Академический Документы
Профессиональный Документы
Культура Документы
BySKMondal
WeldingDefinition
y Welding is a process by which two materials, usually
Requirementforahighqualitywelding
1. A source of satisfactory heat and/or pressure,
2. A means of protecting or cleaning the metal, and
3 Caution to avoid,
3.
avoid or compensate for,
for harmful
metallurgical effects.
Classificationofweldingprocesses
Oxy fuel gas welding (OFW)
Arc welding (Aw)
Resistance welding
Solid state welding (friction welding, ultrasonic welding,
y Unique process
Thermit welding
Laser beam welding
Electroslag welding
Flash welding
Induction welding
Electron beam welding
Weldability /FabricationProcesses
y The weldability of a material will depend on the
10/9/2011
CaseofAluminium
CaseofCastIron
y
y
y
y
CaseofStainlessSteel
CaseofStainlessSteel
welding.
y The electric arc is also preferred for welding stainless
IES2010
Assertion (A): It is generally difficult to weld
Aluminum parts by normal arc welding process.
Reason (R): Hard and brittle Aluminumoxide film
is formed at the welded joints.
(a) Both A and R are individually true and R is the
correct explanation of A
(b) Both A and R are individually true but R is NOT the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
y Welding process:
IES2006
Assertion(A):Aluminium haspoorweldability.
Reason(R):Aluminium hashighthermal
conductivityandhighaffinitytooxygen.
(a) BothAandRareindividuallytrueandRisthe
correctexplanationofA
(b) BothAandRareindividuallytruebutRisnot the
correctexplanationofA
(c) AistruebutRisfalse
(d) AisfalsebutRistrue
10/9/2011
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
(b) DC reverse
(c) AC potential
(d) Reverse polarity of phase of AC potential
IES2006
Fabricationweldability testisusedtodetermine
(a) Mechanicalpropertiesrequiredforsatisfactory
performanceofweldedjoint
(b) Susceptibilityofweldedjointforcracking
(c) Suitabilityforjointdesign
(d) Appropriatemachiningprocess
IES2010
Weldability of ferritic stainless steel used in
automotive exhaust system is improved by
selecting stainless steel electrode having low
content of
(a) Carbon
(b) Nitrogen
(c) Chromium
(d) Carbon and Nitrogen
IES2011
Considerthefollowingstatements.
Castironisdifficulttoweld,becauseof
1.Lowductility
2.Poorfusion
3.Tendencytocrackoncooling
Whichofthesestatementsarecorrect?
(a)1,2and3
(b)1and2only
(c)2and3only
(d)1and3only
IES1999
Thecorrectsequenceofthegivenmaterialsin
ascendingorderoftheirweldability is
(a) MS,copper,castiron,aluminium
(b) Castiron,MS,aluminium
Castiron MS aluminium copper
(c) Copper,castiron,MS,aluminium
(d) Aluminium,copper,castiron,MS
IES2010
Consider the following statements regarding
welded joints:
1. It is a permanent type of joint.
2. It is reliable and economical for pressure vessel
construction.
construction
3. It is free from fabricational residual stresses.
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
(c) 1, 2, 3, 4 and 5
(d) 1, 2 and 5 only
10/9/2011
GasFlameProcesses:
Welding,CuttingandStraightening
y Oxyfuel gas Welding (OFW): Heat source is the
y Combustionofoxygenandacetylene(C2H2)ina
weldingtorchproducesatemp.inatwostagereaction.
y Inthefirststage
C2 H2 + O2 2CO + H2
+Heat
Thisreactionoccursnearthetipofthetorch.
y InthesecondstagecombustionoftheCOandH2 and
occursjustbeyondthefirstcombustionzone.
2CO+O2 2CO2+Heat
1
H2 +O
2 2 H2O+Heat
Oxygenforsecondaryreactionsisobtainedfromthe
atmosphere.
OxyacetylenegasweldingOxidisingflame
Oxyacetylenegasweldingneutralflame
10/9/2011
flame.
y The excess fuel decomposes to carbon and hydrogen,
Metal
MS
High carbon steel
Grey cast iron
Alloy steel
Aluminium
Brass
Copper, Bronze
Nickel alloys
Lead
Flame
N
R
N, slightly oxidizing
N
Slightly carburizing
Slightly oxidizing
N, slightly oxidizing
Slightly carburizing
N
OxyacetylenegasweldingCarburizingflame
IES2009Conventional
Explain the three types of oxyacetylene flames.
Indicate with the help of sketches the various
zones,
respective
temperature
ranges
and
Uses,Advantages,andLimitations
y OFW is fusion welding.
y No pressure is involved.
Diagram
10/9/2011
PressureGasWelding
y Pressure gas welding (PGW) or Oxyacetylene
GATE1994
The ratio of
acetylene to oxygen
is
approximately. for a neutral flames used in
gas welding.
(a)
( ) 1:1
(b) 1 : 2
(c) 1 : 3
(d) 1.5 : 1
Oxyacetyleneweldingequipment
y Oxygen is stored in a cylinder at a pressure ranging
IES2010
The ratio between Oxygen and Acetylene
gases for neutral flame in gas welding is
(a) 2 : 1
(b) 1 : 2
((c)) 1 : 1
((d)) 4 : 1
GATE2003
InOxyacetylenegaswelding,temperatureatthe
innerconeoftheflameisaround
(a) 3500C
(b) 3200
3200C
C
(c) 2900C
(d) 2550C
10/9/2011
IES2010
Assertion (A): Oxidizing flame is used in gas
welding to join medium carbon steels having high
melting point.
Reason (R): In gas welding, oxidizing flame
produces the maximum temperature compared to
neutral and reducing flame.
(a) Both A and R are individually true and R is the
correct explanation of A
(b) Both A and R are individually true but R is NOT the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
IES2009
By which one of the following methods gray cast
iron is usually welded?
(a) TIGwelding
(b) MIGwelding
(c) Gaswelding
(d) Arcwelding
IAS1994
In gas welding of mild steel using an oxy
acetylene flame. the total amount of acetylene
consumed was 10 litre. The oxygen consumption
from the cylinder is
(a) 5litre
(b) 10litre
(c) 15litre
(d) 20litre
GATE2002
The temperature of a carburising flame in gas
welding is that of a neutral or an oxidising flame.
(a) Lowerthan
(b) Higherthan
(c) Equalto
(d) Unrelatedto
IES1998
In oxyacetylene gas welding, for complete
combustion, the volume of oxygen required per
unit of acetylene is
((a)) 1
(b) 1.5
(c) 2
(d) 2.5
IAS1995
Assertion (A): If neutral flame is used in oxy
acetylene welding, both oxygen and acetylene
cylinders of same capacity will be emptied at the same
time.
Reason (R): Neutral flame uses equal amounts of
oxygen and
d acetylene.
l
(a) BothAandRareindividuallytrueandRisthecorrect
explanationofA
(b) BothAandRareindividuallytruebutRisnot the
correctexplanationofA
(c) AistruebutRisfalse
(d) AisfalsebutRistrue
10/9/2011
OxygenTorchCutting(GasCutting)
y Iron and steel oxidize (burn) when heated to a
Fig differencesintorchtipsforgasweldingandgascutting
Contd
Contd
oxygen consumed.
y At kindling temperature (about 870oC), iron form iron
oxide.
y Reaction:
Contd
required
y Due to unoxidized metal blown away the actual
requirement is much less.
y Torch tip
p held verticallyy or slightly
g y inclined in the
direction of travel.
y Torch position is about 1.5 to 3 mm vertical from plate.
Contd
10/9/2011
Fig.Recommendedtorchpositionforcuttingthinsteel
Contd
Application
y Useful only for materials which readily get oxidized
Difficulties
y Metal
Contd
10/9/2011
IES1992
The edge of a steel plate cut by oxygen cutting will
get hardened when the carbon content is
(a) Less than 0.1 percent
(b) Less than 0.3
0 3 percent
(c) More than 0.3 percent
(d) Anywhere between 0.1 to 1.0 percent
IES2007
Considerthefollowingstatementsinrespectofoxy
acetylenewelding:
1. Thejointisnotheatedtoastateoffusion.
2. Nopressureisused.
3.
3 Oxygenisstoredinsteelcylinderatapressureof14
MPa.
4. Whenthereisanexcessofacetyleneused,thereisa
decidedchangeintheappearance
offlame.
Whichofthestatementsgivenabovearecorrect?
(a)1,2and3
(b) 2,3and4
(c) 1,3and4
(d) 1,2and4
IES2001
Oxyacetylenereducingflameisusedwhile
carryingouttheweldingon
(a) Mildsteel
(b) Highcarbonsteel
(c) Greycastiron
(d) Alloysteels
IES1992
Thick steel plate cut with oxygen normally shows
signs of cracking. This tendency for cracking can
be minimised by
((a)) Slow speed
p
g
cutting
(b) Cutting in two or more stages
(c) Preheating the plate
(d) Using oxyacetylene flame
IES2005
Considerthefollowingstatements:
Ingaswelding,thetorchshouldbeheldatanangleof
30 to45 fromthehorizontalplane.
2. Ingaswelding,theSizeofthetorchdependsuponthe
thicknessofmetaltobeformed.
thi k
f t lt b f
d
3. Dragingascuttingisthetimedifferencebetween
heatingoftheplateandstartingtheoxygengasfor
cutting.
1.
Whichofthestatementsgivenabovearecorrect?
(a) 1,2and3 (b) 1and2
(c) 2and3
(d) 1and3
10
10/9/2011
PlasmaCutting
y Uses ionized gas jet (plasma) to cut materials resistant to
oxyfuel cutting,
y High velocity electrons generated by the arc impact gas
ElectricArcWelding
ElectricArcWelding
Fig.Basiccircuitforarcwelding
PrincipleofArc
polarity (RPDC).
y SPDC conditions are preferred.
y DC arcwelding
ldi maintain
i t i a stable
t bl arc and
d preferred
f
d for
f
Contd
11
10/9/2011
Threemodesofmetaltransferduringarcwelding
electrodes
y Baremetal wire used in automatic or semiautomatic
machines.
y Non consumable electrodes (e.g tungsten) is not
consumed
d by
b the
h arc and
d a separate metall wire is used
d
as filler.
y There are three modes of metal transfer (globular,
spray and shortcircuit).
MajorForcestakepartinMetalTransfer
(i)gravityforce
(ii)Surfacetension
g
(iii)electromagneticinteraction
(iv)hydrodynamicactionofplasma
JWM2010
Assertion (A) : Bead is the metal added during
single pass of welding.
Reason (R) : Bead material is same as base metal.
(a) Both A and R are individuallyy true and R is the
correct explanation of A
(b) Both A and R are individually true but R is NOT the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
GATE1993
Ind.c.welding,thestraightpolarity(electrode
negative)resultsin
(a) Lowerpenetration
(b) Lowerdepositionrate
(c) Lessheatingofworkpiece
(d) Smallerweldpod
12
10/9/2011
Arcweldingequipments
1. Droopers: Constant current welding machines
Good for manual welding
2. Constant voltage machines
Good for automatic welding
Fig.Machinewithdifferentsettings
Contd
Formula
Fig.Characteristiccurveofaconstantvoltagearcweldingmachine
V
I
+
=1
OCV SCC
varying from 12 to 30 V.
y To initiate a weld,
ld the
h operator strike
k the
h electrode
l
d and
d
start arc.
IES2010
In arc welding, the arc length should be equal to
(a) 4.5 times the rod diameter
(b) 3 times the rod diameter
(c) 1.5 times the rod diameter
(d) Rod diameter
13
10/9/2011
IES2005
Considerthefollowingstatements:
Inarcwelding,65%to75%heatisgeneratedatthe
anode.
2. Dutycycleincaseofarcweldingisthecycleof
completeweldingofworkpiecefromthe
beginning.
3. ArcblowismorecommonwithDCwelding.
1.
Whichofthestatementsgivenaboveare
correct?
(a) 1,2and3 (b) 1and2
(c) 2and3 (d) 1and3
IES2001
Inarcwelding,d.c.reversepolarityisusedtobear
greateradvantagein
(a) Overheadwelding
(b) Flatweldingoflapjoints
(c) Edgewelding
(d) Flatweldingofbuttjoints
IAS1999
Opencircuit voltage of 60 V and current of 160A
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
(a) 60 V and 80 A
(b) 120 V and 160 A
(c) 60 V and 40 A
(d) 120 V and 40 A
IES2001
Inmanualarcwelding,theequipmentshould
havedroopingcharacteristicsinordertomaintain
(a) Voltageconstantwhenarclengthchanges
(b) Currentconstantwhenarclengthchanges
(c) Temperatureintheareconstant
(d) Weldpoolredhot
IES1998
The voltagecurrent characteristics of a dc
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
maximum arc power will be
(a) 0 V and 150 A
(b) 40 V and 300 A
(c) 40 V and 150 A
(d) 80 V and 300 A
IAS1998
AssumingastraightlineVIcharacteristicsfora
dcweldinggenerator,shortcircuitcurrentas400A
andopencircuitvoltageas400whichoneofthe
followingisthecorrectvoltageandcurrentsetting
formaximumarcpower?
(a) 400Aand100V
(b) 200Aand200V
(c) 400Aand50V
(d) 200Aand50V
14
10/9/2011
DutyCycle
y The percentage of time in a 5 min period that a
I
T
Ia
Requireddutycycle,Ta =
Where,T=rateddutycycle
I=ratedcurrentattherateddutycycle
Io =Maximumcurrentattherateddutycycle
Contd
Electrode
1. NonconsumableElectrodes
2. ConsumableElectrodes
NonconsumableElectrodes
Madeofcarbon,GraphiteorTungsten.
CarbonandGraphiteareusedforD.C.
Electrodeisnotconsumed,thearclengthremains
constant,arcisstableandeasytomaintain.
ConsumableElectrodes
Provides filler materials.
Same composition.
This requires that the electrode be moved toward or
away from the work to maintain the arc and
satisfactory welding conditions.
Contd
Contd
Electrodecoatingcharacteristic
1. Provide a protective atmosphere.
2. Stabilize the arc.
3. Provide a protective slag coating to accumulate
4.
5.
6.
7.
8.
15
10/9/2011
Electrodecoatings
GATE1994
Theelectrodesusedinarcweldingarecoated.
Thiscoatingisnotexpectedto
(a) Provideprotectiveatmospheretoweld
(b) Stabilizetheare
(c) Addalloyingelements
(d) Preventselectrodefromcontamination
Contd
3.DeoxidizingIngredients. Cellulose,Calcium
carbonate,dolo mite,starch,dextrin,woodflour,
graphite,aluminium,ferromanganese.
4.BindingMaterials Sodiumsilicate,potassiumsilicate,
asbestos.
5.AlloyingConstituentstoImproveStrengthofWeld
6.TiO2 andpotassiumcompoundsincreasethemelting
rateofthebasemetalforbetterpenetration.
7.Ironpowderprovideshigherdepositionrate.
Contd
Contd
Binders
filler wire.
with sodium.
16
10/9/2011
IES2007
The coating material of an arc welding electrode
contains which of the following?
1. Deoxidising agent
2.
2 Arc stabilizing agent
3. Slag forming agent
Select the correct answer using the code given below:
(a) 1, 2 and 3
(b) 1 and 2 only
(c) 2 and 3 only
(d) 1 and 3 only
IES2002
MatchListIwithListIIandselectthecorrectanswer:
ListI(Ingredients)
ListII(Welding
functions)
A. Silica
1.
Arc stabilizer
B. Potassium
i
oxalate
l
2.
Deoxidizer
idi
C. Ferrosilicon
3.
Fluxingagent
D. Cellulose
4.
Gasformingmaterial
Codes:A
B
C
D
A
B
C
D
(a) 3
4
2
1
(b) 2
1
3
4
(c) 3
1
2
4
(d) 2
4
3
1
WeldingPositions
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
i l than
h sodium.
di
(a) Both A and R are individually true and R is the correct
explanation of A
(b) Both A and R are individually true but R is not the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
WeldingFlux
Availableinthreeforms
y Granular
y Electrodewirecoating
y Electrodecore
WeldingCurrent
y Weldingcurrentdependsupon:thethicknessofthe
Fig.Thepositionofelectrodeforhorizontalwelding
weldedmetal,typeofjoint,weldingspeed,positionof
theweld,thethicknessandtypeofthecoatingonthe
electrodeanditsworkinglength.
y Weldingcurrent,I=k.d,amperes;disdia.(mm)
Fig.Positioningofelectrodeforweldinginverticallyupwardposition
17
10/9/2011
WeldingVoltage
y Thearcvoltagedependsonlyuponthearclength
V=k1 +k2l
Volts
ArcLength
y For good welds, a short arc length is necessary,
because:
1. Heat is concentrated.
2. More stable
3. More protective atmosphere.
TheminimumArcvoltageisgivenby
Vmin =(20+0.04l)Volt
Contd
Fig.ArcPowerVsArcLength
Arclengthshouldbeequaltothediameteroftheelectrodesize
GATE2002,Conventional
The arc lengthvoltage characteristic of a DC arc is given
by the equation: V = 24 + 4L, where V is voltage in volts
and L is arc length in mm. The static voltampere
characteristic of the power source is approximated by a
Beadwidthshouldbeequaltothreediameteroftheelectrodesize
18
10/9/2011
ArcblowinDCarcwelding
Effectofarcblow
y Low heat penetration.
y Excessive weld spatter.
y Pinch effect in welding is the result of electromagnetic
forces
y Weld spatter occurs due to
High welding current
Too small an electrode arc
Contd
Contd
IES2001
Arcblowismorecommonin
(a) A.C.welding
(b) D.C.weldingwithstraightpolarity
(c)
( ) D.C.weldingwithbareelectrodes
D C ldi ithb l t d
(d) A.C.weldingwithbareelectrodes
IES2001
Pincheffectinweldingistheresultof
(a) Expansionofgasesinthearc
(b) Electromagneticforces
(c)
( ) Electricforce
El t i f
(d) Surfacetensionofthemoltenmetal
19
10/9/2011
GATE1992
Gasshields
Contd
CarbonArcwelding
very well.
work.
y Shielding is not used.
used
y No pressure
y With or without filler metal
y May be used in "twin arc method", that is, between
IES2010
Assertion (A): Straight polarity is always
recommended for Carbonelectrode welding.
Reason (R): Carbon arc is stable in straight polarity.
(a) Both A and R are individually true and R is the
correct explanation of A
(b) Both A and R are individually true but R is NOT the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
TungstenInertGaswelding(TIG)
y Arc
Contd
20
10/9/2011
GATE2011
Whichoneamongthefollowingweldingprocesses
usednon consumableelectrode?
(a)Gasmetalarcwelding
(b)Submergedarcwelding
(c)Gastungstenarcwelding
(d)Fluxcoatedarcwelding
IES2010
In an inert gas welding process, the commonly used
gas is
(a) Hydrogen
(b) Oxygen
(c)
( ) Helium
H li
or Argon
A
(d) Krypton
GATE2002
Whichofthefollowingarcweldingprocessesdoes
notuseconsumableelectrodes?
(a) GMAW
(b) GTAW
(c) SubmergedArcWelding
(d) Noneofthese
21
10/9/2011
IES1994
IES2000
Whichoneofthefollowingweldingprocesses
usesnon consumableelectrodes?
(a) TIGwelding
(b) MIGwelding
(c) Manualarcwelding
(d) Submergedarcwelding.
Whichoneofthefollowingstatementsiscorrect?
(a) Nofluxisusedingasweldingofmildsteel
(b) Boraxisthecommonlyusedfluxcoatingon
weldingelectrodes
(c) Laserbeamweldingemploysavacuumchamber
andthusavoidsuseofashieldingmethod
(d) ACcanbeusedforGTAWprocess
GasMetalArcWelding(GMAW)orMIG
y A consumable electrode in a gas shield.
y Arc is between workpiece and an automatically fed
barewire electrode.
y Argon, helium, and mixtures of the two can be used.
y Any metal can be welded but are used primarily with
the nonferrous metals.
y When welding steel, some O2 or CO2 is usually added
to improve the arc stability and reduce weld spatter.
Contd
Fig.MIG
22
10/9/2011
IES2007
IES1997
InMIGwelding,themetalistransferredintothe
formofwhichoneofthefollowing?
(a) Afinesprayofmetal
(b) Moltendrops
(c) Weldpool
(d) Molecules
Considerthefollowingstatements:
MIGweldingprocessuses
1.Consumableelectrode2. nonconsumableelectrode
3.D.C.powersupply
4.A.C.powersupply
Ofthesestatements
(a) 2and4arecorrect
(b) 2and3arecorrect
(c) 1and4arecorrect
(d) 1and3arecorrect
IES2010
SubmergedArcwelding(SAW)
Assertion(A):Inertgasandbareelectrodeinstead
offluxcoatedelectrodeisusedinthecaseof
automaticTIGandMIGweldingprocesses.
Reason(R):Betterprotectionisprovidedbyacloud
ofinertgasthanthecovercreatedbytheflux.
(a) Both A and R are individually true and R is the
correct explanation of A
(b) Both A and R are individually true but R is NOT the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
steels,
tool
steels,
aluminum,
magnesium,
23
10/9/2011
Advantages
Characteristicofsubmergedarcwelding
y Highspeeds,
y Wireelectrodesareinexpensive.
y Highdepositionrates,
y Noweldspatter.
y Deeppenetration,
Deeppenetration
y Nearly100%depositionefficiency.
Nearly100%depositionefficiency
y Highcleanliness(duetothefluxaction).
y Lesserelectrodeconsumption.
Limitations
y Extensive flux handling,
y Contamination of the flux by moisture.
y Largegrainsize
Large grain size structures.
structures
y Welding is restricted to the horizontal position.
y Chemical control is important
IES2011
The welding process in which bare wire is used as
electrode, granular flux is used and the process is
characterized by its high speed welding, is known as:
(a) Shielded arc welding
(b) Plasma arc welding
(c) Submerged arc welding
(d) Gas metal arc welding
24
10/9/2011
IES2006
IES2005
Inwhichofthefollowingweldingprocesses,flux
isusedintheformofgranules?
(a) ACarcwelding
(b) Submergedarcwelding
(c) Argonarcwelding
(d) DCarcwelding
Whichofthefollowingarethemajor
characteristicsofsubmergedarcwelding?
1. Highweldingspeeds.
2. Highdepositionrates.
3. Lowpenetration.
4. Lowcleanliness.
Selectthecorrectanswerusingthecodegivenbelow:
(a) 2and3
(b) 1,2and3
(c) 3and4
(d) 1and2
IES2008
GATE1999
AtomicHydrogenwelding(AHW)
y An a.c. arc is formed between two tungsten electrodes
Contd
25
10/9/2011
IES2005
Inatomichydrogenwelding,hydrogenactsas
(a) Aheatingagent
(b) Oneofthegasestogeneratetheflame
(c)
( ) Aneffectiveshieldinggasprotectingtheweld
A ff ti hi ldi t ti th ld
(d) Alubricanttoincreasetheflowcharacteristicsof
weldmetal
26
8/26/2011
ResistanceWelding
ResistanceWelding
Principle
y Both heat and pressure are used.
y Heat is generated by the electrical resistance of the
work pieces and the interface between them.
y Pressure is supplied externally and is varied
throughout the weld cycle.
y Due to pressure, a lower temperature needed than
oxyfuel or arc welding.
BySKMondal
Contd
Contd
Fig.
Typical
pressure cycle
welding. The
forging and
operations.
FIG.Thefundamentalresistanceweldingcircuit
current
and
for resistance
cycle includes
post heating
Fig. The arrangement of the electrodes and the work in spot
welding, showing design for replaceable electrode tips.
8/26/2011
Advantages
Limitations
1. Very rapid.
3.
3 Conserve material; no filler metal,
metal shielding gases,
gases or
flux is required.
Application
y The resistance welding processes are among the
Differenttypes
1. Resistance spot welding
2. Resistance seam welding
3 Projection welding
3.
4. Upset welding
5. Flash welding
6. Percussion welding
Resistancespotwelding
HeatinputandEfficiencyCalculations
a lap
p jjoint, forming
g a small nugget
gg at the interface of
the two plates.
Contd
8/26/2011
Example1
Calculate the melting efficiency in the case of arc
welding of steel with a potential of 20 V and current of
200 A. The travel speed is 5 mm/s and the cross
sectional area of the joint is 20 mm2. Heat required to
melt steel may be taken as 10 J/ and the heat transfer
efficiency as 0.85.
[PTU 2004]
Example2
Calculate the melting efficiency in the case of
arcwelding of steel with a potential of 20 V and
a current of 200 A. The travel speed is 5 mm/s
and .the
the cross
crosssectional
sectional area of the joint is 20
mm2. Heat required to melt steel may be taken
as 10 J/mm3 and the heat transfer efficiency as
0.85.
Example4
Two steel sheets of 1.0mm thickness are
resistance welded in a lap joint with a current of
10 000 A for 0.1 second. The effective resistance
of the joint can be taken as 100 micro ohms.
ohms The
joint can be considered as a cylinder of 5 mm
diameter and 1.5mm height. The density of steel
is 0.00786 g/mm3 and heat required for melting
steel is 10 J/mm3.
Example3
Two steel plates each 1 mm thick are spot
welded at a current of 5000 A. The current flow
time is 0.1 s. The electrodes used are 5 mm in
diameter Determine the heat generated and
diameter.
its distribution in the weld zone. The effective
resistance in the operation is 200 .
Example5
How much heat would be generated in the spot
welding of two sheets of 1 mm thick steel that
required
q
a current of 10000 A for 0.1 seconds?
An effective resistance of 100 . is assumed.
8/26/2011
Example6
Example7
Resistanceseamwelding
welds.
Contd
Contd
Projectionwelding
y Limitations of spot welding.
1. Electrode
Fig.Resistanceseamwelding
Contd
8/26/2011
Fig.Principleof
projectionwelding,
(a)priortoapplicationof
currentandpressure
(b)andafterformationof
welds
Contd
Upsetwelding
y Made butt joint compared to lap joint.
y Pieces are held tightly and current is applied.
y Due to pressure joints get slightly upset and hence its
name.
y Useful for joining rods or similar pieces.
Contd
Contd
FlashWelding
y It is similar to upset welding except the arc rather than
resistance heating.
y One pieces is clamped with cam controlled movable
Contd
8/26/2011
PercussionWelding
highly concentrated.
y Small weld metal is produced, little or no upsetting, and
low HAZ.
y Application: Butt welding of bar or tube where heat
Contd
OtherWelding
h i
Technique
Thermit Welding
Contd
8/26/2011
ElectroSlagWelding
supply of filler.
Contd
Contd
Contd
ElectronBeamWelding
y A beam of electrons is magnetically focused on the
precise
beam
control
and
deep
weld
penetration.
y No shield gas (vacuum chamber used)
8/26/2011
LaserBeamWelding
in excess of
10kW/cm2
y Filler metal and inert gas shield may or may not used.
y Deep penetration.
y The high
highintensity
intensity beam produces a very thin column
y No
N vacuum needed.
d d
y No direct contact needed.
Contd
ForgeWelding
y Blacksmith do this.
to weld
Contd
the
polyurethane insulation.
insulation
used by industry.
Contd
FrictionWelding
y Pressure 4
40 MPa for lowcarbon steels to as high
g as 45
450
Contd
8/26/2011
y Very efficient.
y Wide variety of metals or combinations of metals can
Contd
UltrasonicWelding(USW)
Fig frictionweldingprocess
pressure.
Temp. do not exceed onehalf of the melting point.
The ultrasonic transducer is same as ultrasonic
machining.
Contd
Applications
y Joiningthedissimilarmetalsinbimetallics
y Makingmicrocircuitelectricalcontacts.
Contd
ExplosionWelding
y Done at room temperature in air, water or vacuum.
y Surface contaminants tend to be blown off the surface.
y Weldingrefractoryorreactivemetals
ld f
y Bondingultrathinmetal.
8/26/2011
Contd
Contd
Advantages,
y Can bond many dissimilar, normally unweldable
metals
y The lack of heating preserves metal treatment
y The
Th process is
i compact, portable,
bl and
d easy to contain
i
y Inexpensive
y No need for surface preparation
Contd
Disadvantages,
y The metals must have high enough impact resistance,
and ductility (at least 5%)
y The cladding plate cannot be too large.
y Noise and blast can require worker protection,
protection vacuum
chambers, buried in sand/water.
Contd
Typicalapplications:
y Verylargeplatescanbecladded.
y Joinsdissimilarmetals.
(titaniumtosteel,Altosteel,AltoCuetc.)
y Jointubetotubesheetsoflargeheatexchangers.
Contd
Contd
10
8/26/2011
Autogeneous Welding
y Autogeneous welding or fusion of the parent
MicroPlasmaArcWeld(PAW)
y Similar to GTAW except the plasma caused by the arc
BrazingandSoldering
g
g
BrazingandSoldering
y Brazing is the joining of metals through the use of heat
11
8/26/2011
Brazingprocesshasseveraldistinct
advantages:
Corrosion prone
Contd
Brazingmetalsaretypicallyalloyssuchas,
y Brazingbrass(60%Cu,40%Zn)
y Manganesebronze
agents.
g
y Nickelsilver
y Coppersilicon
y Silveralloys(with/withoutphosphorous)
y Copperphosphorous
Contd
Contd
acid.
y Sodium cyanide is used in brazing tungsten to copper.
y Base materials not melted.
melted
12
8/26/2011
BrazeWelding
Fig.BrazeWelding
Contd
Soldering
y By definition, soldering is a brazing type of operation
SolderMetals
SolderFlux
y Ammonium chloride or rosin for soldering tin
galvanized iron
use
Contd
13
8/26/2011
DifficultieswithGreyCastIron
Soldering and brazing are difficult of grey cast Iron due
to surface contamination with graphite having a very low
surface energy.
Weldingdesignanddefect
Welding Problem
Cracking of weld metal
Cracking of base metal
Spatter
Distortion
Slag inclusion
Porosity
LamellarTearing
Causes
High joint rigidity
Excessive stresses
Arc blow
Poor joint selection
Improper cleaning in multipass welding
Excessive H2, O2, N2, in the
welding atmosphere or Damp
electrodes
inclusionssuchasMn FeandS
inthebasemetaland/or
residualstress
Residualstress
y The residual stresses result from the restrained expansion
14
7/11/2011
IES2003
Resistance
Welding
Inresistancewelding,heatisgeneratedduetothe
resistancebetween
(a) Electrodeandworkpiece
(b) Asperitiesbetweentouchingplates
(c) Twodissimilarmetalsbeingincontact
(d) Interatomicforces
Ans.(b)
BySKMondal
Compiledby:SKMondal
MadeEasy
Compiledby:SKMondalMadeEasy
IES2001
GATE2008
Themaximumheatinresistanceweldingisatthe
(a) Tipofthepositiveelectrode
(b) Tipofthenegativeelectrode
(c) Topsurfaceoftheplateatthetimeofelectric
contactwiththeelectrode
(d) InterfacebetweenthetwoplatesbeingJoined
Ans.(d)
Compiledby:SKMondalMadeEasy
GATE2006
In an arc welding process, the voltage and current
are 25 V and 300 A respectively. The arc heat
transfer efficiency is 0.85 and welding speed is 8
mm/see. The net heat input (in J/mm) is
(a) 64
(b) 797
(c) 1103
(d) 79700
Ans. (b)
Compiledby:SKMondalMadeEasy
Compiledby:SKMondalMadeEasy
GATE2007
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 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/m3
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
(iii) The complete weld fusion zone is at the melting temperature.
The melting efficiency (in %) of the process is
(a)
50.37
(b)
60.37
(c)
70.37
(d)
80.37
Ans. (c)
Compiledby:SKMondalMadeEasy
7/11/2011
GATE2005
Spot welding of two 1 mm thick sheets of steel
(density = 8000 kg/m3) is carried out successfully
by passing a certain amount of current for 0.1
second through the electrodes. The resultant weld
nugget formed
f
d is 5 mm in diameter
d
and
d 1.5 mm
thick. If the latent heat of fusion of steel is 1400
kJ/kg and the effective resistance in the welding
operation in 200 , the current passing through the
electrodes is approximately
(a) 1480A
(b) 3300 A
(c) 4060 A
(d) 9400 A
Ans. (c)
Compiledby:SKMondalMadeEasy
GATE2001
Resistance spot welding is performed on two
plates of 1.5 mm thickness with 6 mm diameter
electrode, using 15000 A current for a time
duration of 0.25 seconds. Assuming the interface
resistance to be
b 0.0001 , the
h heat
h
generated
d to
form the weld is
(a) 5625 Wsec
(b) 8437 Wsec
(c) 22500 Wsec
(d) 33750 Wsec
Ans. (a)
Compiledby:SKMondalMadeEasy
GATE2004
GATE1992
Compiledby:SKMondalMadeEasy
Compiledby:SKMondalMadeEasy
GATE2010
IAS2003
Compiledby:SKMondalMadeEasy
Compiledby:SKMondalMadeEasy
7/11/2011
Example1
Calculate the melting efficiency in the case of arc
welding of steel with a potential of 20 V and current of
200 A. The travel speed is 5 mm/s and the cross
sectional area of the joint is 20 mm2. Heat required to
melt steel may be taken as 10 J/ and the heat transfer
efficiency as 0.85.
[PTU 2004]
Compiledby:SKMondalMadeEasy
Example3
Two steel plates each 1 mm thick are spot
welded at a current of 5000 A. The current flow
time is 0.1 s. The electrodes used are 5 mm in
diameter.
diameter Determine the heat generated and
its distribution in the weld zone. The effective
resistance in the operation is 200 .
Compiledby:SKMondalMadeEasy
Example5
How much heat would be generated in the spot
welding of two sheets of 1 mm thick steel that
required
q
a current of 10000 A for 0.1 seconds?
An effective resistance of 100 . is assumed.
Compiledby:SKMondalMadeEasy
Example2
Calculate the melting efficiency in the case of
arcwelding of steel with a potential of 20 V and
a current of 200 A. The travel speed is 5 mm/s
and .the
the cross
crosssectional
sectional area of the joint is 20
mm2. Heat required to melt steel may be taken
as 10 J/mm3 and the heat transfer efficiency as
0.85.
Compiledby:SKMondalMadeEasy
Example4
Two steel sheets of 1.0mm thickness are
resistance welded in a lap joint with a current of
10 000 A for 0.1 second. The effective resistance
of the joint can be taken as 100 micro ohms.
ohms The
joint can be considered as a cylinder of 5 mm
diameter and 1.5mm height. The density of steel
is 0.00786 g/mm3 and heat required for melting
steel is 10 J/mm3.
Compiledby:SKMondalMadeEasy
Example6
Two 1.2 mm thick, flat copper sheets are being spot
welded using a current of 6000 A and a current flow
time of t = 0.18 s. The electrodes are 5 mm in diameter.
Estimate the heat generated in the weld zone. Take
effective resistance as 150 .
Compiledby:SKMondalMadeEasy
7/11/2011
Example7
Two steel sheets of 1.0mm thickness are resistance
welded in a projection welding with a current of 30
000 A for 0.005 second. The effective resistance of the
joint can be taken as 100 micro ohms. The joint can be
considered
d d as a cylinder
l d off 5 mm diameter
d
and
d 1.5 mm
height. The density of steel is 0.00786 g/mm3 and heat
required for melting steel is 10 J/mm3.
OtherWelding
Technique
h i
Compiledby:SKMondalMadeEasy
Compiledby:SKMondalMadeEasy
IES2000
Considerthefollowingprocesses:
1. Gaswelding
2. Thermit welding
33. Arcwelding
g
4. Resistancewelding
Thecorrectsequenceoftheseprocessesinincreasing
orderoftheirweldingtemperaturesis
(a) 1,3,4,2
(b) 1,2,3,4
(c) 4,3,1,2
(d)4,1,3,2
Ans.(d)
Compiledby:SKMondalMadeEasy
IAS2003
Whichoneofthefollowingisnotanelectric
resistancemethodofwelding?
(a) Electroslagwelding
(b) Percussionwelding
(c) Seamwelding
(d) Flashwelding
Ans.(a)
Compiledby:SKMondalMadeEasy
IAS2000
IES2004
Considerthefollowingweldingprocesses:
1. TIGwelding
2. Submergedarcwelding
3. Electroslagwelding4. Thermit welding
Whichoftheseweldingprocessesareusedforwelding
Whi h fth ldi
df ldi
thickpiecesofmetals?
(a) 1,2and3 (b) 1,2and4
(c) 1,3and4 (d) 2,3and4
Ans.(d)
Compiledby:SKMondalMadeEasy
Compiledby:SKMondalMadeEasy
7/11/2011
IES2002
Inwhichoneofthefollowingweldingtechniques
isvacuumenvironmentrequired?
(a) Ultrasonicwelding
(b) Laserbeamwelding
(c) Plasmaarcwelding
(d) Electronbeamwelding
IES1993
Electronbeamweldingcanbecarriedoutin
(a) Openair
(b) Ashieldinggasenvironment
(c)
( ) Apressurizedinertgaschamber
A
i di t h b
(d) Vacuum
Ans.(d)
Ans.(d)
Compiledby:SKMondalMadeEasy
IAS2004
Whichoneofthefollowingweldingprocesses
consistsofsmallerHeatAffectedZone(HAZ)?
(a) Arcwelding
(b) Electronbeamwelding
(c) MIGwelding
(d) Thermit welding
Ans.(b)
Compiledby:SKMondalMadeEasy
Compiledby:SKMondalMadeEasy
IES2007
Considerthefollowingstatementsinrespectofthe
laserbeamwelding:
1. Itcanbeusedforweldinganymetalortheir
combinationsbecauseofveryhightemperatureofthe
focalpoints.
focalpoints
2. Heataffectedzoneisverylargebecauseofquick
heating.
3. Highvacuumisrequiredtocarrytheprocess.
Whichofthestatementsgivenaboveis/arecorrect?
(a) 1and2only (b) 2and3only
(c) 1only
(d) 1,2and3
Ans.(c)
Compiledby:SKMondalMadeEasy
IES2006
IAS2007
Whichoneofthefollowingweldingprocesses
consistsofminimumheataffectedzone(HAZ)?
(a) ShieldedMetalArcWelding(SMAW)
(b) LaserBeamWelding(LBW)
(c) UltrasonicWelding(USW)
(d) MetalInertGasWelding(MIG)
Ans.(b)
Compiledby:SKMondalMadeEasy
Compiledby:SKMondalMadeEasy
7/11/2011
IAS1999
GATE2007
Whichoneofthefollowingisasolidstatejoining
process?
(a) Gastungstenarcwelding
(b) Resistancespotwelding
(c) Frictionwelding
(d) submergedarcwelding
Ans.(c)
Compiledby:SKMondalMadeEasy
Compiledby:SKMondalMadeEasy
IES2011S1Contd
MatchListIwithListIIandselectthecorrectanswer
usingthecodegivenbelowthelists:
GATE1992
Inanexplosiveweldingprocess,the..
(maximum/minimum)velocityofimpactisfixed
bythevelocityofsoundinthe
(flyer/target)platematerial
(a) Maximum;target
(b) Minimum;target
(c) Maximum;flyer
(d) Minimum;flyer
ListI
B.Electron
2.Asoundandcleanweldedjointiscreateddueto
beamwelding rubbingoftwopartsagainsteachotherwith
adequatespeedandpressureproducingintenseheat
raisingtemperatureabovemeltingpoint.
C.Ultrasonic 3.Cleanheatsourcecreatedmuchawayfromjob,a
welding
narrowspotisheated,workchamberoperatesina
highvacuum.
D.Friction
welding
Ans.(c)
ListII
A.Laserbeam 1.Canbeappliedforweldingorrefractorymetals
welding
likeniobium,tantalum,molybdenumandtungsten.
4.Cleanheatsourceveryquickheating,verysmall
focalspot,novacuumchamberisrequired.
Compiledby:SKMondalMadeEasy
Compiledby:SKMondalMadeEasy
IES2011FromS1
Codes:
A
(a) 4
((c)) 4
Ans.(a)
B
3
1
C
1
3
D
2
4
(b)
((d))
A
2
2
B
3
1
IES2009
C
1
3
D
4
4
MatchListIwithListIIandselectthecorrectanswerusingthecodegiven
belowtheLists:
ListI
ListII
(WeldingProcess)
(Application)
A. Laserwelding
1.
Unitinglargeareasheets
B. Frictionwelding
2.
Repairinglargeparts
C.
3.
Weldingarodtoaflatsurface
C Ultrasonicwelding
3
D. Explosivewelding
4.
Fabricationofnuclearreactor
components
5.
Weldingverythinmaterials
Code:
(a)
A
B
C
D
(b)
A
B
C
D
5
4
3
2
1
4
2
5
(c)
A
1
B
3
C
4
D
2
(d)
A
5
B
3
C
4
D
1
Ans.(d)
Compiledby:SKMondalMadeEasy
Compiledby:SKMondalMadeEasy
7/11/2011
IAS2002
IAS2001
MatchListI,(Welding)withListII(Application)andselectthecorrect
answerusingthecodesgivenbelowtheLists:
ListI
ListII
(Welding)
(Application)
A.
Explosive
1.
Joiningthicksheets
g
B.
Ultrasonic
2.
Manufactureofheatexchanges
C.
Thermit
3.
Joiningthinsheetsorwiresof
similar/dissimilar metals
D.
Projection
4.
Joininghydraulicpistonrodsfor
agricultural machinery
5.
Joiningrails,pipesandthicksteel
sections
Codes:A
B
C
D
A
B
C
D
(a) 2
5
1
3
(b)
4
5
1
3
(c) 2
3
5
1
(d)
4
3
5
1
Ans.(c)
MatchListI(Weldingprocesses)withListII(Features)and
selectthecorrectanswerusingthecodesgivenbelowtheLists:
ListI
A. Ultrasonicwelding
1.
B.
Electronbeamwelding2.
C.
Plasmaarcwelding
Codes:
(a)
(c)
Ans.(d)
Compiledby:SKMondalMadeEasy
A
1
2
B
2
1
3.
4.
C
4
4
ListII
Gasheatedtoionizedcondition
forconductionofelectriccurrent
Highfrequencyandhigh
intensityvibrations
Concentratedstreamofhigh
energyelectrons
Exothermalchemicalreaction
A
B
C
(b)
4
3
1
(d)
2
3
1
Compiledby:SKMondalMadeEasy
JWM2010
MatchListIwithListIIandselectthecorrectanswer
usingthecodegivenbelowthelists:
ListI
ListII
A.Atomic
1.Twopiecesarebroughttogetherand
hydrogenwelding powersupplyisswitchedon
B.Plasmaarc
B Plasma arc
welding
C.Spotwelding
2.Nuggetisformedattheinterfaceof
2 Nuggetisformedattheinterfaceof
twoplates
3.Gasisionized
D.Flashwelding
4.Inertgasshieldedarcwelding
Code:A
(a) 4
(c) 4
B
3
2
C
D
A
2
1
(b) 1
3
1
(d) 1
Compiledby:SKMondalMadeEasy
B
3
2
C
2
3
BrazingandSoldering
g
g
D
4
4
Compiledby:SKMondalMadeEasy
IES2006
GATE2005
Thestrengthofabrazedjoint
(a) Decreaseswithincreaseingapbetweenthetwo
joiningsurfaces
(b) Increaseswithincreaseingapbetweenthetwo
joiningsurfaces
j i i f
(c) Decreasesuptocertaingapbetweenthetwo
joiningsurfacesbeyondwhichitincreases
(d) Increasesuptocertaingapbetweenthetwo
joiningsurfacesbeyondwhichitdecreases
Ans.(d)
Compiledby:SKMondalMadeEasy
Whichoneofthefollowingisnotafusionwelding
process?
(a) Gaswelding
(b) Arcwelding
(c) Brazing
(d) Resistancewelding
Ans.(c)
Compiledby:SKMondalMadeEasy
7/11/2011
IES1994
IAS1996
(b) 1
2
4
(c) 2
1
3
4
(d) 2
3
4
MatchListIwithListIIandselectthecorrectanswerusing
thecodesgivenbelowthelists
ListI
ListII
(Fillerrodmaterial)
(Joiningprocess)
A. Mildsteel
1.
MIGwelding
B. Bronze
2.
Soldering
C. Brass
3.
Brazing
D. Leadandtinalloy 4.
Thermit welding
5.
Brazewelding
Codes:A
B
C
D
A
B
C
D
(a) 1
5
3
2
(b)
4
3
2
5
(c) 4
3
5
2
(d) 1
3
5
4
Ans.(a)
Ans.(a)
Compiledby:SKMondalMadeEasy
Compiledby:SKMondalMadeEasy
IES2004
MatchListI(Weldingproblems)withListII(Causes)andselect
thecorrectanswerusingthecodesgivenbelowtheLists:
ListI
ListII
A. Crackingofweldmetal
1.
Excessivestresses
B. Crackingofbasemetal
2.
Highjointrigidity
C.
C
Porosity
3.
3
Failuretoremoveslag
frompreviousdeposit
D. Inclusions
4.
Oxidation
5.
ExcessiveH2,O2,N2,in
theweldingatmosphere
Codes:A
B
C
D
A
B
C
D
(a) 2
1
5
3
(b)
3
4
2
1
(c) 2
4
5
3
(d)
3
1
4
2
Ans.(a)
IES2003
MatchListI(WeldingDefects)withListII(Causes)and
selectthecorrectanswerusingthecodesgivenbelowthe
Lists:
ListI
ListII
(WeldingDefects)
(Causes)
A Spatter
A.
S
1.
D
Dampelectrodes
l
d
B. Distortion
2.
Arcblow
C. Slaginclusion
3.
Impropercleaningin
multipasswelding
D. Porosity
4.
Poorjointselection
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
Ans.(d)
Compiledby:SKMondalMadeEasy
Compiledby:SKMondalMadeEasy
IES2004
Consider the following statements:
The magnitude of residual stresses in welding
depends upon
1. Designofweldment
2. Supportandclampingofcomponents
S
d l
f
3. weldingprocessused
4. Amountofmetalmelted/deposited
Whichofthestatementsgivenabovearecorrect?
(a) 1,2and4
(b)1,2and3
(c) 1and3
(d)2and3
Ans.(b)
Compiledby:SKMondalMadeEasy
GATE2003
Matchthefollowing
Workmaterial
P.Aluminium
Q.DieSteel
R.CopperWire
S.Titaniumsheet
(a)P 2
(b)P 6
(c)P 4
(d)P 5
Ans.(d)
Q 5
Q 3
Q 1
Q 4
R 1
R 4
R 6
R 2
Typeofjoining
1.
SubmergedArcWelding
2.
Soldering
3.
Thermit Welding
4.
AtomicHydrogenWelding
5.
GasTungstenArcWelding
6.
LaserBeamWelding
7.
Brazing
S 3
S 4
S 2
S 6
Compiledby:SKMondalMadeEasy
7/11/2011
IES2004
Considerthefollowingstatements:
Thesizeoftheheataffectedzone(HAZ)willincreasewith
1. Increasedstartingtemperature
2. Increasedweldingspeed
3. Increasedthermalconductivityofthebasemetal
4. Increaseinbasemetalthickness
Whichofthestatementsgivenabovearecorrect?
(a) 1,2and3
(b) 1and3
(c) 1and4
(d) 2and3
Ans.(b)
IES1992
Weldspatteroccursduetoanyofthefollowing
except
(a) Highweldingcurrent
(b) Toosmallanelectrode
(c) Arc
(d) Wrongpolarity
Ans.(d)
Compiledby:SKMondalMadeEasy
Compiledby:SKMondalMadeEasy
JWM2010
Assertion (A) : Spatter is one of the welding defects.
Reason (R) : In submerged arc welding process,
there is no spatter of molten metal.
(a) Both A and R are individually true and R is the
correct explanation of A
(b) Both A and R are individually true but R is not the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
Ans. (b)
IES1998
Anarcweldedjointisshownintheabovefigure.
Thepartlabelled 'B'inthefigureisknownas
(a) Weldpreparation
(b) Penetration
(c) Reinforcement
(d) Slag
Ans.(c)
Compiledby:SKMondalMadeEasy
Compiledby:SKMondalMadeEasy
IES2004
IAS2003
Toolmaterialnotsuitedtoresistanceweldingis
(a) Aluminium oxide
(b) Stellite
(c) Highspeedsteel
(d) Masonite
Compiledby:SKMondalMadeEasy
Ans.(a)
Compiledby:SKMondalMadeEasy
7/11/2011
GATE1996
Preheatingbeforeweldingisdoneto
(a) Makethesteelsofter
(b) Bumawayoil,grease,etc,fromtheplatesurface
(c) Preventcoldcracks
(d) Preventplatedistortion
Ans.(c)
Compiledby:SKMondalMadeEasy
IES2011
Coldcrackinginsteelweldments dependson
1.Carbonequivalent
2.Heatinput
3.Effectivethickness
3.Hydrogencontentinweldpool
H d
i ld
l
(a)1,2and3only
(b)1,2and4only
(c)2,3and4only
(d)1,2,3and4
Ans.(d)
Compiledby:SKMondalMadeEasy
GATE2001
Two plates of the same metal having equal
thickness are to be butt welded with electric arc.
When the plate thickness changes, welding is
achieved by
(a) Adjusting the current
(b) Adjusting the duration of current
(c) Changing the electrode size
(d) Changing the electrode coating
Ans. (a)
Compiledby:SKMondalMadeEasy
Compiledby:SKMondalMadeEasy
10