Joining Lab Class 1

Solid State Welding Processes (FSW, FS, FW)

Note: 1. Use both the sides of A4 sheet
2. Use schematics where ever necessary
Date: 20-08-14
1) List different types of solid state welding processes
2) What are the advantages of solid state welding processes over fusion welding processes
3) List out the important process parameters in friction welding(FW), friction stir welding (FSW)and
friction surfacing(FS)
4) Draw a neat sketch of Tool of FSW also with neat drawings explain different stages in FSW.
5) Draw a neat sketch of FSW joint and Identify different zones in it.
6) With neat schematics explain different stages in FW.
7) Explain with a graph how process parameters vary in each stage during rotary friction welding. Compare
the same with inertia friction welding.
8) Can you think of welding a long pipe, a plate, using FW techniques (Yes/No)?Justify your answer
9) Can you think of 3 possible dissimilar material combinations which are not weldable by fusion based
processes? Do you think solid state welding techniques help you in welding these combinations
(Yes/No)? Justify your answer.
10) List 5 possible industrial applications for these processes FW, FSW, FS
11) Instead of having so many advantages, why do you think above processes are not widely used in day to
day application like fusion based processes
Gas Tungsten Arc Welding
1. Define welding and classify the different types of fusion welding process.
2. With a neat schematic explain the construction of GTAW process.
3. Briefly explain the effect of electrode polarity and different electrode tip configuration in GTAW
process (line drawing).
4. Briefly explain the types of GTA welding technique and explain why pulse technique is advantageous
over normal mode?
5. Briefly explain the technique of arc initiation in GTAW and justify why touch retract method is not
preferred.
6. Brief about the pre , post , back purging in welding process and why is it needed. Give one example that
requires all these purging.
7. For GTAW of Aluminum alloy what kind of polarity do you chose? Justify
8. Why GTAW process is widely used for depositing root pass when compared to subsequent passes in a
multi-pass weld?

Joining Lab class 2

Gas Metal Arc Welding
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With a neat schematic explain the construction of GMAW process

MIG and MAG - Differentiate
List 5 differences between GTAW and GMAW process
What type polarity is preferred in GMAW process and why Alternating Current is not used in GMAW ?
What are different types of shielding gases used in GMAW process
What are different modes of metal transfer in GMAW and how is it achieved?
What are the advantages/ disadvantages of GTAW process over GMAW process and vice versa?

CMT MIG welding

1. What is Cold Metal Transfer MIG? Justify the name Cold Metal Transfer
2. What is the mode of metal transfer in CMT? How does it vary with conventional MIG process?
3. Heat input by CMT MIG is comparatively lower than any other process- Justify the statement
4. What is the effect of Pulsing in CMT compared to normal CMT mode?
5. How does the molten metal detach from the wire consumable to base in CMT process how is it different
from the conventional MIG welding process?
6. Give some industrial application of CMT MIG process
7. Draw backs/ disadvantages that you have noticed while welding with CMT