Casting & Welding Theory & Questions Altogethre 2013

Sandcasting
y Sand
uses ordinary
sand
S d casting
i
di
d as the
h primary
i
MetalCasting
BySKMondal
mould material.
y The sand grains are mixed with small amounts of
other materials,
materials such as clay and water,
water to improve
mouldability and cohesive strength, and are then
packed around a pattern that has the shape of the
desired casting.
y The pattern must be removed before pouring, the
mold is usually made in two or more pieces.
y An opening called a sprue hole is cut from the top of
th mold
the
ld through
th
h the
th sand
d and
d connected
t d to
t a
system of channels called runners.
Contd.
Sequentialstepsinmakingasandcasting
y Apatternboardisplacedbetweenthebottom(drag)
andtop(cope)halvesofaflask,withthebottomsideup.
p( p )
,
p
y Sandisthenpackedintothedraghalfofthemold.
S di h k di h d h lf f h ld
y Abottomboardispositionedontopofthepackedsand,
andthemoldisturnedover,showingthetop(cope)half
andthemoldisturnedover
showingthetop(cope)half
ofpatternwithsprue andriserpinsinplace.
y Thecopehalfofthemoldisthenpackedwithsand.
Thecopehalfofthemoldisthenpackedwithsand
p
y The molten metal is p
poured into the sprue
hole, flows
y
y
y
y
through the runners, and enters the mold cavity

through an opening called a gate.
Gravity flow is the most common means of
i t d i the
introducing
th metal
t l into
i t the
th mold.
ld
After solidification, the mold is broken and the
finished casting is removed.
The casting is then fettled
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
y The mold is opened, the pattern board is drawn
(removed), and the runner and gate are cut into the
surface of the sand.
y The
Th mold
ld is
i reassembled
bl d with
ith the
th pattern
tt
b d
board
removed, and molten metal is poured through the

sprue.
y The contents are shaken from the flask and the metal
segment is
i separated
d from
f
the
h sand,
d ready
d for
f further
f h
processing.
Contd
CastingTerms
y 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.
y Drag: Lower moulding flask.
y Cope: Upper moulding flask.
y Cheek:
h k Intermediate
d
moulding
ld
fl k used
flask
d in three
h
piece moulding.
moulding
For-2013 (IES, GATE & PSUs)
Page 1
Contd
y Pattern: Pattern is a replica of the final object to be
made with some modifications.
y Moulding sand: The freshly prepared refractory
material used for making the mould cavity. It is a

mixture of silica, clay and moisture in appropriate
y Parting
g line: This is the dividing
g line between the two
moulding flasks that makes up the sand mould.
proportions.
i
which is used at the start of the mould making.
of the mould into which the molten metal is poured.

p
y Sprue: The passage through which the molten metal
from the pouring basin reaches the mould cavity.
y Backing
B ki
sand:
d This
Thi is
i made
d up off used
d and
d burnt
b
t
y Bottom board: This is a board normally made of wood,
y Pouring basin: A small funnelshaped

funnel shaped cavity at the top
sand.
sand
y Runner: The passage ways in the parting plane through
which
hi h molten
l
metall flow
fl
i regulated
is
l d before
b f
they
h reach
h
y Core: Used for making hollow cavities in castings.

castings
the mould cavity.

cavity
y Gate: The actual entry
y p
point through
g which molten
metal enters the mould cavity in a controlled rate. Contd
Contd
Padding
y Chaplet: Chaplets are used to support cores inside the
mould cavity.
cavity
y Chill: Chills are metallic objects, which are placed in
the mould to increase the cooling rate of castings.
IES2001
y Tapering of thinner section towards thicker section
is known as 'padding'
padding .
y This will require extra material.
y If padding is not provided, centre line shrinkage or
porosityy will result in the thinner section.
p
y Riser: It is a reservoir of molten metal provided in the
Th main
The
i purpose off chaplets
h l t is
i
(a) To ensure directional solidification
(b) To provide efficient venting
(c) For aligning the mold boxes
casting so that hot metal can flow back into the mould
(d) To support the cores
cavity
i when
h there
h
i a reduction
is
d i in
i volume
l
off metall due
d
to solidification
Contd
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
3.
Employing
l
padding
dd
S l t the
Select
th correctt answer.
IES2007
Which one of the following is the correct
statement?
G
Gate
i provided
is
id d in
i moulds
ld to
((a)) Feed the casting
g at a constant rate
(b) Give passage to gases
( ) Compensate
(c)
C
f shrinkage
for
hi k
((d)) Avoid cavities
(a) 1 and 2 (b) 1 and 3 (c) 2 and 3 (d) 1,

1 2 and 3
Page 2
GATE2009
MatchtheitemsinColumnIandColumnII.
ColumnIColumnII
P.MetallicChills1.Supportforthecore
Q M t lli Ch l t R
Q.MetallicChaplets2.Reservoirofthemoltenmetal
i fth lt t l
R.Riser3.Controlcoolingofcritical
sections
i
S.ExothermicPadding4.Progressivesolidification
(a) P1,Q3,R2,S4
(b)
P1,Q4,R2,S3
((c)) P3,Q4,R2,S1
3, Q 4,
,
((d))
P4,Q1,R2,S3
4, Q ,
, 3
GATE1992
Inagreensandmouldingprocess,uniform
rammingleadsto
(a) Lesschanceofgasporosity
(b) Uniformflowofmoltenmetalintothemould
cavity
(c) Greaterdimensionalstabilityofthecasting
(d) Lesssandexpansiontypeofcastingdefect
PatternAllowances
1. Shrinkageorcontractionallowance
g
GATE2011
Pattern
Green sand mould indicates that

(a) polymeric mould has been cured
(b) mould has been totally dried
(c) mould is green in colour
(d) mould contains moisture
A pattern is a replica of the object to be made by the

casting process, with some modifications.
The main modifications are
y The addition of pattern allowances,
y The provision of core prints, and
y Elimination of fine details, which cannot be obtained
by casting and hence are to be obtained by further
processing
Shrinkageallowance
Liquidshrinkageandsolidshrinkage
y All metals shrink when cooling except perhaps
bismuth.
2. Draftortaperallowance
3. Machiningorfinishallowance
4. Distortionorcamberallowance
y This is because of the interatomic vibrations which
are amplified
l f d by
b an increase in temperature.
volume when the metal changes from liquid to

solid state at the solidus temperature. To account
f this,
for
hi risers
i
are provided
id d in
i the
h moulds.
ld
y Solid shrinkage is the reduction in volume
y The
Th shrinkage
hi k
allowance
ll
i always
is
l
to be
b added
dd d to the
h
5. Rappingallowance
y Liquid shrinkage refers to the reduction in
linear dimensions.
dimensions Even in case of internal dimensions.
dimensions
caused, when a metal loses temperature in the

caused
solid state. The shrinkage allowance is provided to
take
k care off this
hi reduction.
d i
Contd
IES1995
y Pattern Allowances
Cast Iron
Brass, Copper, Aluminium
Steel
Zinc, Lead
10 mm/m
15 mm/m
20 mm/m
25 mm/m
y In grey cast iron and spheroidal graphite iron, the
amount off graphitization

hi i i
controls
l the
h actuall
shrinkage. When graphitization is more, the
shrinkage would be less and vice versa.
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) Copper.
Page 3
GATE1999
Which of the following materials requires the
largest shrinkage allowance, while making a
pattern for casting?
(a) Aluminium
(b) Brass
(c) Cast Iron
(d) Plain Carbon Steel
IES1999
In solidification of metal during casting,
compensation for
f solid
l d contraction is
( ) Provided
(a)
P id d by
b the
h oversize
i pattern
(b) Achieved
A hi d by
b properly
l placed
l d risers
i
(c) Obtained
by
promoting
directional
solidification
GATE2001
ISRO2007
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
(d) Adding to external dimensions and subtracting
from internal dimensions
((d)) Made byy p

providing
g chills
GATE2004
(b) 0.99
0 99
(c) 1.01
1 01
GATE2011
GATE2008
Gray cast iron blocks 200 x 100 x 10 mm are to be

cast in sand moulds. Shrinkage allowance for
pattern making is 1%.
1% The ratio of the volume of
pattern to that of the casting will be
(a) 0.97
0 97
Shrinkage allowance on pattern is provided to

compensate for shrinkage when
(a) The temperature of liquid metal drops from
pouring to freezing temperature
(b) The
Th metal
t l changes
h
f
from
li id to
liquid
t solid
lid state
t t att
freezing temperature
(c) The temperature of solid phase drops from
freezing to room temperature
(d) The temperature of metal drops from pouring
to room temperature
(d) 1.03
1 03
Whil cooling,
While
li
a cubical
bi l casting
ti
off side
id 40 mm
undergoes 3%,
3% 4% and 5% volume shrinkage
during
g the liquid
q
state, p
phase transition and solid
state,
respectively.
The
volume
of
metal
compensated from the riser is

(a) 2%
IAS1995
Assertion (A): A pattern is made exactly similar to
the part to be cast.
Reason (R): Pattern is used to make the mould
cavity for pouring in molten for casting.
casting
(a) Both A and R are individually true and R is the
correct explanation
l
i off A
(b) Both A and R are individuallyy 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
(b) 7%
(c) 8%
(d) 9%
A cubic casting of 50 mm side undergoes volumetric

solidification shrinkage
g
and volumetric solid
contraction of 4% and 6% respectively. No riser is
used Assume uniform cooling in all directions.
used.
directions The
side of the cube after solidification and contraction is
( ) 48.32
(a)
8 mm
((b)) 49
49.90
9 mm
(c) 49.94 mm
(d) 49.96 mm
Draft
IAS2003
Match List I (Material to be cast) with List II
((Shrinkage
g Allowance in mm/m)
/ ) and select the
correct answer using the codes given below the lists:
ListII
List
ListII
List
II
(MaterialtoCast)(ShrinkageAllowanceinmm/m)
(A) Greycastiron
1
1.
7 10
7
(B) Brass
2.
15
( ) Steell
(C)
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
(c) 1
4
3
2
(d) 3
2
1
4
Page 4
y To reduce the chances of the damage of the mould
cavity at the
h time off pattern removal,
l the
h verticall faces
f
of the pattern are always tapered from the parting line.
line
This provision is called draft allowance.
y Inner surfaces of the p
pattern require
q
higher
g
draft than
outer surfaces.
y Draft is always provided as an extra metal.
ShakeAllowance
y At the time of p
pattern removal,, the p
pattern is rapped
pp
DistortionAllowance
y A metal when it has just solidified is very weak and
therefore is likely to be distortion prone.
all around the vertical faces to enlarge the mould

cavity slightly to facilitates its removal.
y It is a negative allowance and is to be applied only to
those dimensions, which are parallel to the parting

plane.
l
y This is particularly so for weaker sections such as long
flatt portions,
fl
ti
V U sections
V,
ti
or in
i a complicated
li t d casting
ti
which may have thin and long sections which are
connected to thick sections.
y The foundry practice should be to make extra
material
i l provision
i i for
f reducing
d i the
h distortion.
di
i
DRAFTALLOWANCE
PatternMaterials
y Wood patterns are relatively easy to make. Wood is not
y
y
veryy dimensionallyy stable. Commonlyy used teak,, white

pine and mahogany wood.
Metal patterns are more expensive but are more
dimensionally stable and more durable. Commonly used
CI Brass,
CI,
Brass aluminium and white metal.
metal
Hard plastics, such as urethanes, and are often preferred
with
h processes that
h use strong, organically
ll bonded
b d d sands
d
that tend to stick to other pattern materials.
In the fullmold process, expanded polystyrene (EPS) is
used.
Investment casting uses wax patterns.
Thepatternmaterialshouldbe
y Easilyworked,shapedandjoined
Which of the following materials can be used for
y Lightinweight
making patterns?
y Strong,hardanddurable
1. Aluminium
y Resistanttowearandabrasion
R i t tt
d b i
y Resistanttocorrosion,andtochemicalreactions
(a)
Wood
(b)
Rubber
(c)
Metal
(d)
Polystyrene
2. Wax
3. Mercury 4. Lead
Select the correct answer using the codes given below:

Codes:
y Dimensionallystableandunaffectedbyvariationsin
temperatureandhumidity.
( ) 1,3 and
(a)
d 4 (b) 2,3 and
d 4 (c)
( ) 1, 2 and
d 4 (d) 1, 2 and
d3
y Availableatlowcost.
TypesofPattern
TypesofPattern
Single Piece Pattern

These are inexpensive and the simplest type of
patterns. As the name indicates, they are made of a
single piece.
piece
Split Pattern or Two Piece Pattern

This is the most widelyy used type
yp of p
pattern for intricate
castings. When the contour of the casting makes its
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
cope.
GATE2000
Di
Disposablepatternsaremadeof
bl tt
d f
IES1994
Gated Pattern
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
productivity of a moulding.
Page 5
TypesofPattern
y Cope and Drag Pattern
These are similar to split patterns. In addition to

splitting
p
g the p
pattern,, the cope
p and drag
g halves of
the pattern along with the gating and riser systems
are attached separately to the metal or wooden
plates along with the alignment pins. They are
called the cope and drag patterns.
patterns
TypesofPattern
y Follow
Board
F ll
B
d Pattern
P
yp of p
pattern is adopted
p
for those
This type
castings where there are some portions, which
are structurally weak and if not supported
properly are likely to break under the force of
ramming.
ramming
TypesofPattern
y Skeleton
Pattern
Sk l
P
TypesofPattern
y Match Plate Pattern
The cope and drag patterns along with the

gating
i and
d the
h risering
i i are mounted
d on a single
i l
g metal or wooden p
plate on either side.
matching
IES2008
y Loose Piece Pattern
This type of pattern is also used when the

contour of the part is such that withdrawing the
pattern from the mould is not possible.
TypesofPattern
y Sweep Pattern
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
called:
(a) Loose piece pattern
(b) Follow board pattern
(c) Skelton pattern
(d) Single piece pattern
g
CoolingCurve
A skeleton of the p
pattern made of strips
p of wood
is used for building the final pattern by packing
sand around the skeleton.
skeleton After packing the
sand, the desired form is obtained with the help
of a strickle.
strickle This type
t pe of pattern is useful
generally for very large castings, required in
small
ll quantities where
h
l
large
expense on
complete
p
wooden p
pattern is not jjustified.
TypesofPattern
Page 6
It is used to sweep the complete casting by means

of a plane sweep. These are used for generating
large shapes,
shapes which are axisymmetrical
axi symmetrical or
prismatic in nature such as bellshaped or
cylindrical.
li d i l
Fluidity
The ability of a metal to flow and fill a mold is known
as fluidity.
Pouring Temperature
y The most important controlling factor of fluidity is the
pouring temperature or the amount of superheat.
y Higher the pouring temperature,
temperature the higher the fluidity.
fluidity
y Excessive temperatures should be avoided, however. At
high pouring temperatures,
temperatures metalmold reactions are
accelerated and the fluidity may be so great as to permit
penetration.
y Penetration is a defect where the metal not only fills the
mold cavity but also fills the small voids between the sand
particles in a sand mold.
Core
ISRO2011
GATE2012(PI)
GATE 2012 (PI)
In sand casting, fluidity of the molten metal
increases with
(A) increase
i
i degree
in
d
off superheat
h
((B)) decrease in p
pouring
g rate
(C) increase in thermal conductivity of the mould
(D) increase
i
i sand
in
d grain
i size
i
Fluidity in casting (CI) operation is greatly

influenced by
y Used for making cavities and hollow projections.

y All sides of core are surrounded by the molten metal
a) Melting temperature of molten metal

b) Pouring temperature of molten metal
c) Finish of the mould
and are therefore subjected to much more severe

thermal and mechanical conditions and as a result the
core sand should be of higher strength than the
moulding
ldi sand.
d
d) Carbon content of molten metal
Desiredcharacteristicsofacore
y Gases evolving
g from the molten metal
y Permeability:
y Green Strength: A core made of green sand should
be strong enough to retain the shape till it goes for

baking.
baking
y 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 p
pressure acting
g on
it.
y Refractoriness: Since in most cases,
cases the core is
surrounded all around it is desirable that the core
material
i l should
h ld have
h
hi h refractoriness.
higher
f
i
Contd
y Calculatethepermeabilitynumberofsandifittakes1min
25stopass2000cm3 ofairatapressureof5g/cm2 through

thestandardsample.
and generated from the mould may have to go

through the core to escape out of the mould. Hence
cores are required to have higher permeability.
y Permeability
P
bilit Number:
N
b
Th rate
The
t off flow
fl
off air
i passing
i
through a standard specimen under a standard pressure is

termed
d as permeability
bili number.
b
y The standard p
permeabilityy test is to measure time
taken by a 2000 cu cm of air at a pressure typically of

980 Pa (10 g/cm2), to pass through a standard sand
specimen confined in a specimen tube. The standard
specimen size is 50.8
50 8 mm in diameter and a length of
50.8 mm.
inthebasicprocessofsandcastingthanporosity.Give
p
g
p
y
oneimportantreasonforthisfeature.
501.28
501
28
R=
= 70.75
5 1.417
WhereV=volumeofair=2000cm3
H=heightofthesandspecimen=5.08cm
p=airpressure,g/cm2
A=crosssectionalareaofsandspecimen=20 268cm2
A=crosssectionalareaofsandspecimen=20.268cm
T=timeinminutesforthecompleteairtopassthrough
Insertingtheabovestandardvaluesintothe
expression,weget
i
501.28
R=
p.T
IES2007
IES 2007
Whatispermeability?Permeabilityismoreimportant
p = 5.0 g / cm 2
T = 1 min 25 s = 1.417 min
Then the permeability number,

number R is obtained by
y Then,
VH
R=
pAT
AT
[2marks]
Page 7
y Collapsibility:Atthetimeofcooling,castingshrinks,and
p
y
g,
g
,
unlessthecorehasgoodcollapsibility(abilitytodecrease
insize)itislikelytoprovideresistanceagainstshrinkage
)
y p
g
g
andthuscancausehottears.
CoreSands
y Friability: The ability to crumble should be a very
important
p
consideration at the time of removal.
y Smoothness: Surface of the core should be smooth
for good finish to the casting.

y Low Gas Emission
y Used clay free silica sand.

y Binders used are linseed oil, core oil, resins, dextrin,
molasses, etc.
y Core oils
l are mixtures off linseed,
l
d soy, fish
f h and
d
petroleum oils and coal tar.

tar
y The general composition of a core sand mixture could
be core oil ((1%)) and water ((2.55 to 6%).

)
CarbonDioxideMoulding
y Sodium
silicate
(water
glass,
SiO2:Na
S di
ili
(
l
N 2O) is
i used
d as a binder.
bi d
This is essentially a quick process of core or mould

preparation.
y The mould is p
prepared
p
with a mixture of sodium silicate and
sand and then treated with carbon dioxide for two to three
minutes such that a dryy compressive
p
strength
g of over 1.4
4
MPa is arrived.
y The carbon dioxide is expected to form a weak acid,
acid which
hydrolyses the sodium silicate resulting in amorphous silica,
which forms the bond.
bond
y The introduction of CO2 gas starts the reaction by forming
h d
hydrated
d sodium
d
carbonate
b
( 2CO
(Na
O3 + H2O).
O)
Contd
y The compressive strength of the bond increases with
standing time due to dehydration.

y Because of the high strength of the bond, the core need not
be provided with any other reinforcements.

y It does not involve any distortions due to baking and also
better dimensional accuracies are achieved.

achieved
y The sand mixture does not have good shelf life and
therefore should be used immediately after preparation.
IES2002
Assertion (A): In CO2 casting process, the mould or
core attains maximum strength.
Reason (R): The optimum gassing time of CO2
through the mould or core forms Silica Gel which
imparts sufficient strength to the mould or core.
( ) Both A and R are individually true but R is not the
(b)
MouldingSandComposition
y Sand: Ordinary silica Sand (SiO2), zircon, or olivine
sands.
d
OtherAdditives
y Cereal binder up to 2% increases the strength.
y Pitch if used up to 3% would improve the hot
y Clay:
Cl
A
Acts
as binding
bi di
agents mixed
i d to the
h moulding
ldi
sands
strength.
y Saw dust up to 2% may improve the collapsibility by
Kaolinite or fire clay (Al2O3 2SiO2 2H2O),

O) and
Bentonite (Al2O3 4SiO2 H2O nH2O).
y Water: Clay
y is activated byy water.
slowly
l l burning,
b
i
and
d increase
i
the
h permeability.
bili
y Other
Oth materials:
t i l sea coal,
l asphalt,
h lt fuel
f l oil,
il graphite,
hit
molasses iron oxide,

molasses,
oxide etc.
etc
Page 8
G
2008 ( )
GATE
2008(PI)
In sand casting of a hollow part of lead,
lead a cylindrical core
of diameter 120 mm and height 180 mm is placed inside
the mould cavity. The densities of core material and lead
are 1600 kg/m3 and 11,300 kg/m3 respectively. The net
force (in N) that tends to lift the core during pouring of
molten metal will be
( ) 19.7
(a)
( ) 64.5
(b)
( ) 193.7
(c)
( ) 257.6
(d)
MouldingSandProperties
y Porosity or Permeability: Permeability or porosity of
the moulding
g sand is the measure of its abilityy to
permit air to flow through it.
y Strength: It is defined as the property of holding
together of sand grains. A moulding sand should have
ample
l strength
h so that
h the
h mould
ld does
d
not collapse
ll
or
get partially destroyed during conveying, turning over
or closing.
y Refractoriness: It is the ability of the moulding sand
mixture to withstand the heat of melt without showing
any signs
i
off softening
ft i or fusion.
f i
Contd
y Plasticity: Itisthemeasureofthemouldingsandtoflow
aroundandoverapatternduringrammingandtouniformly
d d

d i
i d if
l
filltheflask.
y Collapsibility:Thisistheabilityofthemouldingsandto
decreaseinvolumetosomeextentunderthecompressive
p
forcesdevelopedbytheshrinkageofmetalduringfreezing
andsubsequentcooling.
q
g
y Adhesiveness:Thisisthepropertyofsandmixtureto
adheretoanotherbody(here themouldingflasks) The
adheretoanotherbody(here,themouldingflasks).The
mouldingsandshouldclingtothesidesofthemoulding
boxessothatitdoesnotfalloutwhentheflasksarelifted
andturnedover.Thispropertydependsonthetypeand
amountofbinderusedinthesandmix.
t fbi d di th d i
OtherSands
material sprinkled on the inner surface of the mold
cavity
i to give
i a better
b
surface
f
fi i h to the
finish
h castings.
i
y Backing
g sand: It is what constitutes most of the
refractory material found in the mould. This is made
up of used and burnt sand.
sand
y Green Sand: The molding sand that contains
moisture is termed as green sand. The green sand
should have enough
g strength
g so that the constructed
mould retains its shape.
y Dry sand: When the moisture in the moulding sand is
completely expelled, it is called dry sand.
Grainsizenumber
grain size number,
number defined as
n-1
N 2
y Where N is the number of grains per square inch
visible in a prepared specimen at 100X and n is the
ASTM grainsize number.
y Low
L
ASTM numbers
b
mean a few
f
massive
i grains;
i
hi h
high
numbers refer to many small grains.
S ll amountt off carbonaceous

Small
b
material
t i l sprinkled
i kl d
on the inner surface of mould cavity is called
(a) Backing sand
((b)) Facing
g sand
((c)) Green sand
(d) Dry sand
CastingYield
IES2002
y ASTM (American Society for Testing and Materials)
IES2008
y Facing sand: The small amount of carbonaceous
In the grain size determination using standard

charts, the relation between the given size
number
b n and
d the
th average number
b off grains
i
'N'
N
Thecastingyieldistheproportionoftheactual
castingmass,w,tothemassofmetalpouredintothe
mould,W,expressedasapercentage.
p
p
g
per square
p
q
inch at a magnification
g
of 100 X is
Casting yield =
(a) N = 2n
w
100
W
(b) N = 2nl
(c) N = 2n + 1
(d) N = 2n + 1
G ti S t
GatingSystem
G i S
GatingSystem
y Pouring
basin:
P
i
b i A small
ll funnel
f
l shaped
h
d cavity
i at the
h
top of the mould into which the molten metal is

poured.
y Sprue: The passage through which the molten metal,
ffrom the
h pouring basin,
b
reaches
h the
h mould
ld cavity. In
many cases it controls the flow of metal into the
mould.
y Runner: The channel through which the molten
metal is carried from the sprue to the gate.

Contd
Page 9
Contd
y Ingate: Achannelthroughwhichthemoltenmetal
entersthemouldcavity.
y Vent:
V
S ll
Smallopeninginthemouldtofacilitateescape
i i h
ld f ili
ofairandgases.
TypesofGateorIngate
IES2011
Top gate: Causes turbulence in the mould cavity, it is prone

to form
f
d
dross,
f
favourable
bl temperature gradient
d
towards
d the
h
gate only for ferrous alloys.
gate,
alloys
gate: No mould erosion,, used for veryy deep
p moulds,,
Bottom g
higher pouring time, Causes unfavourable temperature
gradients.
Parting Gate: most widely used gate,
gate easiest and most
economical in preparation.
Step Gate: Used
d for
f heavy
h
and
d large
l
castings, size off ingates
are normally increased from top to bottom.
IES 2011
IES2011
g
Match List I with List II and select the correct answer using
the code given below the lists :
ListI
List
I
ListII
List
II
A.Topgate
1.Heavyandlargecastings
B.Bottomgate
2.Mostwidelyusedandeconomical
C.Partinggate
3.Turbulence
D St t
D.Stepgate
4.Unfavourable
U f
bl temperaturegradient
t
t di t
Codes
A
(a) 3
(c) 3
B
4
2
C
2
4
D
1
1
(b)
(d)
A
1
1
B
4
2
C
2
4
D
3
3
Thegoalsforthegatingsystem
y To minimize turbulence to avoid trapping gasses into
the mold
y To get enough metal into the mold cavity before the
metall starts to solidify
lidif
y To avoid shrinkage
g
y Establish the best possible temperature gradient in the
solidifying casting so that the shrinkage if occurs must
be in the gating system not in the required cast part.
y Incorporates a system for trapping the nonmetallic
inclusions.
In light metal casting, runner should be so designed

that:
1. It avoids aspiration
2. It
I avoids
id turbulence
b l
33. The p
path of runner is reduced in area so that
unequal volume of flow through each gate
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
molten
lt metal
t l through
th
h a horizontal
h i
t l runner off circular
i l 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
(d) increase in average velocity of molten metal
IES1998
A sand
mould
d casting
i
ld
assembly is shown in
the above figure. The
elements marked A
and B are respectively
(a) Sprue and riser
(b) Ingate and riser
(c) Drag and runner
(d) Riser
Ri and
d runner
IES1998
Whichofthefollowingaretherequirementsofanideal
gatingsystem?
1. Themoltenmetalshouldenterthemouldcavitywithas
highavelocityaspossible.
2. Itshouldfacilitatecompletefillingofthemouldcavity.
3. Itshouldbeabletopreventtheabsorptionofairorgases
I h ldb bl
h b
i f i
fromthesurroundingsonthemoltenmetalwhile
flowingthroughit.
Selectthecorrectanswerusingthecodesgivenbelow:
g
g
(a)1,2and3
(b)1and2 (c)2and3 (d)1and3
Page 10
GATE2002
The primary purpose of a sprue in a casting
mould is to
(a)Feed the casting at a rate consistent with the rate
of solidification
(b)A as a reservoir
(b)Act
i for
f molten
l
metall
((c)Feed
)
molten metal from the p
pouring
g basin to the
gate
(d)Help feed the casting until all solidification takes
place
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:
PressurizedGatingSystem
UnPressurizedGatingSystem
y The total cross sectional area decreases towards the
y The total cross sectional area increases towards the
mold
ld cavity
it
y Back p
pressure is maintained byy the restrictions in the
metal flow
y Flow of liquid (volume) is almost equal from all gates
y Back pressure helps in reducing the aspiration as the
sprue always runs full
y Because of the restrictions the metal flows at high
velocity leading to more turbulence and chances of
mold erosion.
erosion
y Pressurizedgatingsystem
y Unpressurizedgatingsystem
p
g
g y
S
Sprue
D i
Design
The height of the down

downsprue
sprue is 175 mm and its
crosssectional area at the base is 200 mm2. The
cross sectional area of the horizontal runner is
crosssectional
also 200 mm2. Assuming no losses, indicate the
correct choice
h i for
f the
h time
i
(i seconds)
(in
d ) required
i d to
fill a mould cavity of volume 106 mm3. (Use g = 10
m/s2).
(a)2 67 (b)8.45
(a)2.67
(b)8 45
(c)26 72
(c)26.72
(d)84 50
(d)84.50
y Flow of liquid (volume) is different from all gates

y Aspiration in the gating system as the system never
runs full
f ll
y Less turbulence.
turbulence
At = Ac
Theexacttaperingcanbeobtainedbytheequationof
continuity DenotingthetopandchokesectionsofThesprue by
continuity.DenotingthetopandchokesectionsofThesprue
thesubscriptstand'c'respectively,weget
A t Vt = A c Vc
At = Ac
WhereH=actual
WhereH
actual
sprue height
andht=h+H
h+H
Vc
Vt
Contd
Contd
GATE2001
y Restriction only at the bottom of sprue
Sincethevelocitiesareproportionaltothesquareof
thepotentialheads,ascanbederivedfrom
thepotentialheads ascanbederivedfrom
Bernoulli'sequation,
y Sprue: Sprue is the

h channel
h
l through
h
h which
h h the
h molten
l
metal is brought into the parting plane where it enters the

runners and gates to ultimately reach the mould cavity.
y The molten metal when moving
g from the top
p of the cope
p to
the parting plane gains in velocity and some lowpressure
area would be created around the metal in the sprue.
y Since the sand mould is permeable, atmospheric air would
be breathed into this lowpressure
low pressure area which would then
be carried to the mould cavity.
y To eliminate
l
this
h problem
bl
off air aspiration, the
h 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).
mold cavity
GATE2007
A 200 mm long down sprue has an area of cross
section of 650 mm2 where the pouring basin meets the
d
down
sprue (i.e.
(i at the
h beginning
b i i off the
h down
d
sprue).
)
A constant head of molten metal is maintained by the
pouring basin. The Molten metal flow rate is 6.5 105
mm3/s. Considering the end of down sprue to be open
to atmosphere and an acceleration due to gravity of
104mm/s2, the area of the down sprue in mm2 at its end
(avoiding aspiration effect) should be
( )
(a)650.0
( )
(b)350.0
( )
(c)290.7
( )
(d)190.0
Page 11
Contd
hc
ht
Gatingratio
y Gatingratioisdefinedas:Sprue area:Runnerarea:
Ingate area.
y Forhighqualitysteelcastings,agatingratioof1:2:2or
1:2:1 5willproducecastingsnearlyfreefromerosion
1:2:1.5willproducecastingsnearlyfreefromerosion,
willminimizeoxidation,andwillproduceuniform
,
p
flow.
y Agatingratioof1:4:4mightfavour theformationof
oxidationdefects.
IES2003
A gating ratio of 1: 2: 4 is used to design the gating
system
y
for magnesium
g
alloyy casting.
g This g
gating
g ratio
refers to the cross section areas of the various gating
elements as given below:
1. Down sprue 2.
Runner bar 3.
Ingates
Th correct sequence off the
The
h above
b
elements
l
i the
in
h
ratio 1: 2: 4 is
(a) 1, 2 and 3
(b) 1,3 and 2
(c) 2, 3 and 1
(d) 3, 1 an 2
GATE2010
I ti t
Inagatingsystem,theratio1:2:4represents
th ti
t
(a) Sprue basearea:runnerarea:ingate area
(b) Pouringbasinarea:ingate area:runnerarea
(c) Sprue basearea: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 cross
crosssectional
sectional areas of
sprue, runner and gate are in the ratio of 1: 2: 2, the
y
is known as unpressurised
p
gating
g
g system.
y
system
(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
The gating ratio 2: 8: 1 for copper in gating system

design refers to the ratio of areas of:
( ) Sprue:
(a)
S
R
Runner:
I
Ingate
((b)) Runner: Ingate:
g
Sprue
p
(c) Runner: Sprue: Ingate
(d) Ingate:
I
R
Runner:
S
Sprue
RisersandRiserDesign
y Risers
are added
Ri
dd d reservoirs
i designed
d i
d to feed
f d liquid
li id
metal to the solidifying casting as a means of

compensating for solidification shrinkage.
y To perform this function,
function the risers must solidify after
the casting.
y According
d
to Chvorinov's
Ch
' rule,
l a good
d shape
h
f a riser
for
would be one that has a long freezing time (i.e., a small
surface area per unit volume).
y Live risers (also known as hot risers) receive the last
hot metal that enters the mold and generally do so at a
ti
time
when
h
th metal
the
t l in
i the
th mold
ld cavity
it has
h already
l d
begun to cool and solidify.
Chvorinovs rule
IES1994
Assertion
(A):
is
A
i
(A) In
I a mould,
ld a riser
i
i designed
d i
d and
d placed
l d
so that the riser will solidify after the casting has solidified.
Reason (R): A riser is a reservoir of molten metal which
will supply
pp y molten metal where a shrinkage
g cavityy would
have occurred.
explanation of A
(b) Both
B th A and
d R are individually
i di id ll true
t
b t R is
but
i nott the
th
((d)) A is false but R is true
IES2005
y Totalsolidificationtime(t
l ldf
( s)=B(V/A)
)
(
)n
wheren 1.5to2.0
wheren=1.5to2.0
[Where,B=mouldconstantandisafunctionof(mould
material,castingmaterial,andconditionofcasting]
t i l ti t i l d
diti f ti ]
n=2 andtriser =1.25t
5 casting
2
or
Forcylinder
ofdiameterD
andheightH
V
V
= 1.25
1 25
A
riser
A casting
V = D2H / 4
A = DH + 2 D
4
Page 12
IES2011
The
h relationship
l
h between
b
totall freezing
f
time t,
volume of the casting V and its surface area A,
according to Chvorinovs rule is :
V
(a ) t = k
A
A
(b ) t = k
V
A
(c ) t = k
V
(d ) t = k
Wh
Where
K is
i a constant
GATE2003
IES1998
A spherical
p
drop
p of molten metal of radius 2 mm
IES2006
According
With a solidification
lidifi ti factor
f t off 0.97 x 106 s/m
/ 2, the
th
was found to solidify in 10 seconds. A similar drop
(a) 539
(b) 1078
(c) 4311
(c) 1/v
(c) 28.30 seconds
(d) 1/v2
(d) 40 seconds
Where, v = volume of casting
GATE2007
GATE2011(PI)
GATE 2011 (PI)
Solidification time of a metallic alloy casting is

Volume of a cube of side 'l'l and volume of a sphere of
(a) Directly proportional to its surface area
radius r are equal.

q
Both the cube and the sphere
p
are solid
(b) Directly proportional to the specific heat of the
and of same material. They are being cast. The ratio of the
castt material
t i l
solidification time of the cube to the same of the sphere is:
(c) Directly proportional to the thermal diffusivity of

the molten metal
((d)Inversely
)
y
proportional
p
p
to
the
(a )
4 r
6 l
4 r

6 l
( b )
4 r

6 l
( c )
pouring
p
g
the
(b) v
(d) 3233
(b) 20 seconds
GATE 2010(PI)
equation,
(a) v2
casting
g of 200 mm diameter is
(a) 14.14 seconds
Chvorinov's
solidification time of a casting is proportional to:
solidification time (in seconds) for a spherical
of radius 4 mm would solidify in
to
4 r

6 l
( d )
In a sand casting
gp
process,, a sphere
p
and a cylinder
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
of the cylinder is
(a) 1.14
1 14
(b) 0.87
( ) 1.31
(c)
((d)) 0.76
7
temperature.
IES 2012
( )
GATE2009(PI)
A solid cylinder of diameter D and height equal to D, and a solid
Theratioofsurfaceareaofvolumeforaunitvolumeof
cube of side L are being sand cast by using the same material.
material
riserisminimumincaseoff
Assuming there is no superheat in both the cases, the ratio of

solidification time of the cylinder to the solidification time of the
( )C li d i l i
(a)Cylindricalriser
cube is
(b)S h i l i
(b)Sphericalriser
(a) (L/D)2
(c)Hemisphericalriser
(b) (2L/D)2
(d)Cuboidsriser
( ) (2D/L)
(c)
( D/L)2
(d) (D/L)2
Page 13
IES 2011 C
ti
l
IES2011Conventional
y A round casting
g is 20 mm in diameter and 550 mm in
y It has been empirically established that if the modulus
length. Another casting of the same metal is elliptical in

cross section, with a major to minor axis ratio of 2, and
Compare the solidification time of two optimum side
has the same length and crosssectional area as the
risers off the

h same volume
l
with
h one has
h cylindrical
l d
l shape
h
round casting. Both pieces are cast under the same
and other is parallopiped.

parallopiped
[30 Marks]
Area of ellipse = ab
(a
+ b2 ) / 2
riser
i with
i h a heighttodiameter
h i h
di
ratio
i off 1.
Contd
(approx.)
y Calculate the size of a cylindrical riser (height and diameter
D
4
+ D
satisfactory.
y In steel castings, it is generally preferable to choose a

( 3a + b )( a + 3b )
ConventionalQuestionIES2008
Conventional Question IES2008
2
factor of 1.2,
1 2 the feeding during solidification would be
y Modulus = volume/Surface area
[10 Marks]
Circumference = 3 ( a + b )
= 2
off the
h riser
i
exceeds
d the
h modulus
d l off the
h casting
i
b a
by
MR = 1.2 Mc
conditions What is the difference in the solidification

conditions.
times of the two castings ?
ModulusMethod
ConventionalQuestionESE2003
Caines Method
Freezingratio=ratio ofcoolingcharacteristicsofcastingto
theriser.
A
X=
equal) necessary to feed a steel slab casting of dimensions

30 x 30 x 6 cm with a side riser, casting poured horizontally
( V)
( AV )
AccordingtoCaine
[[10 Marks]]
Table:ConstantsinCaines Method
Riser
Therisershouldsolidifylastsox>1
into the mould.

[Use Modulus Method]
Casting
X=
X
a
+c
Yb
V
Vcasting
riser
Y=anda,b,careconstant.
Y
d b
Conventional QuestionIES2007
Question IES2007
y Calculate the size of a cylindrical
y
riser (height
g and
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]
[ For
F steell a = 0.10, b = 0.03 and
d c = 1.00 ]
Page 14
Chills
IES1995
y External
E
l chills
hill are masses off highheatcapacity,
hi h h
i highthermal
hi h h
l
conductivity material that are placed in the mould (adjacent to

the casting)
th
ti ) to
t accelerate
l t the
th cooling
li off various
i
regions.
i
Chills can effectively promote directional solidification or
i
increase
the
h effective
ff i feeding
f di distance
di
off a riser.
i
Th can often
They
f
be used to reduce the number of risers required for a casting.
y Internal chills are pieces of metal that are placed within the
mould cavity to absorb heat and promote more rapid
solidification.
lidifi i
Si
Since
some off this
hi metall will
ill melt
l during
d i
the
h
operation, it will absorb not only the heatcapacity energy, but
also
l some heat
h t off fusion.
f i
Si
Since
th ultimately
they
lti t l become
b
partt off
the final casting, internal chills must be made from the same
alloy
ll as that
th t being
b i cast.
t
IAS1994
Chillsareusedincastingmouldsto
( ) Achievedirectionalsolidification
(a)
A hi di
i
l lidifi i
((b)) Reducepossibilityofblowholes
p
y
(c) Reducethefreezingtime
(d) Increasethesmoothnessofcastsurface
I
h
h
f
f
IES 2012
Statement
is
St t
t (I):
(I) Cupola
C
l furnace
f
i nott employed
l d for
f
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
individuallyy true and Statement ((II)) is the correct
explanation of Statement (I)
(b) Both Statement (I) and Statement (II) are
individually true but Statement (II) is not the correct
(c) Statement (I) is true but Statement (II) is false
( ) Statement (I)
(d)
( ) is false but Statement (II)
( ) is true
GATE1998,2007
Di ti
Directional
l solidification
lidifi ti
i castings
in
ti
can be
b
Chill are used

Chills
d in
i moulds
ld to
t
improved by using
(a) Achieve directional solidification
(a) Chills and chaplets
(b) Reduce the possibility of blowholes
((b)) Chills and p

padding
g
(c) Reduce freezing time
((c)) Chaplets
p
and p
padding
g
(d) Smoothen metal flow for reducing splatter.
(d) Chills, chaplets and padding.
Cupola
y Cupola has been the most widely used furnace for
IES1997
melting cast iron.

y 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
conventional cupola. Coke is fuel and Lime stone
(C CO3) is
(CaCO
i mostly
l used
d flux.
fl
y Cost of melting
g low.
y Main disadvantages of cupola is that it is not possible to
produce iron below 2.8%
2 8% carbon.
carbon
y Steel can be also prepared in cupola by employing
duplexing and triplexing operations.
Assertion (A): Steel can be melted in hot blast cupola.

Reason (R): In hot blast cupola,
cupola the flue gases are used to
preheat the air blast to the cupola so that the temperature in
th furnace
the
f
i considerably
is
id bl higher
hi h
th
than
th t in
that
i a
conventional cupola.
explanation
p
of A
(d) A is
i false
f l but
b R is
i true
El
ElectricArcFurnace
i A F
y For heavy steel castings, the openhearth type of
f
furnaces
with
h electric
l
arc or oill fired
f d would
ld be
b generally
ll
suitable in view of the large heat required for melting.
melting
y Electric arc furnaces are more suitable for ferrous
materials and are larger

g in capacity.
p
y
Page 15
Crucible Furnace
y Smaller foundries generally prefer the crucible furnace.
y The crucible is generally heated by electric resistance
or gas flame.
Induction Furnace
y 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
get the necessary heat directly from the charge instead
off the
th heat
h t source.
CastingCleaning(fettling)
Ladles
y Twotypesofladlesusedinthepouringofcastings.
P i
Pouringtime
i
GATE2005
Timetakentofillthemouldwithtopgate
Where A=Areaofmould
AH
A.H
tA =
H=Heightofmould
g m
A g 2gh
Ag =AreaofGate
A fG t
Hm =Gateheight
Timetakentofillthemouldwithbottomgate
tB =
(
2g
2A
Ag
hm hm H
Impuritiesinthemoltenmetalarepreventedfrom
reachingthemouldcavitybyprovidinga
g
y yp
g
(i) Strainer
(ii) Bottomwell
B tt ll
(iii) Skimbob
GATE 2007(PI)LinkedS1
( ) k d
In
I a sand
d casting
ti process, a sprue off 10 mm base
b
5 mm height
g leads to a runner
diameter and 250
which fills a cubical mould cavity of 100 mm size
Th volume
The
l
fl rate (in
flow
(i mm3/s)
/ ) is
i
(a) 0.8
0 8 x 105
(b) 1.1
1 1 x 105
(c) 1.7 x 105
(d) 2.3 x 105
A mould has a downsprue whose length is 20 cm

and the cross sectional area at the base of the
downsprue is 1cm2. The downsprue feeds a
horizontal runner leading into the mould cavity of
volume
l
1000 cm3. The
Th time
i
required
i d to fill the
h
mould cavity will be
(a)4.05 s (b)5.05 s (c)6.05 s
(d)7.25 s
GATE 2007(PI)LinkedS2
( ) k d
In
I a sand
d casting
ti process, a sprue off 10 mm base
b
5 mm height
g leads to a runner
diameter and 250
which fills a cubical mould cavity of 100 mm size
Th mould
The
ld filling
filli time
i
(i seconds)
(in
d ) is
i
(a) 2.8
28
(b) 5.78
5 78
(c) 7.54
(d) 8.41
Page 16
GATE1996
Light impurities in the molten metal are prevented
from reaching the mould cavity by providing a
( ) Strainer
(a)
S i
((b)) Button well
(c) Skim bob
(d) All off the
h above
b
GATE2006
d cast
g ope
at o , tthee tota
qu d head
ead iss
In a sa
sand
casting
operation,
total liquid
maintained constant such that it is equal to the mould
height The time taken to fill the mould with a top gate
height.
is tA. If the same mould is filled with a bottom gate,
th the
then
th time
ti
t k is
taken
i tB. Ignore
I
th time
the
ti
required
i d to
t
fill the runner and frictional effects. Assume
atmospheric pressure at the top molten metal surfaces.
The relation between tA and tB is
(A)
tB = 2 t A
((B))
tB = 2 t A
(C)
tB =
(D)
tB = 2 2 t A
tA
2
Expressionforchokearea
CA =
m
mm2
ct 2gH
Wherem=massofthecasting,kg
=Densityofmetal,kg/m
y
, g/ 3
t=pouringtime
c=Efficiencyfactorandisthefunctionofgate
Effi i
f t di th f
ti f t
systemused
H=Effectiveheadofliquidmetal
=hfortopgate
pg
Contd
H=h
=h
IES2009
IES 2009
hm
2
forbottomgate
hc2
2h m
forpartinglinegate
IAS2011Main
IAS2011 Main
y 2marks
Sk t h a mould
Sketch
ld for
f two
t
h ll
hollow
components
t to
t be
b
cast On the diagram,
cast.
diagram indicate runner,
runner gate,
gate riser,
riser
p sprue,
p
pouring
p
g basin, sprue
p
well, drag,
g
core, cope,
parting line.
hC
hm
hm
[10Marks]
hm
li
topgatepartinglinegatebottomgate
CastingDefects
GasDefects
Thefollowingarethemajordefects,whicharelikelyto
y A condition existing in a casting caused by the
occurinsandcastings:
d
trapping of gas in the molten metal or by mold gases

evolved during the pouring of the casting.
y The defects in this category can be classified into
blowholes and p
pinhole p
porosity.
y
y Blowholes are spherical or elongated cavities present
in the casting on the surface or inside the casting.
casting
y Pinhole porosity occurs due to the dissolution of
hydrogen gas, which gets entrapped during heating of
molten metal.
y Gasdefects
G d f
y Shrinkagecavities
Sh i k iti
y Moldingmaterialdefects
y Pouringmetaldefects
y Moldshift.
Moldshift
g
MoldingMaterialDefects
Cutandwashes
y These appear as rough spots and areas of excess metal, and
y Cutsandwashes,
Cutsandwashes
y Scab
y Metalpenetration,
Metalpenetration
y Fusion,and
are caused byy erosion of molding

g sand byy the flowing
g
metal.
y This is caused by the molding sand not having enough
strength and the molten metal flowing at high velocity.
y The
Th former
f
can be
b taken
k care off by
b the
h proper choice
h i off
molding sand and the latter can be overcome by the
proper design
d
off the
h gating system.
y Swell
Page 17
Sh i k
ShrinkageCavities
C ii
y These are caused by liquid shrinkage occurring during the
solidification of the casting.

y To
T compensate for
f this,
hi proper feeding
f di off liquid
li id metall is
i
required. For this reason risers are placed at the

appropriate
i
places
l
i the
in
h mold.
ld
y Sprues
p
mayy be too thin, too long
g or not attached in the
proper location, causing shrinkage cavities.
y It is recommended to use thick sprues to avoid shrinkage
cavities.
S b
Scab
y 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
y When the metal is poured into the cavity, gas may be
di
disengaged
d with
i h such
h violence
i l
as to break
b k up the
h sand,
d
which is then washed away and the resulting cavity filled
with
i h metal.
l
y The reasons can be: too fine sand, low p
permeabilityy of
sand, high moisture content of sand and uneven mould
ramming.
g
Metalpenetration
y When
h
molten
l
metall enters into the
h gaps between
b
sand
d
grains, the result is a rough casting surface.

y This occurs because the sand is coarse or no mold wash was
applied
pp
on the surface of the mold. The coarser the sand
grains more the metal penetration.
Fusion
y This is caused by the fusion of the sand grains with
the molten metal, giving a brittle, glassy appearance

on the casting surface.
y The main reason for this is that the clay or the sand
particles
ti l
are off lower
l
refractoriness
f t i
or that
th t the
th
pouring temperature is too high.
high
PouringMetalDefects
Swe
Swell
Under the influence of metallostatic forces, the mold
wall may move back causing a swell in the dimension
of the casting. A proper ramming of the mold will
correct this defect.
defect
Inclusions
Particles of slag,
slag refractory materials sand or
deoxidation products are trapped in the casting during
pouring solidification.
solidification The provision of choke in the
gating system and the pouring basin at the top of the
mold can prevent this defect
GATE2004
y
y The misrun and cold shut defects are caused either by
The likely defects in this category are

y Mis
Misruns
runs and
y Cold shuts
y A mis
misrun
run is caused when the metal is unable to fill
a lower fluidity of the mold or when the section

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
metal.
the mold cavity completely and thus leaves unfilled

cavities.
cavities
y 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.
Mi
Misrun
i a casting
is
ti defect
d f t which
hi h occurs due
d to
t
(a) Very high pouring temperature of the metal
(b) Insufficient fluidity of the molten metal
(c) Absorption of gases by the liquid metal
(d) Improper alignment of the mould flasks
Contd
GATE2009
MoldShift
Two streams of liquid metal which are not hot
The mold shift defect occurs when cope and drag
enough to fuse properly result into a casting defect
or molding boxes have not been properly aligned.
S bi
Scabisa
(a) Sandcastingdefect
known as
(b) Machiningdefect
(a) Cold shut
(c) Weldingdefect
(b) Swell
(d) Forgingdefect
( ) Sand
(c)
d wash
h
(d) Scab
S b
IES2001
Page 18
IAS2004
MatchListI(CastingDefects)withListII(Explanation)andselectthecorrect
answerusingthecodesgivenbelowthelists:
ListII
List
ListII
List
II
(CastingDefects)
(Explanation)
A.Metallicprojections 1.Consistofroundedorroughinternalorexposedcavities
includingblowholesandpinholes
B.Cavities
2.Formedduringmelting,solidificationandmoulding.
C.Inclusions
3.Includessinglefolds,laps,scarsadheringsandlayersand
oxidescale
D.Discontinuities
4.Includecracks,coldorhottearingandcoldshuts
5.Consistoffins,flashormassiveprojectionsandrough
surfaces
Codes:A
B
C
D
A
B
C
D
(a) 1
5
3
2
(b)
1
5
2
4
(c)
5
1
2
4
(d)
5
1
3
2
IES2005
In gating system design, which one of the
following is the correct sequence in which choke
area, pouring time, pouring basin and sprue sizes
are calculated?
l l d?
((a)) Chokearea Pouringtime
g
Pouringbasin
g
Sprue
p
(b) Pouringbasin Sprue Chokearea Pouringtime
( ) Chokearea
(c)
Ch k
Sprue
S
Pouringbasin
P i b i Pouringtime
P i i
((d)) Pouringbasin
g
Pouringtime
g
Chokearea Sprue
p
IAS2001
Whichofthefollowingpatternmaterialsareused
inPrecisionCasting?
1. PlasterofParis
2. Plastics
3 AnodizedAluminium Alloy
3.
4. FrozenMercury
Selectthecorrectanswerusingthecodesgivenbelow:
(a)1and2(b) 2and4(c)3and4(d)1and3
GATE2003
Hardnessofgreensandmouldincreaseswith
( ) Increaseinmoisturecontentbeyond6percent
(a)
I
i i
b
d6
((b)) Increaseinpermeability
p
y
(c) Decreaseinpermeability
(d) Increaseinbothmoisturecontentand
I
i b h i
d
permeability
IES1997
Ifthemeltingratioofacupolais10:1,thenthe
cokerequirementforonetonmeltwillbe
(a) 0.1ton
(b) 10tons
(c) 1ton
(d) 11tons
IAS2004
Whichoneofthefollowinggatingsystemsisbest
suitedtoobtaindirectionalsolidification?
(a) Topgrating
(b) Partlinegrating
(c) Bottomgrating
(d) Steppedgrating
Page 19
IES1998
Assertion(A):Stiffeningmembers,suchaswebs
andribs,usedonacastingshouldbeliberally
provided.
Reason(R):Theywillprovideadditionalstrength
toacastmember.
( ) BothAandRareindividuallytrueandRisthe
(a)
B hA dR i di id ll
dRi h
correctexplanationofA
(b) BothAandRareindividuallytruebutRisnot the
p
(c) AistruebutRisfalse
(d) AisfalsebutRistrue
IES2009
Inwhichoneofthefollowingfurnacesmostofthe
non ferrousalloysaremelted?
nonferrousalloysaremelted?
(a) Reverberatory furnace
(b) Inductionfurnace
(c) Cruciblefurnace
(d) Potfurnace
C t Al i i
C d
CastAluminiumCode
ou d g t de t cat o syste
y Fourdigitidentificationsystem
y Firstdigitindicatesalloygroup
1 Aluminium,99%ormore
l
2 copper
2
3 Silicon,withcopperand/ormagnesium
4 silicon
5 magnesium
5
6 notused
7 zinc
8 tin
8
9 otherelements
CastAluminiumCodeContd..
y Second
alloy
or
S
d two digits
di i identify
id if the
h aluminium
l i i
ll
indicate the aluminium purity.

y The last digit is separating from the other three by a
decimal point and indicates the product form; that is,

is
castings or ingots
y A modification
df
off the
h originall alloy
ll is indicated
d
d by
b a
serial letter before the numerical designation.
y Alloy A514.0 indicates an aluminium alloy casting with
magnesium as the principal alloy.
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) Aluminium
Al i i
content
((c)) Percentage
g of alloyy element
(d) Magnesium Content
Sp i lC ti g
SpecialCasting
Ans.
s (d)
BySKMondal
ShellMouldingg
y The
e sa
sand
d iss mixed
ed w
with
t a tthermosetting
e osett g resin
es
iss
y Can produce complex parts.
allowed to come in contact with a heated metal pattern

(2000C).
C)
y A skin (shell) of about 3.5 mm of sand and plastic
mixture adhere to the pattern.
y Then the shell is removed from the pattern.
y The cope and drag shells are kept in a flask with
necessary backup
b k
material
t i l and
d the
th molten
lt
metal
t l is
i
poured into the mold.
y A good surface finish and good size tolerance
MoldingSandinShellMolding
Molding Sand in Shell Molding
y Hot coating:
g the mixture is heated to 150
5 oC 180oC p
prior
y The molding sand is a mixture of fine grained quartz sand
and powdered bakelite.

y Cold coating and Hot coating methods are used for
y Materials can be cast: CI, Al and Cu alloys.
Shellmouldingprocess
to loading the sand. In the course of sand mixing, the
allowed
ll
d to cooll up to 80
8 90o C.
C Hot
H coting
i gives
i
b
better
y Very thin sections can be cast.
then the solution of p

powdered bakelite in acetone and
ethyl aldehyde are added. (mixture is 92% quartz sand,
Contd
y Dimensional accuracy.
y Smoother surface finish. (Due to finer size grain used)
Cold coating: quartz sand is poured into the mixer and
5% bakelite, 3% ethylaldehyde )
Advantages
soluble phenol formaldehyde resin is added. The mixer is
properties to the mixtures than cold method.

method
coating
i the
h sand
d grains
i with
i h bakelite.
b k li
y
reduce the need for machining.
Page 20
y Very small amount of sand is needed.
Limitations
Applications
y Expensive pattern
y Small size casting only.
y Highly
Hi hl complicated
li
d shapes
h
cannot be
b obtained.
b i d
y More
M
sophisticated
hi ti t d equipment
i
t is
i needed
d d for
f handling
h dli
y Cylinders
C li d
and
d cylinder
li d heads
h d for
f air
i cooled
l d IC
engines
y Automobile transmission parts.
y Piston rings
g
the shell moldings.

moldings
IES1996
IES2005
Consider the following ingredients used in

moulding:
1. Dry silica sand
2.Clay
3 Phenol formaldehyde
3.Phenol
4.Sodium silicate
Those used for shell mould casting include
(a) 1,
1 2 and 4
(b) 2,
2 3 and 4
(c) 1and 3
(d) 1, 2, 3 and 4
Inshellmoulding,howcantheshellthickness
beaccuratelymaintained?
(a)Bycontrollingthetimeduringwhichthepattern
i i
isincontactwithmould
i h
ld
( ) y
(b)Bycontrollingthetimeduringwhichthepattern
g
g
p
isheated
(c)Bymaintainingthetemperatureofthepatternin
therangeof175oC 380oC
(d)Bythetypeofbinderused
IES2007
IAS2007
Which of the following are employed in shell

moulding?
1. Resin
R i binder
bi d
2. Metal
M l pattern 3. Heating
H i coils
il
g the code g
given
Select the correct answer using
below:
(a) 1 and 2 only
(b) 1 and 3 only
(c) 2 and 3 only
(d) 1, 2 and 3
The mould in shell moulding process is made up

of which of the following?
(a) Gypsum + setting agents
(b) Green sand + clay
(c) Sodium silicate + dried sand
(d) Dried silica + phenolic resin
Page 21
IES2010
Considerthefollowingadvantagesofshell
C
id th f ll i d
t
f h ll
mouldcasting:
g
1.Closedimensionaltolerance.
2.Goodsurfacefinish.
3 Lowcost
3.Lowcost.
4
4.Easier.
Whichofthesearecorrect?
(a)1,2and3only (b)2,3and4only
( ) d l (d)1,2,3and4
(c)1,2and4only
(d) d
IES2006
Shellmouldingcanbeusedfor:
( ) Producingmillingcutters
(a)
P d i illi
((b)) Makinggoldornaments
gg
(c) Producingheavyandthickwalledcasting
(d) Producingthincasting
P d i hi
i
IAS1999
Match List I (Moulding Process) with List II (Binding
Agent) and select the correct answer using the codes
given below
b l
the
h lists:
l
List I
List II
A. Green sand
1. Silicate
B. Core sand
2. Organic
C. Shell moulding
3. Clay
D. CO2 p
process
4. Plaster of Paris
5. Plastic
Codes:A
B
C
D
A
B
C
D
(a) 3
2
5
1
(b) 3
2
4
1
((c)) 2
3
5
4
((d)) 2
3
4
5
InvestmentCasting
CeramicShellInvestmentCasting
Investment casting process or lost wax process

p
Basic steps:
1. Produce expendable wax, plastic, or polystyrene patterns.
2 Assemble these patterns onto a gating system
2.
3. Investing or covering the pattern assembly with refractory
slurry
4. Melting the pattern assembly to remove the pattern material
5. Firing
ii
the
h mould
ld to remove the
h last
l
traces off the
h pattern
material
6. Pouring molten metal
g
7. Knockout, cutoff and finishing.
y In ceramic shell investment casting

g a ceramic shell is
built around a tree assembly by repeatedly dipping a

pattern into a slurry (refractory material such as
zircon with binder).
y After each dipping and stuccoing is completed, the
assembly is allowed to thoroughly dry before the next

coating is applied.
Fig.Investmentflaskcastingprocedure
Advantages
IES2009
IES 2009
y Tight dimensional tolerances
y 2marks
y Excellent surface finish (1.2 to 3.0 m )

y Machining
can
be
reduced
or
completely
eliminated
li i t d
y High melting point alloy can be cast,
cast almost any
metal can be cast

y Almost unlimited intricacy
Limitations
Applications
y Costly
C tl patterns
tt
and
d moulds
ld
y Aerospace
A
and
d rocket
k t components.
t
y Labour costs can be high
y Vanes and blades for gas turbines.

turbines
y Limited size
y Surgical instruments
Page 22
IES2011
The proper sequence of investment casting steps is :
(a) Slurry coating pattern melt out
outShakeout
Shakeout Stucco
coating
(b) Stucco
S
coating
i Slurry
Sl
coating
i Shakeout
Sh k
Pattern
P
melt out
(c) Slurry coating Stucco coating Pattern melt out
Shakeout
(d) Stucco coating Shakeout Slurry coating Pattern
melt
l out
GATE2006
An expendable pattern is used in
(a) Slush casting
(b) Squeeze casting
(c) Centrifugal casting
(d) Investment casting
IES1992
Themostpreferredprocessforcastinggasturbine
bladesis:
(a) Diemoulding
(b) Shellmoulding
(c) Investmentmoulding
(d) Sandcasting
IES 2007
IES2007
Consider the following statements in respect of
investment castings:
1. The
Th pattern
tt
or patterns
tt
i /
is/are
nott joined
j i d to
t a stalk
t lk or
sprue also of wax to form a 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
are correct?
(a) 1 and 2 only
(b) 1 and 3 only
(c)2 and 3 only
(d) 1, 2 and 3
GATE2011(PI)
ISRO2010
Whi h off the

Which
th following
f ll i
casting
ti
processes uses
Investment casting is used for
expendable pattern and expendable mould?
((a)) Shapes
p which are made byy difficultyy using
g complex
p
(a) Shell mould casting

((b)) Investment casting
g
patterns in sand casting

(b) Mass production
(c) Shapes which are very complex and intricate and
((c)) Pressure die casting

g
can'tt be cast by any other method

can
(d) Centrifugal casting
((d)) There is nothing

g like investment casting
g
JWM2010
Considerthefollowingmaterials:
1.Wax
2.Wood
3 Plastic
3.Plastic
Whichofthesematerialscanbeusedaspatternin
investmentcastingprocess?
(a)1 2and3
(a)1,2and3
(b)1and2only
(c)2and3only
(d)1and3only
IES2006
Which of the following materials are used for
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
(c) Only 1, 2 and 4
(d) Only 2, 3 and 4
Page 23
IES2010
Assertion (A): The investment casting is used for
precision parts such as turbine plates, sewing
machines
hi
etc.
) The investment castings
g have a g
good
Reason ((R):
surface finish and are exact reproductions of the
master pattern.
pattern
(b) Both A and R are individually true but R is NOT the
( ) A is
(c)
i true
t
b t R is
but
i false
f l
IAS1996
Light and intricate parts with close dimensional
tolerances of the order of 0.005
0 005 mm are
produced by
(a) Investment casting
(b) Die casting
(c) Centrifugal casting
(d) Shell mould casting
PermanentMouldCasting
y The p
process in which we use a die to make the
castings is called permanent mold casting or gravity

die casting, since the metal enters the mold under
gravity.
y Some
S
ti
time
i diecasting
in
di
ti we inject
i j t the
th molten
lt metal
t l
with a high pressure. When we apply pressure in
injecting the metal it is called pressure die casting
p
process.
y Grey cast iron is used for mould material.
Applications
y Pistons/cylinders/rods
Pi t
/ li d / d
Advantages
y Good su
surface
ace finish
s aand
dd
dimensional
e s o a accu
accuracy
acy
y Metal mold gives rapid cooling and finegrain
structure
t t
y Multipleuse
p
molds.
Disadvantages
y High
g initial mold cost
y Shape, size, and complexity are limited
y Mold life is very limited with highmeltingpoint
metals such as steel.

y Low melting point metals can be cast
Aluminum
Zi
Zinc
Magnesium alloys
Brass
Cast iron
DieCasting
y Molten metal is injected
j
into closed metal dies under
Diecastingmachinescanbe
pressures ranging from 100 to 150 MPa.
y Gears
y Kitchenware
y Pressure is maintained during solidification
y Hotchamber
y After which the dies separate and the casting is ejected
y Coldchamber
along with its attached sprues and runners.

y Cores must be simple and retractable and take the
f
form
off moving
i metall segments
Coldchambermachines
Hotchambermachinesare
Hot chamber machines are
y Good for low temperature (approx. 400
400C)
C)
y Castshighmeltingpointmetals(>600
Castshighmeltingpointmetals(>600C)
C)
y Faster than cold chamber machines
y Highpressuresused
g p
y Cycle times must be short to minimize metal
y Metalisheatedinaseparatecrucible
contamination
y Metal starts in a heated cylinder
y A piston
i
f
forces
metall into
i
the
h die
di
y The p
piston retracts,, and draws metal in
y Metal: Lead, Tin, Zinc
y Metalisladledintoacoldchamber
y Themetalisrapidlyforcedintothemoldbeforeit
cools
l
y Copper,BrassandAluminiumcancast.
HotChamber
Page 24
Ad t
Advantages
y Extremelysmoothsurfaces(1m)
E
l
h f
( )
Limitations
y Excellentdimensionalaccuracy
E ll tdi
i
l
y Highinitialdiecost
y Rapidproductionrate
y Limitedtohigh
Limitedtohighfluiditynonferrousmetals
fluiditynonferrousmetals
y Bettermechanicalpropertiescomparedtosand
y Partsizeislimited
y Porositymaybeaproblem
casting
g
y Intricatepartspossible
p
p
y Minimumfinishingoperations
g p
y Somescrapinsprues,runners,andflash,butthiscan
bedirectlyrecycled
y Thinsectionspossible
IES2011
Applications
A li i
y Carburettors
y Automotive parts
y Bathroom
B h
fi
fixtures
y Toys
y
Common metals
l
y Alloys of aluminum, zinc, magnesium, and lead
y Also possible with alloys of copper and tin
JWM2010
Assertion (A) : In die casting method,
method small
thickness can be filled with liquid metal.
Reason (R) : The air in die cavity trapped inside the
casting
g causes p
problems.
(a) BothAandRareindividuallytrueandRisthe
t l
ti fA
(b) BothAandRareindividuallytruebutRisnot
y
the
Consider
d the
h following
f ll
advantages
d
off die
d casting over
sand casting :
1. Rapidity of the process
2 Smooth surface
2.
3. Strong dense metal structure
Whi h off these
Which
h
advantages
d
are correct ?
((a)) 1,, 2 and 3
(b) 1 and 2 only
(c) 2 and 3 only
(d) 1 and 3 only
IES2005
Which one of the following processes produces a
casting when pressure forces the molten metal
into the mould cavity?
(a) Shell moulding
(b) Investment casting
(c) Die casting
(d) Continuous casting
Page 25
IES2009
Which of the following are the most suitable
materials for die casting?
(a) Zinc and its alloys
(b) Copper and its alloys
(c) Aluminium and its alloys
(d) Lead and its alloys
IES2006
In which of the following are metal moulds used?
( ) Greensand
(a)
G
d mould
ld
((b)) Dryy sand mould
(c) Die casting process
(d) Loam
L
moulding
ldi
IES1995
Assertion (A): An aluminium alloy with 11 % silicon is
g engine
g
pistons by
p
y die casting
g
used for making
technique.
Reason (R): Aluminium has low density and addition
of silicon improves its fluidity and therefore its
y
castability.
explanation of A
IES1995
MatchListIwithListIIandselectthecorrectanswertakingthehelp
ofcodesgivenbelowthelists:
ListI
ListII
(Products)
(Processofmanufacture)
A.
Automobilepistoninaluminium
p
alloyy
1.Pressurediecasting
g
B.
Enginecrankshaftinspheroidal
graphiteiron
2.Gravitydiecasting
C
C.
Carburettor housinginaluminium alloy 3.Sandcasting
3 Sandcasting
D.
Casttitaniumblades
4.Precisioninvestment
casting
5.Shellmoulding
h ll
ld
Code: A
B
C
D
A
B
C
D
(a) 2
3
1
5
(b)
3
2
1
5
(c) 2
1
3
4
(d)
4
1
2
3
IAS1996
Assertion (A): Die casting yields a product of good
accuracy and finish.
Reason (R): Low melting alloys used in die
casting.
casting
correct explanation
l
i off A
(b) Both A and R are individuallyy true but R is not the
IES1995
Assertion (A): Aluminium alloys are cast in hot
g machine.
chamber die casting
Reason (R): Aluminium alloys require high melting
when compared to zinc alloys.
explanation of A
1. Zincdiecastingshavelowstrength.
Zi di
i h l
h
gp
,
y
2. Inthediecastingprocess,verythinsectionsor
complexshapescanbeobtainedeasily.
Whichofthestatementsgivenaboveis/arecorrect?
(a) 1only
(b) 2only
(c) Both1and2
(d) Neither1nor2
IES2011
Consider the following statements :
1 Hot chamber machine is used for casting zinc,
1.
zinc tin and
other low melting alloys.
2. Cold
C ld chamber
h b machine
hi
i used
is
d for
f die
di casting
i
off
ferrous alloys
3. Rapid cooling rate in die casting produces high
strength and quality in many alloys.
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
GATE2009(PI)
GATE 2009 (PI)
Hot chamber die casting process is NOT suited for
GATE2007
Which of the following engineering materials is
the most suitable candidate for hot chamber die
casting?
(a) Low carbon steel
(b) Titanium
(c) Copper
(d) Tin
C
CentrifugalCasting
if l C i
y Process: Molten metal is introduced into a rotating sand,
sand
graphite
p
mould, and held against
g
the mould
metal, or g
wall by centrifugal force until it is solidified
(a) Lead and its alloy
y A mold is set up and rotated along a vertical (rpm is
((b)) Zinc and its alloyy
reasonable), or horizontal (2001000 rpm is reasonable)
(c) Tin and its alloy
axis.
axis
(d) Aluminum and its alloy

IAS2007
y The mold is coated with a refractory coating.

y During
g cooling
g lower densityy impurities
p
will tend to rise
Page 26
towards the center of rotation.
Properties
y 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 easilyy removed byy machining.
g Also, the
pressure acting on the metal throughout the solidification
causes the p
porosityy to be eliminated g
giving
g rise to dense
metal.
y No cores are required for making concentric holes in the
case of true centrifugal casting.
Fig Truecentrifugalcasting
Fig.Truecentrifugalcasting
Limitations
y More segregation of alloy component during pouring under
the forces of rotation

y Contamination of internal surface of castings with non
non
Commonmetals
y
y
y
y
Iron
steel
stainlesssteel
alloysofaluminium,copper,andnickel
ll f l i i
d i k l
metallic inclusions
y Inaccurate internal diameter
Advantages
y Fine grained structure at the outer surface of the
casting free of gas and shrinkage cavities and

porosity
y Formation
F
i off hollow
h ll
i
interiors
i
i cylinders
in
li d
without
ih
cores
y Can produce a wide range of cylindrical parts,
including ones of large size.
size
y Good dimensional accuracy, soundness, and
cleanliness
l
li
y There is no need for g
gates and runners,, which
increases the casting yield, reaching almost 100 %.
GATE2002
In centrifugal casting, the impurities are
(a) Uniformly distributed
(b) Forced towards the outer surface
(c) Trapped near the mean radius of the casting
(d) Collected at the centre of the casting
y Shape is limited.
y Spinning equipment can be expensive
y Poor machinability
GATE1993
Centrifugally cast products have
( ) Large
(a)
L
grain
i structure with
i h high
hi h porosity
i
((b)) Fine g
grain structure with high
g densityy
(c) Fine grain structure with low density
(d) Segregation
S
i off slug
l towards
d the
h outer skin
ki off the
h
casting
GATE2008(PI)
GATE 2008 (PI)
In hollow cylindrical
y
parts,, made byy centrifugal
p
g casting,
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
Page 27
IES2008
Which
h h off the
h following
f ll
casting processes does
d
not
/do not require central core for producing pipe?
1. Sand casting process
2 Die casting process
2.
3. Centrifugal casting process
S l
Select
the
h correct answer using
i the
h code
d given
i
b l
below:
((a)) 1 and 2
(b) 2 only
(c) 2 and 3
(d) 3 only
IES2009
IES2007
Which one of the following casting processes is

best
suited
to
make
bigger
size
hollow
symmetrical pipes?
(a) Die casting
(b) Investment casting
Which one of the following is the correct

statement?
In a centrifugal casting method
(a) No core is used
(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
(a) Chilling
(b) Segregation
(c) Densestructure
(d) Highmouldrotationspeed
( ) Shell
(c)
h ll moulding
ld
(d) Centrifugal
C
if
l casting
i
IES2009
IES2007
Which of the following are the most likely

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
(d) Coarse grain size and high density
MatchListIwithListIIandselectthecorrectanswerusingthecodegiven
belowtheLists:
ListI
ListII
(CastingProcess)
(Principle)
A.
Diecasting
1.Themetalsolidifiesinarotatingmould
B
B.
Investmentcasting
2 Thepatternclusterisrepeatedlydipped
2.Thepatternclusterisrepeatedlydipped
intoaceramicslurryanddustedwith
refractory
C
C.
Shellmoulding
3 Moltenmetalisforcedbypressureinto
3.Moltenmetalisforcedbypressureinto
ametallicmould
D.
Centrifugalcasting
4.Aftercooling,theinvestisremoved
fromthe Castingbypressurejettingor
g yp
j
g
vibratorycleaning
Code: A
B
C
D
A
B
C
D
((a)) 2
1
3
4
((b))
3
4
2
1
(c) 2
4
3
1
(c)
3
1
2
4
IAS2004
y Centrifugal force assists the flow of metal from a
D
3
(c)
(d)
MatchListI(Process)withListII(Products/materials)
andselectthecorrectanswerusingthecodesgiven
b l
belowtheLists:
h
ListI
ListII
A. Diecasting
1.Phenolformaldehyde
B. Shellmolding
2.C.I.pipes
C. CO2 molding
3.Nonferrousalloys
D. Centrifugalcasting
g
g
4.Sodiumsilicate
Codes:A
B
C
D
A
B
C
D
((a)
) 1
33
4
4
2
((b)
) 33
1
4
4
2
(c) 3
1
2
4
(d) 1
3
2
4
SemicentrifugalCasting
MatchListI(NameoftheProcess)withListII(Advantage)andselectthecorrect
answerusingthecodesgivenbelowthelists:
ListI
ListII
(NameoftheProcess)
(Advantage)
A.
SandCasting
1.Largecylindricalpartswithgoodquality
B.
Ceramicmoldcasting
2.Excellentdimensionalaccuracyandsurface
finish
C.
Diecasting
3.Intricateshapesandclosetoleranceparts
D.
Centrifugalcasting
4.Almostanymetaliscastandthereifnolimitto
size,shapeandweight
h
d
h
5.Gooddimensionalaccuracy,finishandlow
p
porosity
y
Codes:A
B
C
D
A
B
C
(a)
2
3
5
1
(b)
4
1
2
2
IES2000
central reservoir to the extremities of a rotating

symmetrical mold, which may be either expendable or
multipleuse
li l
y Rotational
R t ti
l speeds
d are lower
l
th for
than
f true
t
centrifugal
t if
l
casting
y Cores can be used to increase the complexity of the
product.
Page 28
Fig. Semicentrifugalcasting
IAS2003
Assertion (A): Semicentrifugal casting process is
g casting
g except
p that the
similar to true centrifugal
central core is used in it to form inner surface.
Reason (R): In semi
semicentrifugal
centrifugal casting process the
axis of spin is always vertical
explanation of A
Centrifuging
y Uses centrifuging action to force the metal from a central
pouring reservoir into separate mold cavities that are

offset
ff t from
f
th axis
the
i off rotation.
t ti
y Low speed
y May
y used to assist in the p
pouring
g of investment casting
g
trees.
Fig.Methodofcastingbythecentrifugingprocess
IES2000
MatchListI(Typeofcasting)withListII(Workingprinciples)
andselectthecorrectanswerusingthecodesgivenbelowthe
Lists:
ListI
ListII
A. Diecasting
1.Moltenmetalisforcedintothedie
underpressure
B. Centrifugalcasting
2.Axisofrotationdoesnotcoincidewith
axisofmould
C. Centrifuging
3.Metalsolidifieswhenmouldisrotating
D. Continuouscasting 4.Continuouslypouringmoltenmetal
intomould
Codes: A
B
C
D
A
B
C
D
( ) 1
(a)
3
2
4
(b)
(b)
4
3
2
1
(c) 1
2
3
4
(d)
4
2
3
1
IAS2004
Which of the following are produced by slush
casting?
(a) Hollow castings with thick walls
(b) Hollow castings with thin walls
(c) Thin castings
(d) Thick castings
DrySandMolding
SlushCasting
y To reduce gas forming materials air dried mould used.
y Slush casting is a variation of the permanent mold process
Types:
1.Skin drying and
2.Complete mold drying
IES2011
The method of casting for producing ornamental pieces
are:
(a) Slush and gravity casting
(b) Pressed
P
d and
d slush
l h casting
i
((c)) Gravityy and semi p
permanent mould casting
g
(d) Semi permanent mould and pressed casting
Page 29
in which the metal is permitted to remain in the mold only

until a shell of the desired thickness has formed.
y The mold is then inverted and the remaining liquid is
poured out.
y When the mold halves are separated, the resulting casting
iss a hollow
o o sshape
ape with
t good su
surface
ace deta
detail but va
variable
ab e wall
a
thickness.
y Frequently used to cast lowmeltingtemperature
low melting temperature metals
into ornamental objects such as candlesticks, lamp bases,
and statuary.
statuary
IES 2012
The
hollow
castings
off noncircular
Th process off making
ki
h ll
i
i l
shape and desired thickness by permanent mould
without the use of cores is known as
(a) Die casting
(b) Slush casting
(c) Pressed casting
(d) Centrifugal casting
SqueezeCasting
IAS2002
SingleCrystalCasting
Process:
1. Molten
M l
metall is
i poured
d into
i
an open face
f
di
die.
punch is advanced into the die,, and to the metal.
2. A p
3.Pressure (less than forging) is applied to the punch
and die while the part solidifies.
solidifies
4.The punch is retracted, and the part is knocked out
with an ejector pin.
y Overcomes problems with feeding the die,
die and
produces near net, highly detailed parts.
MatchListI(CastingProcess)withListII
(Applications)andselectthecorrectanswerusingthe
codesgivenbelowtheLists:
d
b l
h
ListI
ListII
(CastingProcess)
(Applications)
A. Centrifugalcasting
1.
Carburetor
B. Squeezecasting
2.
Pipes
C. DieCasting
g
33.
Wheelsfor
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
Theprocessiseffectively:
Th
i ff i l
1. Prepareamoldsothatoneendisaheatedoven,and
p
,
theotherendchilled.Thepartshouldbeorientedso
thatthecoolinghappensoverthelongestdistance.
thatthecoolinghappensoverthelongestdistance
2. Castmetalintothemold
3. Solidificationwillbeginatthechillplate.These
de d tes
dendriteswillgrowtowardstheheatedendofthe
g o to a ds t e eated e d o t e
partaslongdendritic crystals.Thepartisslowly
pulledoutoftheoven pastthechillplate
pulledoutoftheoven,pastthechillplate.
4. Removethesolidifiedpart.
IES2009
PlasterCasting
y Process: A slurry of plaster, water, and various additives is
y Creepandthermalshockresistanceproperties.
2marks
PitMoulding
IES1996
y This method is used for very large castings and is done on
Whichofthefollowingpairsarecorrectlymatched?
1. Pitmoulding
Pi
ldi ..................Forlargejobs.
F l
j b
g ...Lostwaxprocess.
p
2. Investmentmoulding
3. Plastermoulding Mouldpreparedin
gypsum.
gypsum
(a) 1,2and3 (b) 1and2
(c) 1and3
(d) 2and3
the foundry floor.

floor
additives is pouted over a pattern and allowed to set. The

pattern is removed and the mould is baked to remove
excess water. After p
pouring
g and solidification, the mould is
broken and the casting is removed.
y Advantage: High dimensional accuracy and smooth
surface finish, thin sections and intricate detail can
produce.
produce
y Limitations: Lowertemperature nonferrous metals only:
y Common metals: Primarily aluminium and copper
LoamMoulding
y Moulding
M ldi
l
loam
i generally
is
ll artificially
ifi i ll composed
d off
common brickclay,
brick clay and sharp sand.
sand
y Loam means mud.
mud
y Loam Moulding is restricted to forms which cannot be
cast conveniently in any other process.

y It is costly.
Page 30
IES1997
Which one of the following pairs is not correctly
matched?
(a) Aluminium alloy piston Pressure die casting
(b) Jewellery.. Lost wax process
(c) Large pipes ..Centrifugal
Centrifugal casting
(d) Large bells Loam moulding
GATE1998
ListI
((A)) Sa
Sandcasting
d cas g
circularshapesonly
((B)) Plastermouldcasting
g
skinsandsoftinterior
(C) Shellmouldcasting
castingprocessing
i
i
(D) Investmentcasting
ListII
()
(1)
Symmetricaland
Sy
e ca a d
((2))
Partshavehardened
(3)
Minimumpost
(4)
Partshaveatendency
ttowarp
Partshavesoftskin
andhardinterior
Suitableonlyfornon
ferrousmetals
(5)
(6)
GATE1996
IES2003
ListI
ListII
(A) Rivetsforaircraftbody
Ri
f i
f b d 1.
F i
Forging
((B)) Carburettor body
y
2.
Coldheading
g
(C) Crankshafts
3.
Aluminiumbased
alloy
(D) Nails
4.
Pressurediecasting
5.
Investmentcasting
MatchListI(Products)withListII(CastingProcess)andselect
thecorrectanswerusingthecodesgivenbelowtheLists:
Li I
ListI
Li II
ListII
(Products)
(CastingProcess)
A
A.
Hollowstatues
1
1.
CentrifugalCasting
B. Dentures
2.
InvestmentCasting
C. Aluminium alloypistons
yp
33.
SlushCasting
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
( ) 1
(c)
2
3
4
(d)
3
2
5
4
IAS2004
MatchListI(NameoftheCastingProcess)withListII(ProcessDefinition)andselect
thecorrectanswerusingthecodesgivenbelowthelists:
List I
ListI
List II
ListII
(NameoftheCastingProcess)
(ProcessDefinition)
A.
Diecasting
1.Thisprocessinvolvesuseofamouldmadeof
Driedsilicasandandphenolic resinmixture
B.
Electroslag casting
2.Inthisprocess,moltenmetalisforcedby
Pressureintoametalmould
C.
Centrifugalcasting
3.Thisprocessemploysaconsumableelectrode
D.
Precisioncasting
4.Thisprocessinvolvesrotatingamouldwhilethe
metalsolidifies
l ldf
5.Thisprocessproducesverysmooth,highly
Accuratecastingsfrombothferrousandnon
g
ferrousalloys
Codes:A
B
C
D
A
B
C
D
(a)
5
4
1
2
(b)
2
3
4
5
(c)
5
3
4
2
(d)
2
4
1
5
GATE1992
Matchthefollowingmoulding/castingprocesseswith
p
theproduct:
Moulding/Castingprocesses
Product
(A) Slushcasting
(P)Turbineblade
(B) Shellmoulding
(Q)Machinetoolbed
(C) Drysandmoulding
D d
ldi
(R)C li d bl k
(R)Cylinderblock
(D) Centrifugalcasting
(S)Hollowcastings
lk l
likelampshades
h d
(T)Rainwaterpipe
(U)Castironshoe
brake
IES1993
MatchtheitemsofListI(Equipment)withtheitems
(
)
g
ofListII(Process)andselectthecorrectanswerusing
thegivencodes.
ListI(Equipment)
ListII(Process)
P HotChamberMachine 1.
Cleaning
Q Muller
Q
2
2.
Coremaking
R DielectricBaker
3.
Diecasting
S SandBlaster
d l
4.
Annealing
l
5.
Sandmixing
(a) P2,Q1,R4,S5
(b) P4,Q2,R3,S5
(c) P
P4,Q5,R1,S2
4,Q 5,R 1,S 2
(d) P
P3,Q5,R2,S1
3,Q 5,R 2,S 1
GATE 2007(PI)
( )
Match the lists
Group 1
Group1
P.SandCasting
Q.CentrifugalCasting
R I
R.InvestmentCasting
C i
S DieCasting
S.DieCasting
Group 2
Group2
1.Turbineblades
2.ICEnginePistons
3.Largebells
L
b ll
4 Pulleys
4.Pulleys
(a) P 4,
4 Q 1,
1 R 3,
3 S2
(c) P 3, Q 4, R 1, S 2
(b) P 2,
2 Q 4,
4 R 3,
3 S1
(d) P 3, Q 2, R 1, S 4
Page 31
BySKMondal
y
WeldingDefinition
y Welding is a process by which two materials, usually
metals, are permanently joined together by

metals
coalescence, which is induced by a combination of
temperature, pressure, and
d metallurgical
ll i l conditions.
di i
y The p
particular combination of these variables can
range from high temperature with no pressure to high
pressure with no increase in temperature.
temperature
l ifi i
f ldi
Classificationofweldingprocesses
Requirementforahighqualitywelding
y fuel g
g ((OFW))
Oxy
gas welding
Arc welding (Aw)
1. A source of satisfactory heat and/or pressure,
Resistance welding
Solid state welding (friction welding, ultrasonic welding,
2. A means of protecting or cleaning the metal, and

3. Caution to avoid, or compensate for, harmful
forge welding etc.)

etc )
y Unique
q p
process
metallurgical effects.
Thermit welding
Laser beam welding
y Welding (positive process)
Electroslag welding
Flash welding
y Machining (negative process)
Induction welding
y Forming,
F
i
casting
i (zero
(
process))
Electron beam welding
IES 2012
Weldability /FabricationProcesses
CaseofAluminium
The
o the
Th advantage
d
h welding
ldi process is
i
((a)) It relieves the jjoint from residual stresses
(b) It helps in checking of distortion of work piece
( ) Large
(c)
L
number
b off metals
l and
d alloys,
ll
b h similar
both
i il and/or
d/
dissimilar can be joined.
(d) Heat produced during the welding does not produce
metallurgical changes.
changes
y The weldability of a material will depend on the
y The oxide coating on aluminum alloys causes some
specific welding or joining process being considered.

considered
y For resistance welding of consistent quality, it is
usually
ll necessary to remove the
h oxide
id immediately
i
di l
before welding.
y Fabrication weldability test is used to determine
mechanical properties required for satisfactory
performance of welded joint.
y The
Th correct sequence off the
h given
i
materials
i l in
i
ascending order of their weldability is
Aluminum < copper < cast iron < MS
Contd
difficultyy in relation to its weldability.

y
y It also has high thermal conductivity and a very short
y
y
y
y
temperature range between liquidus and solidus and when

liquid its viscosity is very low.
Al i i
Aluminium
i poor absorber
is
b b off laser
l
li h
light.
During
g fusion welding,
g the aluminum would oxidize so
readily that special fluxes or protective inertgas
atmospheres
p
must be employed.
p y
Friction welding and TIG welding is good for aluminium.
For aluminium AC current plus high frequency is must.
must
CaseofCastIron
CaseofStainlessSteel
CaseofStainlessSteel
y Cast iron is more difficult to weld because of its high
y Stainless steel is a difficult metal to weld because it
y The ferritic stainless steels are generally less weldable
(poor ductility)
y)
carbon content and brittleness (p
y Massive carbon deposits have a tendency to form in
the areas adjacent to the weld,
weld and high
highcarbon
carbon
martensite tends to form in the heataffected zones.
These microstructures are very brittle and may crack
spontaneously while welding is in progress or later
when load is applied to the workpiece.
workpiece
y Cast iron can be joined by the oxyacetylene brazing
process and shielded metalarc
metal arc welding (stick)
process.
y Some cases preheating
h
and/or
d
post heating
h
is required.
d
contains both nickel and chromium.

y The best method for welding stainless steel is TIG
welding.
welding
y The electric arc is also preferred for welding stainless
steels A heavily coated welding rod,
steels.
rod which produce a
shielded arc, is employed.
y You
Y must do
d a better
b
j b off precleaning.
job
l
i
y Using
g a low arc current setting
g with faster travel
speeds is important when welding stainless steel,
j
to carbide
because some stainless steels are subject
precipitation.
q
both
than the austenitic stainless steel and require
preheating and postweld heat treatments.
y Welds of ferritic stainless steel can be by
Page 32
Contd..
(i) autogenously (i.e. without the addition of filler

metal)
(ii) with an austenitic stainless steel
(iii) using
i a high
hi h nickel
i k l filler
fill alloy.
ll
(iv) Type 405 filler (low 11% Cr, low carbon and small
0.2%
% Al)
l)
y Welding
g p
process:
TIG, MIG, Shieldedmetal arc

welding and Plasma arc welding
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.
j
correctt explanation
l
ti off A
(b) Both A and R are individuallyy true but R is NOT the
IES2011
Considerthefollowingstatements.
d h f ll
Castironisdifficulttoweld,becauseof
,
1.Lowductility
2.Poorfusion
P f i
3
3.Tendencytocrackoncooling
y
g
Whichofthesestatementsarecorrect?
(a)1 2and3
(a)1,2and3
(b)1and2only
(c)2and3only
(d)1and3only
IES2010
Weldability
steel
W ld bilit off ferritic
f iti stainless
t i l
t l used
d in
i
y
is improved
p
by
y
automotive exhaust system
selecting stainless steel electrode having low
content of
((a)) Carbon
((b)) Nitrogen
g
(c) Chromium
(d) Carbon and Nitrogen
IES2006
Assertion(A):Aluminium haspoorweldability.
R
Reason(R):Aluminium
(R) Al
i i
h hi h h
hashighthermal
l
conductivityandhighaffinitytooxygen.
(a) BothAandRareindividuallytrueandRisthe
(b) BothAandRareindividuallytruebutRisnot the
l
i fA
((c)) AistruebutRisfalse
IES2006
Fabricationweldability testisusedtodetermine
(a) Mechanicalpropertiesrequiredforsatisfactory
p
performanceofweldedjoint
j
(b) Susceptibilityofweldedjointforcracking
( ) Suitabilityforjointdesign
(c)
S i bili f j i d i
((d)) Appropriatemachiningprocess
pp p
gp
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
IES1999
Thecorrectsequenceofthegivenmaterialsin
ascendingorderoftheirweldability
di d fth i ld bilit is
i
((a)) MS,copper,castiron,aluminium
, pp ,
,
(b) Castiron,MS,aluminium copper
( ) Copper,castiron,MS,aluminium
(c)
C
i
MS l i i
((d)) Aluminium,copper,castiron,MS
, pp ,
,
IES2010
IES 2012
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.
construction.
3. It is free
f
f
from
f b
fabricational
l residual
d l 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
Whichofthefollowingfactorsimproveweldabilityof
Whi h f h f ll i f
i
ld bili f
steel?
1.Lowcarboncontent
2 Highcarboncontent
2.Highcarboncontent
3.Goodaffinitycontent
4.Pooraffinitytooxygen
( ) d
(a)1and3
(b) d
(b)2and3
(c)1and4
(d)2and4
Page 33
GasFlameProcesses:
Welding,CuttingandStraightening
W ldi
C i
dS i h i
y Oxyfuel gas Welding (OFW): Heat source is the
flame produced by the combustion of a fuel gas and

oxygen.
y OFW has largely been replaced by other processes but
it is still popular because of its portability and the low

capital investment.
y Acetylene is the principal fuel gas employed.
Three types of flames can be obtained by varying

the
(or
th oxygen/acetylene
/
t l
( oxygen/fuel
/f l gas)) ratio.
ti
y If the ratio is about 1 : 1 to 1.15
5 : 1,, all reactions are
carried to completion and a neutral flame is produced.
y Most welding is done with a neutral flame.
flame It is
chemically neutral and neither oxidizes or carburizes
the
h metall being
b i welded.
ld d
y Combustionofoxygenandacetylene(C2H2)ina
weldingtorchproducesatemp.inatwostagereaction.
ldi t h d
t
i t t
ti
y Inthefirststage
g
C2 H2 + O2 2CO + H2
+Heat
Thisreactionoccursnearthetipofthetorch.
Thi
h i f h
h
y InthesecondstagecombustionoftheCOandH
g
2 and
occursjustbeyondthefirstcombustionzone.
2CO+O2 2CO2+Heat
1
H2 +O
2 2 H2O+Heat
Oxygenforsecondaryreactionsisobtainedfromthe
atmosphere.
atmosphere
y A higher ratio, such as 1.5 : 1, produces an oxidizing
flame, hotter than the neutral flame (about 3300oC)

but similar in appearance.
pp
y Used when welding copper and copper alloys but
harmful when welding steel because the excess oxygen
reacts with the carbon, decarburizing the region
around
d the
h weld.
ld
y Excess fuel, on the other hand, produces a carburizing
flame.
flame Carburizing flame can carburize metal also.
also
y The excess fuel decomposes to carbon and hydrogen,
and
d the
h flame
fl
temperature is
i not as great (about
( b
3000oC).
y Flames of this type are used in welding Monel (a
nickelcopper
nickel
copper alloy),
alloy) high
highcarbon
carbon steels,
steels and some
alloy steels, and for applying some types of hardfacing
material.
material
OxyacetylenegasweldingOxidisingflame
Oxyacetylenegasweldingneutralflame
OxyacetylenegasweldingCarburizingflame
IES2009Conventional
Metal
MS
High carbon steel
Grey cast iron
Alloy steel
Aluminium
Brass
C
Copper,
B
Bronze
Nickel alloys
L d
Lead
Flame
N
R
N, slightly oxidizing
N
Slightly carburizing
Slightly oxidizing
N slightly
N,
li h l oxidizing
idi i
Slightly carburizing
N
Explain the three types of oxyacetylene flames.

Indicate with the help of sketches the various
zones,
respective
temperature
ranges
and
applications of each type

t pe of flame.
flame
[20 Marks]
[20
Page 34
Diagram
Di
g
d
d i i i
Uses,Advantages,andLimitations
y OFW is
i fusion
f i welding.
ldi
p
y Exposer
of the heated and molten metal to the various
y No p
pressure is involved.
gases in the flame and atmosphere makes it difficult to
y Filler metal can be added in the form of a wire or rod.
prevent contamination.
y Fluxes
Fl
may be
b used
d to clean
l
the
h surfaces
f
and
d remove
contaminating oxide. The gaseous shield produced by

vaporizing flux can prevent oxidation during welding,
aand
d tthee sslag
ag p
produced
oduced by so
solidifying
d y g flux
u ca
can p
protect
otect
the weld pool. Flux can be added as a powder, the
welding rod can be dipped in a flux paste,
paste or the rods
can be precoated.
y Heat source is not concentrated, a large area of the
metal is heated and distortion is likely to occur.

y Flame
Fl
welding
ldi is
i still
ill quite
i common in
i field
fi ld work,
k in
i
maintenance and repairs,

repairs and in fabricating small
quantities
qua
t t es o
of spec
specialized
a ed p
products.
oducts.
Oxyacetyleneweldingequipment
y Oxygen is stored in a cylinder at a pressure ranging
from 13.8
13 8 MPa to 18.2
18 2 MPa .
y 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
p 4
420 times
by its volume at a pressure 1.75 MPa .
y At the time of acetylene release if acetone comes with
acetylene the flame would give a purple colour.
y Another option is acetylene generator.
CaC2 + 2 H 2O C2 H 2 + Ca (OH ) 2
Contd
PressureGasWelding
Pressure Gas Welding
y Pressure g
gas welding
g ((PGW)) or Oxyacetylene
y
y
Pressure Welding is a process used to make butt

jjoints between the ends of objects
j
such as p
pipe
p
andrailroad rail.
y 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
pressure.
y This
Thi process, therefore,
th f
i actually
is
t ll a 'form
'f
off solid
lid
state welding.
GATE2003
InOxyacetylenegaswelding,temperatureatthe
innerconeoftheflameisaround
(a) 3500C
(b) 3200C
(c) 2900
2900C
C
(d) 2550C
IES2010
The
Oxygen
and
Th ratio
ti between
b t
O
d Acetylene
A t l
gases for neutral flame in g
g
gas welding
g is
(a) 2 : 1
(b) 1 : 2
(c) 1 : 1
(d) 4 : 1
IES2010
Assertion (A): Oxidizing flame is used in gas
welding to join medium carbon steels having high
melting
l i point.
i
) In g
gas welding,
g, oxidizing
g flame
Reason ((R):
produces the maximum temperature compared to
neutral and reducing flame.
flame
( ) A is
(c)
i true
t
b t R is
but
i false
f l
Page 35
GATE1994
The
e ratio
at o o
of
acetylene
acety
e e to o
oxygen
yge
iss
approximately. for a neutral flames used in
gas welding.
welding
(a) 1 : 1
(b) 1 : 2
(c) 1 : 3
(d) 1.5 : 1
GATE2002
The temperature of a carburising flame in gas
welding is that of a neutral or an oxidising flame.
flame
(a) Lowerthan
(b) Higherthan
(c) Equalto
(d) Unrelatedto
IES2009
IES1998
By which one of the following methods gray cast

i
iron
i usually
is
ll welded?
ld d?
((a)) TIGwelding
g
((b)) MIGwelding
g
(c) Gaswelding
(d) Arcwelding
IAS1994
In oxyacetylene gas welding, for complete

combustion,
b ti
th volume
the
l
off oxygen required
i d per
unit of acetylene is
(a) 1
(b) 1.5
15
(c) 2
(d) 2.5
IES 2012
IAS1995
Assertion (A): If neutral flame is used in oxy
acetylene
y
welding,
g, both oxygen
yg
and acetylene
y
cylinders of same capacity will be emptied at the same
time.
Reason (R): Neutral flame uses equal amounts of
oxygen and acetylene.
( ) BothAandRareindividuallytrueandRisthecorrect
(a)
B hA dR i di id ll
dRi h
explanationofA
(b) BothAandRareindividuallytruebutRisnot
B thA dR i di id ll t b tRi t the
th
In gas welding of mild steel using an oxy

acetylene
t l
fl
flame.
th total
the
t t l amountt off acetylene
t l
consumed was 10 litre. The oxygen consumption
from the cylinder is
(a) 5litre
(b) 10litre
(c) 15litre
(d) 20litre
OxygenTorchCutting(GasCutting)
Statement
St t
t (I):
(I) In
I gas welding
ldi the
th metal
t l to
t be
b joined
j i d gets
t
oxidized or carburized
Statement (II): The neutral flame affects no chemical
change on the molten metal.
( ) Statement (I)
(d)
( ) is true
y Iron and steel oxidize (burn) when heated to a
temperature between 8000C to 10000C.

C
y Highpressure oxygen jet (300 KPa) is directed against
a heated steel plate, the oxygen jet burns the metal and
blows it awayy causing
g the cut ((kerf).
)
y For cutting metallic plates shears are used. These are
useful for straightline
straight line cuts and also for cuts up to 40
mm thickness.
Contd
y For thicker plates with specified contour, shearing
y Larger size orifice produces kerf width wider and larger
cannot be used and oxyfuel gas cutting (OFC) is

useful.
y Gascutting is similar to gas welding except torch tip.
oxygen consumed.
d
y At kindling
g temperature
p
(about 870oC), iron form iron
oxide.
y Reaction:
3Fe + 2O2 Fe3O4 +6.67 MJ/kg of iron
The
h other
h reactions:
J g of iron
2Fe + O2 2FeO + 33.18 MJ/kg
4Fe + 3O2 2Fe2O3 + 4.9 MJ/kg of iron
y All exothermic reactions preheat the steel.
steel
Fig differencesintorchtipsforgasweldingandgascutting
Contd
Page 36
Contd
o co
p ete o
dat o 0.
87 m3 o
yge / g o
o iss
y For
complete
oxidation
0.287
oxygen/kg
of iron
required
y Due
D
t unoxidized
to
idi d metal
t l blown
bl
away the
th actual
t l
requirement is much less.
y Torch tip held vertically or slightly inclined in the
direction of travel.
y Torch position is about 1.5 to 3 mm vertical from plate.
Contd
y The drag lines shows the characteristics of the movement
y If torch moved too rapidly, the bottom does not get
sufficient
large
drag
so very rough
ffi i t heat
h t and
d produces
d
l
d
h
and irregularshapedcut edges.
y If torch moved slowly a large amount of slag is
generated and produces irregular cut.
cut
off the
h oxygen stream.
g is more useful with thick p

y Gas cutting
plates.
y For
F thin
thi sheets
h t (less
(l
th 3 mm thick)
than
thi k) tip
ti size
i should
h ld
be small. If small tips are not available then the tip is

inclined at an angle of 15 to 20 degrees.
Fi positioningofcuttingtorchinoxy
Fig
iti i f tti t hi
f l tti
fuelgascutting
y Drag is the amount by which the lower edge of the drag
line trails from the top edge.

edge
y Good cut means negligible drag.
Fig.Recommendedtorchpositionforcuttingthinsteel
Contd
Contd
Application
IAS2011Main
IAS2011 Main
D
Draw
a self
lf explanatory
l
t
sketch
k t h off oxyacetylene
t l
gas
cutting torch.
torch Briefly explain how cutting is
effected.
[20Marks]
y Useful only for materials which readily get oxidized
Difficulties
y Metal
temperature goes beyond lower critical

temperature and structural transformations occur.
occur
and the oxides have lower melting points than the

metals.
y Final microstructure depends on cooling rate.
y Widely used for ferrous materials.
y Steels with less than 0.3 % carbon cause no problem.
y Cannot be used for aluminum, bronze, stainless steel
and
d like
lik metals
t l since
i
th resist
they
i t oxidation.
id ti
Contd
g carbon steel material around the cut should

y For high
be preheated (about 250 to 300oC) and may post heat
also necessary.
y Cutting CI is difficult, since its melting temp. is lower
than iron oxide.

y If chromium
h
i
and
d nickel
i k l etc are present in
i ferrous
f
IES1992
The edge of a steel plate cut by oxygen cutting will
gett hardened
h d
d when
h the
th carbon
b content
t t is
i
((a)) Less than 0.1 p
percent
(b) Less than 0.3 percent
( ) More
(c)
M
than
h 0.3 percent
((d)) Anywhere
y
between 0.1 to 1.0 p
percent
alloys oxidation and cutting is difficult.

difficult
Page 37
IES2007
Considerthefollowingstatementsinrespectofoxy
acetylenewelding:
y
g
1. Thejointisnotheatedtoastateoffusion.
2. Nopressureisused.
3. Oxygenisstoredinsteelcylinderatapressureof14
MPa.
4. Whenthereisanexcessofacetyleneused,thereisa
decidedchangeintheappearance
g
pp
offlame.
Whichofthestatementsgivenabovearecorrect?
g
(a)1,2and3
(b) 2,3and4
((c)) 1,3and4
,3
4
((d)) 1,2and4
,
4
IES2001
Oxyacetylenereducingflameisusedwhile
carryingouttheweldingon
i tth ldi
((a)) Mildsteel
((b)) Highcarbonsteel
g
(c) Greycastiron
(d) Alloysteels
IES1992
Thick steel plate cut with oxygen normally shows
signs
i
off cracking.
ki
Thi tendency
This
t d
f cracking
for
ki
can
be minimised by
(a) Slow speed cutting
(b) Cutting in two or more stages
(c) Preheating the plate
(d) Using oxyacetylene flame
PowderCutting
GATE2009(PI)
GATE2009 (PI)
y Cast iron,
iron stainless steel,
steel and others high alloy steels are
difficult to cut by oxyfuel cutting and we can use powder

cutting.
i
y By
y injecting
j
g a finelyy divided 200mesh iron p
powder into
the flame, a lower melting point eutectic oxide is formed
at the cutting interface,
interface where additional ironoxygen
reaction is generated and cutting proceeds in a similar
way off oxyfuel
f l cutting.
tti
y The heat and the fluxing
g action of the burning
g iron
powder enable the cutting oxygen stream to oxidize the
base metal continuously, just as in cutting carbon steel.
Whi h off the

Which
th following
f ll i powders
d
should
h ld be
b fed
f d for
f
effective oxy
oxyfuel
fuel cutting of stainless steel?
IES2005
I ldi th t h h ldb h ld t
Ingaswelding,thetorchshouldbeheldatanangleof
l f
30 to45 fromthehorizontalplane.
2. Ingaswelding,theSizeofthetorchdependsuponthe
I ldi h Si f h
hd
d
h
thicknessofmetaltobeformed.
3. Dragingascuttingisthetimedifferencebetween
h
d ff
b
heatingoftheplateandstartingtheoxygengasfor
cutting.
tti
1.
(a) 1,2and3 (b) 1and2
(c) 2and3
(d) 1and3
PlasmaCutting
l
y Uses ionized gas jet (plasma) to cut materials resistant to
y
y
(a) Steel
y
((b)) Aluminum
((c)) Copper
pp
(d) Ceramic
oxyfuel cutting,
High
h velocity
l
electrons
l
generated
d by
b the
h arc impact gas
molecules, and ionize them.
The ionized gas is forced through nozzle (upto 500 m/s), and
the jjet heats the metal,, and blasts the molten metal away.
y
More economical, more versatile and much faster (5 to 8
times) than oxyfuel cutting,
cutting produces narrow kerfs and
smooth surfaces.
HAZ is
i 1/3
/ to th
h than
h oxyfuel
f l cutting.
i
Maximum plate thickness = 200 mm
l
i
ldi
ElectricArcWelding
PrincipleofArc
y An arc is generated between cathode and anode when
they are touched to establish the flow of current and
ElectricArcWelding
l
i
ldi
then separated by a small distance.

y 65% to 75% heat is generated at the anode.
y If DC is used and the work is positive (the anode of the
Fig Basiccircuitforarcwelding
Fig.Basiccircuitforarcwelding
circuit),
i it) the
th condition
diti is
i known
k
as straight
t i ht polarity
l it
(SPDC).
(SPDC)
Page 38
Contd
polarity (RPDC).
y Manual arc welding is done with shielded (covered)
ISRO2011
y Work is negative
g
and electrode is p
positive is reverse
I ldi
Inarcwelding,penetrationisminimumfor
t ti i i i
f
y SPDC conditions are preferred.

y DC arcwelding maintain a stable arc and preferred for
( )DCSP
(a)DCSP
(b)DCRP
difficult tasks such as overhead welding.
( )AC
(c)AC
y For a stable arc, the gap should be maintained.
electrodes
y Bare
Baremetal
metal wire used in automatic or semiautomatic
machines.
y Non
N
consumable
bl electrodes
l t d
(
(e.g
t
tungsten)
t ) is
i nott
consumed by the arc and a separate metal wire is used
as filler.
y There are three modes of metal transfer (globular,
(globular
spray and shortcircuit).
(d)DCEN
(d)
Contd
Threemodesofmetaltransferduringarcwelding
MajorForcestakepartinMetalTransfer
(i)gravityforce
Assertion (A) : Bead is the metal added during

single pass of welding.
Reason (R) : Bead material is same as base metal.
correct explanation
p
of A
(ii)Surfacetension
(iii)electromagneticinteraction
( )
(iv)hydrodynamicactionofplasma
GATE1993
Ind.c.welding,thestraightpolarity(electrode
negative)resultsin
(a) Lowerpenetration
(b) Lowerdepositionrate
(c) Lessheatingofworkpiece
(d) Smallerweldpool
JWM2010
Arcweldingequipments
1. Droopers: Constant current welding machines
Good
G d for
f manuall welding
ldi
2. Constant voltage
g machines
Good for automatic welding
Page 39
Fig.Machinewithdifferentsettings
Contd
Fig.Characteristiccurveofaconstantvoltagearcweldingmachine
Formula
IES2010
y Requires a large current (150 to 1000 A),
A) voltage is
between 30 and 40 V, actual voltage across the arc

varying from 12 to 30 V.
y To initiate a weld, the operator strike the electrode and
In
the
I arc welding,
ldi
th arc length
l
th should
h ld be
b equall to
t
((a)) 4
4.55 times the rod diameter
(b) 3 times the rod diameter
( ) 1.5 times
(c)
i
the
h rod
d diameter
di
((d)) Rod diameter
start arc.
V
I
+
=1
OCV SCC
IES2005
IES2001
Inarcwelding,65%to75%heatisgeneratedatthe
anode.
d
2. Dutycycleincaseofarcweldingisthecycleof
y y
g
y
completeweldingofworkpiecefromthe
beginning.
beginning
3. ArcblowismorecommonwithDCwelding.
Inmanualarcwelding,theequipmentshould
g
q p
Whichofthestatementsgivenaboveare
correct?
((a)) 1,2and3
,
3 ((b)) 1and2
(c) 2and3 (d) 1and3
(c) Temperatureintheareconstant
1.
IES1998
The voltagecurrent characteristics of a dc
generator
t
f
for
arc welding
ldi
i a straight
is
t i ht line
li
between an opencircuit voltage of 80 V and short
circuit current of 300 A. The generator settings for
maximum arc p
power will be
(a) 0 V and 150 A
(b) 40 V and 300 A
( ) 40 V and
(c)
d 150 A
(d) 80
8 V and
d 300 A
havedroopingcharacteristicsinordertomaintain
(a) Voltageconstantwhenarclengthchanges
(b) Currentconstantwhenarclengthchanges
IES2001
Inarcwelding,d.c.reversepolarityisusedtobear
greateradvantagein
t d
t
i
((a)) Overheadwelding
g
(b) Flatweldingoflapjoints
( ) Edgewelding
(c)
Ed ldi
((d)) Flatweldingofbuttjoints
g
j
(d) Weldpoolredhot
IAS1999
Opencircuit voltage of 60 V and current of 160A
were the
th welding
ldi
conditions
diti
f arc welding
for
ldi
off a
certain class of steel strip of thickness 10 mm. For
arc welding of 5mm thick strip of the same steel,
the welding
g voltage
g and current would be
(a) 60 V and 80 A
(b) 120 V and
d 160
6 A
((c)) 60 V and 4
40 A
(d) 120 V and 40 A
Page 40
IAS1998
AssumingastraightlineVIcharacteristicsfora
d ldi
dcweldinggenerator,shortcircuitcurrentas400A
t h t i
it
t
A
andopencircuitvoltageas400whichoneofthe
followingisthecorrectvoltageandcurrentsetting
formaximumarcpower?
p
(a) 400Aand100V
(b) 200Aand200V
( ) 400Aand50V
(c)
A d V
(d) 200Aand50V
A d V
GATE 2007(PI)
( )
GATE2012SameQinGATE2012(PI)
In a DC arc welding operation, the voltagearc
length characteristic was obtained as Varc = 20 + 5L
where the arc length L was varied between 5 mm
and 7 mm.
mm Here Varc denotes the arc voltage in Volts.
Volts
The arc current was varied from 400 A to 500 A.
A
Assuming
i
li
linear
power source characteristic,
h
i i the
h
open circuit voltage and the short circuit current for
the welding operation are
(a) 45 V,
V 450 A
(b) 75 V,
V 750 A
(c) 95 V, 950 A
(d) 150 V, 1500 A
The
has
Th DC power source for
f arc welding
ldi
h the
th
4 where V = Voltage
g and
characteristic 33V + I = 240,
I = Current in amp. For maximum arc power at
the electrode,
electrode voltage should be set at
((a)) 20 V ((b)) 4
40 V ((c)) 60 V ((d)) 80 V
DutyCycle
A low carbon steel plate is to be welded by the manual

metal arc welding process using a linear V I
characteristic DC Power source. The following data are
available
il bl :
OCV of Power source = 62 V
Short circuit current = 130 A
A length,
Arc
l
h L = 4 mm
p
of welding
g = 155 cm/s
/
Traverse speed
Efficiency of heat input = 85%
V l
Voltage
i given
is
i
as V = 20 + 1.5 L
Calculate the heat input into the workprice
IFS2011
y The percentage of time in a 5 min period that a
welding machine can be used at its rated output

without overloading.
y Time is spent in setting up, metal chipping, cleaning
and inspection.
p
y For manual welding a 60% duty cycle is suggested and
for automatic welding 100% duty cycle.
cycle
GATE1992
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.
cycle
[3Marks]
I
T
Ia
Requireddutycycle Ta =
Requireddutycycle,
Where,T=rateddutycycle
I=ratedcurrentattherateddutycycle
Io =Maximumcurrentattherateddutycycle
Contd
Electrode
1. NonconsumableElectrodes
2. ConsumableElectrodes
C
bl El
d
NonconsumableElectrodes
Madeofcarbon,GraphiteorTungsten.
M d f b G hi T
CarbonandGraphiteareusedforD.C.
p
Electrodeisnotconsumed,thearclengthremains
constant arcisstableandeasytomaintain
constant,arcisstableandeasytomaintain.
Contd
ConsumableElectrodes
Provides filler materials.
Same composition.
composition
This requires that the electrode be moved toward or
away from the work to maintain the arc and
satisfactoryy welding
g conditions.
Page 41
Contd
Consumable electrodes are three kinds:

(a) Bare
(b) Fluxed
Fl
d or lightly
li htl coated
t d
((c)) Coated or extruded / shielded
y For automatic welding, bare electrode is in the form of
continuous wire (coil).
(coil)
Electrodecoatingcharacteristic
1. Provide a protective atmosphere.
2. Stabilize
S bili the
h arc.
33. Provide a p
protective slag
g coating
g to accumulate
4.
5.
6
6.
7.
8.
impurities, prevent oxidation, and slow the cooling of

the weld metal.
metal
Reduce spatter.
Add alloying elements.
Affect arc penetration
Influence the shape of the weld bead.
Add additional filler metal.
Electrodecoatings
GATE1994
Theelectrodesusedinarcweldingarecoated.
Thiscoatingisnotexpectedto
(a) Provideprotectiveatmospheretoweld
(b) Stabilizetheare
(c) Addalloyingelements
(d) Preventselectrodefromcontamination
l. Slag Forming Ingredients. asbestos, mica, silica,

fluorspar titanium dioxide,
fluorspar,
dioxide Iron oxide,
oxide magnesium
carbonate, Calcium carbonate and aluminium oxide.
2. Arc Stabilizing Ingredients. or ionizing agents:
potassium silicate, TiO2 + ZrO2 (Rutile), Mica,
Calcium oxide,
oxide sodium oxide,
oxide magnesium oxide,
oxide
feldspar (KAI Si3 O8)
Contd
y The slag is then easily chipped.
3.DeoxidizingIngredients. Cellulose,Calcium
carbonate,dolo
b
d l mite,starch,dextrin,woodflour,
i
h d
i
dfl
graphite,aluminium,ferromanganese.
y Coatings are designed to melt more slowly than the
filler wire.
4.BindingMaterials
g
Sodiumsilicate,potassiumsilicate,
asbestos.
5.AlloyingConstituentstoImproveStrengthofWeld
6.TiO2 andpotassiumcompoundsincreasethemelting
rateofthebasemetalforbetterpenetration.
rateofthebasemetalforbetterpenetration
7.Ironpowderprovideshigherdepositionrate.
I
d
id hi h d
ii
Contd
Binders
y AC arc welding used potassium silicate binders.
y DC arc welding used sodium silicate binders.
y Potassium has a lower ionization potential as compared
with
h sodium.
d
Contd
IES2007
The coating material of an arc welding electrode
contains
t i which
hi h off the
th following?
f ll i ?
1. Deoxidising
g agent
g
2. Arc stabilizing agent
3. Slag
Sl forming
f
i agent
g the code g
given below:
Select the correct answer using
(a) 1, 2 and 3
(b) 1 and 2 only
( ) 2 and
(c)
d 3 only
l
(d) 1 and
d 3 only
l
Page 42
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.
( ) Both
(a)
B h A and
i di id ll true and
d R is
i the
h correct
explanation of A
(b) Both
B th A and
i di id ll true
t
b t R is
but
i nott the
th
IES2002
WeldingFlux
MatchListIwithListIIandselectthecorrectanswer:
ListI(Ingredients)
ListII(Welding
functions)
A Silica
A.
Sili
1.
A stabilizer
Arc
t bili
B. Potassium oxalate
2.
Deoxidizer
C. Ferrosilicon
3.
Fluxingagent
4.
4
Gasformingmaterial
g
D. Cellulose
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
LowHydrogenElectrode
Low Hydrogen Electrode
Availableinthreeforms
y Granular
y Electrodewirecoating
y Electrodecore
y The basic coatings contain large amount of
calcium carbonate (limestone) and calcium

fluoride (fluorspar) and produce low hydrogen.
hydrogen
y But it can absorb moisture therefore coated low
hydrogen electrodes are backed before use to a
temperature
p
of 200oC to 33000C and stored in an
o
oven at 110 C to 150oC
y Other types of electrode release large amount of
hydrogen, which can dissolve in the weld metal
and
d lead
l d to embrittlement
bi l
or cracking.
ki
W ldi P iti
WeldingPositions
IFS2011
ldi
WeldingCurrent
y Weldingcurrentdependsupon:thethicknessofthe
Whatismeantbylow hydrogenelectrode?
Whatismeantbylowhydrogenelectrode?
weldedmetal,typeofjoint,weldingspeed,positionof
weldedmetal
typeofjoint weldingspeed positionof
theweld,thethicknessandtypeofthecoatingonthe
electrodeanditsworkinglength.
l
d di
ki l
h
y Weldingcurrent,I=k.d,amperes;disdia.(mm)
g
,
,
p
;
(
)
[2marks]
Fig.Thepositionofelectrodeforhorizontalwelding
Fig.Positioningofelectrodeforweldinginverticallyupwardposition
WeldingVoltage
y Thearcvoltagedependsonlyuponthearclength
V=k1 +k2l
Volts
Wherelisthearclengthinmmandk
Wh
li h l
hi
dk1 andk
dk2 are
constants,
k1 =10to12;andk2 =2to3
TheminimumArcvoltageisgivenby
Vmin =(20+0.04l)Volt
ArcLength
g arc results in
A long
y For good welds, a short arc length is necessary,
because:
1. Heat is concentrated.
2. More stable
3 More protective atmosphere.
3.
atmosphere
Page 43
y Large heat loss into atmosphere.

y Unstable
U t bl arc.
y Weld p
pool is not p
protected.
y Weld has low strength, less ductility, poor fusion and
excessive spatter.
spatter
Contd
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
d L is
i arc length
l
h in
i mm. The
Th static
i voltampere
l
characteristic of the power source is approximated by a
Beadwidthshouldbeequaltothreediameteroftheelectrodesize
q
straight
g line with a no load voltage
g of 80 V and a short
circuit current of 600A. Determine the optimum arc
length for maximum power.
Fig.ArcPowerVsArcLength
GATE2010(PI)
During
a steady
with
D i
t d gas metal
t l arc welding
ldi
ith direct
di t
current electrode positive polarity, the welding current,
voltage
lt
and
d weld
ld speed
d are 150 A,
A 30 V and
d 6 m/min,
/ i
respectively. A metallic wire electrode of diameter 1.2
mm is
i being
b i
f d att a constant
fed
t t rate
t off 12 m/min.
/ i The
Th
density, specific heat and melting temperature of the
wire
i electrode
l t d are 7000 kg/m
k / 3, 500 J/kg
J/k oC and
d 1530oC,
C
respectively. Assume the ambient temperature to be 30oC
and
d neglect
l
the
h latent
l
h
heat
off melting.
li
F h consider
Further,
id
that twothird of the total electrical power is available for
melting
l i off the
h wire
i electrode.
l
d The
Th melting
l i efficiency
ffi i
(i
(in
percentage) of the wire electrode is
(a) 39.58
(b) 45.25
(c) 49.38 (d) 54.98
GATE2009(PI)
GATE2009 (PI)
A t
Autogenous
gas tungsten
t
t
arc welding
ldi
off a steel
t l
plate is carried out with welding current of 500 A,
A
g of 20 V, and weld speed
p
of 20 mm/sec.
voltage
Consider the heat transfer efficiency from the arc
to the weld pool as 90%. The heat input per unit
GATE2008
In arc welding of a butt joint, the welding speed is
to be selected such that highest cooling rate is
achieved. Melting efficiency and heat transfer
efficiency
ffi i
are 0.5 and
d 0.7, respectively.
i l The
Th area off
the weld cross section is 5 mm2 and the unit
energy required to melt the metal is 10 J/mm3. If
the welding
gp
power is 2 kW,, the welding
g speed
p
in
mm/s is closest to
(a) 4
(b) 14
(c) 24
(d) 34
Example
GATE2006
In an arc welding process, the voltage and current
are 25 V and 300 A respectively.
respectively The arc heat
transfer efficiency is 0.85 and welding speed is 8
mm/sec.
/
Th net heat
The
h
i
input
(i J/mm)
(in
J/
) is
i
((a)) 64
4
(b) 797
( ) 1103
(c)
((d)) 797
79700
ArcblowinDCarcwelding
Calculate the melting efficiency in the case of

arcwelding
ldi off steel
t l with
ith a potential
t ti l off 20 V and
d
a current of 200 A. The travel speed
p
is 5 mm/s
/
and .the crosssectional 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.
length (in KJ/mm) is

(a) 0.25
(b) 0.35
(c) 0.45
(d) 0.55
Page 44
Contd
y Arc
occurs during
the
off magnetic
A blow
bl
d i
th welding
ldi
ti
materials with DC.

y The effect of arc blow is maximum when welding
corners where magnetic field concentration is
maximum.
y The effect is p
particularlyy noticeable when welding
g with
bare electrodes or when using currents below or above
y 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
metals.
y Cause:
C
U b l
Unbalanced
d magnetic
ti forces.
f
Effectofarcblow
y Low heat penetration.
y Excessive
E
i weld
ld spatter.
y Pinch effect in welding
g is the result of electromagnetic
g
forces
y Weld spatter occurs due to
High welding current
Too small an electrode arc
Contd
The effects of arc blow can be minimized with D.C.

welding
ldi by
b
y Shortening
g the arc.
y Reduce current
y Reducing
R d i weld
ld speed.
d
y Balance magnetic
g
field byy p
placing
g one g
ground lead at
each end of the work piece.
y Wrapping the electrode cable a few turns around the
work piece.
Contd
IES2001
ISRO2006
IES2001
Arcblowismorecommonin
(a) A.C.welding
(b) D.C.weldingwithstraightpolarity
(c) D.C.weldingwithbareelectrodes
(d) A.C.weldingwithbareelectrodes
Pincheffectinweldingistheresultof
(a) Expansionofgasesinthearc
(b) Electromagneticforces
(c) Electricforce
(d) Surfacetensionofthemoltenmetal
Gasshields
Too high welding current in arc welding would result in

(a) Excessive spatter,
spatter under cutting along edges,
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) Excessive
E
i
piling
ili
up off weld
ld metal,
l overlapping
l
i
without penetration of edges, wasted electrodes
CarbonArcwelding
y Helium, most expensive, has a better thermal
y An inert gas is blown into the weld zone to drive away
conductivity, is useful for thicker sheets, copper and

aluminium welding, higher deposition rate.
other atmospheric gases.

y Gases are argon, helium, nitrogen, carbon dioxide and
y The arc in carbon dioxide shielding gas is unstable,
l t expensive,
least
i deoxidizers
d idi
needed.
d d
a mixture of the above gases.

y Argon ionizes easily requiring smaller arc voltages.It is
y It is
i a heavy
h
gas and
d therefore
th f
covers the
th weld
ld zone
very well.
well
good
d for
f welding
ldi thin
thi sheets.
h t
y Arc is produced between a carbon electrode and the
work.
y Shielding is not used.
y No pressure
y With or without filler metal
y May be used in "twin arc method", that is, between
two carbon
b (graphite)
(
hi ) electrodes.
l
d
Contd
Page 45
IES2010
Assertion (A): Straight polarity is always
recommended for Carbonelectrode welding.
Reason (R): Carbon arc is stable in straight polarity.
(b) Both
h A and
d d ll true but
b R is NOT the
h
correct explanation
p
of A
(d) A is
i false
f l but
b t R is
i true
t
TungstenInertGaswelding(TIG)
y Arc
is established between a nonconsumable

tungsten electrode and the workpiece.
workpiece
y Tungsten is alloyed with thorium or zirconium for
better currentcarrying
and
electronemission
characteristics.
y Arc length is constant, arc is stable and easy to
maintain.
maintain
y With or without filler.
y Very clean welds.

y All metals and alloys can be welded. (Al, Mg also)
y Straight polarity is used.
y Weld voltage 20 to 40 V and weld current 125 A for
RPDC to 1000 A for SPDC.

SPDC
y Shielded Gas: Argon
y Torch is water or air cooled.
cooled
Contd
GATE2011
Whichoneamongthefollowingweldingprocesses
usednon consumableelectrode?
(a)Gasmetalarcwelding
(b)S b
(b)Submergedarcwelding
d ldi
( )
(c)Gastungstenarcwelding
g
g
(d)Fluxcoatedarcwelding
IES2010
In an inert gas welding process,
process the commonly used
gas is
(a) Hydrogen
(b) Oxygen
(c) Helium or Argon
(d) Krypton
Fig.TIG
ISRO2009
Following gases are used in tungsten inert
gas welding
(a) CO2 and H2
(b) Argon
A
and
d neon
(c) Argon and helium
(d) Helium and neon
GATE2002
Whichofthefollowingarcweldingprocessesdoes
notuseconsumableelectrodes?
(a) GMAW
(b) GTAW
(c) SubmergedArcWelding
(d) Noneofthese
Page 46
IES1994
Whichoneofthefollowingweldingprocesses
usesnon
consumableelectrodes?
bl l t d ?
((a)) TIGwelding
g
(b) MIGwelding
( ) Manualarcwelding
(c)
M
l ldi
((d)) Submergedarcwelding.
g
g
IES2000
Whichoneofthefollowingstatementsiscorrect?
(a) Nofluxisusedingasweldingofmildsteel
(b) Boraxisthecommonlyusedfluxcoatingon
weldingelectrodes
( ) Laserbeamweldingemploysavacuumchamber
(c)
L
b
ldi
l
h b
andthusavoidsuseofashieldingmethod
(d) ACcanbeusedforGTAWprocess
GasMetalArcWelding(GMAW)orMIG
y A consumable electrode in a gas shield.
y Arc
A is
i between
b
workpiece
k i
and
d an automatically
i ll fed
f d
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
p
the arc stabilityy and reduce weld spatter.
p
y Fast and economical.

y A reversepolarity dc arc is generally used because
off its
i deep
d
penetration,
i
spray transfer,
f and
d ability
bili
to produce smooth welds with good profile.
Contd
IES2007
IES1997
InMIGwelding,themetalistransferredintothe
f
formofwhichoneofthefollowing?
f hi h
fth f ll i ?
((a)) Afinesprayofmetal
p y
(b) Moltendrops
( ) Weldpool
(c)
W ld
l
((d)) Molecules
MIG ldi
MIGweldingprocessuses
1.Consumableelectrode2. nonconsumableelectrode
3.D.C.powersupply
4.A.C.powersupply
Ofthesestatements
(a) 2and4arecorrect
(b) 2and3arecorrect
(c) 1and4arecorrect
(d) 1and3arecorrect
Fig.MIG
IES2010
Assertion(A):Inertgasandbareelectrodeinstead
offluxcoatedelectrodeisusedinthecaseof
automaticTIGandMIGweldingprocesses.
i TIG dMIG ldi
( )
p
p
y
Reason(R):Betterprotectionisprovidedbyacloud
ofinertgasthanthecovercreatedbytheflux.
( ) Both
(a)
B th A and
i di id ll true
t
and
d R is
i the
th
IES 2012
Statement(I):DCwithreversepolarityisusedinMIG
St t
t(I) DC ith
l it i di MIG
welding
Statement(II):UseofDCwithreversepolarityenables
deeperpenetrationandacleanSurface
( ) Statement (I)
(d)
( ) is true
Page 47
SubmergedArcwelding(SAW)
y 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
small
ll flames
fl
b i visible.
being
i ibl
y A portion
ti
off the
th flux
fl
melts.
lt Molten
M lt
fl
flux
and
d flux
fl
provides thermal insulation,

insulation slows cooling rate and
produce soft,, ductile welds.
p
Contd
Characteristicofsubmergedarcwelding
y Most suitable for flat butt or fillet welds in low
y Highspeeds,
carbon steel (< 0.3% carbon).
y Highdepositionrates,
y The process is not recommended for highcarbon
steels,
t l
t l
tool
steels,
t l
aluminum,
l
i
y Deeppenetration,
magnesium,
i
y Highcleanliness(duetothefluxaction).
titanium, lead, or zinc.

zinc
Advantages
Limitations
y Wireelectrodesareinexpensive.
y Extensive flux handling,
y Noweldspatter.
y Contamination of the flux by moisture.
y Nearly100%depositionefficiency.
y Largegrainsize structures.
y Lesserelectrodeconsumption.
y Welding is restricted to the horizontal position.

y Chemical control is important
IES2006
IES2005
Inwhichofthefollowingweldingprocesses,flux
i
isusedintheformofgranules?
di th f
f
l ?
((a)) ACarcwelding
g
(b) Submergedarcwelding
( ) Argonarcwelding
(c)
A
ldi
((d)) DCarcwelding
g
Whichofthefollowingarethemajor
characteristicsofsubmergedarcwelding?
1. Highweldingspeeds.
2. Highdepositionrates.
3. Lowpenetration.
o pe et at o .
4. Lowcleanliness.
S l tth
Selectthecorrectanswerusingthecodegivenbelow:
t
i th d i b l
(a) 2and3
(b) 1,2and3
(c) 3and4
(d) 1and2
Page 48
IES2011
The welding process in which bare wire is used as
electrode,, g
granular flux is used and the p
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
IES2008
Assertion (A): Submerged arc welding is not
recommended for high
g carbon steels,, tool steels,,
aluminium, magnesium etc.
Reason ((R):
) This is because of unavailability
y of
suitable fluxes, reactivity at high temperatures and
low sublimation temperatures.
( ) Both
(a)
B h A and
d R are true and
d R is
i the
h correct explanation
l
i
of A
(b) Both
B th A and
d R are true
t
b t R is
but
i NOT the
th correctt
explanation of A
AtomicHydrogenwelding(AHW)
GATE1999
For butt welding 40 mm thick steel plates, when
the expected quantity of such jobs is 5000 per
month over a period of 10 year, choose the best
suitable
i bl welding
ldi
process out off the
h following
f ll i
available alternatives.
(a) Submerged arc welding
(b) Oxyacetylene
Oxy acetylene welding
(c) Electron beam welding
(d) MIG welding
y An a.c. arc is formed between two tungsten electrodes
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
between the electrodes. The formation of atomic
hydrogen proceeds with the absorption of heat:
H2 = 2H 421.2 k J / mol
y This
Thi atomic
i hydrogen
h d
recombines
bi
to form
f
molecular
l
l
hydrogen outside the arc, particularly on the relatively
cold
ld surface
f
off the
h work
k being
b i welded,
ld d releasing
l i
the
h
heat gained previously:
2H = H2 + 421.2 k J / mol.
y Temperature of about 3700oC.

C
y Hydrogen acts as shielding also.
also
y Used for very thin sheets or small diameter wires.
wires
y Lower thermal efficiency than Arc welding.
welding
y Ceramics may be arc welded.
y AC used.
Contd
IES2005
ResistanceWelding
Inatomichydrogenwelding,hydrogenactsas
(a) Aheatingagent
(b) Oneofthegasestogeneratetheflame
(c) Aneffectiveshieldinggasprotectingtheweld
(d) Alubricanttoincreasetheflowcharacteristicsof
weldmetal
Principle
ResistanceWelding
R i t
W ldi
y Both heat and pressure are used.

used
y Heat is generated by the electrical resistance of the
work
k pieces
i
and
d the
h interface
i
f
b
between
them.
h
is supplied
pp
externallyy and is varied
throughout the weld cycle.
y Due to pressure,
pressure a lower temperature needed than
oxyfuel or arc welding.
y Pressure
BySKMondal
y They are not officially classified as solid

state welding
solidstate
Contd
y Overall resistance very low.

y Very highcurrent (up to 100,000 A)
byy the American Welding

g Society.
y
y Very lowvoltage (0.5 to 10 V) is used.
y Very rapid and economical.

y Extremely well suited to automated manufacturing.
y No filler metal, no flux, no shielding gases.
Fig. The desired temperature

di t ib ti
distribution
across
th
the
electrodes and the work
pieces in lap
p
p resistance
welding.
Contd
FIG.Thefundamentalresistanceweldingcircuit
Page 49
Fig.
Typical
pressure cycle
welding. The
forging and
operations.
current
and
for resistance
cycle includes
post heating
Advantages
IES2007
IES 2007
Wh t is
What
i the
th principle
i i l off resistance
i t
welding?
ldi ?
Indicate where the resistance is maximum in spot
1. Very rapid.
2. Fully automation possible.
3. Conserve material; no filler metal, shielding gases, or
welding
g operation.
p
[2marks]
flux is required.
4. Skilled operators are not required.
5.Dissimilar metals can be easily joined.
6. High reliability and High reproducibility.
Fig. The arrangement of the electrodes and the work in spot

welding, showing design for replaceable electrode tips.
Limitations
1. High initial cost.
2. Limitations to the type of joints (mostly lap joints).
Application
Differenttypes
y The resistance welding processes are among the
most common technique for high volume

joining.
joining
1. Resistance spot welding

2. Resistance seam welding
3. Skilled maintenance personne1 are required:
3. Projection welding
4. special surface treatment needed.
4. Upset welding
5. Flash welding
6. Percussion welding
Resistancespotwelding
HeatinputandEfficiencyCalculations
ect c Res
sta ce We
d g
Electric
Resistance
Welding
y The process description given so far is called resistance
spot welding (RSW) or simply spot welding.

welding
y 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
Joules
l law
l applicable
l bl
2
Q = I Rt, Joules
Page 50
Contd
IES2003
Inresistancewelding,heatisgeneratedduetothe
resistancebetween
i t
b t
((a)) Electrodeandworkpiece
p
(b) Asperitiesbetweentouchingplates
( ) Twodissimilarmetalsbeingincontact
(c)
T di i il
l b i i
((d)) Interatomicforces
GATE2009(PI)LinkedS1
Resistance
spot welding
is
R i
ldi off two steell sheets
h
i carried
i d out in
i
lap joint configuration by using a welding current of 3 kA and
a weld
ld time off 0.2 S. A molten
l
weld
ld nugget off volume
l
20 mm3
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/m3, (iii) melting temperature: 1520oC, (iv) specific heat:
0.55 kJ/kg
goC. The ambient temperature
p
is 20oC.
Heat (in Joules) used for producing weld nugget will be
(assuming 100% heat transfer efficiency)
(a) 324
(b) 334
(c) 344
(d) 354
GATE2001
Resistance spot welding is performed on two
plates of 1.5
1 5 mm thickness with 6 mm diameter
electrode, using 15000 A current for a time
d
duration
i
off 0.25 seconds.
d Assuming
A
i
the
h interface
i
f
resistance to be 0.0001 , the heat generated to
form the weld is
(a) 5625 W
Wsec
sec
(b) 8437 W
Wsec
sec
(c) 22500 Wsec
(d) 33750 Wsec
IES2001
Themaximumheatinresistanceweldingisatthe
(a) Tipofthepositiveelectrode
(b) Tipofthenegativeelectrode
(c) Topsurfaceoftheplateatthetimeofelectric
contactwiththeelectrode
i h h l
d
((d)) InterfacebetweenthetwoplatesbeingJoined
p
gJ
GATE2009(PI)LinkedS2
Resistance
spot welding
is
R i
ldi off two steell sheets
h
i carried
i d out in
i
lap joint configuration by using a welding current of 3 kA and
a weld
ld time off 0.2 S. A molten
l
weld
ld nugget off volume
l
20 mm3
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/m3, (iii) melting temperature: 1520oC, (iv) specific heat:
0.55 kJ/kg
goC. The ambient temperature
p
is 20oC.
Heat (in Joules) dissipated to the base metal will be
(neglecting all other heat losses)
(a) 10
(b) 16
(c) 22
(d) 32
GATE2004
Two 1 mm thick steel sheets are to be spot welded
at a current of 5000 A.
A Assuming effective
resistance to be 200 microohms and current flow
time
i
off 0.2 second,
d heat
h
generated
d during
d i
the
h
process will be
(a) 0.2 Joule (b) 1 Joule
(c) 5 Joule
(d) 1000 Joules
Page 51
GATE2007
Two
T metallic
lli sheets,
h
each
h off 2.0 mm thickness,
hi k
are welded
ld d in
i a lap
l joint
j i
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
t the
th full
f ll thickness
thi k
off each
h sheet
h t is
i formed.
f
d The
Th properties
ti off the
th
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
( ) 50.37 (b)
(a)
6
60.37
( )
(c)
70.37 (d)
8
80.37
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
d through
h
h the
h electrodes.
l
d The
Th resultant
l
weld
ld
nugget formed is 5 mm in diameter and 1.5 mm
thick. If the latent heat of fusion of steel is 1400
kJ/kg
J/ g and the effective resistance in the welding
g
operation in 200 , the current passing through the
electrodes is approximately
(a) 1480A
(b) 3300 A
(c) 4060 A
(d) 9400 A
GATE1992
For resistance spot welding of 1.5 mm thick steel
sheets the current required is of the order of
sheets,
(a) 10 A
(b) 100 A
(c) 1000 A
(d) 10,000 A
Two pipes of inner diameter 100 mm and outer

diameter 110 mm each joined by flash butt
welding using 30 V power supply. At the interface,
1 mm off material
i l melts
l from
f
each
h pipe
i which
hi h has
h
a resistance of 42.4 . If the unit melt energy is
64.4 MJm3, then time required for welding in
seconds is
(a) 1
(b) 5
(c) 10
(d) 20
Assertion (A): Spot welding is adopted to weld two

overlapped
pp
metal p
pieces between two electrode
points.
Reason ((R):
) In this p
process when current is switched
on, the lapped pieces of metal are heated in a
restricted area.
( ) Both
(a)
B h A and
i di id ll true and
d R is
i the
h correct
explanation of A
(b) Both
B th A and
i di id ll true
t
b t R is
but
i nott the
th
GATE 2008(PI)
Aluminum strips of 2 mm thickness are joined together
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/mm3. The diameter 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
((a)) 28
((b)) 35
((c)) 655
((d)) 772
IES2007Conventionall
IAS2003
GATE2010
Resistanceseamwelding
Two steel sheets of thickness one mm are welded

by resistance projection welding technique. A
currentt off 30,000 A for
f 0005 second
d is
i made
d to
t
flow. The effective resistance of joint can be taken
as 100 micro ohms.
h
The
h joint can be
b considered
d d as
a cylinder
y
of diameter 5 mm and height
g 155 mm.
The density of steel is 000786 gm/mm3. The heat
needed for welding steel is 10 J/mm3. Calculate the
efficiency of welding.
[20]
y Welding current is a bit higher than spot welding, to
y Weld is made between overlapping sheets of metal.
The seam is a series of overlapping spot welds.
compensate
t short
h t circuit
i it off the
th adjacent
dj
t weld.
ld
y In other p
process a continuous seam is p
produced byy
passing a continuous current through the rotating
electrodes with a speed of 1.5
1 5 m/min for thin sheet.
sheet
y The basic equipment is the same as for spot welding.
except that the electrodes are now in the form of

rotating
t ti disks.
di k
y Timed
Ti d pulses
l
off currentt pass to
t form
f
th overlapping
the
l
i
welds.
welds
Contd
GATE
GATE 2012(PI)
2012 (PI)
In resistance seam welding, the electrode is in the
form of a
( ) cylinder
(a)
li d
((b)) flat p
plate
(c) coil of wire
(d) circular
i l disc
di
Fig.Resistanceseamwelding
Page 52
Contd
Projectionwelding
y Limitations of spot welding.
1. Electrode
El
d
condition
di i
must be
b
maintained
i i d
continually, and only one spot weld at a time.
2. For additional strength multiple welds needed.
y Projection welding
(RPW) overcomes above
limitations.
Contd
y Dimples are embossed on work pieces at the weld
locations and then placed between largearea

large area
electrodes, and pressure and current applied like spot
welding.
ldi
y Current flows through
g the dimples
p
and heats them
and pressure causes the dimples to flatten and form a
weld.
weld
Upsetwelding
y Projections
j
are p
pressformed in anyy shape.
p
y Multiple
p welds at a time.
y Made butt joint compared to lap joint.
y No indentation mark on the surface.
y Pieces are held tightly and current is applied.
y Bolts and nuts can be attached to other metal parts.
y Due to pressure joints get slightly upset and hence its
name.
y Useful for joining rods or similar pieces.
Fig.Principleof
p j
projectionwelding,
g
(a)priortoapplicationof
currentandpressure
(b)andafterformationof
welds
Contd
Contd
y This is the process used for making electric resistance
welded
ld d (ERW) pipes
i
starting
i from
f
a metall plate
l
off suitable
i bl
thickness.
y The plate is first formed into the shape of the pipe with the
help
p of the three roll set as shown in Fig.
g above. The ends
of the plate would then be forming the butt joint.
y The two rotating copper disc electrodes are made to
contact the two ends of the plate through which the
current is passed.
passed The ends get heated and then forge
forge
welded under the pressure of the rolls.
y The
Th ends
d off the
h pieces
i
to be
b upset welded
ld d must be
b perfectly
f l
parallel. Any high spots if present on the ends would get
melted first before the two ends are completely joined.
Contd
PercussionWelding
y Similar to flash welding except arc power by a rapid
discharge of stored electrical energy.

y The arc duration is only 1 to 10 ms, heat is intense and
highly concentrated.
concentrated
y Small weld metal is produced,
produced little or no upsetting,
upsetting and
low HAZ.
y Application: Butt welding of bar or tube where heat
y It is similar to upset welding except the arc rather than
resistance heating.
y One pieces is clamped with cam controlled movable
platen and other with is fixed platen.
Contd
y Two pieces are brought together and the power supply is
switched on.
on Momentarily the two pieces are separated
to create the arc to melt the ends of the two pieces.
Th
Then
again
i the
h pieces
i
are brought
b
h together
h and
d the
h
power switched off while the two ends are fused under
force. Most of the metal melted would flash out
through
g the jjoint and forms like a fin around the jjoint.
y Faster than upset welding.
FlashWelding
damage is a major concern.

Page 53
Contd
Thermit Welding
p 2750C p
p
g
y Temp.
produced in 30 seconds, superheating
y Heating and coalescence is by superheated molten
g
OtherWelding
Technique
metal obtained from a chemical reaction between a

metal oxide and a metallic reducing agent.
the molten iron which provide both heat and filler

metal.
y Runners and risers are provided like casting.
y Used mixture one part aluminum and three parts iron
oxide
id and
d ignited
i it d by
b a magnesium
i
f
fuse.
(
(1150C).
C)
y Copper, brass, and bronze can be welded using a
diff
different
starting
i mixture.
i
8Al F 3O4 9Fe+4Al

8Al+3Fe
F Al2O3 +heat
h t
y Used
U d to joint
j i thick
hi k sections,
i
i remote locations.
in
l
i
Contd
IES2000
ElectroSlagWelding
Considerthefollowingprocesses:
1. Gaswelding
G ldi
2. Thermit welding
3. Arcwelding
4 Resistancewelding
4.
Thecorrectsequenceoftheseprocessesinincreasing
orderoftheirweldingtemperaturesis
d fth i ldi t
t
i
(a) 1,3,4,2
(b) 1,2,3,4
(c) 4,3,1,2
(d)4,1,3,2
p layer
y of molten slag,
g p
y A 65mm deep
protect and
cleanse the molten metal.
y Very effective for welding thick sections.

y Heat is derived from the passage of electrical current
y Watercooled copper molding plates confined the
liquid and moved upward.
through a liquid slag and temp. 1760C
y Multiple electrodes are used to provide an adequate
supply
l off filler.
fill
Contd
IAS2003
y Applications: Shipbuilding, machine manufacture,
heavy pressure vessels, and the joining of large
Whichoneofthefollowingisnotanelectric
resistancemethodofwelding?
i t
th d f ldi ?
((a)) Electroslagwelding
g
g
(b) Percussionwelding
( ) Seamwelding
(c)
S
ldi
((d)) Flashwelding
g
castings and forgings.

y Slow cooling produces a coarse grain structure.
y Large HAZ.
Contd
Contd
Page 54
IAS2000
Considerthefollowingweldingprocesses:
1. TIGwelding
2. Submergedarcwelding
3. Electro
Electroslagwelding4.
slagwelding4. Thermit welding
Whichoftheseweldingprocessesareusedforwelding
thickpiecesofmetals?
hi k i
f
l ?
((a)) 1,2and3
,
3 ((b)) 1,2and4
,
4
(c) 1,3and4 (d) 2,3and4
ElectronBeamWelding
y A beam of electrons is magnetically focused on the
work piece in a vacuum chamber.

y Heat of fusion is produced by electrons decelerate.
y Allows
precise
beam
control
and
deep
weld
penetration.
y No shield
h ld gas (vacuum
(
chamber
h b used)
d)
IES2004
Assertion (A): In electron beam welding process,
vacuum is an essential process parameter
Reason (R): Vacuum provides a highly efficient
shield
hi ld on weld
ld zone
IAS2004
consistsofsmallerHeatAffectedZone(HAZ)?
i t f
ll H tAff t dZ
(HAZ)?
((a)) Arcwelding
g
((b)) Electronbeamwelding
g
(c) MIGwelding
(d) Thermit welding
IES2002
IES1993
Inwhichoneofthefollowingweldingtechniques
iisvacuumenvironmentrequired?
i
t
i d?
((a)) Ultrasonicwelding
g
(b) Laserbeamwelding
( ) Plasmaarcwelding
(c)
Pl
ldi
((d)) Electronbeamwelding
g
LaserBeamWelding
y thin HAZ and little thermal distortion.

y Very
y Used a focused laser beam provides power intensities
in excess of
Electronbeamweldingcanbecarriedoutin
(a) Openair
(b) Ashieldinggasenvironment
(c) Apressurizedinertgaschamber
(d) Vacuum
10kW/cm2
y Filler metal and inert gas shield may or may not used.
y Deep penetration.
y The highintensity beam produces a very thin column
of vaporized metal with a surrounding liquid pool.
y No vacuum needed.
y No direct contact needed.
y Depthtowidth ratio greater than 4: 1.
Page 55
Contd
Contd
IES2007
p is veryy low, often in the range

g 0.1 to 10 J.
y Heat input
y Adopted by the electronics industry.
y Possible
to weld
wires without removing
the
polyurethane insulation.
IES2006
Considerthefollowingstatementsinrespectofthe
laserbeamwelding:
1. Itcanbeusedforweldinganymetalortheir
combinationsbecauseofveryhightemperatureofthe
focalpoints.
2 Heataffectedzoneisverylargebecauseofquick
2.
heating.
3. Highvacuumisrequiredtocarrytheprocess.
Hi h
i
i dt
th
Whichofthestatementsgivenaboveis/arecorrect?
(a) 1and2only (b) 2and3only
((c)) 1onlyy
((d)) 1,2and33
consistsofminimumheataffectedzone(HAZ)?
i t f i i
h t ff t d
(HAZ)?
((a)) ShieldedMetalArcWelding(SMAW)
g(
)
(b) LaserBeamWelding(LBW)
( ) UltrasonicWelding(USW)
(c)
Ul
i W ldi (USW)
((d)) MetalInertGasWelding(MIG)
g(
)
Contd
GATE2012(PI)
Which of the following welding processes results in
th smallest
the
ll t heat
h t affected
ff t d zone??
((a)) Shielded metal arc welding
g
(b) Gas welding
( ) Laser
(c)
L
b
beam
welding
ldi
((d)) Thermit welding
g
ForgeWelding
y Blacksmith do this.
y Borax is used as a flux.
y The ends to be joined were then overlapped on the
anvil and hammered to the degree necessary to

produce an acceptable weld.
y Quality
l
d
depends
d on the
h skill
k ll off the
h worker
k and
d not
used by industry.
industry
IAS2007
IAS1999
Consider the following welding processes:

1. Arc welding
2.
MIG welding
3. Laser beam welding
4.
Submerged arc
welding
S l
Select
the
h correct sequence in
i increasing
i
i order
d off Heat
H
affected zone (HAZ) using the code
given below:
(a) 1 2 3 4 (b) 1 4 2 3
(c) 3 2 4 1 (d) 4 3 2 1
FrictionWelding
Match List I (Shielding method) with List II (Welding

process)) and select the correct answer using
p
g the codes
given below the lists:
List I
List II
A. Flux
l coating
1.
Gas metall arc welding
ld
B. Flux granules
2.
Submerged arc welding
C CO2
C.
3.
Shi ld d metall arc welding
Shielded
ldi
D. Vacuum
4.
Laser beam welding
5.
El t
Electron
b
beam
welding
ldi
Codes:A B
C
D
A
B
C
D
(a) 1
2
5
3
(b)
1
4
2
5
(c) 3
5
1
4
(d)
3
2
1
5
y Machine is similar to a centre lathe.
y Heat is obtained by the friction between the ends of
the two parts to be joined.
y Power requirements 25 kVA to 175 kVA.

y The
Th axial
i l pressure depends
d
d on the
th strength
t
th and
d
hardness of the metals being joined.
y One part is rotated at a high speed and other part is
axially aligned and pressed tightly against it.
y Pressure 40 MPa for lowcarbon steels to as high as 450
MPa for alloy steels.
y Friction raises the temperature of both the ends. Then
rotation
t ti
i stopped
is
t
d abruptly
b
tl and
d the
th pressure is
i
increased to join.
join
Page 56
Contd
Contd
GATE2007
y Very efficient.
efficient
Whichoneofthefollowingisasolidstatejoining
process?
(a) Gastungstenarcwelding
(b) Resistancespotwelding
(c) Frictionwelding
(d) submergedarcwelding
y Wide variety of metals or combinations of metals can
be joined
b
d such
h as aluminium
l
to steel.
l
y Grain size is refined
y Strength is same as base metal.
y Only round bars or tubes of the same size, or
connecting
g bars or tubes to flat surfaces can jjoin.
y One of the components must be ductile.
y Friction
F i ti welding
ldi is
i a solid
lid state
t t welding.
ldi
Fig frictionweldingprocess
Contd
GATE2010(PI)
UltrasonicWelding(USW)
IFS2011
Two steel bars, each of diameter 10 mm, are coaxially
USW is a solidstate welding.
friction welded, end to end, at an axial pressure of 200
Di
Discusswithfigurethevariousstepsrequiredfor
ithfi
th i t
i df
Highfrequency
Hi h f
( to 200, KHz)
(10
KH ) is
i applied.
li d
MP and
MPa
d at a rotational
i
l speed
d off 4000 rpm. The
Th
frictionwelding mentioningatleasttwomethods
frictionwelding,mentioningatleasttwomethods
Surfaces are held together

g
under light
g
normal
coefficient of friction between the mating faces of the
ofcontrol.
pressure.
Temp.
Temp do not exceed onehalf
one half of the melting point.
point
[5marks]
rotating
g bars is 0.50.
5 The torque
q is assumed to act at the
The ultrasonic transducer is same as ultrasonic
machining.
3/4th 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
Contd
Restricted to the lap joint

Weld
foil,
the
W ld thin
hi materialssheet,
i l h
f il and
d wireor
i
h
attaching thin sheets to heavier structural members.

Maximum thickness 2.5 mm for aluminum and 1.0
mm for harder metals.
metals
Number of metals and dissimilar metal combinations
and
d non metals
l can be
b joined
j i d such
h as aluminum
l i
to
ceramics or glass.
Equipment is simple and reliable.
Less surface preparation and less energy is needed.
needed
Applications
y Joiningthedissimilarmetalsinbimetallics
y Makingmicrocircuitelectricalcontacts.
g
ExplosionWelding
y Done at room temperature in air, water or vacuum.
y Surface contaminants tend to be blown off the surface.
y Weldingrefractoryorreactivemetals
y Typical impact pressures are millions of psi.
y Bondingultrathinmetal.
y Well suited to metals that is prone to brittle joints
when heat welded, such as,

y Aluminum on steel
y Titanium
Ti i
on steell
Contd
Page 57
Contd
y Typically the detonation velocity should not exceed
Important factors are,

y Critical
C i i l velocity
l i
y Critical angle
g
y The cladding plate can be supported with tack welded
supports at the edges,
edges or the metal inserts.
inserts
120%
% off the
th sonic
i velocity
l it in
i the
th metal.
t l
Contd
Advantages,
Advantages
y Can bond many dissimilar, normally unweldable
metals
y The lack of heating preserves metal treatment
y The process is compact, portable, and easy to contain
y Inexpensive
y No need for surface preparation
High velocity explosives, 45727620 m/s.

y TNT
y RDX
y PETN
y Composition B
y Composition C4
y Datasheet
y Primacord
Medium velocity explosives, 15244572 m/s
y Ammonium nitrate
y Ammonium perchlorate
y Amatol
y Nitroguonidine
y Dynamites
y diluted PETN
Contd
Disadvantages,
Disadvantages
y The metals must have high enough impact resistance,
and
d ductility
d
l (at
( least
l
5%)
%)
y The cladding plate cannot be too large.
y Noise and blast can require worker protection, vacuum
chambers,
h b
b i d in
buried
i sand/water.
d/ t
Contd
Typicalapplications:
y Verylargeplatescanbecladded.
Verylargeplatescanbecladded
y Joinsdissimilarmetals.
Joinsdissimilarmetals
(titaniumtosteel,Altosteel,AltoCuetc )
(titaniumtosteel,Altosteel,AltoCuetc.)
y Jointubetotubesheetsoflargeheatexchangers.
Contd
Contd
Contd
IES2011S1Contd
GATE1992
Inanexplosiveweldingprocess,the..
(maximum/minimum)velocityofimpactisfixed
bythevelocityofsoundinthe
(fl /
(flyer/target)platematerial
) l
i l
((a)) Maximum;target
; g
(b) Minimum;target
( ) Maximum;flyer
(c)
M i
fl
((d)) Minimum;flyer
; y
Page 58
MatchListIwithListIIandselectthecorrectanswer
usingthecodegivenbelowthelists:
ListI
A.Laserbeam
A
L
b
welding
B.Electron
beamwelding
ListII
1.Canbeappliedforweldingorrefractorymetals
C b
li df ldi f
l
likeniobium,tantalum,molybdenumandtungsten.
2.Asoundandcleanweldedjointiscreateddueto
rubbingoftwopartsagainsteachotherwith
adequatespeedandpressureproducingintenseheat
d
d d
d
h
raisingtemperatureabovemeltingpoint.
C.Ultrasonic 3.Cleanheatsourcecreatedmuchawayfromjob,a
welding
narrowspotisheated,workchamberoperatesina
highvacuum.
4.Cleanheatsourceveryquickheating,verysmall
4
yq
g
y
D.Friction
welding
focalspot,novacuumchamberisrequired.
IES2011FromS1
Codes:
A
(a) 4
(c) 4
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:
List I
ListI
List II
ListII
(WeldingProcess)
(Application)
A. Laserwelding
1.
Unitinglargeareasheets
B. Frictionwelding
i i ldi
2.
Repairinglargeparts
i i l
C. Ultrasonicwelding
3.
Weldingarodtoaflatsurface
D. Explosivewelding
g
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)
IFS
IFS 2009
T plates
Two
l t off aluminium
l i i
and
d stainless
t i l
steel
t l are to
t
be welded back to back to create a single plate of
IAS2002
A
1
B
3
C
4
D
2
(d)
A
5
B
3
C
4
D
1
MatchListI,(Welding)withListII(Application)andselectthecorrect
answerusingthecodesgivenbelowtheLists:
Li I
ListI
Li II
ListII
(Welding)
(Application)
A.
Explosive
1.
Joiningthicksheets
B.
Ultrasonic
2.
Manufactureofheatexchanges
C.
Thermit
3.
Joiningthinsheetsorwiresof
similar/dissimilar metals
D.
Projection
4.
Joininghydraulicpistonrodsfor
agricultural machinery
5.
Joiningrails,pipesandthicksteel
sections
C
D
A
B
C
D
Codes:A
B
(a) 2
5
1
3
(b)
4
5
1
3
(c) 2
3
5
1
(d)
4
3
5
1
Autogeneous Welding
MicroPlasmaArcWeld(PAW)
y Autogeneous welding or fusion of the parent
y Similar to GTAW except the plasma caused by the arc
material
t i l in
i an inert
i t gas shield
hi ld without
ith t the
th use
of filler metals.
is constricted by a watercooled orifice

y Capable of high welding speeds where size permits
thickness equal
q
to the sum of the thicknesses of
y Argon is used as the shielding gas.
the two plates. Suggest the suitable process and

explain it in brief.
[10 marks]
DiffusionWelding
y It is
process which
i a solid
lid state
t t welding
ldi
hi h produces
d
coalescence of the faying surfaces by the application of

pressure and
d elevated
l t d temperatures
t
t
( b t 50 to
(about
t 80%
8 %
of absolute melting point of the parent materials) for a
ti
time
ranging
i from
f
a couple
l off minutes
i t to
t a few
f hours.
h
y Produces high quality bonds with good strength with
little or no distortion.
y Ca
Can jo
join ve
veryy d
dissimilar
ss
a materials.
ate a s.
y A solid filler metal may or may not be inserted.
y Materials
M t i l welded
ld d for
f aircraft
i
ft and
d rocket
k t industry:
i d t
Boron, Titanium, Aluminium, Ceramic, Composite,
G hit Magnesium
Graphite,
M
i
etc.
t
GATE 2008(PI)
Which pair among the following solid state welding
processes uses heat from an external source?
P Diffusion welding;
Q Friction welding
R Ultrasonic
l
welding
ld
S Forge welding
ld
( ) P and
(a)
dR
(b) R and
dS
( ) Q and
(c)
dS
(d) P and
dS
Page 59
IAS2001
MatchListI(Weldingprocesses)withListII(Features)and
selectthecorrectanswerusingthecodesgivenbelowtheLists:
ListI
A
A.
Ultrasonicwelding
1
1.
B.
Electronbeamwelding2.
C.
Plasmaarcwelding
3.
4.
Codes:A
(a) 1
(c) 2
B
2
1
C
4
4
(b)
(d)
ListII
Gasheatedtoionizedcondition
forconductionofelectriccurrent
Highfrequencyandhigh
intensityvibrations
b
Concentratedstreamofhigh
energyelectrons
Exothermalchemicalreaction
A
B
C
4
3
1
2
3
1
JWM2010
MatchListIwithListIIandselectthecorrectanswer
g
g
usingthecodegivenbelowthelists:
ListI
ListII
A Atomic
A.Atomic
11.Twopiecesarebroughttogetherand
Twopiecesarebroughttogetherand
hydrogenwelding powersupplyisswitchedon
IES 2011 C
IES2011Conventional
ti
l
Discuss the process capabilities and applications of Gas
M t l Arc
Metal
A Welding,
W ldi
G tungsten
Gas
t
t
A Welding,
Arc
W ldi
and
d
BrazingandSoldering
Diffusion Bonding processes.

processes
B.Plasmaarc
welding
C.Spotwelding
2.Nuggetisformedattheinterfaceof
twoplates
3.Gasisionized
D.Flashwelding
4.Inertgasshieldedarcwelding
Code:A
d
(a) 4
(c) 4
B
3
2
C
2
3
D
1
1
(b)
(d)
A
1
1
B
3
2
C
2
3
[15Marks]
D
4
4
B i
h
l di i
Brazingprocesshasseveraldistinct
advantages:
BrazingandSoldering
y Brazing is the joining of metals through the use of heat
and a filler metal whose melting temperature is above

450C; but
b below
b l
the
h melting
l
point off the
h metals
l being
b
joined.
C
Comparison
i
with
ith welding
ldi and
d the
th brazing
b i process
1. The composition of the brazing alloy is significantly
different from that of the base metal.
metal
2. The strength of the brazing alloy is substantially lower
than that of the base metal.
metal
3. The melting point of the brazing alloy is lower than that
of the base metal,
metal so the base metal is not melted.
melted
4. Capillary action or capillary attraction draws the
molten filler metal into the jjoint,, even against
g
the flow of
gravity.
1 All metals can be joined.

1.
joined
2. Suited for dissimilar metals.
3. Qu
Quick
c aand
d eco
economical.
o ca .
4. Less defects.
4
Contd
y Extremely clean surface needed.
Corrosion prone
Brazingmetalsaretypicallyalloyssuchas,
y Brazingbrass(60%Cu,40%Zn)
B i b
(6 %C %Z )
y Manganesebronze
g
y Nickelsilver
y Coppersilicon
C
ili
y Silveralloys(with/withoutphosphorous)
y (
/
p
p
)
y Copperphosphorous
Page 60
y Fluxes used are combinations of borax, boric acid,
chlorides, fluorides, tetraborates and other wetting

agents.
Contd
Contd
GATE2005
p
p
yA p
popular
composition
is 75% borax and 25% boric
Thestrengthofabrazedjoint
( ) Decreaseswithincreaseingapbetweenthetwo
(a)
D
i hi
i b
h
joiningsurfaces
(b) Increaseswithincreaseingapbetweenthetwo
joiningsurfaces
(c) Decreasesuptocertaingapbetweenthetwo
j i i f
joiningsurfacesbeyondwhichitincreases
b
d hi hi i
((d)) Increasesuptocertaingapbetweenthetwo
p
g p
joiningsurfacesbeyondwhichitdecreases
acid.
y Sodium cyanide is used in brazing tungsten to copper.
y Base materials not melted.
IES2006
Whichoneofthefollowingisnotafusionwelding
process??
((a)) Gaswelding
g
(b) Arcwelding
( ) Brazing
(c)
B i
((d)) Resistancewelding
g
ISRO2010
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
prior to brazing
( ) To prevent oxides
(c)
d from
f
f
forming
d
during
the
h brazing
b
operation
p
on both the base metal and the brazing
g
material
(d) To facilitate the wetting process by reducing the
viscosity of the melt
BrazeWelding
y Capillary action is not required.
y Edge preparation needed.
y Can join cast iron.
Contd
Soldering
y Done with an oxyacetylene torch.
y By definition, soldering is a brazing type of operation
where the filler metal has a melting temperature

below 450C.
y Strength of the filler metal is low.
y Soldering is used for a neat leakproof joint or a low
resistance
i t
electrical
l t i l joint.
j i t
y Not suitable for hightemp.
high temp application.
application
Fig.BrazeWelding
Page 61
Contd
Effective soldering generally involves six important

steps:
(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,
(5) Application of flux, solder, and sufficient heat to
allow
ll
the
h molten
l
solder
ld to fill the
h joint
j i by
b capillary
ill
action and solidify, and
(6) Removal of the flux residue, if necessary.
ld
l
SolderMetals
SolderFlux
y Ammonium chloride or rosin for soldering tin
y Most solders are alloys of lead and tin.

y Three commonly used alloys contain 60, 50, and 40%
y Silver solders uses for highertemperature

higher temperature service,
service
Electrical and Electronic purpose.
y Hydrochloric acid and zinc chloride for soldering
galvanized
l
i d iron
i
tin and all melt below 240C.
y Some
S
fl
fluxes
are corrosive
i and
d should
h ld be
b removed
d after
ft
use
Contd
DifficultieswithGreyCastIron
Difficulties with Grey Cast Iron
S ld i and
Soldering
d brazing
b i are difficult
diffi lt off grey castt Iron
I
d
due
to surface contamination with graphite having a very low
surface energy.
gy
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 multi
multipass welding
Excessive H2, O2, N2, in the
welding atmosphere or Damp
electrodes
inclusionssuchasMn FeandS
inthebasemetaland/or
residualstress
IES1994
MatchList IwithList IIandselectthecorrect
answerusingthecodesgivenbelowtheLists:
g
g
List I(Filler)
List II(Joiningprocess)
A. Cu,Zn,Agalloy
1.
Brazewelding.
B. Cu,Sn,alloy
2.
Brazing
C Pb,Sb,alloy
C.
Pb Sb alloy
3
3.
Soldering
D.Iron oxideandaluminium powder4.
TIGweldingof
aluminium
Codes:A B
C
D
A
B
C
D
(a) 2
1
3
(b) 1
2
4
(c) 2
1
3
4
(d) 2
3
4
IES2004
MatchListI(Weldingproblems)withListII(Causes)andselect
thecorrectanswerusingthecodesgivenbelowtheLists:
ListI
ListII
A. Crackingofweldmetal
1.
Excessivestresses
B
B.
C ki fb t l
Crackingofbasemetal
2.
Hi hj i t i idit
Highjointrigidity
C. Porosity
3.
Failuretoremoveslag
p
p
frompreviousdeposit
D. Inclusions
4.
Oxidation
5.
ExcessiveH2,O2,N2,in
theweldingatmosphere
h ldi
h
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
Page 62
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
5.
B
Brazewelding
ldi
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
IES2003,ISRO2011
MatchListI(WeldingDefects)withListII(Causes)and
selectthecorrectanswerusingthecodesgivenbelowthe
g
g
Lists:
ListI
ListII
( ldi
(WeldingDefects)
f
)
(
(Causes)
)
A. Spatter
1.
Dampelectrodes
B
B.
Di
Distortion
i
2.
A bl
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
Cracks
y Cracks may be of micro or macro size and may appear in
the weld metal or base metal or base metal and weld

metal
t l boundary.
b
d
y Different categories
g
of cracks are longitudinal
g
cracks,
transverse cracks or radiating/star cracks and cracks in
the weld crater.
y Cracks occur when localized stresses exceed the ultimate
t il strength
tensile
t
th off material.
t i l
y These stresses are developed
p
due to shrinkage
g during
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
p
i.e. fast cooling
g rates, too concave or convex weld
bead and high hydrogen contents in the weld metal.
HAZ Cracking
HAZCracking
y Crackinginheataffectedzonemaybecausedby:
(i)Hydrogeninweldingatmosphere
(ii)hotcracking
(iii)lowductility
(iv)highresidualstresses
( )
(v)brittlephaseinthemicrostructure
p
Fig VariousTypesofCracksinWelds
Fig.VariousTypesofCracksinWelds
Hydrogen Induced Cracking

HydrogenInducedCracking
ue to t e p ese ce o o stu e, g ease, ust etc.,
y Duetothepresenceofmoisture,grease,rustetc.,
hydrogenmayentertheweldpoolandgetdissolvedin
theweldmetal
theweldmetal.
y DuringcoolinghydrogendiffusestotheHAZ.
y Crackingmaydevelopduetoresidualstressesassistedby
hydrogencoalesence.
y Thefactorsthatdeterminetheprobabilityofhydrogen
i d d b ittl
inducedembrittlementandcrackingofweldare:
t d
ki f ld
( ) y g
(a)Hydrogencontent
(b)fracturetoughnessofweldandHAZ
( )
(c)stresstowhichthejointisexposedasaresultof
hi h h j i i
d
l f
theweldthermalcycle.
Residualstress
y The residual stresses result from the restrained expansion
and contraction that occur during localized heating and

cooling in the region of weld deposit.
y The magnitude of residual stresses depends on the weldment
design, support and clamping of the components being
welded their materials,
welded,
materials welding process used,
used part
dimensions, welding sequence, post weld treatment, size of
the deposited weld beads,
beads etc.
etc
y Residual stresses should not have a harmful effect on the
strength
h performance
f
off weldments,
ld
reduces
d
f i
fatigue
strength, May cause distortion. This residual stress may
result
l in the
h cracking
k
off a brittle
b l materiall and
d is not
important as far as a ductile material.
Solid Inclusion
SolidInclusion
Porosity
y Solid inclusions may be in the form of slag or any other
y Porosity
the
P
i results
l when
h
h gases are entrapped
d in
i the
h
solidifying weld metal.

y These gases are generated from the flux or coating
constituents of the electrode or shielding gases used
during welding or from absorbed moisture in the
coating.
coating
y Porosity can also be controlled if excessively high
welding currents, faster welding speeds and long arc
lengths are avoided flux and coated electrodes are
properly baked.
Fig.DifferentFormsofPorosities
Page 63
nonmetallic material entrapped in the weld metal as

these mayy not able to float on the surface of the
solidifying weld metal.
y During arc welding flux either in the form of granules or
coating after melting, reacts with the molten weld metal
removing
i oxides
id and
d other
h impurities
i
i i in
i the
h form
f
off slag
l
and it floats on the surface of weld metal due to its low
density.
y Slag inclusion can be prevented if proper groove is
selected, all the slag from the previously deposited bead
is removed,
removed too high or too low welding currents and
long arcs are avoided.
Lack of Fusion
LackofFusion
ac o
us o iss tthee failure
a u e to fuse
use toget
e eeither
t e tthee
y Lack
of fusion
together
base metal and weld metal or subsequent beads in
multipass welding because of failure to raise the
temperature of base metal or previously deposited weld
l
layer
t melting
to
lti point
i t during
d i welding.
ldi
y Lack of fusion can be avoided by
y p
properly
p y cleaning
g of
surfaces to be welded, selecting proper current, proper
welding technique and correct size of electrode.
IncompletePenetration
y Incomplete
penetration
I
l
i means that
h the
h weld
ld depth
d h is
i not
upto the desired level or root faces have not reached to

melting point in a groove joint.
y 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.
penetration
Fig SlagInclusioninWeldments
Fig.SlagInclusioninWeldments
ImperfectShape,Distortions
p
p ,
IES2011Conventionall
y Imperfect shape means the variation from the desired shape and
y
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
and
d fast
f travell speeds.
d
Underfilling may be due to low currents, fast travel speeds and
small
ll size
i off electrodes.
l
d Overlap
O l may occur due
d to low
l
currents,
longer arc lengths and slower welding speeds.
E
Excessive
i reinforcement
i f
t is
i formed
f
d if high
hi h currents,
t low
l
voltages,
lt
slow travel speeds and large size electrodes are used. Excessive
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
heat input during welding.
y Enumeratefourdefectscausedduetoresidualstressesin
E
f d f
dd id l
i
weldedjoints.
[2Marks]
Ans.
1. Distortion
2. Crackinginthebasemetal
3.
LamellarTearing
4. Reductionoffatiguestrength
IES2004
Consider the following statements:
The magnitude of residual stresses in welding
depends upon
1. Designofweldment
D i f ld
t
2. Supportandclampingofcomponents
3. weldingprocessused
4. Amountofmetalmelted/deposited
4
p
(a) 1,2and4
1 2and4
(b)1 2and3
(b)1,2and3
(c) 1and3
(d)2and3
Page 64
GATE2003
Matchthefollowing
Workmaterial
P.Aluminium
Q.DieSteel
R.CopperWire
S.Titaniumsheet
(a)P 2
(b)P 6
(c)P 4
(d)P 5
(d)
Q 5
Q 3
Q 1
Q 4
R 1
R 4
R 6
R 2
Typeofjoining
yp
j
g
1.
SubmergedArcWelding
2.
Soldering
3.
Thermit Welding
4.
AtomicHydrogenWelding
5.
GasTungstenArcWelding
6.
LaserBeamWelding
7.
Brazing
S 3
S 4
S 2
S 6
IES2004
Th i f h h ff
Thesizeoftheheataffectedzone(HAZ)willincreasewith
d
(HAZ) illi
ih
1. Increasedstartingtemperature
g
p
2. Increasedweldingspeed
3 Increasedthermalconductivityofthebasemetal
3.
4. Increaseinbasemetalthickness
(a) 1,2and3
(b) 1and3
(c) 1and4
(d) 2and3
IES1998
Anarcweldedjointisshownintheabovefigure.
Th
Thepartlabelled
tl b ll d 'B'inthefigureisknownas
'B'i th fi
i k
((a)) Weldpreparation
p p
(b) Penetration
( ) Reinforcement
(c)
R i f
((d)) Slag
g
GATE1996
Preheatingbeforeweldingisdoneto
( ) Makethesteelsofter
(a)
M k h
l f
((b)) Bumawayoil,grease,etc,fromtheplatesurface
y ,g
,
,
p
(c) Preventcoldcracks
(d) Preventplatedistortion
P
l di
i
IES1992
Weldspatteroccursduetoanyofthefollowing
exceptt
((a)) Highweldingcurrent
g
g
(b) Toosmallanelectrode
( ) Arc
(c)
A
((d)) Wrongpolarity
gp
y
IES2004
Assertion (A): A sound welded joint should not only
be strong enough but should also exhibits a good
amount of ductility
Reason (R): Welding process is used for fabricating
mild steel components only
explanation of A
(b) Both
B th A and
i di id ll true
t
b t R is
but
i nott the
th
( ) A is
(c)
i true
t
b t R is
but
i false
f l
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
Page 65
JWM2010
Assertion (A) : Spatter is one of the welding defects.
defects
Reason (R) : In submerged arc welding process,
there is no spatter of molten metal.
(b) Both
h A and
d d ll true but
b R is not the
h
correct explanation
p
of A
(d) A is
i false
f l but
b t R is
i true
t
IAS2003
Toolmaterialnotsuitedtoresistanceweldingis
( ) Aluminium oxide
(a)
(c) Highspeedsteel
( )
(b)
(d)
Stellite
Masonite
GATE2001
Two plates of the same metal having equal
thickness are to be butt welded with electric arc.
arc
When the plate thickness changes, welding is
achieved
hi
d by
b
((a)) Adjusting
j
g the current
(b) Adjusting the duration of current
( ) Changing
(c)
Ch
i the
h electrode
l
d size
i
((d)) Changing
g g the electrode coating
g
IES 2012
Brittle
B i l welds
ld are mainly
i l obtained
b i d due
d to
((a)) Wrong
g electrode,, faultyy p
preheating
g and metal
hardened by air
(b) Faulty welds,
welds faulty sequence and rigid joints
(c) Wrong speed, current improperly adjusted and faulty
preparation
(d) Uneven heat,
heat improper sequence and deposited
metal shrinks
IES 2012
WhichofthefollowingareassociatedwithHeatAffected
Whi h f h f ll i
i d i hH Aff
d
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
Page 66
IES 2012
Statement
induced
St t
t (I):
(I) Hydrogen
H d
i d d cracking
ki occurs in
i the
th heat
h t
effected zone adjacent to fusion zone and classified as solid
state cracking
Statement (II):Hydrogen from burning of flux coating
penetrates martensitic micro cracks preventing healing as
well as enlarging them.
( ) Both
(a)
B th Statement
St t
t (I) and
d Statement
St t
t (II) are individually
i di id ll
true and Statement (II) is the correct explanation of
Statement (I)
(b) Both Statement (I) and Statement (II) are individually
t
true
b t Statement
but
St t
t (II) is
i nott the
th correctt explanation
l
ti
off
Statement (I)
( ) Statement
(c)
S
(I) is
i true but
b Statement
S
(II) is
i false
f l
(d) Statement (I) is false but Statement (II) is true

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Sandcasting

through the runners, and enters the mold cavity

y The mold is opened, the pattern board is drawn

removed, and molten metal is poured through the

mould intact. It is made up of wood for temporary

y Pattern: Pattern is a replica of the final object to be

made with some modifications.

y Moulding sand: The freshly prepared refractory

material used for making the mould cavity. It is a

moulding flasks that makes up the sand mould.

which is used at the start of the mould making.

of the mould into which the molten metal is poured.

from the pouring basin reaches the mould cavity.

y Bottom board: This is a board normally made of wood,

y Pouring basin: A small funnelshaped

y Runner: The passage ways in the parting plane through

y Core: Used for making hollow cavities in castings.

the mould cavity.

metal enters the mould cavity in a controlled rate. Contd

the mould to increase the cooling rate of castings.

y Tapering of thinner section towards thicker section

y Riser: It is a reservoir of molten metal provided in the

(d) To support the cores

Suitable placement of chills

Suitable placement of chaplets

(a) 1 and 2 (b) 1 and 3 (c) 2 and 3 (d) 1,

Green sand mould indicates that

A pattern is a replica of the object to be made by the

y All metals shrink when cooling except perhaps

y This is because of the interatomic vibrations which

volume when the metal changes from liquid to

y Liquid shrinkage refers to the reduction in

caused, when a metal loses temperature in the

y In grey cast iron and spheroidal graphite iron, the

amount off graphitization

Which one of the following materials will require

((d)) Made byy p

Gray cast iron blocks 200 x 100 x 10 mm are to be

Shrinkage allowance on pattern is provided to

compensated from the riser is

A cubic casting of 50 mm side undergoes volumetric

y To reduce the chances of the damage of the mould

therefore is likely to be distortion prone.

all around the vertical faces to enlarge the mould

those dimensions, which are parallel to the parting

y This is particularly so for weaker sections such as long

veryy dimensionallyy stable. Commonlyy used teak,, white

Which of the following materials can be used for

For-2013 (IES, GATE & PSUs)

Select the correct answer using the codes given below:

Single Piece Pattern

Split Pattern or Two Piece Pattern

Gating and runner system are integral with the

These are similar to split patterns. In addition to

The cope and drag patterns along with the

y Loose Piece Pattern

This type of pattern is also used when the

The pattern adopted for those castings where there

For-2013 (IES, GATE & PSUs)

It is used to sweep the complete casting by means

Fluidity in casting (CI) operation is greatly

y Used for making cavities and hollow projections.

a) Melting temperature of molten metal