1.1 Welding Q&A For Students PDF

7/11/2011
IES 2010
Assertion (A): It is generally difficult to weld
Aluminum parts by normal arc welding process.
Reason (R): Hard and brittle Aluminum‐oxide film
is formed at the welded joints.
(a) Both A and R are individually true and R is the
correct explanation of A
(b) Both A and R are individually true but R is NOT the
(c) A is true but R is false
(d) A is false but R is true
By S K Mondal
Ans. (a)
Compiled by: S K Mondal Made Easy Compiled by: S K Mondal Made Easy
IES‐2006 IES 2011
Assertion (A): Aluminium has poor weldability. During plasma arc welding of aluminium, improved
removal of the surface oxide from the base metal is
Reason (R): Aluminium has high thermal
obtained with typical polarity of :
conductivity and high affinity to oxygen.
(a) DC Straight
(a) Both A and R are individually true and R is the
correct explanation of A (b) DC reverse
(b) Both A and R are individually true but R is not the (c) AC potential
correct explanation of A (d) Reverse polarity of phase of AC potential
(c) A is true but R is false Ans. (c)
Ans. (a)
IES 2011 IES‐2006
Consider the following statements.
Fabrication weldability test is used to determine
Cast iron is difficult to weld, because of
(a) Mechanical properties required for satisfactory
1. Low ductility
performance of welded joint
2. Poor fusion
(b) Susceptibility of welded joint for cracking
3. Tendency to crack on cooling
(c) Suitability for joint design
Which of these statements are correct ?
(a) 1, 2 and 3 (d) Appropriate machining process
(b) 1 and 2 only Ans. (a)
(c) 2 and 3 only
(d) 1 and 3 only
Ans. (a) Compiled by: S K Mondal Made Easy Compiled by: S K Mondal Made Easy
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IES‐1999 IES 2010
Weldability of ferritic stainless steel used in
The correct sequence of the given materials in automotive exhaust system is improved by
ascending order of their weldability is
selecting stainless steel electrode having low
(a) MS, copper, cast iron, aluminium
content of
(b) Cast iron, MS, aluminium
Cast iron MS aluminium copper
(a) Carbon (b) Nitrogen
(c) Copper, cast iron, MS, aluminium
(d) Aluminium, copper, cast iron, MS (c) Chromium (d) Carbon and Nitrogen
Ans. (c)
Ans. (d)
IES 2010 IES 2010
Consider the following statements regarding The ratio between Oxygen and Acetylene
welded joints: gases for neutral flame in gas welding is
1. It is a permanent type of joint.
(a) 2 : 1 (b) 1 : 2
2. It is reliable and economical for pressure vessel
construction.
construction ((c)) 1 : 1 ((d)) 4 : 1
3. It is free from fabricational residual stresses.
4. Such joints are suitable for static loading only.
5. Welding is a versatile and flexible metal joining process.
Which of the above statements are correct? Ans. (c)
(a) 1, 2 and 3 only (b) 2, 3 and 4 only
(c) 1, 2, 3, 4 and 5Compiled by: S K Mondal Made Easy
(d) 1, 2 and 5 only Ans. (d) Compiled by: S K Mondal Made Easy
GATE‐1994 GATE‐2003
In Oxyacetylene gas welding, temperature at the
The ratio of acetylene to oxygen is inner cone of the flame is around
approximately………. for a neutral flames used in
(a) 3500°C
gas welding.
(b) 3200
3200°C
C
(a)
( ) 1:1
(c) 2900°C
(b) 1 : 2
(d) 2550°C
(c) 1 : 3
Ans. (b)
(d) 1.5 : 1
Ans. (a)
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IES 2010 GATE‐2002
Assertion (A): Oxidizing flame is used in gas
welding to join medium carbon steels having high The temperature of a carburising flame in gas
melting point. welding is that of a neutral or an oxidising flame.
Reason (R): In gas welding, oxidizing flame (a) Lower than
produces the maximum temperature compared to (b) Higher than
neutral and reducing flame. (c) Equal to
(a) Both A and R are individually true and R is the (d) Unrelated to
correct explanation of A Ans. (a)
Compiled by: S K Mondal Made Easy
Ans. (a) Compiled by: S K Mondal Made Easy
IES‐2009 IES‐1998
By which one of the following methods gray cast In oxy‐acetylene gas welding, for complete
iron is usually welded? combustion, the volume of oxygen required per
(a) TIG welding (b) MIG welding unit of acetylene is
(c) Gas welding (d) Arc welding ((a)) 1
(b) 1.5
Ans. (c) (c) 2
(d) 2.5
Ans. (a)
IAS 1994 IAS‐1995
In gas welding of mild steel using an oxy‐ Assertion (A): If neutral flame is used in oxy‐
acetylene welding, both oxygen and acetylene
acetylene flame. the total amount of acetylene cylinders of same capacity will be emptied at the same
consumed was 10 litre. The oxygen consumption time.
from the cylinder is Reason (R): Neutral flame uses equal amounts of
oxygen and d acetylene.
l
(a) 5 litre (a) Both A and R are individually true and R is the correct
(b) 10 litre explanation of A
(c) 15litre (b) Both A and R are individually true but R is not the
(d) 20 litre (c) A is true but R is false
Ans. (b) (d) A is false but R is true
Ans. (a)
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IES‐1992 IES 2007
The edge of a steel plate cut by oxygen cutting will Consider the following statements in respect of oxy‐
acetylene welding:
get hardened when the carbon content is
1. The joint is not heated to a state of fusion.
(a) Less than 0.1 percent 2. No pressure is used.
(b) Less than 0.3
0 3 percent 3.
3 Oxygen is stored in steel cylinder at a pressure of 14
MPa.
(c) More than 0.3 percent 4. When there is an excess of acetylene used, there is a
(d) Anywhere between 0.1 to 1.0 percent decided change in the appearance
Ans. (c) of flame.
Which of the statements given above are correct?
(a) 1, 2 and 3 (b) 2, 3 and 4
(c) 1, 3 and 4 (d) 1, 2 and 4
Ans. (b)
IES‐2001 IES‐1992
Oxyacetylene reducing flame is used while Thick steel plate cut with oxygen normally shows
carrying out the welding on signs of cracking. This tendency for cracking can
(a) Mild steel (b) High carbon steel be minimised by
(c) Grey cast iron (d) Alloy steels ((a)) Slow speed
p cutting
g
(b) Cutting in two or more stages
Ans. (b) (c) Preheating the plate
(d) Using oxy‐acetylene flame
Ans. (c)
IES‐2005
Consider the following statements:
1. In gas welding, the torch should be held at an angle of 30°
to 45° from the horizontal plane.
2. In gas welding, the Size of the torch depends upon the
thickness of metal to be formed.
h k f l b f d Electric Arc Welding
3. Drag in gas cutting is the time difference between heating
of the plate and starting the oxygen gas for cutting.
(a) 1, 2 and 3 (b) 1 and 2
(c) 2 and 3 (d) 1 and 3
Ans. (b)
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JWM 2010 GATE‐1993
Assertion (A) : Bead is the metal added during In d.c. welding, the straight polarity (electrode
single pass of welding. negative) results in
Reason (R) : Bead material is same as base metal. (a) Lower penetration
(a) Both A and R are individuallyy true and R is the (b) Lower deposition rate
correct explanation of A (c) Less heating of work piece
(b) Both A and R are individually true but R is NOT the (d) Smaller weld pod
Ans. (b)
Ans. (a) Compiled by: S K Mondal Made Easy Compiled by: S K Mondal Made Easy
IES 2010 IES‐2005
In arc welding, the arc length should be equal to
Consider the following statements:
(a) 4.5 times the rod diameter
1. In arc welding, 65% to 75% heat is generated at the anode.
(b) 3 times the rod diameter
2. Duty cycle in case of arc welding is the cycle of complete
(c) 1.5 times the rod diameter welding of work piece from the beginning.
(d) Rod diameter 3. Arc blow is more common with DC welding.
Ans. (d) (a) 1, 2 and 3 (b) 1 and 2
(c) 2 and 3 (d) 1 and 3
Ans. (d)
IES‐2001 IES‐2001
In manual arc welding, the equipment should In arc welding, d.c. reverse polarity is used to bear
have drooping characteristics in order to maintain greater advantage in
(a) Voltage constant when arc length changes (a) Overhead welding
(b) Current constant when arc length changes (b) Flat welding of lap joints
(c) Temperature in the are constant (c) Edge welding
(d) Weld pool red‐hot (d) Flat welding of butt joints
Ans. (b) Ans. (a)
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IES‐1998 IAS‐1999
The voltage‐current characteristics of a dc Open‐circuit voltage of 60 V and current of 160A
generator for arc welding is a straight line were the welding conditions for arc welding of a
between an open‐circuit voltage of 80 V and short‐ certain class of steel strip of thickness 10 mm. For
circuit current of 300 A. The generator settings for arc welding of 5mm thick strip of the same steel,
maximum arc power will be the welding voltage and current would be
(a) 0 V and 150 A (b) 40 V and 300 A (a) 60 V and 80 A
(c) 40 V and 150 A (d) 80 V and 300 A (b) 120 V and 160 A
Ans. (c) (c) 60 V and 40 A
(d) 120 V and 40 A
Ans. (a)
IAS‐1998 GATE‐1994
Assuming a straight line V‐I characteristics for a The electrodes used in arc welding are coated.
dc welding generator, short circuit current as 400A This coating is not expected to
and open circuit voltage as 400 which one of the (a) Provide protective atmosphere to weld
following is the correct voltage and current setting (b) Stabilize the are
for maximum arc power?
(c) Add alloying elements
(a) 400 A and 100 V (b) 200 A and 200 V
(d) Prevents electrode from contamination
(c) 400 A and 50 V (d) 200 A and 50 V
Ans. (d)
Ans. (b)
IES 2007 IES‐1997
The coating material of an arc welding electrode Assertion (A): The electrodes of ac arc welding are
contains which of the following? coated with sodium silicate, whereas electrodes used
for dc arc welding are coated with potassium silicate
1. Deoxidising agent binders.
2. Arc stabilizing agent Reason (R): Potassium has a lower ionization
potential
i l than
h sodium.
di
3. Slag forming agent
(a) Both A and R are individually true and R is the correct
Select the correct answer using the code given below: explanation of A
(a) 1, 2 and 3 (b) 1 and 2 only (b) Both A and R are individually true but R is not the
(c) 2 and 3 only (d) 1 and 3 only correct explanation of A
Ans. (a) Ans. (d)
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IES‐2002 GATE‐2002, Conventional
Match List I with List II and select the correct answer: The arc length‐voltage characteristic of a DC arc is given
List I (Ingredients) List II (Welding
functions)
by the equation: V = 24 + 4L, where V is voltage in volts
A. Silica 1. Arc stabilizer and L is arc length in mm. The static volt‐ampere
B. Potassium oxalate
l 2. De‐oxidizer
d
characteristic of the power source is approximated by a
C. Ferro silicon 3. Fluxing agent
D. Cellulose 4. Gas forming material straight line with a no load voltage of 80 V and a short
Codes:A B C D A B C D
circuit current of 600A. Determine the optimum arc
(a) 3 4 2 1 (b) 2 1 3 4
(c) 3 1 2 4 (d) 2 4 3 1 length for maximum power.
Ans. (c)
Ans. 4 mm Compiled by: S K Mondal Made Easy
IES‐2001 IES‐2001
Arc blow is more common in Pinch effect in welding is the result of
(a) A.C. welding (a) Expansion of gases in the arc
(b) D.C. welding with straight polarity (b) Electromagnetic forces
(c) D.C. welding with bare electrodes
D C elding ith bare electrodes (c) Electric force
(d) A.C. welding with bare electrodes (d) Surface tension of the molten metal
Ans. (c) Ans. (b)
GATE‐1992 IES 2010
Assertion (A): Straight polarity is always
A low carbon steel plate is to be welded by the manual recommended for Carbon‐electrode welding.
metal arc welding process using a linear V ‐ I
Reason (R): Carbon arc is stable in straight polarity.
characteristic DC Power source. The following data are
available : (a) Both A and R are individually true and R is the
OCV of Power source = 62 V
Short circuit current = 130 A
Arc length, L = 4 mm
Traverse speed of welding = 15 cm/s
Efficiency of heat input = 85%
Ans. (c)
Voltage is given as V = 20 + 1.5 L
Calculate the heat input into the workprice Ans. 1668.5 J
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GATE 2011 IES 2010
Which one among the following welding processes In an inert gas welding process, the commonly used
used non – consumable electrode? gas is
(a) Gas metal arc welding (a) Hydrogen
(b) Submerged arc welding (b) Oxygen
(c) Gas tungsten arc welding (c)
( ) Helium
H li or Argon
A
(d) Flux coated arc welding (d) Krypton
Ans. (c) Ans. (c)
GATE‐2002 IES‐1994
Which of the following arc welding processes does Which one of the following welding processes
not use consumable electrodes? uses non‐ consumable electrodes?
(a) GMAW (a) TIG welding
(b) GTAW (b) MIG welding
(c) Submerged Arc Welding (c) Manual arc welding
(d) None of these (d) Submerged arc welding
Ans. (b) Ans. (a)
IES‐2000 IES 2007
Which one of the following statements is correct? In MIG welding, the metal is transferred into the
(a) No flux is used in gas welding of mild steel form of which one of the following?
(b) Borax is the commonly used flux coating on (a) A fine spray of metal
welding electrodes (b) Molten drops
(c) Laser beam welding employs a vacuum chamber (c) Weld pool
and thus avoids use of a shielding method (d) Molecules
(d) AC can be used for GTAW process Ans. (b)
Ans. (d)
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IES‐1997 IES 2010
Assertion (A): Inert gas and bare electrode instead
Consider the following statements: of flux coated electrode is used in the case of
MIG welding process uses automatic TIG and MIG welding processes.
1. Consumable electrode 2. non‐consumable electrode Reason (R): Better protection is provided by a cloud
3. D.C. power supply 4. A.C. power supply of inert gas than the cover created by the flux.
Of these statements (a) Both A and R are individually true and R is the
(a) 2 and 4 are correct correct explanation of A
(b) 2 and 3 are correct (b) Both A and R are individually true but R is NOT the
(c) 1 and 4 are correct correct explanation of A
(d) 1 and 3 are correct (c) A is true but R is false
Ans. (d) (d) A is false but R is true Ans. (b)
IES 2011 IES‐2006
The welding process in which bare wire is used as
In which of the following welding processes, flux
electrode, granular flux is used and the process is
is used in the form of granules?
characterized by its high speed welding, is known as:
(a) AC arc welding
(a) Shielded arc welding
(b) Submerged arc welding
(b) Plasma arc welding
(c) Argon arc welding
(c) Submerged arc welding
(d) DC arc welding
(d) Gas metal arc welding
Ans. (b)
y Ans. (c)
IES‐2005 IES‐2008
Which of the following are the major Assertion (A): Submerged arc welding is not
characteristics of submerged arc welding? recommended for high carbon steels, tool steels,
aluminium, magnesium etc.
1. High welding speeds. Reason (R): This is because of unavailability of
2. High deposition rates. suitable fluxes, reactivity at high temperatures and
low
l sublimation
bli i temperatures.
3. Low penetration.
(a) Both A and R are true and R is the correct explanation
4. Low cleanliness. of A
Select the correct answer using the code given below: (b) Both A and R are true but R is NOT the correct
(a) 2 and 3 (b) 1, 2 and 3 explanation of A
(c) 3 and 4 (d) 1 and 2 (d) A is false but R is true
Ans. (d) Ans. (a)
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GATE‐1999 IES‐2005
For butt ‐welding 40 mm thick steel plates, when In atomic hydrogen welding, hydrogen acts as
the expected quantity of such jobs is 5000 per (a) A heating agent
month over a period of 10 year, choose the best
(b) One of the gases to generate the flame
suitable welding process out of the following
available
l bl alternatives.
l (c)
( ) An effective shielding gas protecting the weld
A ff ti hi ldi t ti th ld
(a) Submerged arc welding (d) A lubricant to increase the flow characteristics of
weld metal
(b) Oxy‐acetylene welding
Ans. (a)
(c) Electron beam welding
(d) MIG welding
Ans. (a)
10

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