9-Casting & Welding Theory & Questions Altogethre 2013 PDF

Sandcasting
y The molten metal is p p

poured into the sprue hole, flows
y Sand
S d casting
i uses ordinary
di sand
d as the
h primary
i through the runners, and enters the mold cavity
mould material. through an opening called a gate.
y The sand grains are mixed with small amounts of y Gravity flow is the most common means of
other materials,
materials such as clay and water,
water to improve i t d i the
introducing th metalt l into
i t the
th mold.
ld
MetalCasting mouldability and cohesive strength, and are then

packed around a pattern that has the shape of the
desired casting.
y After solidification, the mold is broken and the
finished casting is removed.
y The casting is then fettled
fettled by cutting off the ingate
y The pattern must be removed before pouring, the
and the feeder head.
mold is usually made in two or more pieces.
y Because the mold is destroyed, a new mold must be
y An opening called a sprue hole is cut from the top of
made for each casting.g
BySKMondal th mold
the ld through
th h the
th sand d andd connected
t d to
t a
system of channels called runners. Contd. Contd
Sequentialstepsinmakingasandcasting y The mold is opened, the pattern board is drawn

y Apatternboardisplacedbetweenthebottom(drag) (removed), and the runner and gate are cut into the
andtop(cope)halvesofaflask,withthebottomsideup.
p( p ) , p surface of the sand.
y Sandisthenpackedintothedraghalfofthemold.
S di h k di h d h lf f h ld 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 Abottomboardispositionedontopofthepackedsand,
andthemoldisturnedover,showingthetop(cope)half
andthemoldisturnedover showingthetop(cope)half
ofpatternwithsprue andriserpinsinplace. 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.
y Thecopehalfofthemoldisthenpackedwithsand.
Thecopehalfofthemoldisthenpackedwithsand
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 Moulding sand: The freshly prepared refractory
y Pattern: Pattern is a replica of the final object to be y Pouring basin: A small funnelshaped
funnel shaped cavity at the top
material used for making the mould cavity. It is a
made with some modifications. of the mould into which the molten metal is poured.
p
mixture of silica, clay and moisture in appropriate
y Parting
g line: This is the dividing
g line between the two y Sprue: The passage through which the molten metal
proportions.
i
moulding flasks that makes up the sand mould. 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 Runner: The passage ways in the parting plane through
y Bottom board: This is a board normally made of wood,
sand.
sand which
hi h molten
l metall flow
fl i regulated
is l d before
b f they
h reach
h
which is used at the start of the mould making.
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
Contd metal enters the mould cavity in a controlled rate. Contd
Padding IES2001
y Chaplet: Chaplets are used to support cores inside the y Tapering of thinner section towards thicker section
mould cavity.
cavity is known as 'padding'
padding . Th main
The i purpose off chaplets
h l t isi
y This will require extra material.
y Chill: Chills are metallic objects, which are placed in (a) To ensure directional solidification
y If padding is not provided, centre line shrinkage or
the mould to increase the cooling rate of castings. porosityy will result in the thinner section.
p (b) To provide efficient venting
y Riser: It is a reservoir of molten metal provided in the
(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 IES2007 GATE2009

Which of the following methods are used for Which one of the following is the correct
obtaining directional solidification for riser design statement? MatchtheitemsinColumnIandColumnII.
ColumnIColumnII
G
Gate i provided
is id d in
i moulds ld to
1. Suitable placement of chills P.MetallicChills1.Supportforthecore
((a)) Feed the casting g at a constant rate
Q M t lli Ch l t R
Q.MetallicChaplets2.Reservoirofthemoltenmetal
i fth lt t l
2. Suitable placement of chaplets (b) Give passage to gases R.Riser3.Controlcoolingofcritical
3. Employing
l padding
dd ( ) Compensate
(c) C f shrinkage
for hi k sections
i
((d)) Avoid cavities S.ExothermicPadding4.Progressivesolidification
S l t the
Select th correctt answer. (a) P1,Q3,R2,S4 (b) P1,Q4,R2,S3
(a) 1 and 2 (b) 1 and 3 (c) 2 and 3 (d) 1,
1 2 and 3 ((c)) P3,Q4,R2,S1
3, Q 4, , ((d)) P4,Q1,R2,S3
4, Q , , 3
For-2013 (IES, GATE & PSUs) Page 2

GATE1992 GATE2011 Pattern
Inagreensandmouldingprocess,uniform Green sand mould indicates that
A pattern is a replica of the object to be made by the
rammingleadsto (a) polymeric mould has been cured
casting process, with some modifications.
(a) Lesschanceofgasporosity (b) mould has been totally dried
The main modifications are
(b) Uniformflowofmoltenmetalintothemould (c) mould is green in colour
y The addition of pattern allowances,
cavity (d) mould contains moisture
y The provision of core prints, and
(c) Greaterdimensionalstabilityofthecasting
y Elimination of fine details, which cannot be obtained
(d) Lesssandexpansiontypeofcastingdefect by casting and hence are to be obtained by further
processing
PatternAllowances Shrinkageallowance Liquidshrinkageandsolidshrinkage

y All metals shrink when cooling except perhaps y Liquid shrinkage refers to the reduction in
1. Shrinkageorcontractionallowance
g
volume when the metal changes from liquid to
bismuth. solid state at the solidus temperature. To account
2. Draftortaperallowance
y This is because of the interatomic vibrations which f this,
for hi risers
i are provided
id d in
i the
h moulds.
ld
3. Machiningorfinishallowance
are amplified
l f d by
b an increase in temperature.
4. Distortionorcamberallowance 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 caused, when a metal loses temperature in the
caused
5. Rappingallowance solid state. The shrinkage allowance is provided to
linear dimensions.
dimensions Even in case of internal dimensions.
dimensions take
k care off this
hi reduction.
d i
Contd
y Pattern Allowances IES1995 GATE1999

Cast Iron 10 mm/m
Which one of the following materials will require
Brass, Copper, Aluminium 15 mm/m Which of the following materials requires the
Steel 20 mm/m the largest size of riser for the same size of casting? largest shrinkage allowance, while making a
Zinc, Lead 25 mm/m pattern for casting?
(a) Aluminium
(a) Aluminium
(b) Cast iron (b) Brass
y In grey cast iron and spheroidal graphite iron, the
amount off graphitization
hi i i controls
l the
h actuall (c) Steel (c) Cast Iron
shrinkage. When graphitization is more, the (d) Plain Carbon Steel
shrinkage would be less and vice versa. (d) Copper.

IES1999 GATE2001
In solidification of metal during casting,
ISRO2007
Shrinkage allowance on pattern is provided to
Shrinkage allowance is made by
compensation for
f solid
l d contraction is compensate for shrinkage when
(a) Adding to external and internal dimensions
(a) The temperature of liquid metal drops from
( ) Provided
(a) P id d byb the
h oversize
i pattern (b) Subtracting from external and internal pouring to freezing temperature
dimensions
(b) Achieved
A hi d byb properly
l placed
l d risers
i (b) The
Th metalt l changes
h f
from li id to
liquid t solid
lid state
t t att
(c) Subtracting from external dimensions and freezing temperature
(c) Obtained by promoting directional adding to internal dimensions
(c) The temperature of solid phase drops from
solidification (d) Adding to external dimensions and subtracting freezing to room temperature
from internal dimensions
(d) The temperature of metal drops from pouring
((d)) Made byy p
providing
g chills
to room temperature
GATE2004 GATE2008 GATE2011

A cubic casting of 50 mm side undergoes volumetric
Gray cast iron blocks 200 x 100 x 10 mm are to be solidification shrinkage g and volumetric solid
Whil cooling,
While li a cubical
bi l casting
ti off side
id 40 mm
cast in sand moulds. Shrinkage allowance for contraction of 4% and 6% respectively. No riser is
pattern making is 1%.1% The ratio of the volume of undergoes 3%,
3% 4% and 5% volume shrinkage used Assume uniform cooling in all directions.
used. directions The
pattern to that of the casting will be side of the cube after solidification and contraction is
during
g the liquid
q state, p
phase transition and solid
( ) 48.32
(a) 8 mm
state, respectively. The volume of metal ((b)) 49
49.90
9 mm
(a) 0.97
0 97 (b) 0.99
0 99 (c) 1.01
1 01 (d) 1.03
1 03
compensated from the riser is (c) 49.94 mm
(a) 2% (b) 7% (c) 8% (d) 9% (d) 49.96 mm
IAS1995 IAS2003 Draft

Assertion (A): A pattern is made exactly similar to Match List I (Material to be cast) with List II y To reduce the chances of the damage of the mould
the part to be cast. ((Shrinkage g Allowance in mm/m) / ) and select the
correct answer using the codes given below the lists: cavity at the
h time off pattern removal,
l the
h verticall faces
f
Reason (R): Pattern is used to make the mould
cavity for pouring in molten for casting.
casting ListII
List ListII
List II of the pattern are always tapered from the parting line.
line
(a) Both A and R are individually true and R is the (MaterialtoCast)(ShrinkageAllowanceinmm/m)
(A) Greycastiron 1
1. 7 10
7 This provision is called draft allowance.
correct explanation
l i off A
(b) Both A and R are individuallyy true but R is not the (B) Brass 2. 15
y Inner surfaces of the p
pattern require
q higher
g draft than
correct explanation of A ( ) Steell
(C) 3. 20
(c) A is true but R is false (D) Zinc 4. 24 outer surfaces.
(d) A is false but R is true Codes:A B C D A B C D
y Draft is always provided as an extra metal.
(a) 1 2 3 4 (b) 3 4 1 2
(c) 1 4 3 2 (d) 3 2 1 4
ShakeAllowance DistortionAllowance
y At the time of p
pattern removal,, the p
pattern is rapped
pp 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 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
y It is a negative allowance and is to be applied only to which may have thin and long sections which are
those dimensions, which are parallel to the parting connected to thick sections.
plane.
l
y The foundry practice should be to make extra
material
i l provision
i i for
f reducing
d i theh distortion.
di i
DRAFTALLOWANCE
PatternMaterials Thepatternmaterialshouldbe IES1994

y Wood patterns are relatively easy to make. Wood is not
y Easilyworked,shapedandjoined Which of the following materials can be used for
veryy dimensionallyy stable. Commonlyy used teak,, white
pine and mahogany wood. y Lightinweight making patterns?
y Metal patterns are more expensive but are more
y Strong,hardanddurable 1. Aluminium 2. Wax 3. Mercury 4. Lead
dimensionally stable and more durable. Commonly used
CI Brass,
CI, Brass aluminium and white metal.
metal y Resistanttowearandabrasion
R i t tt d b i
Select the correct answer using the codes given below:
y Hard plastics, such as urethanes, and are often preferred
y Resistanttocorrosion,andtochemicalreactions
withh processes that
h use strong, organicallyll bonded
b d d sands
d Codes:
that tend to stick to other pattern materials. y Dimensionallystableandunaffectedbyvariationsin
y In the fullmold process, expanded polystyrene (EPS) is ( ) 1,3 and
(a) d 4 (b) 2,3 and
d 4 (c)
( ) 1, 2 and
d 4 (d) 1, 2 and
d3
temperatureandhumidity.
used.
y Investment casting uses wax patterns. y Availableatlowcost.
GATE2000 TypesofPattern TypesofPattern

Single Piece Pattern Split Pattern or Two Piece Pattern
These are inexpensive and the simplest type of This is the most widelyy used type
yp of ppattern for intricate
Di
Disposablepatternsaremadeof
bl tt d f
patterns. As the name indicates, they are made of a castings. When the contour of the casting makes its
(a) Wood single piece.
piece withdrawal from the mould difficult, or when the depth
of the casting is too high, then the pattern is split into two
(b) Rubber parts so that one part is in the drag and the other in the
Gated Pattern cope.
(c) Metal Gating and runner system are integral with the
pattern. This would eliminate the hand cutting of
(d) Polystyrene the runners and gates and help in improving the
productivity of a moulding.

TypesofPattern TypesofPattern TypesofPattern
y Cope and Drag Pattern y Loose Piece Pattern
y Match Plate Pattern
These are similar to split patterns. In addition to This type of pattern is also used when the
splitting
p g the p
pattern,, the cope
p and dragg halves of The cope and drag patterns along with the
gating
i andd the
h risering
i i are mounted d on a single
i l contour of the part is such that withdrawing the
the pattern along with the gating and riser systems pattern from the mould is not possible.
are attached separately to the metal or wooden g metal or wooden p
matching plate on either side.
plates along with the alignment pins. They are
called the cope and drag patterns.
patterns
TypesofPattern IES2008 TypesofPattern

y Follow
F ll Board
B d Pattern
P y Sweep Pattern
yp of p
This type pattern is adopted
p for those The pattern adopted for those castings where there It is used to sweep the complete casting by means
castings where there are some portions, which are some portions which are structurally weak and of a plane sweep. These are used for generating
are structurally weak and if not supported are likely to break by the force of ramming are large shapes,
shapes which are axisymmetrical
axi symmetrical or
properly are likely to break under the force of called: prismatic in nature such as bellshaped or
ramming.
ramming (a) Loose piece pattern cylindrical.
li d i l
(b) Follow board pattern
(c) Skelton pattern
(d) Single piece pattern
TypesofPattern g
CoolingCurve Fluidity
y Skeleton
Sk l Pattern
P The ability of a metal to flow and fill a mold is known
A skeleton of the p
pattern made of strips p of wood as fluidity.
is used for building the final pattern by packing Pouring Temperature
sand around the skeleton.
skeleton After packing the y The most important controlling factor of fluidity is the
sand, the desired form is obtained with the help pouring temperature or the amount of superheat.
of a strickle.
strickle This type
t pe of pattern is useful y Higher the pouring temperature,
temperature the higher the fluidity.
fluidity
generally for very large castings, required in y Excessive temperatures should be avoided, however. At
high pouring temperatures,
temperatures metalmold reactions are
smallll quantities where
h l
large expense on
accelerated and the fluidity may be so great as to permit
complete
p wooden ppattern is not jjustified. 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.
ISRO2011 Core
GATE2012(PI)
GATE 2012 (PI)
Fluidity in casting (CI) operation is greatly y Used for making cavities and hollow projections.
In sand casting, fluidity of the molten metal
increases with influenced by
y All sides of core are surrounded by the molten metal
(A) increase
i i degree
in d off superheat
h
a) Melting temperature of molten metal and are therefore subjected to much more severe
((B)) decrease in p
pouring
g rate thermal and mechanical conditions and as a result the
(C) increase in thermal conductivity of the mould b) Pouring temperature of molten metal core sand should be of higher strength than the
(D) increase
i i sand
in d grain
i size
i moulding
ldi sand.
d
c) Finish of the mould
d) Carbon content of molten metal
y Then,
Then the permeability number,
number R is obtained by
Desiredcharacteristicsofacore y Permeability:
y Gases evolving
g from the molten metal R=
VH
and generated from the mould may have to go pAT
AT
y Green Strength: A core made of green sand should through the core to escape out of the mould. Hence WhereV=volumeofair=2000cm3
be strong enough to retain the shape till it goes for cores are required to have higher permeability. H=heightofthesandspecimen=5.08cm
baking.
baking y Permeability
P bilit Number:
N b Th rate
The t off flow
fl off air
i passing
i
p=airpressure,g/cm2
y Dry Strength: It should have adequate dry strength through a standard specimen under a standard pressure is
termed
d as permeability
bili number.
b A=crosssectionalareaofsandspecimen=20 268cm2
A=crosssectionalareaofsandspecimen=20.268cm
so that when the core is placed in the mould, it
should be able to resist the metal p
pressure acting
g on y The standard p
permeabilityy test is to measure time T=timeinminutesforthecompleteairtopassthrough
it. taken by a 2000 cu cm of air at a pressure typically of
Insertingtheabovestandardvaluesintothe
y Refractoriness: Since in most cases,cases the core is 980 Pa (10 g/cm2), to pass through a standard sand
expression,weget
i
surrounded all around it is desirable that the core specimen confined in a specimen tube. The standard 501.28
specimen size is 50.8
50 8 mm in diameter and a length of R=
material
i l should
h ld have
h hi h refractoriness.
higher f i p.T
Contd 50.8 mm.
y Calculatethepermeabilitynumberofsandifittakes1min
25stopass2000cm3 ofairatapressureof5g/cm2 through
thestandardsample.
IES2007
IES 2007
y Collapsibility:Atthetimeofcooling,castingshrinks,and
p y g, g ,
Whatispermeability?Permeabilityismoreimportant
unlessthecorehasgoodcollapsibility(abilitytodecrease
p = 5.0 g / cm 2 inthebasicprocessofsandcastingthanporosity.Give
p g p y insize)itislikelytoprovideresistanceagainstshrinkage
) y p g g
T = 1 min 25 s = 1.417 min andthuscancausehottears.
oneimportantreasonforthisfeature.
501.28
501 28
R= = 70.75 [2marks]
5 1.417

CoreSands CarbonDioxideMoulding
y Friability: The ability to crumble should be a very y Sodium
S di silicate
ili (water
( glass,
l SiO2:Na
N 2O) is
i used
d as a binder.
bi d
y Used clay free silica sand. This is essentially a quick process of core or mould
important
p consideration at the time of removal.
preparation.
y Binders used are linseed oil, core oil, resins, dextrin,
y Smoothness: Surface of the core should be smooth y The mould is pprepared
p with a mixture of sodium silicate and
molasses, etc. sand and then treated with carbon dioxide for two to three
for good finish to the casting.
minutes such that a dryy compressive
p strength
g of over 1.44
y Core oils
l are mixtures off linseed,
l d soy, fish
f h and
d MPa is arrived.
y Low Gas Emission
petroleum oils and coal tar.
tar y The carbon dioxide is expected to form a weak acid,
acid which
hydrolyses the sodium silicate resulting in amorphous silica,
y The general composition of a core sand mixture could which forms the bond.
bond
be core oil ((1%)) and water ((2.55 to 6%).
) 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
IES2002 G
GATE 2008 ( )
2008(PI)
y The compressive strength of the bond increases with In sand casting of a hollow part of lead,
lead a cylindrical core
Assertion (A): In CO2 casting process, the mould or
standing time due to dehydration. core attains maximum strength. of diameter 120 mm and height 180 mm is placed inside
y Because of the high strength of the bond, the core need not Reason (R): The optimum gassing time of CO2
through the mould or core forms Silica Gel which the mould cavity. The densities of core material and lead
be provided with any other reinforcements. imparts sufficient strength to the mould or core. are 1600 kg/m3 and 11,300 kg/m3 respectively. The net
y It does not involve any distortions due to baking and also (a) Both A and R are individually true and R is the
correct explanation of A force (in N) that tends to lift the core during pouring of
better dimensional accuracies are achieved.
achieved ( ) Both A and R are individually true but R is not the
(b) molten metal will be
y The sand mixture does not have good shelf life and correct explanation of A
(c) A is true but R is false ( ) 19.7
(a) ( ) 64.5
(b) ( ) 193.7
(c) ( ) 257.6
(d)
therefore should be used immediately after preparation.
(d) A is false but R is true
MouldingSandComposition OtherAdditives MouldingSandProperties

y Sand: Ordinary silica Sand (SiO2), zircon, or olivine y Porosity or Permeability: Permeability or porosity of
y Cereal binder up to 2% increases the strength.
the moulding g sand is the measure of its abilityy to
sands.
d permit air to flow through it.
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 y Strength: It is defined as the property of holding
strength.
together of sand grains. A moulding sand should have
sands amplel strength h so that
h the
h mouldld does
d not collapse
ll or
y Saw dust up to 2% may improve the collapsibility by
Kaolinite or fire clay (Al2O3 2SiO2 2H2O),
O) and get partially destroyed during conveying, turning over
slowly
l l burning,
b i and
d increase
i the
h permeability.
bili or closing.
Bentonite (Al2O3 4SiO2 H2O nH2O). y Other
Oth materials:
t i l sea coal,
l asphalt,
h lt fuel
f l oil,
il graphite,
hit y Refractoriness: It is the ability of the moulding sand
mixture to withstand the heat of melt without showing
y Water: Clay
y is activated byy water. molasses iron oxide,
molasses, oxide etc.
etc any signs
i off softening
ft i or fusion.
f i
y Plasticity: Itisthemeasureofthemouldingsandtoflow OtherSands IES2008
aroundandoverapatternduringrammingandtouniformly
d d d i i d if l y Facing sand: The small amount of carbonaceous
filltheflask. material sprinkled on the inner surface of the mold
y Collapsibility:Thisistheabilityofthemouldingsandto cavity
i to give
i a better
b surface
f fi i h to the
finish h castings.
i S ll amountt off carbonaceous
Small b material
t i l sprinkled
i kl d
decreaseinvolumetosomeextentunderthecompressive
p y Backing g sand: It is what constitutes most of the on the inner surface of mould cavity is called
forcesdevelopedbytheshrinkageofmetalduringfreezing refractory material found in the mould. This is made
andsubsequentcooling.
q g up of used and burnt sand.
sand (a) Backing sand
y Adhesiveness:Thisisthepropertyofsandmixtureto y Green Sand: The molding sand that contains
adheretoanotherbody(here themouldingflasks) The
adheretoanotherbody(here,themouldingflasks).The ((b)) Facing
g sand
moisture is termed as green sand. The green sand
mouldingsandshouldclingtothesidesofthemoulding
should have enough g strength
g so that the constructed ((c)) Green sand
boxessothatitdoesnotfalloutwhentheflasksarelifted
mould retains its shape.
andturnedover.Thispropertydependsonthetypeand (d) Dry sand
amountofbinderusedinthesandmix.
t fbi d di th d i y Dry sand: When the moisture in the moulding sand is
completely expelled, it is called dry sand.
Grainsizenumber IES2002 CastingYield

y ASTM (American Society for Testing and Materials) In the grain size determination using standard Thecastingyieldistheproportionoftheactual
grain size number,
number defined as castingmass,w,tothemassofmetalpouredintothe
n-1
charts, the relation between the given size
N 2 mould,W,expressedasapercentage.
p p g
number
b n and
d the
th average number
b off grains
i 'N'
N
y Where N is the number of grains per square inch
visible in a prepared specimen at 100X and n is the per square
p q inch at a magnification
g of 100 X is
w
ASTM grainsize number.
(a) N = 2n Casting yield = 100
y Low
L ASTM numbers b mean a few
f massive
i grains;
i hi h
high W
numbers refer to many small grains. (b) N = 2nl
(c) N = 2n + 1
(d) N = 2n + 1
G i S
GatingSystem G ti S t
GatingSystem
y Ingate: Achannelthroughwhichthemoltenmetal
y Pouring
P i basin:
b i A small
ll funnel
f l shaped
h d cavity
i at the
h
entersthemouldcavity.
top of the mould into which the molten metal is
poured. y Vent:
V S ll
Smallopeninginthemouldtofacilitateescape
i i h ld f ili
ofairandgases.
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.
For-2013 (IES, GATE & PSUs) Contd Page 9 Contd
TypesofGateorIngate IES2011 GATE 2010(PI)
Top gate: Causes turbulence in the mould cavity, it is prone In light metal casting, runner should be so designed During the filling process of a given sand mould cavity by
that:
to form
f d
dross, f
favourable
bl temperature gradient
d towards
d the
h molten
lt metal
t l through
th h a horizontal
h i t l runner off circular
i l cross
1. It avoids aspiration
gate only for ferrous alloys.
gate, alloys section the frictional head loss of the molten metal in the
2. It
I avoids
id turbulence
b l
runner will increase with the
Bottom g
gate: No mould erosion,, used for veryy deep
p moulds,, 33. The p
path of runner is reduced in area so that
higher pouring time, Causes unfavourable temperature
unequal volume of flow through each gate (a) increase in runner diameter
takes place (b) decrease in internal surface roughness of runner
gradients.
(a) 1 and 2 only (b) 1 and 3 only
Parting Gate: most widely used gate,gate easiest and most (c) decrease in length of runner
economical in preparation. (c) 2 and 3 only (d) 1, 2 and 3
(d) increase in average velocity of molten metal
Step Gate: Usedd for
f heavy
h and
d large
l castings, size off ingates
are normally increased from top to bottom.
IES 2011
g
Match List I with List II and select the correct answer using
the code given below the lists : A sand d casting
i mould
ld
assembly is shown in The primary purpose of a sprue in a casting
ListI
List I ListII
List II
the above figure. The mould is to
A.Topgate 1.Heavyandlargecastings elements marked A (a)Feed the casting at a rate consistent with the rate
B.Bottomgate 2.Mostwidelyusedandeconomical and B are respectively of solidification
C.Partinggate 3.Turbulence (a) Sprue and riser (b)A as a reservoir
(b)Act i for
f molten
l metall
(b) Ingate and riser ((c)Feed
) molten metal from the ppouring g basin to the
D St t
D.Stepgate 4.Unfavourable
U f bl temperaturegradient
t t di t
(c) Drag and runner gate
Codes
(d) Riser
Ri and d runner (d)Help feed the casting until all solidification takes
A B C D A B C D place
(a) 3 4 2 1 (b) 1 4 2 3
(c) 3 2 4 1 (d) 1 2 4 3
Thegoalsforthegatingsystem IES1998 IES2009

y To minimize turbulence to avoid trapping gasses into Whichofthefollowingaretherequirementsofanideal Considerthefollowingstatements:
the mold gatingsystem?
1 Theactualentrypointthroughwhichthemolten
1.Theactualentrypointthroughwhichthemolten
1. Themoltenmetalshouldenterthemouldcavitywithas
y To get enough metal into the mold cavity before the metalentersthemouldcavityiscalledingate.
highavelocityaspossible.
metall starts to solidify
lidif 2.Bottomgateincaseofamouldcreatesunfavourable
2. Itshouldfacilitatecompletefillingofthemouldcavity.
y To avoid shrinkageg temperaturegradient.
p g
3. Itshouldbeabletopreventtheabsorptionofairorgases
I h ldb bl h b i f i
y Establish the best possible temperature gradient in the fromthesurroundingsonthemoltenmetalwhile 3.Sprueincaseofamouldismadetaperedtoavoidair
solidifying casting so that the shrinkage if occurs must flowingthroughit. inclusion.
inclusion
be in the gating system not in the required cast part. Selectthecorrectanswerusingthecodesgivenbelow:
g g Whichoftheabovestatementsis/arecorrect?
y Incorporates a system for trapping the nonmetallic (a)1,2and3 (b)1and2 (c)2and3 (d)1and3 (a)1only (b)1and2 (c)2and3 (d)1and3
inclusions.

TypesofGatingSystems PressurizedGatingSystem UnPressurizedGatingSystem
y The total cross sectional area decreases towards the y The total cross sectional area increases towards the
Thegatingsystemsareoftwotypes: mold
ld cavity
it
mold cavity
y Back ppressure is maintained byy the restrictions in the
y Pressurizedgatingsystem metal flow y Restriction only at the bottom of sprue
y Flow of liquid (volume) is almost equal from all gates
y Flow of liquid (volume) is different from all gates
y Unpressurizedgatingsystem
p g g y y Back pressure helps in reducing the aspiration as the
sprue always runs full y Aspiration in the gating system as the system never
y Because of the restrictions the metal flows at high runs full
f ll
velocity leading to more turbulence and chances of
mold erosion.
erosion y Less turbulence.
turbulence
S
Sprue D i
Design Sincethevelocitiesareproportionaltothesquareof
y Sprue: Sprue is the
h channel
h l through
h h which
h h the
h molten
l thepotentialheads,ascanbederivedfrom
thepotentialheads ascanbederivedfrom
metal is brought into the parting plane where it enters the Bernoulli'sequation,
runners and gates to ultimately reach the mould cavity.
hc
y The molten metal when moving g from the topp of the cope
p to At = Ac
ht
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 Theexacttaperingcanbeobtainedbytheequationof
be breathed into this lowpressure
low pressure area which would then continuity DenotingthetopandchokesectionsofThesprue by
continuity.DenotingthetopandchokesectionsofThesprue
be carried to the mould cavity. thesubscriptstand'c'respectively,weget
WhereH=actual
WhereH actual
y To eliminate
l this
h problem
bl off air aspiration, the
h sprue is
sprue height
tapered to gradually reduce the cross section as it moves Vc
A t Vt = A c Vc At = Ac andht=h+H
h+H
away from the top of the cope as shown in Figure below (b). Vt
Contd Contd
GATE2007
GATE2001 A 200 mm long down sprue has an area of cross
section of 650 mm2 where the pouring basin meets the
The height of the down
downsprue
sprue is 175 mm and its
d
down sprue (i.e.
(i at the
h beginning
b i i off the h down
d sprue).)
crosssectional area at the base is 200 mm2. The
A constant head of molten metal is maintained by the
cross sectional area of the horizontal runner is
crosssectional
pouring basin. The Molten metal flow rate is 6.5 105
also 200 mm2. Assuming no losses, indicate the
mm3/s. Considering the end of down sprue to be open
correct choice
h i for
f the
h time
i (i seconds)
(in d ) required
i d to
to atmosphere and an acceleration due to gravity of
fill a mould cavity of volume 106 mm3. (Use g = 10
104mm/s2, the area of the down sprue in mm2 at its end
m/s2).
(avoiding aspiration effect) should be
(a)2 67 (b)8.45
(a)2.67 (b)8 45 (c)26 72
(c)26.72 (d)84 50
(d)84.50
( )
(a)650.0 ( )
(b)350.0 ( )
(c)290.7 ( )
(d)190.0
Contd
Gatingratio IES2003 IES2005
A gating ratio of 1: 2: 4 is used to design the gating
y Gatingratioisdefinedas:Sprue area:Runnerarea:
system
y for magnesium
g alloyy casting.
g This g
gating
g ratio The gating ratio 2: 8: 1 for copper in gating system
Ingate area. refers to the cross section areas of the various gating design refers to the ratio of areas of:
elements as given below:
y Forhighqualitysteelcastings,agatingratioof1:2:2or ( ) Sprue:
(a) S R
Runner: I
Ingate
1. Down sprue 2. Runner bar 3. Ingates
1:2:1 5willproducecastingsnearlyfreefromerosion
1:2:1.5willproducecastingsnearlyfreefromerosion, ((b)) Runner: Ingate:
g Sprue
p
Th correct sequence off the
The h above
b elements
l i the
in h
ratio 1: 2: 4 is (c) Runner: Sprue: Ingate
willminimizeoxidation,andwillproduceuniform
, p
(a) 1, 2 and 3 (d) Ingate:
I R
Runner: S
Sprue
flow.
(b) 1,3 and 2
y Agatingratioof1:4:4mightfavour theformationof (c) 2, 3 and 1
oxidationdefects. (d) 3, 1 an 2
GATE2010 IAS1999 RisersandRiserDesign

Assertion (A): The rate of flow of metal through sprue
y Risers
Ri are added
dd d reservoirs
i designed
d i d to feed
f d liquid
li id
is NOT a function of the crosssectional areas of metal to the solidifying casting as a means of
I ti t
Inagatingsystem,theratio1:2:4represents
th ti t sprue, runner and gate. compensating for solidification shrinkage.
(a) Sprue basearea:runnerarea:ingate area Reason (R): If respective cross
crosssectional
sectional areas of y To perform this function,
function the risers must solidify after
sprue, runner and gate are in the ratio of 1: 2: 2, the the casting.
(b) Pouringbasinarea:ingate area:runnerarea y
system is known as unpressurised
p gating
g g system.
y
(a) Both A and R are individually true and R is the correct y According
d to Chvorinov's
Ch ' rule,
l a goodd shape
h f a riser
for
(c) Sprue basearea:ingate area:castingarea explanation of A would be one that has a long freezing time (i.e., a small
(b) Both A and R are individually true but R is not the surface area per unit volume).
(d) Runnerarea:ingate area:castingarea correct explanation of A y Live risers (also known as hot risers) receive the last
(c) A is true but R is false hot metal that enters the mold and generally do so at a
(d) A is false but R is true ti
time when
h th metal
the t l in
i the
th moldld cavity
it has
h already
l d
begun to cool and solidify.
IES1994 Chvorinovs rule IES2011

Assertion
A i (A):
(A) In
I a mould, ld a riser
i is
i designed
d i d andd placed
l d y Totalsolidificationtime(t
l ldf )n
( s)=B(V/A)
) ( The
h relationship
l h between
b totall freezing
f time t,
so that the riser will solidify after the casting has solidified. volume of the casting V and its surface area A,
wheren 1.5to2.0
wheren=1.5to2.0
Reason (R): A riser is a reservoir of molten metal which according to Chvorinovs rule is :
[Where,B=mouldconstantandisafunctionof(mould
will supply
pp y molten metal where a shrinkage g cavityy would
material,castingmaterial,andconditionofcasting]
t i l ti t i l d diti f ti ] V
have occurred. (a ) t = k
A
(a) Both A and R are individually true and R is the correct n=2 andtriser =1.25t
5 casting
A
explanation of A (b ) t = k
V
2
V
2 V
(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 or A = 1.25
1 25
A
2
riser A casting (c ) t = k
correct explanation of A V
(c) A is true but R is false V
2
Forcylinder V = D2H / 4 (d ) t = k
( )
((d)) A is false but R is true ofdiameterD 2 A
A = DH + 2 D Wh
Where K is
i a constant
andheightH 4
IES1998 GATE2003 IES2006
A spherical
p drop
p of molten metal of radius 2 mm According to Chvorinov's equation, the
With a solidification f t off 0.97 x 106 s/m
lidifi ti factor / 2, the
th
was found to solidify in 10 seconds. A similar drop solidification time of a casting is proportional to:
solidification time (in seconds) for a spherical
of radius 4 mm would solidify in (a) v2
casting
g of 200 mm diameter is
(a) 14.14 seconds (b) v
(a) 539 (b) 1078 (c) 4311 (d) 3233
(b) 20 seconds (c) 1/v
(c) 28.30 seconds (d) 1/v2
(d) 40 seconds Where, v = volume of casting
GATE 2010(PI) GATE2007

Solidification time of a metallic alloy casting is
GATE2011(PI)
GATE 2011 (PI)
Volume of a cube of side 'l'l and volume of a sphere of In a sand casting gpprocess,, a sphere
p and a cylinder
y
(a) Directly proportional to its surface area of equal volumes are separately cast from the same
radius r are equal.
q Both the cube and the sphere
p are solid molten metal under identical conditions. The
(b) Directly proportional to the specific heat of the height and diameter of the cylinder are equal. The
and of same material. They are being cast. The ratio of the
ratio of the solidification time of the sphere to that
castt material
t i l
solidification time of the cube to the same of the sphere is: of the cylinder is
(c) Directly proportional to the thermal diffusivity of 3 6 2 2 3 2 4
(a) 1.14
1 14
4 r 4 r 4 r 4 r
(a ) 6 l ( b ) ( c ) ( d ) (b) 0.87
the molten metal 6 l 6 l 6 l
( ) 1.31
(c)
((d)Inversely
) y proportional
p p to the pouring
p g ((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/L)2
( ) (2D/L)
(c) (d)Cuboidsriser
(d) (D/L)2

IES 2011 C ti l
IES2011Conventional ModulusMethod
y A round casting
g is 20 mm in diameter and 550 mm in ConventionalQuestionESE2003
y It has been empirically established that if the modulus
length. Another casting of the same metal is elliptical in
Compare the solidification time of two optimum side off the
h riser
i exceeds
d the
h modulus
d l off the
h casting
i b a
by
cross section, with a major to minor axis ratio of 2, and
factor of 1.2,
1 2 the feeding during solidification would be
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
satisfactory.
round casting. Both pieces are cast under the same and other is parallopiped.
parallopiped [30 Marks]
MR = 1.2 Mc
conditions What is the difference in the solidification
conditions.
y Modulus = volume/Surface area
times of the two castings ? [10 Marks]
Area of ellipse = ab y In steel castings, it is generally preferable to choose a
Circumference = 3 ( a + b ) ( 3a + b )( a + 3b )
riser
i with
i h a heighttodiameter
h i h di ratio
i off 1.
= 2 (a 2
+ b2 ) / 2 (approx.) Contd
Caines Method
ConventionalQuestionIES2008
Conventional Question IES2008 Freezingratio=ratio ofcoolingcharacteristicsofcastingto
y Calculate the size of a cylindrical riser (height and diameter
theriser. A ( V)
X= Casting
D 2
+ D 2
equal) necessary to feed a steel slab casting of dimensions ( AV ) Riser
4 30 x 30 x 6 cm with a side riser, casting poured horizontally Therisershouldsolidifylastsox>1

into the mould.
a
AccordingtoCaine X=
X +c
[Use Modulus Method] Yb
[[10 Marks]] V riser
Y=anda,b,careconstant.
Y d b
Vcasting
Table:ConstantsinCaines Method
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 ]

Chills IES1995 GATE1998,2007
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 theth cooling
li off various
i regions.
i 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
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 improved by using (a) Achieve directional solidification
be used to reduce the number of risers required for a casting.
(a) Chills and chaplets (b) Reduce the possibility of blowholes
y Internal chills are pieces of metal that are placed within the
mould cavity to absorb heat and promote more rapid ((b)) Chills and p
padding
g
solidification.
lidifi i Si
Since some off this
hi metall willill meltl during
d i the
h (c) Reduce freezing time
operation, it will absorb not only the heatcapacity energy, but ((c)) Chaplets
p and p
padding
g
also
l some heat h t off fusion.
f i Si
Since th ultimately
they lti t l become
b partt off (d) Smoothen metal flow for reducing splatter.
the final casting, internal chills must be made from the same (d) Chills, chaplets and padding.
alloy
ll as that
th t being
b i cast.t
Cupola
IAS1994 y Cupola has been the most widely used furnace for IES1997
melting cast iron. Assertion (A): Steel can be melted in hot blast cupola.
Chillsareusedincastingmouldsto
y In hot blast cupola, the flue gases are used to preheat the Reason (R): In hot blast cupola,
cupola the flue gases are used to
( ) Achievedirectionalsolidification
(a) A hi di i l lidifi i
air blast to the cupola so that the temperature in the preheat the air blast to the cupola so that the temperature in
((b)) Reducepossibilityofblowholes
p y furnace is considerably higher than that in a th furnace
the f i considerably
is id bl higher
hi h th
than th t in
that i a
(c) Reducethefreezingtime conventional cupola. Coke is fuel and Lime stone conventional cupola.
(d) Increasethesmoothnessofcastsurface
I h h f f (C CO3) is
(CaCO i mostlyl used d flux.
fl (a) Both A and R are individually true and R is the correct
y Cost of meltingg low. explanation
p of A
y Main disadvantages of cupola is that it is not possible to (b) Both A and R are individually true but R is not the
produce iron below 2.8%
2 8% carbon.
carbon correct explanation of A
y Steel can be also prepared in cupola by employing (c) A is true but R is false
duplexing and triplexing operations. (d) A is
i false
f l but
b R isi true
IES 2012 El
ElectricArcFurnace
i A F
Statement
St t t (I):
(I) Cupola
C l furnace
f is
i nott employed
l d for
f Crucible Furnace
y For heavy steel castings, the openhearth type of
melting steel in foundry y Smaller foundries generally prefer the crucible furnace.
Statement (II): The temperatures generated within a f
furnaces with
h electric
l arc or oill fired
f d would
ld be
b generally
ll y The crucible is generally heated by electric resistance
cupola are not adequate for melting Steel or gas flame.
suitable in view of the large heat required for melting.
melting
(a) Both Statement (I) and Statement (II) are
individuallyy true and Statement ((II)) is the correct y Electric arc furnaces are more suitable for ferrous
explanation of Statement (I) Induction Furnace
(b) Both Statement (I) and Statement (II) are materials and are larger
g in capacity.
p y y The induction furnaces are used for all types of
individually true but Statement (II) is not the correct materials, the chief advantage being that the heat
explanation of Statement (I) source is isolated from the charge and the slag and flux
(c) Statement (I) is true but Statement (II) is false get the necessary heat directly from the charge instead
( ) Statement (I)
(d) ( ) is false but Statement (II)
( ) is true off the
th heat
h t source.
Ladles CastingCleaning(fettling) GATE1996
Impuritiesinthemoltenmetalarepreventedfrom
y Twotypesofladlesusedinthepouringofcastings.
reachingthemouldcavitybyprovidinga
g y yp g Light impurities in the molten metal are prevented
(i) Strainer from reaching the mould cavity by providing a
(ii) Bottomwell
B tt ll ( ) Strainer
(a) S i
(iii) Skimbob ((b)) Button well
(c) Skim bob
(d) All off the
h above
b
P i
Pouringtime
i GATE2005 GATE2006
In a sasandd cast g ope
casting at o , tthee tota
operation, qu d head
total liquid ead iss
Timetakentofillthemouldwithtopgate maintained constant such that it is equal to the mould
Where A=Areaofmould A mould has a downsprue whose length is 20 cm height The time taken to fill the mould with a top gate
height.
AH
A.H
tA = H=Heightofmould and the cross sectional area at the base of the is tA. If the same mould is filled with a bottom gate,
A g 2ghg m
Ag =AreaofGate
A fG t downsprue is 1cm2. The downsprue feeds a th the
then th time
ti t k is
taken i tB. Ignore
I th time
the ti required
i d to
t
Hm =Gateheight horizontal runner leading into the mould cavity of fill the runner and frictional effects. Assume
volume
l 1000 cm3. The
Th time
i required
i d to fill the
h atmospheric pressure at the top molten metal surfaces.
mould cavity will be The relation between tA and tB is
Timetakentofillthemouldwithbottomgate
(a)4.05 s (b)5.05 s (c)6.05 s (d)7.25 s (A) tB = 2 t A
( )
2A ((B)) tB = 2 t A
tB = hm hm H tA
Ag 2g (C) tB =
2
(D) tB = 2 2 t A
GATE 2007(PI)LinkedS1
( ) k d GATE 2007(PI)LinkedS2
( ) k d Expressionforchokearea
In
I a sand d casting
ti process, a sprue off 10 mm base
b In
I a sand d casting
ti process, a sprue off 10 mm base
b m
diameter and 250 5 mm height
g leads to a runner diameter and 250 5 mm height
g leads to a runner CA = mm2
ct 2gH
which fills a cubical mould cavity of 100 mm size which fills a cubical mould cavity of 100 mm size
Th volume
The l (i mm3/s)
fl rate (in
flow / ) is
i Th mould
The ld filling
filli time
i (i seconds)
(in d ) is
i Wherem=massofthecasting,kg
0 8 x 105
(a) 0.8 1 1 x 105
(b) 1.1 (a) 2.8
28 (b) 5.78
5 78 y , g/ 3
=Densityofmetal,kg/m
t=pouringtime
(c) 1.7 x 105 (d) 2.3 x 105 (c) 7.54 (d) 8.41
c=Efficiencyfactorandisthefunctionofgate
Effi i f t di th f ti f t
systemused
H=Effectiveheadofliquidmetal
=hfortopgate
pg

H=h
hm
forbottomgate
IES2009
IES 2009 IAS2011Main
IAS2011 Main
2 y 2marks
hc2
Sk t h a mould
Sketch ld for
f two
t h ll
hollow components
t to
t be
b
=h forpartinglinegate
2h m cast On the diagram,
cast. diagram indicate runner,
runner gate,
gate riser,
riser
p sprue,
core, cope, p pouring
p g basin, sprue
p well, drag,
g
parting line.
hC
hm
[10Marks]
hm hm
P i li
topgatepartinglinegatebottomgate
CastingDefects GasDefects Sh i k
ShrinkageCavities
C ii
y These are caused by liquid shrinkage occurring during the
Thefollowingarethemajordefects,whicharelikelyto y A condition existing in a casting caused by the solidification of the casting.
occurinsandcastings:
d trapping of gas in the molten metal or by mold gases y To
T compensate for
f this,
hi proper feeding
f di off liquid
li id metall is
i
evolved during the pouring of the casting. required. For this reason risers are placed at the
y Gasdefects
G d f y The defects in this category can be classified into appropriate
i places
l i the
in h mold.
ld
blowholes and p pinhole p
porosity.
y y Sprues
p mayy be too thin, too long
g or not attached in the
y Shrinkagecavities
Sh i k iti proper location, causing shrinkage cavities.
y Blowholes are spherical or elongated cavities present
y Moldingmaterialdefects in the casting on the surface or inside the casting.
casting y It is recommended to use thick sprues to avoid shrinkage
cavities.
y Pinhole porosity occurs due to the dissolution of
y Pouringmetaldefects
hydrogen gas, which gets entrapped during heating of
y Moldshift.
Moldshift molten metal.
Cutandwashes S b
Scab
g
MoldingMaterialDefects y This defect occurs when a portion of the face of a mould
y These appear as rough spots and areas of excess metal, and lifts or breaks down and the recess thus made is filled by
y Cutsandwashes,
Cutsandwashes are caused byy erosion of molding g sand byy the flowing
g metal.
metal
metal.
y When the metal is poured into the cavity, gas may be
y Scab y This is caused by the molding sand not having enough di
disengaged d with
i h such
h violence
i l as to break
b k up the
h sand, d
strength and the molten metal flowing at high velocity. which is then washed away and the resulting cavity filled
y Metalpenetration,
Metalpenetration y The
Th former
f can beb taken
k care off by
b the
h proper choice
h i off with
i h metal.
l
molding sand and the latter can be overcome by the y The reasons can be: too fine sand, low p permeabilityy of
y Fusion,and
proper design
d off the
h gating system. sand, high moisture content of sand and uneven mould
y Swell ramming. g

Metalpenetration
y When
h molten
l metall enters into the
h gaps between
b sand
d
Fusion Swe
Swell
grains, the result is a rough casting surface. y This is caused by the fusion of the sand grains with Under the influence of metallostatic forces, the mold
wall may move back causing a swell in the dimension
y This occurs because the sand is coarse or no mold wash was the molten metal, giving a brittle, glassy appearance of the casting. A proper ramming of the mold will
applied
pp on the surface of the mold. The coarser the sand correct this defect.
defect
grains more the metal penetration. on the casting surface.
y The main reason for this is that the clay or the sand Inclusions
particles
ti l are off lower
l refractoriness
f t i or that
th t the
th Particles of slag,
slag refractory materials sand or
deoxidation products are trapped in the casting during
pouring temperature is too high.
high 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
PouringMetalDefects y The misrun and cold shut defects are caused either by
y
GATE2004
The likely defects in this category are a lower fluidity of the mold or when the section
y Mis
Misruns
runs and thickness of the casting is very small. Fluidity can be Mi
Misrun i a casting
is ti defect
d f t which
hi h occurs due
d tot
y Cold shuts improved by changing the composition of the metal
and by increasing the pouring temperature of the (a) Very high pouring temperature of the metal
metal.
y A mis
misrun
run is caused when the metal is unable to fill (b) Insufficient fluidity of the molten metal
the mold cavity completely and thus leaves unfilled
cavities.
cavities (c) Absorption of gases by the liquid metal
y A cold shut is caused when two streams while meeting (d) Improper alignment of the mould flasks
in the mold cavity, do not fuse together properly thus
forming a discontinuity in the casting.
Contd
GATE2009 MoldShift IES2001

Two streams of liquid metal which are not hot The mold shift defect occurs when cope and drag
S bi
Scabisa
enough to fuse properly result into a casting defect or molding boxes have not been properly aligned.
(a) Sandcastingdefect
known as
(b) Machiningdefect
(a) Cold shut
(c) Weldingdefect
(b) Swell
(d) Forgingdefect
( ) Sand
(c) d wash
h
(d) Scab
S b
IAS2004 GATE2003 IES1998
MatchListI(CastingDefects)withListII(Explanation)andselectthecorrect
answerusingthecodesgivenbelowthelists: Hardnessofgreensandmouldincreaseswith Assertion(A):Stiffeningmembers,suchaswebs
ListII
List ListII
List II
( ) Increaseinmoisturecontentbeyond6percent
(a) I i i b d6 andribs,usedonacastingshouldbeliberally
(CastingDefects) (Explanation)
A.Metallicprojections 1.Consistofroundedorroughinternalorexposedcavities
provided.
includingblowholesandpinholes ((b)) Increaseinpermeability
p y Reason(R):Theywillprovideadditionalstrength
B.Cavities 2.Formedduringmelting,solidificationandmoulding.
C.Inclusions 3.Includessinglefolds,laps,scarsadheringsandlayersand (c) Decreaseinpermeability toacastmember.
oxidescale
D.Discontinuities 4.Includecracks,coldorhottearingandcoldshuts (d) Increaseinbothmoisturecontentand
I i b h i d ( ) BothAandRareindividuallytrueandRisthe
(a) B hA dR i di id ll dRi h
5.Consistoffins,flashormassiveprojectionsandrough permeability correctexplanationofA
surfaces
Codes:A B C D A B C D (b) BothAandRareindividuallytruebutRisnot the
(a) 1 5 3 2 (b) 1 5 2 4 correctexplanationofA
p
(c) 5 1 2 4 (d) 5 1 3 2
(c) AistruebutRisfalse
(d) AisfalsebutRistrue
IES2005 IES1997 IES2009

In gating system design, which one of the Ifthemeltingratioofacupolais10:1,thenthe Inwhichoneofthefollowingfurnacesmostofthe
following is the correct sequence in which choke cokerequirementforonetonmeltwillbe non ferrousalloysaremelted?
nonferrousalloysaremelted?
area, pouring time, pouring basin and sprue sizes (a) 0.1ton (a) Reverberatory furnace
are calculated?
l l d? (b) 10tons (b) Inductionfurnace
((a)) Chokearea Pouringtime
g Pouringbasin
g Sprue
p (c) 1ton (c) Cruciblefurnace
(b) Pouringbasin Sprue Chokearea Pouringtime (d) 11tons (d) Potfurnace
( ) Chokearea
(c) Ch k Sprue
S Pouringbasin
P i b i Pouringtime
P i i
((d)) Pouringbasin
g Pouringtime
g Chokearea Sprue
p
C t Al i i C d
CastAluminiumCode
IAS2001 IAS2004 y Fourdigitidentificationsystem
ou d g t de t cat o syste
Whichofthefollowingpatternmaterialsareused Whichoneofthefollowinggatingsystemsisbest y Firstdigitindicatesalloygroup
inPrecisionCasting? suitedtoobtaindirectionalsolidification? 1 Aluminium,99%ormore
l
1. PlasterofParis (a) Topgrating 2 copper
2
2. Plastics (b) Partlinegrating 3 Silicon,withcopperand/ormagnesium
3 AnodizedAluminium Alloy
3. (c) Bottomgrating 4 silicon
4. FrozenMercury (d) Steppedgrating 5 magnesium
5
Selectthecorrectanswerusingthecodesgivenbelow: 6 notused
(a)1and2(b) 2and4(c)3and4(d)1and3 7 zinc
8 tin
8
9 otherelements
CastAluminiumCodeContd.. IES2011
y Second
S d two digits
di i identify
id if the
h aluminium
l i i alloy
ll or In the designation of Aluminium casting A514.0
indicate the aluminium purity. indicates :
y The last digit is separating from the other three by a (a) Aluminium purity
Sp i lC ti g
SpecialCasting
decimal point and indicates the product form; that is, is (b) Aluminium
Al i i content
castings or ingots
((c)) Percentage
g of alloyy element
y A modification
df off the
h originall alloy
ll is indicated
d d by
b a
(d) Magnesium Content
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 Ans.
s (d)
the original alloy has made, as indicated by the letter A.
BySKMondal
ShellMouldingg
y Can produce complex parts.
y The
e sa
sand
d iss mixed
ed w
with
t a tthermosetting
e osett g resin
es iss
allowed to come in contact with a heated metal pattern y A good surface finish and good size tolerance
(2000C).
C)
reduce the need for machining.
y A skin (shell) of about 3.5 mm of sand and plastic
mixture adhere to the pattern. y Materials can be cast: CI, Al and Cu alloys.
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 andd the
th molten
lt metal
t l is
i
poured into the mold.
Shellmouldingprocess
Advantages
MoldingSandinShellMolding
Molding Sand in Shell Molding y Hot coating: 5 oC 180oC p
g the mixture is heated to 150 prior
y Dimensional accuracy.
y The molding sand is a mixture of fine grained quartz sand to loading the sand. In the course of sand mixing, the
and powdered bakelite. soluble phenol formaldehyde resin is added. The mixer is y Smoother surface finish. (Due to finer size grain used)
allowed
ll 8 90o C.
d to cooll up to 80 C Hot
H coting
i gives
i b
better y Very thin sections can be cast.
y Cold coating and Hot coating methods are used for
properties to the mixtures than cold method.
method
coating
i the
h sand
d grains
i with
i h bakelite.
b k li y Very small amount of sand is needed.
y Cold coating: quartz sand is poured into the mixer and
then the solution of p
powdered bakelite in acetone and
ethyl aldehyde are added. (mixture is 92% quartz sand,
5% bakelite, 3% ethylaldehyde )
For-2013 (IES, GATE & PSUs) Contd Page 20
Limitations IES2010
y Expensive pattern
Applications Considerthefollowingadvantagesofshell
C id th f ll i d t f h ll
mouldcasting: g
y Small size casting only. y Cylinders
C li d and
d cylinder
li d heads
h d for
f air
i cooled
l d IC
1.Closedimensionaltolerance.
y Highly
Hi hl complicated
li d shapes
h cannot be
b obtained.
b i d engines
2.Goodsurfacefinish.
y Automobile transmission parts. 3 Lowcost
3.Lowcost.
y More
M sophisticated
hi ti t d equipment
i t is
i needed
d d for
f handling
h dli
the shell moldings.
moldings y Piston rings
g 4
4.Easier.
Whichofthesearecorrect?
(a)1,2and3only (b)2,3and4only
( ) d l (d)1,2,3and4
(c)1,2and4only (d) d
IES1996 IES2005 IES2006

Consider the following ingredients used in Inshellmoulding,howcantheshellthickness Shellmouldingcanbeusedfor:
moulding: beaccuratelymaintained? ( ) Producingmillingcutters
(a) P d i illi
1. Dry silica sand (a)Bycontrollingthetimeduringwhichthepattern ((b)) Makinggoldornaments
gg
2.Clay i i
isincontactwithmould
i h ld
(c) Producingheavyandthickwalledcasting
3 Phenol formaldehyde
3.Phenol ( ) y
(b)Bycontrollingthetimeduringwhichthepattern
g g p
(d) Producingthincasting
P d i hi i
isheated
4.Sodium silicate
(c)Bymaintainingthetemperatureofthepatternin
Those used for shell mould casting include
therangeof175oC 380oC
(a) 1,
1 2 and 4 (b) 2,
2 3 and 4
(d)Bythetypeofbinderused
(c) 1and 3 (d) 1, 2, 3 and 4
IES2007 IAS2007 IAS1999

Match List I (Moulding Process) with List II (Binding
The mould in shell moulding process is made up Agent) and select the correct answer using the codes
Which of the following are employed in shell
given below
b l the
h lists:
l
moulding? of which of the following? List I List II
1. Resin
R i binder
bi d 2. Metal
M l pattern 3. Heating
H i coils il A. Green sand 1. Silicate
(a) Gypsum + setting agents
Select the correct answer using
g the code g given B. Core sand 2. Organic
below: (b) Green sand + clay C. Shell moulding 3. Clay
D. CO2 p process 4. Plaster of Paris
(c) Sodium silicate + dried sand 5. Plastic
(c) 2 and 3 only (d) 1, 2 and 3 Codes:A B C D A B C D
(d) Dried silica + phenolic resin (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: y In ceramic shell investment casting
g a ceramic shell is
1. Produce expendable wax, plastic, or polystyrene patterns.
built around a tree assembly by repeatedly dipping a
2 Assemble these patterns onto a gating system
2.
3. Investing or covering the pattern assembly with refractory pattern into a slurry (refractory material such as
slurry
zircon with binder).
4. Melting the pattern assembly to remove the pattern material
5. Firing
ii the
h mould ld to remove theh last
l traces off the
h pattern y After each dipping and stuccoing is completed, the
material
6. Pouring molten metal assembly is allowed to thoroughly dry before the next
7. Knockout, cutoff and finishing.
g 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 IES2011

The proper sequence of investment casting steps is :
y Costly
C tl patterns
tt and
d moulds
ld y Aerospace
A and
d rocket
k t components.
t (a) Slurry coating pattern melt out
outShakeout
Shakeout Stucco
coating
y Labour costs can be high y Vanes and blades for gas turbines.
turbines (b) Stucco
S coating
i Slurry
Sl coating
i Shakeout
Sh k Pattern
P
melt out
y Limited size y Surgical instruments
(c) Slurry coating Stucco coating Pattern melt out
Shakeout
(d) Stucco coating Shakeout Slurry coating Pattern
melt
l out

GATE2006 GATE2011(PI)
ISRO2010
An expendable pattern is used in Whi h off the
Which th following
f ll i casting
ti processes uses Investment casting is used for
(a) Slush casting
expendable pattern and expendable mould? ((a)) Shapes
p which are made byy difficultyy using
g complex
p
(b) Squeeze casting
patterns in sand casting
(c) Centrifugal casting (a) Shell mould casting
(d) Investment casting (b) Mass production
((b)) Investment casting
g
(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
IES1992 JWM2010 IES2010

Considerthefollowingmaterials: Assertion (A): The investment casting is used for
Themostpreferredprocessforcastinggasturbine precision parts such as turbine plates, sewing
1.Wax
bladesis: machines
hi etc.
2.Wood
(a) Diemoulding Reason ((R): ) The investment castings g have a g good
3 Plastic
3.Plastic
(b) Shellmoulding surface finish and are exact reproductions of the
Whichofthesematerialscanbeusedaspatternin master pattern.
pattern
(c) Investmentmoulding
investmentcastingprocess?
(d) Sandcasting (a) Both A and R are individually true and R is the
(a)1 2and3
(a)1,2and3 (b)1and2only correct explanation of A
(c)2and3only (d)1and3only (b) Both A and R are individually true but R is NOT the
correct explanation of A
( ) A is
(c) i true
t b t R is
but i false
f l
IES 2007
IES2007 IES2006 IAS1996
Consider the following statements in respect of
investment castings: Which of the following materials are used for Light and intricate parts with close dimensional
1. The
Th pattern
tt or patterns
tt i /
is/are nott joined
j i d to
t a stalk
t lk or making patterns in investment casting method? tolerances of the order of 0.0050 005 mm are
sprue also of wax to form a tree of patterns. 1. Wax 2. Rubber 3. Wood 4. Plastic produced by
2.The prepared moulds are placed in an oven and heated Select the correct answer using the codes given below: (a) Investment casting
gently to dry off the invest and melt out the bulk of wax. (b) Die casting
(a) Only 1 and 3 (b) Only 2 and 3
3.The moulds are usually poured by placing the moulds in
(c) Only 1, 2 and 4 (d) Only 2, 3 and 4 (c) Centrifugal casting
a vacuum chamber. Which of the statements given above
are correct? (d) Shell mould casting
(c)2 and 3 only (d) 1, 2 and 3

PermanentMouldCasting Advantages Disadvantages
y The p
process in which we use a die to make the y Good su
surface
ace finish
s aand
dddimensional
e s o a accu
accuracy
acy y High
g initial mold cost
castings is called permanent mold casting or gravity y Metal mold gives rapid cooling and finegrain y Shape, size, and complexity are limited
die casting, since the metal enters the mold under structure
t t y Mold life is very limited with highmeltingpoint
gravity. metals such as steel.
y Multipleuse
p molds.
y Some
S ti
time i diecasting
in di ti we inject
i j t the
th molten
lt metalt l y Low melting point metals can be cast
with a high pressure. When we apply pressure in Aluminum
injecting the metal it is called pressure die casting Zi
Zinc
p
process. Magnesium alloys
y Grey cast iron is used for mould material. Brass
Cast iron
Applications DieCasting
y Molten metal is injected
j into closed metal dies under
Diecastingmachinescanbe
y Pistons/cylinders/rods
Pi t / li d / d
pressures ranging from 100 to 150 MPa.
y Gears
y Pressure is maintained during solidification y Hotchamber
y Kitchenware
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
Hotchambermachinesare
Hot chamber machines are Coldchambermachines
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
contamination y Metalisheatedinaseparatecrucible
y Metal starts in a heated cylinder y Metalisladledintoacoldchamber
y A piston
i f
forces metall into
i the
h die
di y Themetalisrapidlyforcedintothemoldbeforeit
y The ppiston retracts,, and draws metal in
cools
l
y Metal: Lead, Tin, Zinc
y Copper,BrassandAluminiumcancast.
For-2013 (IES, GATE & PSUs) 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
casting
g y Porositymaybeaproblem
y Somescrapinsprues,runners,andflash,butthiscan
y Intricatepartspossible
p p
bedirectlyrecycled
y Minimumfinishingoperations
g p
y Thinsectionspossible
IES2011 IES2009
Applications
A li i Consider d theh following
f ll advantages
d off die
d casting over
Which of the following are the most suitable
y Carburettors sand casting :
materials for die casting?
y Automotive parts 1. Rapidity of the process
(a) Zinc and its alloys
2 Smooth surface
2.
y Bathroom
B h fi
fixtures (b) Copper and its alloys
3. Strong dense metal structure
y Toys
y (c) Aluminium and its alloys
Whi h off these
Which h advantages
d are correct ?
((a)) 1,, 2 and 3 (d) Lead and its alloys
Common metals
l (b) 1 and 2 only
y Alloys of aluminum, zinc, magnesium, and lead (c) 2 and 3 only
y Also possible with alloys of copper and tin (d) 1 and 3 only
JWM2010 IES2005 IES2006

Assertion (A) : In die casting method, method small
thickness can be filled with liquid metal. Which one of the following processes produces a In which of the following are metal moulds used?
casting when pressure forces the molten metal ( ) Greensand
(a) G d mould
ld
Reason (R) : The air in die cavity trapped inside the
into the mould cavity? ((b)) Dryy sand mould
castingg causes pproblems.
(a) Shell moulding (b) Investment casting (c) Die casting process
(a) BothAandRareindividuallytrueandRisthe
correctexplanationofA
t l ti fA (c) Die casting (d) Continuous casting (d) Loam
L moulding
ldi
(b) BothAandRareindividuallytruebutRisnot
y the
(c) AistruebutRisfalse
(d) AisfalsebutRistrue

IES1995 IES1995 IAS2007
Assertion (A): An aluminium alloy with 11 % silicon is MatchListIwithListIIandselectthecorrectanswertakingthehelp
ofcodesgivenbelowthelists: Considerthefollowingstatements:
used for making g engine
g pistons by
p y die casting g ListI ListII
technique. 1. Zincdiecastingshavelowstrength.
Zi di i h l h
(Products) (Processofmanufacture)
Reason (R): Aluminium has low density and addition A. Automobilepistoninaluminium
p alloyy 1.Pressurediecasting
g gp , y
2. Inthediecastingprocess,verythinsectionsor
B. Enginecrankshaftinspheroidal
of silicon improves its fluidity and therefore its
graphiteiron 2.Gravitydiecasting
complexshapescanbeobtainedeasily.
y
castability. C
C. Carburettor housinginaluminium alloy 3.Sandcasting
3 Sandcasting Whichofthestatementsgivenaboveis/arecorrect?
(a) Both A and R are individually true and R is the correct D. Casttitaniumblades 4.Precisioninvestment
explanation of A casting (a) 1only
5.Shellmoulding
h ll ld
(b) Both A and R are individually true but R is not the Code: A B C D A B C D (b) 2only
correct explanation of A (a) 2 3 1 5 (b) 3 2 1 5 (c) Both1and2
(c) 2 1 3 4 (d) 4 1 2 3
(c) A is true but R is false
(d) Neither1nor2
IAS1996 IES2011 GATE2007

Assertion (A): Die casting yields a product of good Consider the following statements :
accuracy and finish. 1 Hot chamber machine is used for casting zinc,
1. zinc tin and Which of the following engineering materials is
Reason (R): Low melting alloys used in die other low melting alloys. the most suitable candidate for hot chamber die
casting.
casting 2. Cold
C ld chamber
h b machine hi i used
is d for
f die
di casting
i off casting?
(a) Both A and R are individually true and R is the ferrous alloys (a) Low carbon steel
correct explanation
l i off A (b) Titanium
3. Rapid cooling rate in die casting produces high
(b) Both A and R are individuallyy true but R is not the strength and quality in many alloys.
alloys
correct explanation of A (c) Copper
Which of these statements are correct? (d) Tin
(d) A is false but R is true (a) 1, 2 and 3 (b) 1 and 2 only
(c) 2 and 3 only (d) 1 and 3 only
IES1995 C
CentrifugalCasting
if l C i
Assertion (A): Aluminium alloys are cast in hot
GATE2009(PI)
GATE 2009 (PI) y Process: Molten metal is introduced into a rotating sand,
sand
chamber die casting g machine. metal, or g
graphite
p mould, and held against
g the mould
Hot chamber die casting process is NOT suited for
Reason (R): Aluminium alloys require high melting wall by centrifugal force until it is solidified
when compared to zinc alloys. (a) Lead and its alloy
(a) Both A and R are individually true and R is the correct y A mold is set up and rotated along a vertical (rpm is
explanation of A ((b)) Zinc and its alloyy
reasonable), or horizontal (2001000 rpm is reasonable)
(b) Both A and R are individually true but R is not the (c) Tin and its alloy
correct explanation of A axis.
axis
(c) A is true but R is false (d) Aluminum and its alloy
y The mold is coated with a refractory coating.
(d) A is false but R is true y During
g cooling
g lower densityy impurities
p will tend to rise
towards the center of rotation.
Properties Advantages
y The mechanical properties of centrifugally cast jobs are y Fine grained structure at the outer surface of the
better compared to other processes, because the inclusions casting free of gas and shrinkage cavities and
such as slag and oxides get segregated towards the centre porosity
and can be easilyy removed byy machining. g Also, the
pressure acting on the metal throughout the solidification y Formation
F i off hollow
h ll i
interiors
i i cylinders
in li d without
ih
causes the pporosityy to be eliminated g
giving
g rise to dense cores
metal. y Can produce a wide range of cylindrical parts,
y No cores are required for making concentric holes in the including ones of large size.
size
case of true centrifugal casting. y Good dimensional accuracy, soundness, and
cleanliness
l li
Fig Truecentrifugalcasting
Fig.Truecentrifugalcasting y There is no need for g gates and runners,, which
increases the casting yield, reaching almost 100 %.
Limitations Commonmetals GATE2002

y More segregation of alloy component during pouring under y Iron
the forces of rotation y steel In centrifugal casting, the impurities are
y stainlesssteel (a) Uniformly distributed
y Contamination of internal surface of castings with non
non
y alloysofaluminium,copper,andnickel
ll f l i i d i k l (b) Forced towards the outer surface
metallic inclusions
(c) Trapped near the mean radius of the casting
y Inaccurate internal diameter (d) Collected at the centre of the casting
y Shape is limited.
y Spinning equipment can be expensive
y Poor machinability
GATE1993 IES2008
Centrifugally cast products have
GATE2008(PI)
GATE 2008 (PI) Which
h h off the
h following
f ll casting processes does
d not
In hollow cylindrical
y parts,, made byy centrifugal
p g casting,
g, /do not require central core for producing pipe?
( ) Large
(a) L grain
i structure with
i h high
hi h porosity
i 1. Sand casting process
((b)) Fine g
grain structure with high
g densityy the density of the part is
2 Die casting process
2.
(c) Fine grain structure with low density (a) maximum at the outer region 3. Centrifugal casting process
(d) Segregation
S i off slug
l towards d the
h outer skin
ki off the
h S l
Select the
h correct answer using
i the
h code
d given
i b l
below:
casting (b) maximum at the inner region ((a)) 1 and 2
(c) maximum at the midpoint between outer and inner (b) 2 only
(c) 2 and 3
surfaces
(d) 3 only
(d) uniform throughout
IES2009 IES2007 IES1998
Which one of the following casting processes is Which one of the following is the correct Poormachinability ofcentrifugallycastironpipe
statement? isdueto
best suited to make bigger size hollow In a centrifugal casting method (a) Chilling
symmetrical pipes? (a) No core is used (b) Segregation
(b) Core may be made of any metal (c) Densestructure
(a) Die casting
(c) Core is made of sand (d) Highmouldrotationspeed
(b) Investment casting (d) Core is made of ferrous metal
( ) Shell
(c) h ll moulding
ld
(d) Centrifugal
C if l casting
i
IES2009 IES2007 IES2000

Which of the following are the most likely MatchListIwithListIIandselectthecorrectanswerusingthecodegiven
belowtheLists:
MatchListI(Process)withListII(Products/materials)
ListI ListII andselectthecorrectanswerusingthecodesgiven
characteristics in centrifugal casting? (CastingProcess) (Principle) b l
belowtheLists:
h
(a) Fine grain size and high porosity A. Diecasting 1.Themetalsolidifiesinarotatingmould ListI ListII
B
B. Investmentcasting 2 Thepatternclusterisrepeatedlydipped
2.Thepatternclusterisrepeatedlydipped
(b) Coarse grain size and high porosity intoaceramicslurryanddustedwith A. Diecasting 1.Phenolformaldehyde
refractory
C
C. Shellmoulding 3 Moltenmetalisforcedbypressureinto
3.Moltenmetalisforcedbypressureinto
B. Shellmolding 2.C.I.pipes
(c) Fine grain size and high density ametallicmould C. CO2 molding 3.Nonferrousalloys
D. Centrifugalcasting 4.Aftercooling,theinvestisremoved
(d) Coarse grain size and high density fromthe Castingbypressurejettingor
g yp j g D. Centrifugalcasting
g g 4.Sodiumsilicate
vibratorycleaning
Code: A B C D A B C D
Codes:A B C D A B C D
((a)) 2 1 3 4 ((b)) 3 4 2 1 ((a)
) 1 33 4
4 2 ((b)
) 33 1 4
4 2
(c) 2 4 3 1 (c) 3 1 2 4 (c) 3 1 2 4 (d) 1 3 2 4
IAS2004 SemicentrifugalCasting
MatchListI(NameoftheProcess)withListII(Advantage)andselectthecorrect y Centrifugal force assists the flow of metal from a
answerusingthecodesgivenbelowthelists:
ListI ListII central reservoir to the extremities of a rotating
(NameoftheProcess) (Advantage)
A. SandCasting 1.Largecylindricalpartswithgoodquality
B. Ceramicmoldcasting 2.Excellentdimensionalaccuracyandsurface
symmetrical mold, which may be either expendable or
finish
C. Diecasting 3.Intricateshapesandclosetoleranceparts multipleuse
li l
D. Centrifugalcasting 4.Almostanymetaliscastandthereifnolimitto
size,shapeandweight
h d h y Rotational
R t ti l speeds
d are lower
l th for
than f true
t centrifugal
t if l
5.Gooddimensionalaccuracy,finishandlow
p
porosityy
casting
(a) 2 3 5 1 (b) 4 1 2 3
y Cores can be used to increase the complexity of the
(c) 2 1 5 3 (d) 4 3 2 1
For-2013 (IES, GATE & PSUs) product. Page 28 Fig. Semicentrifugalcasting
IAS2003 Centrifuging
Assertion (A): Semicentrifugal casting process is y Uses centrifuging action to force the metal from a central
similar to true centrifugal g casting g except
p that the
central core is used in it to form inner surface. pouring reservoir into separate mold cavities that are
Reason (R): In semisemicentrifugal
centrifugal casting process the offset
ff t from
f th axis
the i off rotation.
t ti
axis of spin is always vertical
(a) Both A and R are individually true and R is the correct y Low speed
explanation of A
(b) Both A and R are individually true but R is not the y May
y used to assist in the p
pouring
g of investment casting
g
correct explanation of A trees.
Fig.Methodofcastingbythecentrifugingprocess
IES2000 DrySandMolding SlushCasting

MatchListI(Typeofcasting)withListII(Workingprinciples)
andselectthecorrectanswerusingthecodesgivenbelowthe y To reduce gas forming materials air dried mould used. y Slush casting is a variation of the permanent mold process
Lists: in which the metal is permitted to remain in the mold only
ListI ListII Types: until a shell of the desired thickness has formed.
A. Diecasting 1.Moltenmetalisforcedintothedie
underpressure y The mold is then inverted and the remaining liquid is
B. Centrifugalcasting 2.Axisofrotationdoesnotcoincidewith 1.Skin drying and poured out.
axisofmould
C. Centrifuging 3.Metalsolidifieswhenmouldisrotating 2.Complete mold drying y When the mold halves are separated, the resulting casting
D. Continuouscasting 4.Continuouslypouringmoltenmetal iss a hollow
o o sshape
ape with
t good susurface
ace deta
detail but va
variable
ab e wall
a
intomould thickness.
Codes: A B C D A B C D
( ) 1
(a) 3 2 4 (b)
(b) 4 3 2 1 y Frequently used to cast lowmeltingtemperature
low melting temperature metals
(c) 1 2 3 4 (d) 4 2 3 1 into ornamental objects such as candlesticks, lamp bases,
and statuary.
statuary
IAS2004 IES2011 IES 2012

The method of casting for producing ornamental pieces The
Th process off making
ki hollow
h ll castings
i off noncircular
i l
Which of the following are produced by slush
are: shape and desired thickness by permanent mould
casting?
(a) Slush and gravity casting without the use of cores is known as
(a) Hollow castings with thick walls
(b) Pressed
P d andd slush
l h casting
i (a) Die casting (b) Slush casting
(b) Hollow castings with thin walls
((c)) Gravityy and semi ppermanent mould casting
g (c) Pressed casting (d) Centrifugal casting
(c) Thin castings
(d) Thick castings (d) Semi permanent mould and pressed casting

SqueezeCasting IAS2002 SingleCrystalCasting
MatchListI(CastingProcess)withListII Theprocessiseffectively:
Th i ff i l
Process:
(Applications)andselectthecorrectanswerusingthe 1. Prepareamoldsothatoneendisaheatedoven,and
p ,
1. Molten
M l metall is
i pouredd into
i an open face
f di
die. codesgivenbelowtheLists:
d b l h
theotherendchilled.Thepartshouldbeorientedso
2. A p
punch is advanced into the die,, and to the metal. ListI ListII
thatthecoolinghappensoverthelongestdistance.
thatthecoolinghappensoverthelongestdistance
(CastingProcess) (Applications)
3.Pressure (less than forging) is applied to the punch 2. Castmetalintothemold
A. Centrifugalcasting 1. Carburetor
and die while the part solidifies.
solidifies B. Squeezecasting 2. Pipes 3. Solidificationwillbeginatthechillplate.These
4.The punch is retracted, and the part is knocked out C. DieCastingg 33. Wheelsfor de d tes
dendriteswillgrowtowardstheheatedendofthe
g o to a ds t e eated e d o t e
with an ejector pin. automobiles
partaslongdendritic crystals.Thepartisslowly
4. Gearhousings
y Overcomes problems with feeding the die, die and pulledoutoftheoven pastthechillplate
pulledoutoftheoven,pastthechillplate.
Codes:A B C A B C
produces near net, highly detailed parts. 4. Removethesolidifiedpart.
(a) 2 3 1 (b) 4 1 3
(c) 2 1 3 (d) 4 3 1
IES2009
PlasterCasting
y Process: A slurry of plaster, water, and various additives is
y Creepandthermalshockresistanceproperties. 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:
2marks
y Common metals: Primarily aluminium and copper
PitMoulding IES1996 LoamMoulding

y This method is used for very large castings and is done on Whichofthefollowingpairsarecorrectlymatched?
the foundry floor.
floor 1. Pitmoulding
Pi ldi ..................Forlargejobs.
F l j b y Moulding
M ldi l
loam i generally
is ll artificially
ifi i ll composed
d off
2. Investmentmoulding g ...Lostwaxprocess.
p common brickclay,
brick clay and sharp sand.
sand
3. Plastermoulding Mouldpreparedin
gypsum.
gypsum y Loam means mud.
mud
(a) 1,2and3 (b) 1and2 y Loam Moulding is restricted to forms which cannot be
(c) 1and3 (d) 2and3
cast conveniently in any other process.
y It is costly.

IES1997 GATE1998 GATE1992
Which one of the following pairs is not correctly ListI ListII Matchthefollowingmoulding/castingprocesseswith
matched? ((A)) SaSandcasting
d cas g ()
(1) Symmetricaland
Sy e ca a d p
theproduct:
circularshapesonly Moulding/Castingprocesses Product
(a) Aluminium alloy piston Pressure die casting ((B)) Plastermouldcasting
g ((2)) Partshavehardened (A) Slushcasting (P)Turbineblade
(b) Jewellery.. Lost wax process skinsandsoftinterior
(C) Shellmouldcasting (3) Minimumpost (B) Shellmoulding (Q)Machinetoolbed
(c) Large pipes ..Centrifugal
Centrifugal casting castingprocessing
i i (C) Drysandmoulding
D d ldi (R)C li d bl k
(R)Cylinderblock
(d) Large bells Loam moulding (D) Investmentcasting (4) Partshaveatendency (D) Centrifugalcasting (S)Hollowcastings
ttowarp
lk l
likelampshades
h d
(5) Partshavesoftskin (T)Rainwaterpipe
andhardinterior
(U)Castironshoe
(6) Suitableonlyfornon
ferrousmetals brake
GATE1996 IES2003 IES1993

ListI ListII MatchListI(Products)withListII(CastingProcess)andselect MatchtheitemsofListI(Equipment)withtheitems
thecorrectanswerusingthecodesgivenbelowtheLists:
( )
ofListII(Process)andselectthecorrectanswerusingg
(A) Rivetsforaircraftbody
Ri f i f b d 1. F i
Forging Li I
ListI Li II
ListII
thegivencodes.
(Products) (CastingProcess)
((B)) Carburettor body
y 2. Coldheadingg A
A. Hollowstatues 1
1. CentrifugalCasting ListI(Equipment) ListII(Process)
(C) Crankshafts 3. Aluminiumbased B. Dentures 2. InvestmentCasting P HotChamberMachine 1. Cleaning
C. Aluminium alloypistons
yp 33. SlushCasting
g
alloy Q Muller
Q 2
2. Coremaking
D. Rockerarms 4. ShellMoulding
(D) Nails 4. Pressurediecasting 5. GravityDieCasting R DielectricBaker 3. Diecasting
5. Investmentcasting Codes: A B C D A B C D S SandBlaster
d l 4. Annealing
l
(a) 3 2 4 5 (b) 1 3 4 5 5. Sandmixing
( ) 1
(c) 2 3 4 (d) 3 2 5 4
(a) P2,Q1,R4,S5 (b) P4,Q2,R3,S5
(c) PP4,Q5,R1,S2
4,Q 5,R 1,S 2 (d) P P3,Q5,R2,S1
3,Q 5,R 2,S 1
IAS2004 GATE 2007(PI)

( )
MatchListI(NameoftheCastingProcess)withListII(ProcessDefinition)andselect
Match the lists
thecorrectanswerusingthecodesgivenbelowthelists:
List I
ListI List II
ListII Group 1
Group1 Group 2
Group2
(NameoftheCastingProcess) (ProcessDefinition)
A. Diecasting 1.Thisprocessinvolvesuseofamouldmadeof P.SandCasting 1.Turbineblades
Driedsilicasandandphenolic resinmixture
B. Electroslag casting 2.Inthisprocess,moltenmetalisforcedby Q.CentrifugalCasting 2.ICEnginePistons
Pressureintoametalmould
C. Centrifugalcasting 3.Thisprocessemploysaconsumableelectrode R I
R.InvestmentCasting
C i 3.Largebells
L b ll
D. Precisioncasting 4.Thisprocessinvolvesrotatingamouldwhilethe
metalsolidifies
l ldf S DieCasting
S.DieCasting 4 Pulleys
4.Pulleys
5.Thisprocessproducesverysmooth,highly
Accuratecastingsfrombothferrousandnon
g
ferrousalloys
(a) P 4,
4 Q 1,
1 R 3,
3 S2 (b) P 2,
2 Q 4,
4 R 3,
3 S1
Codes:A
(a) 5
B
4
C
1
D
2 (b)
A
2
B
3
C
4
D
5
(c) P 3, Q 4, R 1, S 2 (d) P 3, Q 2, R 1, S 4 BySKMondal
y
(c) 5 3 4 2 (d) 2 4 1 5
WeldingDefinition Requirementforahighqualitywelding l ifi i f ldi
Classificationofweldingprocesses
Oxy
y fuel g g ((OFW))
gas welding
y Welding is a process by which two materials, usually Arc welding (Aw)
1. A source of satisfactory heat and/or pressure,
metals, are permanently joined together by
metals Resistance welding
coalescence, which is induced by a combination of 2. A means of protecting or cleaning the metal, and Solid state welding (friction welding, ultrasonic welding,
temperature, pressure, and
d metallurgical
ll i l conditions.
di i forge welding etc.)
etc )
3. Caution to avoid, or compensate for, harmful
y The pparticular combination of these variables can y Unique
q p process
range from high temperature with no pressure to high metallurgical effects. Thermit welding
pressure with no increase in temperature.
temperature 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
Th advantage
d o the
h welding
ldi process isi y The weldability of a material will depend on the y The oxide coating on aluminum alloys causes some
((a)) It relieves the jjoint from residual stresses specific welding or joining process being considered.
considered difficultyy in relation to its weldability.
y
(b) It helps in checking of distortion of work piece y For resistance welding of consistent quality, it is y It also has high thermal conductivity and a very short
( ) Large
(c) L number
b off metals l and
d alloys,
ll b h similar
both i il and/or
d/ usually
ll necessary to remove the h oxideid immediately
i di l temperature range between liquidus and solidus and when
before welding. liquid its viscosity is very low.
dissimilar can be joined.
y Al i i
Aluminium i poor absorber
is b b off laser
l li h
light.
(d) Heat produced during the welding does not produce y Fabrication weldability test is used to determine
mechanical properties required for satisfactory y During g fusion welding, g the aluminum would oxidize so
metallurgical changes.
changes
readily that special fluxes or protective inertgas
performance of welded joint.
atmospheres
p must be employed.
p y
y The
Th correct sequence off the h given
i materials
i l ini
y Friction welding and TIG welding is good for aluminium.
ascending order of their weldability is
y For aluminium AC current plus high frequency is must.
must
Aluminum < copper < cast iron < MS Contd
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
carbon content and brittleness (p
(poor ductility)
y) contains both nickel and chromium. q
than the austenitic stainless steel and require both
y Massive carbon deposits have a tendency to form in y The best method for welding stainless steel is TIG preheating and postweld heat treatments.
the areas adjacent to the weld,
weld and high
highcarbon
carbon welding.
welding y Welds of ferritic stainless steel can be by
martensite tends to form in the heataffected zones. y The electric arc is also preferred for welding stainless (i) autogenously (i.e. without the addition of filler
These microstructures are very brittle and may crack steels A heavily coated welding rod,
steels. rod which produce a metal)
spontaneously while welding is in progress or later shielded arc, is employed. (ii) with an austenitic stainless steel
when load is applied to the workpiece.
workpiece y You
Y must do d a better
b j b off precleaning.
job l i (iii) using
i a high
hi h nickel
i k l filler
fill alloy.
ll
y Cast iron can be joined by the oxyacetylene brazing (iv) Type 405 filler (low 11% Cr, low carbon and small
y Usingg a low arc current setting g with faster travel
process and shielded metalarc
metal arc welding (stick) speeds is important when welding stainless steel, 0.2%% Al)
l)
process. because some stainless steels are subject j to carbide y Welding
g p
process: TIG, MIG, Shieldedmetal arc
y Some cases preheating
h and/or
d post heating
h is required.
d precipitation. welding and Plasma arc welding
Contd..
IES2010 IES2006 IES2011
Assertion (A): It is generally difficult to weld During plasma arc welding of aluminium, improved
Aluminum parts by normal arc welding process. Assertion(A):Aluminium haspoorweldability.
removal of the surface oxide from the base metal is
Reason (R): Hard and brittle Aluminumoxide film R
Reason(R):Aluminium
(R) Al i i h hi h h
hashighthermal
l
obtained with typical polarity of :
is formed at the welded joints.
j conductivityandhighaffinitytooxygen.
(a) DC Straight
(a) Both A and R are individually true and R is the (a) BothAandRareindividuallytrueandRisthe
correctexplanationofA (b) DC reverse
correctt explanation
l ti off A
(b) BothAandRareindividuallytruebutRisnot the (c) AC potential
(b) Both A and R are individuallyy true but R is NOT the
l i fA (d) Reverse polarity of phase of AC potential
(c) A is true but R is false ((c)) AistruebutRisfalse
(d) A is false but R is true (d) AisfalsebutRistrue
IES2011 IES2006 IES1999

Considerthefollowingstatements.
d h f ll
Fabricationweldability testisusedtodetermine Thecorrectsequenceofthegivenmaterialsin
Castironisdifficulttoweld,becauseof
,
(a) Mechanicalpropertiesrequiredforsatisfactory ascendingorderoftheirweldability
di d fth i ld bilit is i
1.Lowductility
p
performanceofweldedjoint
j ((a)) MS,copper,castiron,aluminium
, pp , ,
2.Poorfusion
P f i
(b) Susceptibilityofweldedjointforcracking (b) Castiron,MS,aluminium copper
3
3.Tendencytocrackoncooling
y g
( ) Suitabilityforjointdesign
(c) S i bili f j i d i ( ) Copper,castiron,MS,aluminium
(c) C i MS l i i
Whichofthesestatementsarecorrect?
(a)1 2and3
(a)1,2and3 ((d)) Appropriatemachiningprocess
pp p gp ((d)) Aluminium,copper,castiron,MS
, pp , ,
(b)1and2only
(c)2and3only
(d)1and3only
IES2010 IES2010 IES 2012

Weldability
W ld bilit off ferritic
f iti stainless
t i l steel
t l used
d in
i Consider the following statements regarding Whichofthefollowingfactorsimproveweldabilityof
Whi h f h f ll i f i ld bili f
automotive exhaust systemy is improved
p byy welded joints: steel?
selecting stainless steel electrode having low 1. It is a permanent type of joint. 1.Lowcarboncontent
content of 2 It is reliable and economical for pressure vessel
2. 2 Highcarboncontent
2.Highcarboncontent
construction. 3.Goodaffinitycontent
((a)) Carbon ((b)) Nitrogen
g
3. It is free
f f
from f b
fabricationall residual
d l stresses. 4.Pooraffinitytooxygen
(c) Chromium (d) Carbon and Nitrogen
4. Such joints are suitable for static loading only. ( ) d
(a)1and3 (b) d
(b)2and3
5. Welding is a versatile and flexible metal joining process. (c)1and4 (d)2and4
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
GasFlameProcesses: y Combustionofoxygenandacetylene(C2H2)ina
Welding,CuttingandStraightening
W ldi C i dS i h i weldingtorchproducesatemp.inatwostagereaction.
ldi t h d t i t t ti
y Oxyfuel gas Welding (OFW): Heat source is the y Inthefirststage
g
flame produced by the combustion of a fuel gas and C2 H2 + O2 2CO + H2 +Heat
oxygen. Thisreactionoccursnearthetipofthetorch.
Thi i h i f h h
y InthesecondstagecombustionoftheCOandH
g 2 and
y OFW has largely been replaced by other processes but occursjustbeyondthefirstcombustionzone.
it is still popular because of its portability and the low 2CO+O2 2CO2+Heat
1
capital investment.
2 2 H2O+Heat
H2 +O
Oxygenforsecondaryreactionsisobtainedfromthe
y Acetylene is the principal fuel gas employed. atmosphere.
atmosphere
Three types of flames can be obtained by varying y Excess fuel, on the other hand, produces a carburizing
y A higher ratio, such as 1.5 : 1, produces an oxidizing
the
th oxygen/acetylene
/ t l (or
( oxygen/fuel
/f l gas)) ratio.
ti flame.
flame Carburizing flame can carburize metal also.
also
flame, hotter than the neutral flame (about 3300oC)
y If the ratio is about 1 : 1 to 1.15
5 : 1,, all reactions are but similar in appearance.
pp y The excess fuel decomposes to carbon and hydrogen,
carried to completion and a neutral flame is produced. andd the
h flame
fl temperature isi not as great (about
( b
y Used when welding copper and copper alloys but
3000oC).
y Most welding is done with a neutral flame. flame It is harmful when welding steel because the excess oxygen
chemically neutral and neither oxidizes or carburizes reacts with the carbon, decarburizing the region y Flames of this type are used in welding Monel (a
the
h metall being
b i welded.
ld d aroundd the
h weld.
ld 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 Flame Explain the three types of oxyacetylene flames.
MS N Indicate with the help of sketches the various
High carbon steel R
Grey cast iron
Alloy steel
Aluminium
N, slightly oxidizing
N
Slightly carburizing
zones, respective
applications of each type
temperature
t pe of flame.
flame
ranges and
Diagram
Di g
Brass Slightly oxidizing
C
Copper, B
Bronze N slightly
N, li h l oxidizing
idi i [20 Marks]
[20
Nickel alloys Slightly carburizing
L d
Lead N

d d i i i
Uses,Advantages,andLimitations Oxyacetyleneweldingequipment
y Exposer
p of the heated and molten metal to the various
y OFW is
i fusion
f i welding.
ldi
gases in the flame and atmosphere makes it difficult to y Oxygen is stored in a cylinder at a pressure ranging
y No p
pressure is involved. from 13.8
13 8 MPa to 18.2
18 2 MPa .
y Filler metal can be added in the form of a wire or rod. prevent contamination.
y Due to high explosiveness of free acetylene it is stored
y Fluxes
Fl may be
b used
d to clean
l the
h surfaces
f and
d remove y Heat source is not concentrated, a large area of the in a cylinder with 8085% porous calcium silicate and
contaminating oxide. The gaseous shield produced by then filled with acetone which absorb upto
p 4 420 times
vaporizing flux can prevent oxidation during welding, metal is heated and distortion is likely to occur. by its volume at a pressure 1.75 MPa .
aand
d tthee sslag
ag p
produced
oduced by so
solidifying
d y g fluxu ca
can p
protect
otect y At the time of acetylene release if acetone comes with
y Flame
Fl welding
ldi isi still
ill quite
i common in
i field
fi ld work,
k in
i
the weld pool. Flux can be added as a powder, the acetylene the flame would give a purple colour.
welding rod can be dipped in a flux paste,
paste or the rods maintenance and repairs,
repairs and in fabricating small
y Another option is acetylene generator.
can be precoated.
quantities
qua t t es o
of spec
specialized
a ed p products.
oducts.
CaC2 + 2 H 2O C2 H 2 + Ca (OH ) 2
Contd
IES2010 GATE1994
PressureGasWelding
Pressure Gas Welding The
Th ratioti between
b t Oxygen
O andd Acetylene
A t l
y Pressure g
gas welding
g ((PGW)) or Oxyacetylene
y y gases for neutral flame in g
g gas welding
g is Thee ratioat o o
of acetylene
acety e e to o oxygen
yge iss
Pressure Welding is a process used to make butt (a) 2 : 1 (b) 1 : 2 approximately. for a neutral flames used in
jjoints between the ends of objects
j such as ppipe
p gas welding.
welding
andrailroad rail. (c) 1 : 1 (d) 4 : 1
(a) 1 : 1
y The ends are heated with a gas flame to a
temperature below the melting point, and the soft (b) 1 : 2
metal is then forced together under considerable (c) 1 : 3
pressure. (d) 1.5 : 1
y This
Thi process, therefore,
th f i actually
is t ll a 'form
'f off solid
lid
state welding.
GATE2003 IES2010 GATE2002

Assertion (A): Oxidizing flame is used in gas
InOxyacetylenegaswelding,temperatureatthe welding to join medium carbon steels having high The temperature of a carburising flame in gas
innerconeoftheflameisaround melting
l i point.i welding is that of a neutral or an oxidising flame.
flame
(a) 3500C Reason ((R): ) In g gas welding,
g, oxidizingg flame (a) Lowerthan
(b) 3200C produces the maximum temperature compared to (b) Higherthan
(c) 2900
2900C
C neutral and reducing flame.flame (c) Equalto
(d) 2550C (a) Both A and R are individually true and R is the (d) Unrelatedto
(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
IES2009 IES1998 IAS1994
By which one of the following methods gray cast In oxyacetylene gas welding, for complete In gas welding of mild steel using an oxy
i
iron i usually
is ll welded?
ld d? combustion,
b ti th volume
the l off oxygen required
i d per acetylene
t l fl
flame. th total
the t t l amountt off acetylene
t l
((a)) TIGweldingg ((b)) MIGwelding
g unit of acetylene is consumed was 10 litre. The oxygen consumption
(c) Gaswelding (d) Arcwelding (a) 1 from the cylinder is
(b) 1.5
15 (a) 5litre
(c) 2 (b) 10litre
(d) 2.5 (c) 15litre
(d) 20litre
IAS1995 IES 2012 OxygenTorchCutting(GasCutting)

Statement
St t t (I):
(I) In
I gas welding
ldi the
th metal
t l to
t beb joined
j i d gets
t
Assertion (A): If neutral flame is used in oxy oxidized or carburized y Iron and steel oxidize (burn) when heated to a
acetylene
y welding,g, both oxygen
yg and acetylene
y temperature between 8000C to 10000C. C
cylinders of same capacity will be emptied at the same Statement (II): The neutral flame affects no chemical
time. change on the molten metal. y Highpressure oxygen jet (300 KPa) is directed against
Reason (R): Neutral flame uses equal amounts of (a) Both Statement (I) and Statement (II) are a heated steel plate, the oxygen jet burns the metal and
oxygen and acetylene. blows it awayy causingg the cut ((kerf).
)
individuallyy true and Statement ((II)) is the correct
( ) BothAandRareindividuallytrueandRisthecorrect
(a) B hA dR i di id ll dRi h explanation of Statement (I)
explanationofA y For cutting metallic plates shears are used. These are
(b) BothAandRareindividuallytruebutRisnot
B thA dR i di id ll t b tRi t the th (b) Both Statement (I) and Statement (II) are useful for straightline
straight line cuts and also for cuts up to 40
correctexplanationofA individually true but Statement (II) is not the correct mm thickness.
(c) AistruebutRisfalse explanation of Statement (I)
(d) AisfalsebutRistrue (c) Statement (I) is true but Statement (II) is false
( ) Statement (I)
( ) is true
Contd
y For thicker plates with specified contour, shearing y Larger size orifice produces kerf width wider and larger
y For
o co p ete o
complete dat o 0.
oxidation 87 m3 o
0.287 yge / g o
oxygen/kg o iss
of iron
cannot be used and oxyfuel gas cutting (OFC) is oxygen consumed. d
required
useful. y At kindlingg temperature
p (about 870oC), iron form iron
oxide. y Due
D t unoxidized
to idi d metalt l blown
bl away theth actual
t l
y Gascutting is similar to gas welding except torch tip. requirement is much less.
y Reaction:
3Fe + 2O2 Fe3O4 +6.67 MJ/kg of iron
y Torch tip held vertically or slightly inclined in the
direction of travel.
The
h other
h reactions:
y Torch position is about 1.5 to 3 mm vertical from plate.
2Fe + O2 2FeO + 33.18 MJ/kg
J g of iron
4Fe + 3O2 2Fe2O3 + 4.9 MJ/kg of iron
y All exothermic reactions preheat the steel.
steel
Fig differencesintorchtipsforgasweldingandgascutting
Contd
y The drag lines shows the characteristics of the movement y If torch moved too rapidly, the bottom does not get y Gas cutting
g is more useful with thick p
plates.
off the
h oxygen stream. sufficient
ffi i t heat
h t and
d produces
d large
l drag
d so very rough
h
and irregularshapedcut edges.
y For
F thin
thi sheets
h t (less
(l th 3 mm thick)
than thi k) tip
ti size
i should
h ld
y If torch moved slowly a large amount of slag is
be small. If small tips are not available then the tip is
generated and produces irregular cut.
cut
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 Difficulties
IAS2011Main
IAS2011 Main y Metal temperature goes beyond lower critical
y Useful only for materials which readily get oxidized
D
Draw a self
lf explanatory
l t sketch
k t h off oxyacetylene
t l gas temperature and structural transformations occur.
occur
and the oxides have lower melting points than the
cutting torch.
torch Briefly explain how cutting is
metals. y Final microstructure depends on cooling rate.
effected.
y Widely used for ferrous materials.
[20Marks] 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
y For high
g carbon steel material around the cut should IES1992 IES2007
be preheated (about 250 to 300oC) and may post heat The edge of a steel plate cut by oxygen cutting will Considerthefollowingstatementsinrespectofoxy
acetylenewelding:
y g
gett hardened
h d d when
h theth carbon
b content t t is
i
also necessary. 1. Thejointisnotheatedtoastateoffusion.
((a)) Less than 0.1 p
percent 2. Nopressureisused.
y Cutting CI is difficult, since its melting temp. is lower (b) Less than 0.3 percent 3. Oxygenisstoredinsteelcylinderatapressureof14
MPa.
than iron oxide. ( ) More
(c) M than
h 0.3 percent 4. Whenthereisanexcessofacetyleneused,thereisa
((d)) Anywhere
y between 0.1 to 1.0 p
percent decidedchangeintheappearance
g pp
y If chromium
h i and
d nickel
i k l etc are present in
i ferrous
f offlame.
alloys oxidation and cutting is difficult.
difficult Whichofthestatementsgivenabovearecorrect?
g
(a)1,2and3 (b) 2,3and4
((c)) 1,3and4
,3 4 ((d)) 1,2and4
, 4

IES2001 IES1992 IES2005
Oxyacetylenereducingflameisusedwhile Thick steel plate cut with oxygen normally shows Considerthefollowingstatements:
carryingouttheweldingon
i tth ldi signs
i off cracking.
ki Thi tendency
This t d f cracking
for ki can 1. I ldi th t h h ldb h ld t
Ingaswelding,thetorchshouldbeheldatanangleof
l f
be minimised by 30 to45 fromthehorizontalplane.
((a)) Mildsteel ((b)) Highcarbonsteel
g
2. Ingaswelding,theSizeofthetorchdependsuponthe
I ldi h Si f h hd d h
(c) Greycastiron (d) Alloysteels (a) Slow speed cutting
thicknessofmetaltobeformed.
(b) Cutting in two or more stages 3. Dragingascuttingisthetimedifferencebetween
h d ff b
(c) Preheating the plate heatingoftheplateandstartingtheoxygengasfor
cutting.
tti
(d) Using oxyacetylene flame
Whichofthestatementsgivenabovearecorrect?
(a) 1,2and3 (b) 1and2
(c) 2and3 (d) 1and3
PowderCutting PlasmaCutting
l
y Cast iron,
iron stainless steel,
steel and others high alloy steels are GATE2009(PI)
GATE2009 (PI) y Uses ionized gas jet (plasma) to cut materials resistant to
difficult to cut by oxyfuel cutting and we can use powder oxyfuel cutting,
cutting.
i Whi h off the
Which th following
f ll i powders
d should
h ld be
b fed
f d for
f y Highh velocity
l electrons
l generated d by
b the
h arc impact gas
y By
y injecting
j g a finelyy divided 200mesh iron p
powder into molecules, and ionize them.
effective oxy
oxyfuel
fuel cutting of stainless steel?
the flame, a lower melting point eutectic oxide is formed y The ionized gas is forced through nozzle (upto 500 m/s), and
at the cutting interface,
interface where additional ironoxygen (a) Steel the jjet heats the metal,, and blasts the molten metal away.
y
reaction is generated and cutting proceeds in a similar y More economical, more versatile and much faster (5 to 8
((b)) Aluminum times) than oxyfuel cutting,
cutting produces narrow kerfs and
way off oxyfuel
f l cutting.
tti
smooth surfaces.
y The heat and the fluxing g action of the burningg iron ((c)) Copper
pp
powder enable the cutting oxygen stream to oxidize the y HAZ is i 1/3
/ to thh than
h oxyfuel
f l cutting.
i
base metal continuously, just as in cutting carbon steel. (d) Ceramic y 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) theth condition
diti isi known
k as straight
t i ht polarity
l it
(SPDC).
(SPDC)
y Manual arc welding is done with shielded (covered)
y Work is negative
g and electrode is p
positive is reverse ISRO2011 electrodes
polarity (RPDC). y Bare
Baremetal
metal wire used in automatic or semiautomatic
I ldi
Inarcwelding,penetrationisminimumfor
t ti i i i f
y SPDC conditions are preferred. machines.
( )DCSP
(a)DCSP y Non
N consumable
bl electrodes
l t d (
(e.g t
tungsten)
t ) isi nott
y DC arcwelding maintain a stable arc and preferred for consumed by the arc and a separate metal wire is used
(b)DCRP as filler.
difficult tasks such as overhead welding.
y There are three modes of metal transfer (globular,
(globular
y For a stable arc, the gap should be maintained. ( )AC
(c)AC
spray and shortcircuit).
(d)DCEN
(d)
Contd
Threemodesofmetaltransferduringarcwelding MajorForcestakepartinMetalTransfer JWM2010

(i)gravityforce Assertion (A) : Bead is the metal added during
single pass of welding.
(ii)Surfacetension
Reason (R) : Bead material is same as base metal.
(iii)electromagneticinteraction (a) Both A and R are individually true and R is the
correct explanation
p of A
( )
(iv)hydrodynamicactionofplasma
(b) Both A and R are individually true but R is NOT the
GATE1993 Arcweldingequipments
Ind.c.welding,thestraightpolarity(electrode 1. Droopers: Constant current welding machines
negative)resultsin Good
G d for
f manuall welding
ldi
(a) Lowerpenetration 2. Constant voltage
g machines
(b) Lowerdepositionrate Good for automatic welding Fig.Machinewithdifferentsettings
(c) Lessheatingofworkpiece
(d) Smallerweldpool
For-2013 (IES, GATE & PSUs) Page 39 Contd Fig.Characteristiccurveofaconstantvoltagearcweldingmachine

IES2010
Formula y Requires a large current (150 to 1000 A),
A) voltage is InI arc welding,
ldi the
th arc length
l th should
h ld be
b equall to
t
between 30 and 40 V, actual voltage across the arc ((a)) 44.55 times the rod diameter
(b) 3 times the rod diameter
varying from 12 to 30 V.
( ) 1.5 times
(c) i the
h rodd diameter
di
y To initiate a weld, the operator strike the electrode and ((d)) Rod diameter
start arc.
V I
+ =1
OCV SCC
IES2005 IES2001 IES2001

Considerthefollowingstatements:
1. Inarcwelding,65%to75%heatisgeneratedatthe Inmanualarcwelding,theequipmentshould
g q p Inarcwelding,d.c.reversepolarityisusedtobear
anode.
d greateradvantagein
t d t i
havedroopingcharacteristicsinordertomaintain ((a)) Overheadwelding g
2. Dutycycleincaseofarcweldingisthecycleof
y y g y
completeweldingofworkpiecefromthe (a) Voltageconstantwhenarclengthchanges (b) Flatweldingoflapjoints
beginning.
beginning ( ) Edgewelding
(c) Ed ldi
3. ArcblowismorecommonwithDCwelding. (b) Currentconstantwhenarclengthchanges
((d)) Flatweldingofbuttjoints
g j
Whichofthestatementsgivenaboveare (c) Temperatureintheareconstant
correct?
(d) Weldpoolredhot
((a)) 1,2and3
, 3 ((b)) 1and2
(c) 2and3 (d) 1and3
IES1998 IAS1999 IAS1998

The voltagecurrent characteristics of a dc Opencircuit voltage of 60 V and current of 160A AssumingastraightlineVIcharacteristicsfora
generator
t f
for arc welding
ldi i a straight
is t i ht line
li were the
th welding
ldi conditions
diti f arc welding
for ldi off a d ldi
dcweldinggenerator,shortcircuitcurrentas400A
t h t i it t A
between an opencircuit voltage of 80 V and short certain class of steel strip of thickness 10 mm. For andopencircuitvoltageas400whichoneofthe
circuit current of 300 A. The generator settings for arc welding of 5mm thick strip of the same steel, followingisthecorrectvoltageandcurrentsetting
maximum arc p power will be the welding g voltage
g and current would be formaximumarcpower?
p
(a) 0 V and 150 A (b) 40 V and 300 A (a) 60 V and 80 A (a) 400Aand100V (b) 200Aand200V
( ) 40 V and
(c) d 150 A (d) 808 V and
d 300 A (b) 120 V and d 160
6 A ( ) 400Aand50V
(c) A d V (d) 200Aand50V
A d V
((c)) 60 V and 4
40 A
(d) 120 V and 40 A

GATE2012SameQinGATE2012(PI) GATE 2007(PI)
( ) GATE1992
In a DC arc welding operation, the voltagearc
The
Th DC power source for f arc welding
ldi has
h the
th
A low carbon steel plate is to be welded by the manual
length characteristic was obtained as Varc = 20 + 5L characteristic 33V + I = 240,
4 where V = Voltage
g and metal arc welding process using a linear V I
where the arc length L was varied between 5 mm I = Current in amp. For maximum arc power at characteristic DC Power source. The following data are
and 7 mm.
mm Here Varc denotes the arc voltage in Volts.
Volts the electrode,
electrode voltage should be set at available
il bl :
The arc current was varied from 400 A to 500 A. ((a)) 20 V ((b)) 4
40 V ((c)) 60 V ((d)) 80 V OCV of Power source = 62 V
A
Assumingi li
linear power source characteristic,
h i i the h
Short circuit current = 130 A
open circuit voltage and the short circuit current for
the welding operation are A length,
Arc l h L = 4 mm
(a) 45 V,
V 450 A (b) 75 V,
V 750 A p
Traverse speed of weldingg = 155 cm/s
/
(c) 95 V, 950 A (d) 150 V, 1500 A 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
DutyCycle
y The percentage of time in a 5 min period that a
IFS2011
welding machine can be used at its rated output What is the maximum output current that can be
without overloading. 2 drawn at 100% duty cycle from a welding power source
I
Requireddutycycle Ta =
Requireddutycycle, T rated at 600A at 60% duty cycle.
cycle
y Time is spent in setting up, metal chipping, cleaning Ia [3Marks]
and inspection.
p
y For manual welding a 60% duty cycle is suggested and Where,T=rateddutycycle
for automatic welding 100% duty cycle.
cycle I=ratedcurrentattherateddutycycle
Io =Maximumcurrentattherateddutycycle
Contd
Electrode ConsumableElectrodes Consumable electrodes are three kinds:

1. NonconsumableElectrodes Provides filler materials. (a) Bare
2. ConsumableElectrodes
C bl El d Same composition.
composition (b) Fluxed
Fl d or lightly
li htl coated
t d
This requires that the electrode be moved toward or ((c)) Coated or extruded / shielded
away from the work to maintain the arc and y For automatic welding, bare electrode is in the form of
NonconsumableElectrodes
satisfactoryy welding
g conditions.
Madeofcarbon,GraphiteorTungsten.
M d f b G hi T continuous wire (coil).
(coil)
CarbonandGraphiteareusedforD.C.
p
Electrodeisnotconsumed,thearclengthremains
constant arcisstableandeasytomaintain
constant,arcisstableandeasytomaintain.

Electrodecoatingcharacteristic GATE1994 Electrodecoatings
1. Provide a protective atmosphere. Theelectrodesusedinarcweldingarecoated. l. Slag Forming Ingredients. asbestos, mica, silica,
2. Stabilize
S bili theh arc. Thiscoatingisnotexpectedto fluorspar titanium dioxide,
fluorspar, dioxide Iron oxide,
oxide magnesium
33. Provide a p
protective slag
g coating
g to accumulate (a) Provideprotectiveatmospheretoweld carbonate, Calcium carbonate and aluminium oxide.
impurities, prevent oxidation, and slow the cooling of (b) Stabilizetheare
the weld metal.
metal (c) Addalloyingelements 2. Arc Stabilizing Ingredients. or ionizing agents:
4. Reduce spatter. (d) Preventselectrodefromcontamination potassium silicate, TiO2 + ZrO2 (Rutile), Mica,
5. Add alloying elements. Calcium oxide,
oxide sodium oxide,
oxide magnesium oxide,
oxide
feldspar (KAI Si3 O8)
6
6. Affect arc penetration
7. Influence the shape of the weld bead.
8. Add additional filler metal.
Contd
3.DeoxidizingIngredients. Cellulose,Calcium y The slag is then easily chipped.

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
4.BindingMaterials
g Sodiumsilicate,potassiumsilicate, filler wire.
asbestos.
5.AlloyingConstituentstoImproveStrengthofWeld
6.TiO2 andpotassiumcompoundsincreasethemelting
rateofthebasemetalforbetterpenetration.
rateofthebasemetalforbetterpenetration
7.Ironpowderprovideshigherdepositionrate.
I d id hi h d ii
Contd Contd
Binders IES2007 IES1997

y AC arc welding used potassium silicate binders. The coating material of an arc welding electrode Assertion (A): The electrodes of ac arc welding are
coated with sodium silicate,, whereas electrodes used
contains
t i which hi h off the
th following?
f ll i ? for dc arc welding are coated with potassium silicate
y DC arc welding used sodium silicate binders.
1. Deoxidising g agent
g binders.
y Potassium has a lower ionization potential as compared Reason (R): Potassium has a lower ionization
2. Arc stabilizing agent potential than sodium.
with
h sodium.
d 3. Slag
Sl forming
f i agent ( ) Both
(a) B h A and d R are individually
i di id ll true and
d R is
i the
h correct
explanation of A
Select the correct answer using g the code g
given below:
(b) Both
i di id ll true
t b t R is
but i nott the
th
(a) 1, 2 and 3 (b) 1 and 2 only correct explanation of A
( ) 2 and
(c) d 3 only
l (d) 1 andd 3 only
l (c) A is true but R is false

IES2002 WeldingFlux
LowHydrogenElectrode
Low Hydrogen Electrode
MatchListIwithListIIandselectthecorrectanswer: Availableinthreeforms
ListI(Ingredients) ListII(Welding y The basic coatings contain large amount of
functions)
y Granular calcium carbonate (limestone) and calcium
A Silica
A. Sili 1. A stabilizer
Arc t bili y Electrodewirecoating fluoride (fluorspar) and produce low hydrogen.
hydrogen
B. Potassium oxalate 2. Deoxidizer y Electrodecore y But it can absorb moisture therefore coated low
C. Ferrosilicon 3. Fluxingagent hydrogen electrodes are backed before use to a
D. Cellulose 4.
4 Gasformingmaterial
g temperature
p of 200oC to 33000C and stored in an
Codes:A B C D A B C D oven at 110 C to 150oC
o
(a) 3 4 2 1 (b) 2 1 3 4 y Other types of electrode release large amount of

(c) 3 1 2 4 (d) 2 4 3 1 hydrogen, which can dissolve in the weld metal
andd lead
l d to embrittlement
bi l or cracking.
ki
W ldi P iti
WeldingPositions ldi
WeldingCurrent
IFS2011 y Weldingcurrentdependsupon:thethicknessofthe
Whatismeantbylow hydrogenelectrode?
Whatismeantbylowhydrogenelectrode? weldedmetal,typeofjoint,weldingspeed,positionof
weldedmetal typeofjoint weldingspeed positionof
[2marks] theweld,thethicknessandtypeofthecoatingonthe
electrodeanditsworkinglength.
l d di ki l h
Fig.Thepositionofelectrodeforhorizontalwelding y Weldingcurrent,I=k.d,amperes;disdia.(mm)
g , , p ; ( )
Fig.Positioningofelectrodeforweldinginverticallyupwardposition
WeldingVoltage ArcLength g arc results in

A long
y Thearcvoltagedependsonlyuponthearclength y For good welds, a short arc length is necessary, y Large heat loss into atmosphere.
because: y Unstable
U t bl arc.
V=k1 +k2l Volts 1. Heat is concentrated. y Weld p
pool is not p
protected.
2. More stable y Weld has low strength, less ductility, poor fusion and
Wherelisthearclengthinmmandk
Wh li h l hi dk1 andk
dk2 are 3 More protective atmosphere.
3. atmosphere excessive spatter.
spatter
constants,
k1 =10to12;andk2 =2to3
TheminimumArcvoltageisgivenby
Vmin =(20+0.04l)Volt
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) GATE2008 GATE2006

During
D i a steady
t d gas metal t l arc welding
ldi with
ith direct
di t
current electrode positive polarity, the welding current, In arc welding of a butt joint, the welding speed is In an arc welding process, the voltage and current
voltage
lt andd weld
ld speed d are 150 A,
A 30 V and d 6 m/min,
/ i to be selected such that highest cooling rate is are 25 V and 300 A respectively.
respectively The arc heat
respectively. A metallic wire electrode of diameter 1.2 achieved. Melting efficiency and heat transfer transfer efficiency is 0.85 and welding speed is 8
mm is i being
b i f d att a constant
fed t t ratet off 12 m/min.
/ i The Th efficiency
ffi i are 0.5 and
d 0.7, respectively.
i l TheTh area off mm/sec./ Th net heat
The h i
input (i J/mm)
(in J/ ) is
i
density, specific heat and melting temperature of the the weld cross section is 5 mm2 and the unit ((a)) 64 4
wire
i electrode
l t d are 7000 kg/m k / 3, 500 J/kg
J/k oC and d 1530oC,
C energy required to melt the metal is 10 J/mm3. If
respectively. Assume the ambient temperature to be 30oC (b) 797
the welding gp
power is 2 kW,, the welding g speed
p in
andd neglect
l the
h latent
l h
heat off melting.
li F h consider
Further, id ( ) 1103
(c)
mm/s is closest to
that twothird of the total electrical power is available for ((d)) 797
79700
melting
l i off the
h wirei electrode.
l d TheTh melting
l i efficiency
ffi i (i
(in (a) 4 (b) 14 (c) 24 (d) 34
percentage) of the wire electrode is
(a) 39.58 (b) 45.25 (c) 49.38 (d) 54.98
Example ArcblowinDCarcwelding
GATE2009(PI)
GATE2009 (PI)
Calculate the melting efficiency in the case of
A t
Autogenous gas tungsten
t t arc welding
ldi off a steel
t l arcwelding
ldi off steel
t l with
ith a potential
t ti l off 20 V andd
plate is carried out with welding current of 500 A,
A a current of 200 A. The travel speed
p is 5 mm/s/
and .the crosssectional area of the joint is 20
g of 20 V, and weld speed
voltage p of 20 mm/sec.
mm2. Heat required to melt steel may be taken
Consider the heat transfer efficiency from the arc as 10 J/mm3 and the heat transfer efficiency as
to the weld pool as 90%. The heat input per unit 0.85.
length (in KJ/mm) is
(a) 0.25 (b) 0.35 (c) 0.45 (d) 0.55

Effectofarcblow The effects of arc blow can be minimized with D.C.
y Arc
A blow
bl occurs during
d i the
th welding
ldi off magnetic
ti welding
ldi byb
materials with DC. y Low heat penetration.
y Shortening
g the arc.
y The effect of arc blow is maximum when welding y Excessive
E i weld
ld spatter.
y Reduce current
corners where magnetic field concentration is y Pinch effect in welding
g is the result of electromagnetic
g
maximum. y Reducing
R d i weld ld speed.
d
forces
y The effect is p
particularlyy noticeable when welding
g with y Balance magnetic
g field byy p
placing
g one g
ground lead at
y Weld spatter occurs due to
bare electrodes or when using currents below or above each end of the work piece.
High welding current
y Again the problem of arc blow gets magnified when y Wrapping the electrode cable a few turns around the
welding highly magnetic materials such as Ni alloys, Too small an electrode arc
work piece.
because of the strong magnetic fields set up by these
metals.
y Cause:
C U b l
Unbalanced d magneticti forces.
f
Contd Contd
IES2001 IES2001 ISRO2006

Arcblowismorecommonin Pincheffectinweldingistheresultof Too high welding current in arc welding would result in
(a) A.C.welding (a) Expansionofgasesinthearc (a) Excessive spatter,
spatter under cutting along edges,
edges irregular
deposits, wasted electrodes
(b) D.C.weldingwithstraightpolarity (b) Electromagneticforces
(b) Excessive piling up of weld metal, poor penetration,
(c) D.C.weldingwithbareelectrodes (c) Electricforce
wasted electrodes
(d) A.C.weldingwithbareelectrodes (d) Surfacetensionofthemoltenmetal
(c) Too small bead, weak weld and wasted electrodes
(d) Excessive
E i piling
ili up off weldld metal,l overlapping
l i
without penetration of edges, wasted electrodes
Gasshields y Helium, most expensive, has a better thermal CarbonArcwelding

y An inert gas is blown into the weld zone to drive away conductivity, is useful for thicker sheets, copper and y Arc is produced between a carbon electrode and the
other atmospheric gases. aluminium welding, higher deposition rate. work.
y Gases are argon, helium, nitrogen, carbon dioxide and y The arc in carbon dioxide shielding gas is unstable, y Shielding is not used.
a mixture of the above gases. l t expensive,
least i deoxidizers
d idi needed.
d d
y No pressure
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
y With or without filler metal
good
d for
f welding
ldi thin
thi sheets.
h t very well.
well
y May be used in "twin arc method", that is, between
two carbon
b (graphite)
( hi ) electrodes.
l d
IES2010 TungstenInertGaswelding(TIG) y Very clean welds.
Assertion (A): Straight polarity is always
y Arc is established between a nonconsumable y All metals and alloys can be welded. (Al, Mg also)
recommended for Carbonelectrode welding.
tungsten electrode and the workpiece.
workpiece
Reason (R): Carbon arc is stable in straight polarity. y Straight polarity is used.
y Tungsten is alloyed with thorium or zirconium for
(a) Both A and R are individually true and R is the
better currentcarrying and electronemission y Weld voltage 20 to 40 V and weld current 125 A for
characteristics.
(b) Bothh A and d R are individually
d d ll true but
b R is NOT the
h RPDC to 1000 A for SPDC.
SPDC
y Arc length is constant, arc is stable and easy to
correct explanation
p of A
maintain.
maintain y Shielded Gas: Argon
y With or without filler.
(d) A is
i false
f l but
b t R is
i true
t y Torch is water or air cooled.
cooled
Contd
GATE2011 IES2010
Whichoneamongthefollowingweldingprocesses In an inert gas welding process,
process the commonly used
usednon consumableelectrode? gas is
(a)Gasmetalarcwelding (a) Hydrogen
(b)S b
(b)Submergedarcwelding
d ldi (b) Oxygen
( )
(c)Gastungstenarcwelding
g g (c) Helium or Argon
(d)Fluxcoatedarcwelding (d) Krypton
Fig.TIG
GATE2002 IES1994
ISRO2009 Whichofthefollowingarcweldingprocessesdoes Whichoneofthefollowingweldingprocesses
Following gases are used in tungsten inert notuseconsumableelectrodes? usesnon consumableelectrodes?
bl l t d ?
gas welding (a) GMAW ((a)) TIGweldingg
(a) CO2 and H2 (b) GTAW (b) MIGwelding
(b) Argon
A and
d neon (c) SubmergedArcWelding ( ) Manualarcwelding
(c) M l ldi
(c) Argon and helium (d) Noneofthese ((d)) Submergedarcwelding.
g g
(d) Helium and neon

IES2000 GasMetalArcWelding(GMAW)orMIG
Whichoneofthefollowingstatementsiscorrect? y A consumable electrode in a gas shield.
y Fast and economical.
(a) Nofluxisusedingasweldingofmildsteel y Arc
A isi between
b workpiece
k i and
d an automatically
i ll fed
f d
barewire electrode. y A reversepolarity dc arc is generally used because
(b) Boraxisthecommonlyusedfluxcoatingon off its
i deep
d penetration,
i spray transfer,
f andd ability
bili
weldingelectrodes y Argon, helium, and mixtures of the two can be used.
to produce smooth welds with good profile.
( ) Laserbeamweldingemploysavacuumchamber
(c) L b ldi l h b y Any metal can be welded but are used primarily with
andthusavoidsuseofashieldingmethod the nonferrous metals.
(d) ACcanbeusedforGTAWprocess y When welding steel, some O2 or CO2 is usually added
to improve
p the arc stabilityy and reduce weld spatter.
p
Contd
IES2007 IES1997
InMIGwelding,themetalistransferredintothe Considerthefollowingstatements:
f
formofwhichoneofthefollowing?
f hi h fth f ll i ? MIG ldi
MIGweldingprocessuses

((a)) Afinesprayofmetal
p y 1.Consumableelectrode2. nonconsumableelectrode
(b) Moltendrops 3.D.C.powersupply 4.A.C.powersupply
( ) Weldpool
(c) W ld l Ofthesestatements
((d)) Molecules (a) 2and4arecorrect
(b) 2and3arecorrect
(c) 1and4arecorrect
(d) 1and3arecorrect
Fig.MIG
IES2010 IES 2012 SubmergedArcwelding(SAW)

Assertion(A):Inertgasandbareelectrodeinstead Statement(I):DCwithreversepolarityisusedinMIG
St t t(I) DC ith l it i di MIG
offluxcoatedelectrodeisusedinthecaseof welding y A thick layer of granular flux is deposited just ahead of
automaticTIGandMIGweldingprocesses.
i TIG dMIG ldi Statement(II):UseofDCwithreversepolarityenables
a bare wire consumable electrode, and an arc is
( ) p p y
Reason(R):Betterprotectionisprovidedbyacloud deeperpenetrationandacleanSurface
ofinertgasthanthecovercreatedbytheflux. (a) Both Statement (I) and Statement (II) are maintained beneath the blanket of flux with only a few
individuallyy true and Statement ((II)) is the correct
( ) Both
(a) B th A and d R are individually
i di id ll true
t and
d R is
i the
th small
ll flames
fl b i visible.
being i ibl
explanation of Statement (I)
(b) Both Statement (I) and Statement (II) are y A portion
ti off the
th flux
fl melts.
lt Molten
M lt fl
flux and
d flux
fl
(b) Both A and R are individually true but R is NOT the individually true but Statement (II) is not the correct
correct explanation of A explanation of Statement (I) provides thermal insulation,
insulation slows cooling rate and
(c) A is true but R is false (c) Statement (I) is true but Statement (II) is false produce soft,, ductile welds.
p
(d) A is false but R is true ( ) Statement (I)
( ) is true
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
y Deeppenetration,
steels,
t l t l
tool steels,
t l aluminum,
l i magnesium,
i
y Highcleanliness(duetothefluxaction).
titanium, lead, or zinc.
zinc
Advantages Limitations IES2011

The welding process in which bare wire is used as
y Wireelectrodesareinexpensive. y Extensive flux handling, electrode,, g
granular flux is used and the p process is
y Noweldspatter. y Contamination of the flux by moisture.
characterized by its high speed welding, is known as:
(a) Shielded arc welding
y Nearly100%depositionefficiency. y Largegrainsize structures. (b) Plasma arc welding
y Lesserelectrodeconsumption. y Welding is restricted to the horizontal position. (c) Submerged arc welding
(d) Gas metal arc welding
y Chemical control is important
IES2006 IES2005 IES2008

Inwhichofthefollowingweldingprocesses,flux Whichofthefollowingarethemajor Assertion (A): Submerged arc welding is not
characteristicsofsubmergedarcwelding? recommended for high g carbon steels,, tool steels,,
i
isusedintheformofgranules?
di th f f l ? aluminium, magnesium etc.
((a)) ACarcweldingg 1. Highweldingspeeds. Reason ((R): ) This is because of unavailability y of
2. Highdepositionrates. suitable fluxes, reactivity at high temperatures and
(b) Submergedarcwelding low sublimation temperatures.
3. Lowpenetration.
o pe et at o .
( ) Argonarcwelding
(c) A ldi ( ) Both
(a) B h A and d R are true and
d R is
i the
h correct explanation
l i
4. Lowcleanliness. of A
((d)) DCarcwelding
g
S l tth
Selectthecorrectanswerusingthecodegivenbelow:
t i th d i b l (b) Both
B th A and d R are true
t b t R is
but i NOT theth correctt
(a) 2and3 (b) 1,2and3 explanation of A
(c) 3and4 (d) 1and2 (d) A is false but R is true

GATE1999 AtomicHydrogenwelding(AHW)
y Temperature of about 3700oC.
C
For butt welding 40 mm thick steel plates, when y An a.c. arc is formed between two tungsten electrodes
the expected quantity of such jobs is 5000 per along which streams of hydrogen are fed to the y Hydrogen acts as shielding also.
also
month over a period of 10 year, choose the best welding zone. The molecules of hydrogen are
suitable
i bl welding
ldi process out off the
h following
f ll i dissociated by the high heat of the arc in the gap y Used for very thin sheets or small diameter wires.
wires
between the electrodes. The formation of atomic
available alternatives. hydrogen proceeds with the absorption of heat: y Lower thermal efficiency than Arc welding.
welding
(a) Submerged arc welding H2 = 2H 421.2 k J / mol
(b) Oxyacetylene
Oxy acetylene welding y Ceramics may be arc welded.
y This
Thi atomic i hydrogen
h d recombines
bi to form
f molecular
l l
(c) Electron beam welding hydrogen outside the arc, particularly on the relatively y AC used.
(d) MIG welding 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.
Contd
IES2005 ResistanceWelding
Principle
Inatomichydrogenwelding,hydrogenactsas
y Both heat and pressure are used.
used
(a) Aheatingagent ResistanceWelding
R i t W ldi y Heat is generated by the electrical resistance of the
(b) Oneofthegasestogeneratetheflame
workk pieces
i andd the
h interface
i f b
between them.
h
(c) Aneffectiveshieldinggasprotectingtheweld
y Pressure is supplied
pp externallyy and is varied
(d) Alubricanttoincreasetheflowcharacteristicsof throughout the weld cycle.
weldmetal
y Due to pressure,
pressure a lower temperature needed than
oxyfuel or arc welding.
BySKMondal Contd
y Overall resistance very low.

y They are not officially classified as solid state welding
solidstate
byy the American Welding
g Society.
y y Very highcurrent (up to 100,000 A)
y Very rapid and economical. y Very lowvoltage (0.5 to 10 V) is used.
y Extremely well suited to automated manufacturing.
y No filler metal, no flux, no shielding gases.
Fig. The desired temperature Fig. Typical current and

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

1. High initial cost. y The resistance welding processes are among the 1. Resistance spot welding
2. Limitations to the type of joints (mostly lap joints).

most common technique for high volume 2. Resistance seam welding
joining.
joining
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

Electric sta ce We
Resistance d g
Welding
y The process description given so far is called resistance
spot welding (RSW) or simply spot welding.
welding Joules
l law
l applicable
l bl
y This is essentially done to join two sheetmetal jobs in 2
Q = I Rt, Joules
a lap joint, forming a small nugget at the interface of
the two plates.
p

Two
T metallic lli sheets,
h eachh 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
Inresistancewelding,heatisgeneratedduetothe Themaximumheatinresistanceweldingisatthe and welding time of 10 millisecond. A spherical fusion zone extending
resistancebetween
i t b t (a) Tipofthepositiveelectrode up tot the
th full
f ll thickness
thi k off each
metallic sheets are given as:
h sheet
h t isi formed.
f d The
Th properties
ti off the
th
((a)) Electrodeandworkpiece
p (b) Tipofthenegativeelectrode ambient temperature = 293 K
melting temperature = 1793 K
(b) Asperitiesbetweentouchingplates (c) Topsurfaceoftheplateatthetimeofelectric latent heat of fusion = 300 kJ/kg
density = 7000 kg/m3
( ) Twodissimilarmetalsbeingincontact
(c) T di i il l b i i contactwiththeelectrode
i h h l d specific heat = 800 J/kg K
((d)) Interatomicforces ((d)) InterfacebetweenthetwoplatesbeingJoined
p gJ 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
GATE2009(PI)LinkedS1 GATE2009(PI)LinkedS2 GATE2005

Resistance
R i spot welding
ldi off two steell sheets
h is
i carried
i d out in
i Resistance
R i spot welding
ldi off two steell sheets
h is
i carried
i d out in
i
lap joint configuration by using a welding current of 3 kA and lap joint configuration by using a welding current of 3 kA and Spot welding of two 1 mm thick sheets of steel
a weldld time off 0.2 S. A molten
l weld
ld nugget off volume
l 20 mm3 a weldld time off 0.2 S. A molten
l weld
ld nugget off volume
l 20 mm3 (density = 8000 kg/m3) is carried out successfully
is obtained. The effective contact resistance is 200 is obtained. The effective contact resistance is 200 by passing a certain amount of current for 0.1
(microohms). The material properties of steel are given as: (microohms). The material properties of steel are given as: secondd through
h h the
h electrodes.
l d TheTh resultant
l weld
ld
(i) latent heat of melting: 1400 kJ/kg, (ii) density: 8000 (i) latent heat of melting: 1400 kJ/kg, (ii) density: 8000 nugget formed is 5 mm in diameter and 1.5 mm
kg/m3, (iii) melting temperature: 1520oC, (iv) specific heat: kg/m3, (iii) melting temperature: 1520oC, (iv) specific heat: thick. If the latent heat of fusion of steel is 1400
0.55 kJ/kggoC. The ambient temperature
p is 20oC. 0.55 kJ/kggoC. The ambient temperature
p is 20oC. kJ/kg
J/ g and the effective resistance in the welding g
Heat (in Joules) used for producing weld nugget will be Heat (in Joules) dissipated to the base metal will be operation in 200 , the current passing through the
(assuming 100% heat transfer efficiency) (neglecting all other heat losses) electrodes is approximately
(a) 324 (b) 334 (c) 344 (d) 354 (a) 10 (b) 16 (c) 22 (d) 32 (a) 1480A (b) 3300 A
(c) 4060 A (d) 9400 A
GATE2001 GATE2004 GATE1992

Resistance spot welding is performed on two Two 1 mm thick steel sheets are to be spot welded For resistance spot welding of 1.5 mm thick steel
plates of 1.5
1 5 mm thickness with 6 mm diameter at a current of 5000 A. A Assuming effective sheets the current required is of the order of
sheets,
electrode, using 15000 A current for a time resistance to be 200 microohms and current flow (a) 10 A
d
duration
i off 0.25 seconds.
d Assuming
A i the
h interface
i f time
i off 0.2 second,
d heat
h generated
d during
d i the
h (b) 100 A
resistance to be 0.0001 , the heat generated to process will be
form the weld is (c) 1000 A
(a) 0.2 Joule (b) 1 Joule
(a) 5625 W
Wsec
sec (b) 8437 W
Wsec
sec (d) 10,000 A
(c) 5 Joule (d) 1000 Joules
(c) 22500 Wsec (d) 33750 Wsec

GATE2010 IAS2003 IES2007Conventionall
Two steel sheets of thickness one mm are welded
Two pipes of inner diameter 100 mm and outer Assertion (A): Spot welding is adopted to weld two by resistance projection welding technique. A
diameter 110 mm each joined by flash butt overlapped
pp metal p pieces between two electrode
points. currentt off 30,000 A for
f 0005 second d is
i made
d tot
welding using 30 V power supply. At the interface, Reason ((R):) In this p process when current is switched flow. The effective resistance of joint can be taken
1 mm off material
i l melts
l from
f eachh pipe
i which
hi h has
h on, the lapped pieces of metal are heated in a as 100 micro ohms.
h The
h joint can be
b considered
d d as
a resistance of 42.4 . If the unit melt energy is restricted area. a cylinder
y of diameter 5 mm and height g 155 mm.
64.4 MJm3, then time required for welding in ( ) Both
(a) B h A and d R are individually
i di id ll true and
d R is
i the
h correct The density of steel is 000786 gm/mm3. The heat
explanation of A
seconds is needed for welding steel is 10 J/mm3. Calculate the
(b) Both
i di id ll true
t b t R is
but i nott the
th
(a) 1 (b) 5 (c) 10 (d) 20 correct explanation of A efficiency of welding. [20]
GATE 2008(PI) Resistanceseamwelding y Welding current is a bit higher than spot welding, to
Aluminum strips of 2 mm thickness are joined together compensatet short
h t circuit
i it off the
th adjacent
dj t weld.
ld
y Weld is made between overlapping sheets of metal. y In other p
process a continuous seam is p produced byy
by resistance spot welding process by applying an
The seam is a series of overlapping spot welds. passing a continuous current through the rotating
electric current of 6000 A for 0.15 sec. The heat required
electrodes with a speed of 1.5
1 5 m/min for thin sheet.
sheet
for melting aluminum is 2.9 J/mm3. The diameter and y The basic equipment is the same as for spot welding.
the thickness of weld nugget are found to be 5 mm and
except that the electrodes are now in the form of
2.5 mm, respectively. Assuming the electrical resistance
rotating
t ti disks.
di k
to be 75 (micro ohms), the percentage of total
energy utilized in forming the weld nugget is y Timed
Ti d pulses
l off currentt pass to
t form
f th overlapping
the l i
((a)) 28 ((b)) 35 ((c)) 655 ((d)) 772 welds.
welds
Contd Contd
Projectionwelding
GATE
GATE 2012(PI)
2012 (PI) y Limitations of spot welding.
In resistance seam welding, the electrode is in the 1. Electrode
El d condition
di i must be b maintained
i i d
form of a continually, and only one spot weld at a time.
( ) cylinder
(a) li d 2. For additional strength multiple welds needed.
((b)) flat p
plate y Projection welding (RPW) overcomes above
(c) coil of wire limitations.
(d) circular
i l discdi
Fig.Resistanceseamwelding
y Dimples are embossed on work pieces at the weld
y Projections
j are p
pressformed in anyy shape.
p
Upsetwelding
locations and then placed between largearealarge area
electrodes, and pressure and current applied like spot y Multiple
p welds at a time. y Made butt joint compared to lap joint.
welding.
ldi
y Current flows throughg the dimples
p and heats them y No indentation mark on the surface. y Pieces are held tightly and current is applied.
and pressure causes the dimples to flatten and form a y Due to pressure joints get slightly upset and hence its
y Bolts and nuts can be attached to other metal parts.
weld.
weld
name.
Fig.Principleof y Useful for joining rods or similar pieces.

p j
projectionwelding,
g
(a)priortoapplicationof
currentandpressure
(b)andafterformationof
welds
Contd Contd
y This is the process used for making electric resistance FlashWelding

welded
ld d (ERW) pipesi starting
i from
f a metall plate
l off suitable
i bl
thickness. y It is similar to upset welding except the arc rather than
y The plate is first formed into the shape of the pipe with the resistance heating.
helpp of the three roll set as shown in Fig.
g above. The ends
of the plate would then be forming the butt joint. y One pieces is clamped with cam controlled movable
y The two rotating copper disc electrodes are made to
contact the two ends of the plate through which the platen and other with is fixed platen.
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 beb perfectly
f l
parallel. Any high spots if present on the ends would get
melted first before the two ends are completely joined.
Contd Contd
y Two pieces are brought together and the power supply is PercussionWelding
switched on.
on Momentarily the two pieces are separated
to create the arc to melt the ends of the two pieces. y Similar to flash welding except arc power by a rapid
Th
Then again
i theh pieces
i are brought
b h together
h and d the
h
discharge of stored electrical energy.
power switched off while the two ends are fused under
force. Most of the metal melted would flash out y The arc duration is only 1 to 10 ms, heat is intense and
through
g the jjoint and forms like a fin around the jjoint. highly concentrated.
concentrated
y Faster than upset welding.
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

damage is a major concern.
Thermit Welding y Temp.
p 2750C p p g
produced in 30 seconds, superheating
y Heating and coalescence is by superheated molten the molten iron which provide both heat and filler
g
OtherWelding metal obtained from a chemical reaction between a
metal oxide and a metallic reducing agent.
metal.
y Runners and risers are provided like casting.

Technique y Used mixture one part aluminum and three parts iron y Copper, brass, and bronze can be welded using a
oxide
id and
d ignited
i it d by
b a magnesium
i f
fuse. (
(1150C).
C) 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 y A 65mm deep

p layer
y of molten slag,
g pprotect and
Considerthefollowingprocesses: y Very effective for welding thick sections. cleanse the molten metal.
1. Gaswelding
G ldi
2. Thermit welding y Heat is derived from the passage of electrical current y Watercooled copper molding plates confined the
3. Arcwelding through a liquid slag and temp. 1760C liquid and moved upward.
4 Resistancewelding
4.
y Multiple electrodes are used to provide an adequate
Thecorrectsequenceoftheseprocessesinincreasing
orderoftheirweldingtemperaturesis
d fth i ldi t t i supply
l off filler.
fill
(a) 1,3,4,2 (b) 1,2,3,4
(c) 4,3,1,2 (d)4,1,3,2
Contd Contd
y Applications: Shipbuilding, machine manufacture, IAS2003

heavy pressure vessels, and the joining of large Whichoneofthefollowingisnotanelectric
castings and forgings. resistancemethodofwelding?
i t th d f ldi ?
((a)) Electroslagwelding
g g
y Slow cooling produces a coarse grain structure. (b) Percussionwelding
y Large HAZ. ( ) Seamwelding
(c) S ldi
((d)) Flashwelding
g

IAS2000 ElectronBeamWelding
Considerthefollowingweldingprocesses: y A beam of electrons is magnetically focused on the
1. TIGwelding 2. Submergedarcwelding
work piece in a vacuum chamber.
3. Electro
Electroslagwelding4.
slagwelding4. Thermit welding
Whichoftheseweldingprocessesareusedforwelding y Heat of fusion is produced by electrons decelerate.
thickpiecesofmetals?
hi k i f l ?
y Allows precise beam control and deep weld
((a)) 1,2and3
, 3 ((b)) 1,2and4
, 4
penetration.
(c) 1,3and4 (d) 2,3and4
y No shield
h ld gas (vacuum
( chamber
h b used)
d)
IES2004 IES2002 IES1993

Assertion (A): In electron beam welding process, Inwhichoneofthefollowingweldingtechniques Electronbeamweldingcanbecarriedoutin
vacuum is an essential process parameter iisvacuumenvironmentrequired?
i t i d? (a) Openair
Reason (R): Vacuum provides a highly efficient ((a)) Ultrasonicwelding
g
shield
hi ld on weld ld zone (b) Ashieldinggasenvironment
(b) Laserbeamwelding (c) Apressurizedinertgaschamber
(a) Both A and R are individually true and R is the
correct explanation of A ( ) Plasmaarcwelding
(c) Pl ldi (d) Vacuum
(b) Both A and R are individually true but R is not the ((d)) Electronbeamweldingg
IAS2004 LaserBeamWelding y Very

y thin HAZ and little thermal distortion.
Whichoneofthefollowingweldingprocesses y Used a focused laser beam provides power intensities y Filler metal and inert gas shield may or may not used.
consistsofsmallerHeatAffectedZone(HAZ)?
i t f ll H tAff t dZ (HAZ)?
in excess of 10kW/cm2 y Deep penetration.
((a)) Arcwelding
g ((b)) Electronbeamwelding
g
(c) MIGwelding (d) Thermit welding y The highintensity beam produces a very thin column y No vacuum needed.
of vaporized metal with a surrounding liquid pool.
y No direct contact needed.
y Depthtowidth ratio greater than 4: 1.
For-2013 (IES, GATE & PSUs) Page 55 Contd Contd

y Heat input
p is veryy low, often in the range
g 0.1 to 10 J. IES2007 IES2006
Considerthefollowingstatementsinrespectofthe Whichoneofthefollowingweldingprocesses
y Adopted by the electronics industry.
laserbeamwelding: consistsofminimumheataffectedzone(HAZ)?
i t f i i h t ff t d (HAZ)?
y Possible to weld wires without removing the 1. Itcanbeusedforweldinganymetalortheir
combinationsbecauseofveryhightemperatureofthe ((a)) ShieldedMetalArcWelding(SMAW)
g( )
polyurethane insulation. focalpoints. (b) LaserBeamWelding(LBW)
2 Heataffectedzoneisverylargebecauseofquick
2. ( ) UltrasonicWelding(USW)
(c) Ul i W ldi (USW)
heating.
((d)) MetalInertGasWelding(MIG)
g( )
3. Highvacuumisrequiredtocarrytheprocess.
Hi h i i dt th
Whichofthestatementsgivenaboveis/arecorrect?
(a) 1and2only (b) 2and3only
((c)) 1onlyy ((d)) 1,2and33
Contd
GATE2012(PI) IAS2007 IAS1999

Which of the following welding processes results in Consider the following welding processes: Match List I (Shielding method) with List II (Welding
process)) and select the correct answer using
p g the codes
th smallest
the ll t heat
h t affected
ff t d zone?? 1. Arc welding 2. MIG welding given below the lists:
((a)) Shielded metal arc welding
g List I List II
3. Laser beam welding 4. Submerged arc
A. Fluxl coating 1. Gas metall arc welding
ld
(b) Gas welding welding B. Flux granules 2. Submerged arc welding
( ) Laser
(c) L b
beam welding
ldi S l
Select the
h correct sequence in i increasing
i i order
d off Heat
H C CO2
C. 3. Shi ld d metall arc welding
Shielded ldi
affected zone (HAZ) using the code D. Vacuum 4. Laser beam welding
((d)) Thermit weldingg
5. El t
Electron b
beam welding
ldi
given below: Codes:A B C D A B C D
(a) 1 2 3 4 (b) 1 4 2 3 (a) 1 2 5 3 (b) 1 4 2 5
(c) 3 5 1 4 (d) 3 2 1 5
(c) 3 2 4 1 (d) 4 3 2 1
ForgeWelding FrictionWelding y Machine is similar to a centre lathe.
y Blacksmith do this. y Heat is obtained by the friction between the ends of 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
y Borax is used as a flux. the two parts to be joined. hardness of the metals being joined.
y One part is rotated at a high speed and other part is y Pressure 40 MPa for lowcarbon steels to as high as 450
y The ends to be joined were then overlapped on the
MPa for alloy steels.
anvil and hammered to the degree necessary to axially aligned and pressed tightly against it.
produce an acceptable weld. y Friction raises the temperature of both the ends. Then
y Quality
l d
depends
d on the
h skill
k ll off the
h worker
k and
d not rotation
t ti i stopped
is t d abruptly
b tl and
d the
th pressure is
i
used by industry.
industry increased to join.
join
y Very efficient.
efficient
GATE2007
y Wide variety of metals or combinations of metals can Whichoneofthefollowingisasolidstatejoining
be joined
b d suchh as aluminium
l to steel.
l process?
y Grain size is refined (a) Gastungstenarcwelding
y Strength is same as base metal. (b) Resistancespotwelding
y Only round bars or tubes of the same size, or (c) Frictionwelding
connecting g bars or tubes to flat surfaces can jjoin. (d) submergedarcwelding
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)
Two steel bars, each of diameter 10 mm, are coaxially
IFS2011 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
frictionwelding mentioningatleasttwomethods
frictionwelding,mentioningatleasttwomethods Surfaces are held together
g under light
g normal
MP and
MPa d at a rotational
i l speed
d off 4000 rpm. The
Th pressure.
coefficient of friction between the mating faces of the ofcontrol.
Temp.
Temp do not exceed onehalf
one half of the melting point.
point
rotating
g bars is 0.50.
5 The torque
q is assumed to act at the [5marks] 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 ExplosionWelding

Weld
W ld thin
hi materialssheet,
i l h foil,
f il and
d wireor
i the
h Applications
attaching thin sheets to heavier structural members. y Done at room temperature in air, water or vacuum.
y Joiningthedissimilarmetalsinbimetallics
Maximum thickness 2.5 mm for aluminum and 1.0
y Makingmicrocircuitelectricalcontacts.
g
y Surface contaminants tend to be blown off the surface.
mm for harder metals.
metals
Number of metals and dissimilar metal combinations y Weldingrefractoryorreactivemetals y Typical impact pressures are millions of psi.
andd non metalsl can beb joined
j i d such h as aluminum
l i to
y Bondingultrathinmetal. y Well suited to metals that is prone to brittle joints
ceramics or glass.
Equipment is simple and reliable. when heat welded, such as,
Less surface preparation and less energy is needed.
needed y Aluminum on steel
y Titanium
Ti i on steell
y Typically the detonation velocity should not exceed High velocity explosives, 45727620 m/s.
120%
% off the
th sonic
i velocity
l it ini the
th metal.
t l y TNT
Important factors are, y RDX
y PETN
y Critical
C i i l velocity
l i
y Composition B
y Critical angle
g y Composition C4
y The cladding plate can be supported with tack welded y Datasheet
supports at the edges,
edges or the metal inserts.
inserts y Primacord
Medium velocity explosives, 15244572 m/s
y Ammonium nitrate
y Ammonium perchlorate
y Amatol
y Nitroguonidine
y Dynamites
y diluted PETN
Contd Contd Contd
Advantages,
Advantages Disadvantages,
Disadvantages Typicalapplications:
y Can bond many dissimilar, normally unweldable y The metals must have high enough impact resistance,
and
d ductility
d l (at( least
l 5%)
%) y Verylargeplatescanbecladded.
Verylargeplatescanbecladded
metals
y The lack of heating preserves metal treatment y The cladding plate cannot be too large. y Joinsdissimilarmetals.
Joinsdissimilarmetals
y The process is compact, portable, and easy to contain y Noise and blast can require worker protection, vacuum
chambers,
h b b i d in
buried i sand/water.
d/ t (titaniumtosteel,Altosteel,AltoCuetc )
(titaniumtosteel,Altosteel,AltoCuetc.)
y Inexpensive
y No need for surface preparation y Jointubetotubesheetsoflargeheatexchangers.
Contd Contd Contd
IES2011S1Contd
MatchListIwithListIIandselectthecorrectanswer
GATE1992 usingthecodegivenbelowthelists:
Inanexplosiveweldingprocess,the.. ListI ListII
(maximum/minimum)velocityofimpactisfixed A.Laserbeam
A L b 1.Canbeappliedforweldingorrefractorymetals
C b li df ldi f l
bythevelocityofsoundinthe welding likeniobium,tantalum,molybdenumandtungsten.
(fl /
(flyer/target)platematerial
) l i l B.Electron 2.Asoundandcleanweldedjointiscreateddueto
((a)) Maximum;target
; g beamwelding rubbingoftwopartsagainsteachotherwith
adequatespeedandpressureproducingintenseheat
d d d d h
(b) Minimum;target raisingtemperatureabovemeltingpoint.
( ) Maximum;flyer
(c) M i fl C.Ultrasonic 3.Cleanheatsourcecreatedmuchawayfromjob,a
((d)) Minimum;flyer
; y welding narrowspotisheated,workchamberoperatesina
highvacuum.
D.Friction 4.Cleanheatsourceveryquickheating,verysmall
4 yq g y
welding focalspot,novacuumchamberisrequired.
IES2011FromS1 IES2009 IAS2002
Codes: MatchListIwithListIIandselectthecorrectanswerusingthecodegiven MatchListI,(Welding)withListII(Application)andselectthecorrect
belowtheLists: answerusingthecodesgivenbelowtheLists:
A B C D A B C D List I
ListI List II
ListII Li I
ListI Li II
ListII
(WeldingProcess) (Application) (Welding) (Application)
(a) 4 3 1 2 (b) 2 3 1 4 A. Laserwelding 1. Unitinglargeareasheets
A. Explosive 1. Joiningthicksheets
B. Frictionwelding
i i ldi 2. Repairinglargeparts
i i l
(c) 4 1 3 4 (d) 2 1 3 4 C. Ultrasonicwelding 3. Weldingarodtoaflatsurface B. Ultrasonic 2. Manufactureofheatexchanges
D. Explosivewelding
g 4. Fabricationofnuclearreactor C. Thermit 3. Joiningthinsheetsorwiresof
components similar/dissimilar metals
5. Weldingverythinmaterials D. Projection 4. Joininghydraulicpistonrodsfor
Code: agricultural machinery
(a) A B C D (b) A B C D 5. Joiningrails,pipesandthicksteel
5 4 3 2 1 4 2 5 sections
(c) A B C D (d) A B C D (a) 2 5 1 3 (b) 4 5 1 3
1 3 4 2 5 3 4 1 (c) 2 3 5 1 (d) 4 3 5 1
Autogeneous Welding MicroPlasmaArcWeld(PAW)

IFS
IFS 2009
y Autogeneous welding or fusion of the parent y Similar to GTAW except the plasma caused by the arc
T plates
Two l t off aluminium
l i i and
d stainless
t i l steel
t l are to
t material
t i l in
i an inert
i t gas shield
hi ld without
ith t the
th use
is constricted by a watercooled orifice
be welded back to back to create a single plate of of filler metals.
y Capable of high welding speeds where size permits
thickness equal
q to the sum of the thicknesses of
the two plates. Suggest the suitable process and y Argon is used as the shielding gas.
explain it in brief.
[10 marks]
DiffusionWelding GATE 2008(PI) IAS2001

y It is
i a solid
lid state
t t welding
ldi process which
hi h produces
d
coalescence of the faying surfaces by the application of Which pair among the following solid state welding MatchListI(Weldingprocesses)withListII(Features)and
selectthecorrectanswerusingthecodesgivenbelowtheLists:
pressure and d elevated
l t d temperatures
t t ( b t 50 to
(about t 80%
8 % processes uses heat from an external source?
of absolute melting point of the parent materials) for a ListI ListII
ti
time ranging
i from
f a couplel off minutes
i t tot a few
f hours.
h A
A. Ultrasonicwelding 1
1. Gasheatedtoionizedcondition
P Diffusion welding; Q Friction welding forconductionofelectriccurrent
y Produces high quality bonds with good strength with B. Electronbeamwelding2. Highfrequencyandhigh
little or no distortion. R Ultrasonic
l welding
ld S Forge welding
ld intensityvibrations
b
C. Plasmaarcwelding 3. Concentratedstreamofhigh
y Ca
Can jojoin ve
veryy d
dissimilar
ss a materials.
ate a s. energyelectrons
( ) P and
(a) dR (b) R and
dS 4. Exothermalchemicalreaction
y A solid filler metal may or may not be inserted.
Codes:A B C A B C
y Materials
M t i l welded ld d forf aircraft
i ft and
d rocket
k t industry:
i d t ( ) Q and
(c) dS (d) P and
dS (a) 1 2 4 (b) 4 3 1
Boron, Titanium, Aluminium, Ceramic, Composite, (c) 2 1 4 (d) 2 3 1
G hit Magnesium
Graphite, M i etc.
t
JWM2010
MatchListIwithListIIandselectthecorrectanswer IES 2011 C
IES2011Conventional
ti l
g g
usingthecodegivenbelowthelists:
ListI ListII Discuss the process capabilities and applications of Gas
A Atomic
A.Atomic 11.Twopiecesarebroughttogetherand
Twopiecesarebroughttogetherand M t l Arc
Metal A Welding,
W ldi G tungsten
Gas t t A Welding,
Arc W ldi and
d
hydrogenwelding powersupplyisswitchedon
B.Plasmaarc 2.Nuggetisformedattheinterfaceof
Diffusion Bonding processes.
processes BrazingandSoldering
welding twoplates [15Marks]
C.Spotwelding 3.Gasisionized
D.Flashwelding 4.Inertgasshieldedarcwelding
Code:A
d B C D A B C D
(a) 4 3 2 1 (b) 1 3 2 4
(c) 4 2 3 1 (d) 1 2 3 4
BrazingandSoldering B i h l di i
Brazingprocesshasseveraldistinct
y Brazing is the joining of metals through the use of heat
advantages:
and a filler metal whose melting temperature is above 1 All metals can be joined.
1. joined
450C; but
b below
b l the
h melting
l point off the
h metalsl being
b
joined.
C
Comparisoni with
ith welding
ldi and d the
th brazing
b i process 2. Suited for dissimilar metals.
1. The composition of the brazing alloy is significantly
different from that of the base metal.
metal 3. Qu
Quick
c aand
d eco
economical.
o ca .
2. The strength of the brazing alloy is substantially lower
than that of the base metal.
metal 4. Less defects.
4
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.
Contd
y Corrosion prone y Extremely clean surface needed.

Brazingmetalsaretypicallyalloyssuchas, y Fluxes used are combinations of borax, boric acid,
y Brazingbrass(60%Cu,40%Zn)
B i b (6 %C %Z )
chlorides, fluorides, tetraborates and other wetting
y Manganesebronze
g
y Nickelsilver agents.
y Coppersilicon
C ili
y Silveralloys(with/withoutphosphorous)
y ( / p p )
y Copperphosphorous

yA p p
popular p
composition is 75% borax and 25% boric GATE2005
acid. Thestrengthofabrazedjoint
( ) Decreaseswithincreaseingapbetweenthetwo
(a) D i hi i b h
y Sodium cyanide is used in brazing tungsten to copper. joiningsurfaces
y Base materials not melted. (b) Increaseswithincreaseingapbetweenthetwo
joiningsurfaces
(c) Decreasesuptocertaingapbetweenthetwo
j i i f
joiningsurfacesbeyondwhichitincreases
b d hi hi i
((d)) Increasesuptocertaingapbetweenthetwo
p g p
joiningsurfacesbeyondwhichitdecreases
IES2006 ISRO2010 BrazeWelding

Which is not correct statement about the function of
Whichoneofthefollowingisnotafusionwelding flux in brazing y Capillary action is not required.
process?? (a) To avoid thermal distortion and cracking
((a)) Gaswelding g y Edge preparation needed.
(b) To dissolve surface oxide coatings which have formed
(b) Arcwelding prior to brazing y Can join cast iron.
( ) Brazing
(c) B i ( ) To prevent oxides
(c) d from
f f
forming d
during the
h brazing
b
((d)) Resistancewelding
g 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
Contd
y Done with an oxyacetylene torch. Soldering Effective soldering generally involves six important
steps:
y By definition, soldering is a brazing type of operation
(1) Design of an acceptable solder joint,
where the filler metal has a melting temperature (2) Selection of the correct solder for the job,
below 450C. (3) Selection of the proper type of flux,
(4) Cleaning the surfaces to be joined,
y Strength of the filler metal is low.
(5) Application of flux, solder, and sufficient heat to
y Soldering is used for a neat leakproof joint or a low allow
ll the
h molten
l solder
ld to fill theh joint
j i by b capillary
ill
action and solidify, and
resistance
i t electrical
l t i l joint.
j i t
(6) Removal of the flux residue, if necessary.
y Not suitable for hightemp.
high temp application.
application
Fig.BrazeWelding
ld l
SolderMetals SolderFlux
y Silver solders uses for highertemperature
higher temperature service,
service
y Ammonium chloride or rosin for soldering tin
y Most solders are alloys of lead and tin. Electrical and Electronic purpose.
y Hydrochloric acid and zinc chloride for soldering
y Three commonly used alloys contain 60, 50, and 40%
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
IES1994 IAS1996
DifficultieswithGreyCastIron
Difficulties with Grey Cast Iron MatchList IwithList IIandselectthecorrect MatchListIwithListIIandselectthecorrectanswerusing
answerusingthecodesgivenbelowtheLists:
g g thecodesgivenbelowthelists
g
S ld i and
Soldering d brazing
b i are difficult
diffi lt off grey castt Iron
I d
due ListI ListII
List I(Filler) List II(Joiningprocess)
to surface contamination with graphite having a very low A. Cu,Zn,Agalloy 1. Brazewelding. (Fillerrodmaterial) (Joiningprocess)
B. Cu,Sn,alloy 2. Brazing A. Mildsteel 1. MIGwelding
surface energy.
gy B. Bronze 2. Soldering
C Pb,Sb,alloy
C. Pb Sb alloy 3
3. Soldering
C. Brass 3. Brazing
D.Iron oxideandaluminium powder4. TIGweldingof
aluminium D. Leadandtinalloy 4. Thermit welding
5. B
Brazewelding
ldi
Codes:A B C D A B C D Codes:A B C D A B C D
(a) 2 1 3 (b) 1 2 4 (a) 1 5 3 2 (b) 4 3 2 5
(c) 2 1 3 4 (d) 2 3 4 (c) 4 3 5 2 (d) 1 3 5 4
Weldingdesignanddefect IES2004 IES2003,ISRO2011

Welding Problem Causes MatchListI(Weldingproblems)withListII(Causes)andselect MatchListI(WeldingDefects)withListII(Causes)and
Cracking of weld metal High joint rigidity thecorrectanswerusingthecodesgivenbelowtheLists: selectthecorrectanswerusingthecodesgivenbelowthe
g g
ListI ListII Lists:
Cracking of base metal Excessive stresses
A. Crackingofweldmetal 1. Excessivestresses ListI ListII
Spatter Arc blow B
B. C ki fb t l
Crackingofbasemetal 2. Hi hj i t i idit
Highjointrigidity ( ldi
(WeldingDefects)
f ) (
(Causes) )
Distortion Poor joint selection C. Porosity 3. Failuretoremoveslag A. Spatter 1. Dampelectrodes
Slag inclusion Improper cleaning in multi
multi- p p
frompreviousdeposit
B
B. Di
Distortion
i 2. A bl
Arcblow
pass welding D. Inclusions 4. Oxidation
C. Slaginclusion 3. Impropercleaningin
5. ExcessiveH2,O2,N2,in
Porosity Excessive H2, O2, N2, in the theweldingatmosphere
h ldi h multipasswelding
welding atmosphere or Damp Codes:A B C D A B C D D. Porosity 4. Poorjointselection
electrodes (a) 2 1 5 3 (b) 3 4 2 1 Codes:A B C D A B C D
LamellarTearing inclusionssuchasMn FeandS (c) 2 4 5 3 (d) 3 1 4 2 (a) 4 2 3 1 (b) 4 2 1 3
inthebasemetaland/or (c) 2 4 1 3 (d) 2 4 3 1
residualstress
Cracks HAZ Cracking
HAZCracking
Cracks may be developed due to poor ductility of base
y Cracks may be of micro or macro size and may appear in y Crackinginheataffectedzonemaybecausedby:
metal, high sulphur and carbon contents, high arc travel
the weld metal or base metal or base metal and weld
speeds
p i.e. fast cooling
g rates, too concave or convex weld (i)Hydrogeninweldingatmosphere
metal
t l boundary.
b d
bead and high hydrogen contents in the weld metal.
y Different categories
g of cracks are longitudinal
g cracks, (ii)hotcracking
transverse cracks or radiating/star cracks and cracks in
the weld crater. (iii)lowductility
y Cracks occur when localized stresses exceed the ultimate
(iv)highresidualstresses
t il strength
tensile t th off material.
t i l
y These stresses are developed p due to shrinkage
g duringg ( )
(v)brittlephaseinthemicrostructure
p
solidification of weld metal.
Fig VariousTypesofCracksinWelds
Fig.VariousTypesofCracksinWelds
Hydrogen Induced Cracking

HydrogenInducedCracking Residualstress
y Duetothepresenceofmoisture,grease,rustetc.,
ue to t e p ese ce o o stu e, g ease, ust etc.,
hydrogenmayentertheweldpoolandgetdissolvedin y The residual stresses result from the restrained expansion
and contraction that occur during localized heating and
theweldmetal
theweldmetal.
cooling in the region of weld deposit.
y DuringcoolinghydrogendiffusestotheHAZ.
y The magnitude of residual stresses depends on the weldment
y Crackingmaydevelopduetoresidualstressesassistedby design, support and clamping of the components being
hydrogencoalesence. welded their materials,
welded, materials welding process used,
used part
y Thefactorsthatdeterminetheprobabilityofhydrogen dimensions, welding sequence, post weld treatment, size of
i d d b ittl
inducedembrittlementandcrackingofweldare:
t d ki f ld the deposited weld beads,
beads etc.
etc
( ) y g
(a)Hydrogencontent y Residual stresses should not have a harmful effect on the
strength
h performance
f off weldments,
ld reduces
d f i
fatigue
(b)fracturetoughnessofweldandHAZ strength, May cause distortion. This residual stress may
( )
(c)stresstowhichthejointisexposedasaresultof
hi h h j i i d l f result
l in theh cracking
k off a brittle
b l materiall andd is not
theweldthermalcycle. 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
P i results
l when
h the
h gases are entrapped
d in
i the
h nonmetallic material entrapped in the weld metal as
solidifying weld metal. these mayy not able to float on the surface of the
y These gases are generated from the flux or coating solidifying weld metal.
constituents of the electrode or shielding gases used y During arc welding flux either in the form of granules or
during welding or from absorbed moisture in the coating after melting, reacts with the molten weld metal
coating.
coating removing
i oxides
id and d other
h impurities
i i i in
i the
h form
f off slag
l
y Porosity can also be controlled if excessively high and it floats on the surface of weld metal due to its low
welding currents, faster welding speeds and long arc density.
lengths are avoided flux and coated electrodes are y Slag inclusion can be prevented if proper groove is
properly baked. selected, all the slag from the previously deposited bead
Fig.DifferentFormsofPorosities is removed,
removed too high or too low welding currents and
For-2013 (IES, GATE & PSUs) Page 63 long arcs are avoided.
Lack of Fusion
LackofFusion IncompletePenetration
y Lack
ac o us o iss tthee failure
of fusion a u e to fuse
use toget e eeither
together t e tthee
y Incomplete
I l penetration
i means that
h the
h weld
ld depth
d h isi not
base metal and weld metal or subsequent beads in
upto the desired level or root faces have not reached to
multipass welding because of failure to raise the
melting point in a groove joint.
temperature of base metal or previously deposited weld
l
layer t melting
to lti point
i t during
d i welding.
ldi y If either low currents or larger arc lengths or large root
face or small root gap or too narrow groove angles are
y Lack of fusion can be avoided by y pproperly
p y cleaning
g of
used then it results into poor penetration.
penetration
surfaces to be welded, selecting proper current, proper
welding technique and correct size of electrode.
Fig SlagInclusioninWeldments
Fig.SlagInclusioninWeldments
ImperfectShape,Distortions
p p ,
y Imperfect shape means the variation from the desired shape and IES2011Conventionall
size of the weld bead.
y Enumeratefourdefectscausedduetoresidualstressesin
E f d f dd id l i
y During undercutting a notch is formed either on one side of the
weld bead or both sides in which stresses tend to concentrate and weldedjoints.
it can result in the early failure of the joint. Main reasons for [2Marks]
undercutting are the excessive welding currents, long arc lengths
andd fast
f travell speeds.
d
y Underfilling may be due to low currents, fast travel speeds and Ans.
smallll size
i off electrodes.
l d Overlap
O l may occur due d to lowl currents,
longer arc lengths and slower welding speeds. 1. Distortion
y 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 2. Crackinginthebasemetal
root penetration and sag occur if excessive high currents and slow
travel speeds are used for relatively thinner members. 3. LamellarTearing
y Distortion is caused because of shrinkage occurring due to large
heat input during welding. 4. Reductionoffatiguestrength
IES2004 GATE2003
Consider the following statements: Matchthefollowing
Workmaterial Typeofjoining
yp j g
The magnitude of residual stresses in welding
P.Aluminium 1. SubmergedArcWelding
depends upon
Q.DieSteel 2. Soldering
1. Designofweldment
D i f ld t R.CopperWire 3. Thermit Welding
2. Supportandclampingofcomponents S.Titaniumsheet 4. AtomicHydrogenWelding
3. weldingprocessused 5. GasTungstenArcWelding
4. Amountofmetalmelted/deposited
4 p 6. LaserBeamWelding
7. Brazing
Whichofthestatementsgivenabovearecorrect?
(a)P 2 Q 5 R 1 S 3
(a) 1,2and4
1 2and4 (b)1 2and3
(b)1,2and3 (b)P 6 Q 3 R 4 S 4
(c) 1and3 (d)2and3 (c)P 4 Q 1 R 6 S 2
(d)P 5
(d) Q 4 R 2 S 6

IES2004 IES1992 JWM2010
Assertion (A) : Spatter is one of the welding defects.
defects
Considerthefollowingstatements: Weldspatteroccursduetoanyofthefollowing Reason (R) : In submerged arc welding process,
Th i f h h ff
Thesizeoftheheataffectedzone(HAZ)willincreasewith
d (HAZ) illi ih exceptt there is no spatter of molten metal.
1. Increasedstartingtemperature
g p ((a)) Highweldingcurrent
g g (a) Both A and R are individually true and R is the
2. Increasedweldingspeed (b) Toosmallanelectrode correct explanation of A
3 Increasedthermalconductivityofthebasemetal
3. ( ) Arc
(c) A (b) Bothh A and d R are individually
d d ll true but
b R is not the
h
4. Increaseinbasemetalthickness ((d)) Wrongpolarity
gp y correct explanation
p of A
Whichofthestatementsgivenabovearecorrect? (c) A is true but R is false
(a) 1,2and3 (b) 1and3 (d) A is
i false
f l but
b t R is
i true
t
(c) 1and4 (d) 2and3
IES1998 IES2004 IAS2003

Anarcweldedjointisshownintheabovefigure. Assertion (A): A sound welded joint should not only Toolmaterialnotsuitedtoresistanceweldingis
Th
Thepartlabelled
tl b ll d 'B'inthefigureisknownas
'B'i th fi i k be strong enough but should also exhibits a good
amount of ductility
((a)) Weldpreparation
p p Reason (R): Welding process is used for fabricating ( ) Aluminium oxide
(a) ( )
(b) Stellite
(b) Penetration mild steel components only (c) Highspeedsteel (d) Masonite
( ) Reinforcement
(c) R i f (a) Both A and R are individually true and R is the correct
explanation of A
((d)) Slag
g
(b) Both
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
GATE1996 IES2011 GATE2001

Preheatingbeforeweldingisdoneto Coldcrackinginsteelweldments dependson Two plates of the same metal having equal
( ) Makethesteelsofter
(a) M k h l f 1 Carbonequivalent
1.Carbonequivalent thickness are to be butt welded with electric arc.
arc
((b)) Bumawayoil,grease,etc,fromtheplatesurface
y ,g , , p 2.Heatinput When the plate thickness changes, welding is
3.Effectivethickness achieved
hi d by
b
(c) Preventcoldcracks
3 Hydrogencontentinweldpool
3.Hydrogencontentinweldpool ((a)) Adjusting
j g the current
(d) Preventplatedistortion
P l di i
(a)1,2and3only (b) Adjusting the duration of current
(b)1,2and4only ( ) Changing
(c) Ch i theh electrode
l d size
i
(c)2 3and4only
(c)2,3and4only ((d)) Changing
g g the electrode coating
g
(d)1,2,3and4

IES 2012 IES 2012 IES 2012
Brittle
B i l welds
ld are mainly
i l obtained
b i d due
d to WhichofthefollowingareassociatedwithHeatAffected
Whi h f h f ll i i d i hH Aff d Statement
St t t (I):
(I) Hydrogen
H d induced
i d d cracking
ki occurs in i the
th heat
h t
Zone? effected zone adjacent to fusion zone and classified as solid
((a)) Wrong g electrode,, faultyy p
preheatingg and metal state cracking
hardened by air 1.Coldcracking Statement (II):Hydrogen from burning of flux coating
(b) Faulty welds,
welds faulty sequence and rigid joints 2 Notchtoughness
2.Notchtoughness penetrates martensitic micro cracks preventing healing as
(c) Wrong speed, current improperly adjusted and faulty 3.Hydrogenembrittlement well as enlarging them.
preparation ( ) Both
(a) B th Statement
St t t (I) and
d Statement
St t t (II) are individually
i di id ll
4.Stresscorrosioncracking true and Statement (II) is the correct explanation of
(d) Uneven heat,
heat improper sequence and deposited ( ) d l
(a)1,2and3only Statement (I)
metal shrinks (b)1,3and4only
y (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
(c)2,3and4only Statement (I)
(d) d
(d)1,2,3and4 ( ) 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

y The molten metal is p p

MetalCasting mouldability and cohesive strength, and are then

Sequentialstepsinmakingasandcasting y The mold is opened, the pattern board is drawn

y Drag: Lower moulding flask.

y Cope: Upper moulding flask.

IES1996 IES2007 GATE2009

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PatternAllowances Shrinkageallowance Liquidshrinkageandsolidshrinkage

y Pattern Allowances IES1995 GATE1999

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GATE2004 GATE2008 GATE2011

IAS1995 IAS2003 Draft

PatternMaterials Thepatternmaterialshouldbe IES1994

GATE2000 TypesofPattern TypesofPattern

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TypesofPattern IES2008 TypesofPattern

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MouldingSandComposition OtherAdditives MouldingSandProperties

Grainsizenumber IES2002 CastingYield

y Runner: The channel through which the molten

Thegoalsforthegatingsystem IES1998 IES2009

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GATE2010 IAS1999 RisersandRiserDesign

IES1994 Chvorinovs rule IES2011

(c) 28.30 seconds (d) 1/v2

(d) 40 seconds Where, v = volume of casting

GATE 2010(PI) GATE2007

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4 30 x 30 x 6 cm with a side riser, casting poured horizontally Therisershouldsolidifylastsox>1

[Use Caines Method]

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For-2013 (IES, GATE & PSUs) Page 16 Contd

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GATE2009 MoldShift IES2001

IES2005 IES1997 IES2009

IES1996 IES2005 IES2006

IES2007 IAS2007 IAS1999

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y Machining can be reduced or completely

Limitations Applications IES2011

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IES1992 JWM2010 IES2010

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y Cores must be simple and retractable and take the

For-2013 (IES, GATE & PSUs) HotChamber

JWM2010 IES2005 IES2006

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IAS1996 IES2011 GATE2007

Limitations Commonmetals GATE2002

y Spinning equipment can be expensive

IES2009 IES2007 IES2000

IES2000 DrySandMolding SlushCasting

IAS2004 IES2011 IES 2012

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PitMoulding IES1996 LoamMoulding

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GATE1996 IES2003 IES1993

IAS2004 GATE 2007(PI)

IES 2012 Weldability /FabricationProcesses CaseofAluminium

CaseofCastIron CaseofStainlessSteel CaseofStainlessSteel

IES2011 IES2006 IES1999

IES2010 IES2010 IES 2012