten metal.
(b) h d d d ll b h (b) Both A and R are individually true but R is not the
(d) A i f l b t R i t (d) A is false but R is true
IES1998
Anarcweldedjointisshownintheabovefigure.
Th tl b ll d 'B'i th fi i k Thepartlabelled 'B'inthefigureisknownas
(a) Weldpreparation ( ) p p
(b) Penetration
( ) R i f (c) Reinforcement
(d) Slag ( ) g
IES2004
Assertion (A): A sound welded joint should not only
be strong enough but should also exhibits a good be strong enough but should also exhibits a good
amount of ductility
Reason (R): Welding process is used for fabricating Reason (R): Welding process is used for fabricating
mild steel components only
explanation of A
IAS2003
Toolmaterialnotsuitedtoresistanceweldingis
(a) Aluminiumoxide (b) Stellite ( ) ( )
(c) Highspeedsteel (d) Masonite
GATE1996
Preheatingbeforeweldingisdoneto
( ) M k h l f (a) Makethesteelsofter
(b) Bumawayoil,grease,etc,fromtheplatesurface ( ) y , g , , p
(c) Preventcoldcracks
(d) P l di i (d) Preventplatedistortion
IES2011
Coldcrackinginsteelweldments dependson
1 Carbonequivalent 1.Carbonequivalent
2.Heatinput
3.Effectivethickness
3 Hydrogencontentinweldpool 3.Hydrogencontentinweldpool
(a)1,2and3only
(b)1,2and4only
(c)2 3and4only (c)2,3and4only
(d)1,2,3and4
GATE2001
Two plates of the same metal having equal
thickness are to be butt welded with electric arc thickness are to be butt welded with electric arc.
When the plate thickness changes, welding is
hi d b achieved by
(a) Adjusting the current ( ) j g
(b) Adjusting the duration of current
( ) Ch i h l d i (c) Changing the electrode size
(d) Changing the electrode coating ( ) g g g
IES 2012
B i l ld i l b i d d Brittle welds are mainly obtained due to
(a) Wrong electrode, faulty preheating and metal ( ) g , y p g
hardened by air
(b) Faulty welds faulty sequence and rigid joints (b) Faulty welds, faulty sequence and rigid joints
(c) Wrong speed, current improperly adjusted and faulty
preparation
(d) Uneven heat improper sequence and deposited (d) Uneven heat, improper sequence and deposited
metal shrinks
IES 2012
Whi h f h f ll i i d i hH Aff d WhichofthefollowingareassociatedwithHeatAffected
Zone?
1.Coldcracking
2 Notchtoughness 2.Notchtoughness
3.Hydrogenembrittlement
4.Stresscorrosioncracking
( ) d l (a)1,2and3only
(b)1,3and4only y
(c)2,3and4only
(d) d (d)1,2,3and4
IES 2012
St t t (I) H d i d d ki i th h t Statement (I): Hydrogen induced cracking occurs in the heat
effected zone adjacent to fusion zone and classified as solid
state cracking state cracking
Statement (II):Hydrogen from burning of flux coating
penetrates martensitic micro cracks preventing healing as penetrates martensitic micro cracks preventing healing as
well as enlarging them.
( ) B th St t t (I) d St t t (II) i di id ll (a) Both Statement (I) and Statement (II) are individually
true and Statement (II) is the correct explanation of
Statement (I) Statement (I)
(b) Both Statement (I) and Statement (II) are individually
t b t St t t (II) i t th t l ti f true but Statement (II) is not the correct explanation of
Statement (I)
( ) S (I) i b S (II) i f l (c) Statement (I) is true but Statement (II) is false
(d) Statement (I) is false but Statement (II) is true

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