MM: 10

Tutorial Sheet-I
Write down your name, college no./faculty no. and enrolment no. on first page of the sheet.
Answer all the questions.
Assume suitable data if missing.
Notations used have their usual meaning.
Draw neat sketches to support your answers.

Q1. Two different pairs of sheets of the same material have to be spot welded. In one pair, there are
25 bridges per cm2 and the average radius of each bridge is 0.1 mm. The other pair of sheets contains
20 bridges per cm2 with the same average radius of each bridge. Determine the ratio of the voltages
to be applied in these two cases in order to generate the same rate of heating per unit area.

Q2. Two flat copper sheets of 1.2 mm thickness each are spot welded. The process parameters are:
current = 5000A, current flow time = 0.20 s, and diameter of electrodes = 6mm. Estimate the heat
generated in the welding zone.

Q3. In a resistance welding of a lap joint or two mild steel sheets of 1.5 mm thick, a current of 10,000
A is passed for a period of 0.1 seconds. The effective resistance of the joint is 120 micro ohms.
Density of steel is 0.00786 g/mm3 and heat required to melt is 1381 J/g. The joint can be considered
as a cylinder of 5 mm diameter and 2.25 mm in height. Calculate the percentage of heat distributed
to the surroundings.

Q4. For spot welding of two steel sheets (base metal) each of 3 mm thickness, welding current of
10000 A is applied for 0.2 seconds. The heat dissipated to the base metal is 1000 J. Assuming that
the heat required for melting 1 mm3 volume of steel is 20 J and interfacial contact resistance between
sheets is 0.0002 Ω, calculate the volume (in mm3) of weld nugget.

Q5. Spot welding of two 1 mm thick sheets of steel (density=8000 kg/m3) is carried out successfully
by passing a certain amount of current for 0.1 second through the electrodes. The resultant weld
nugget formed is 5 mm in diameter and 1.5 mm thick. If the latent heat of fusion of steel is 1400 kJ/kg
and the effective resistance in the welding operation in 200Ω, obtain the current passing through the
electrodes.

Q6. Two metallic sheets, each of 2.5 mm thickness, are welded in a lap joint configuration by
resistance spot welding at a welding current of 8000 A and welding time of 15 milli-second. A
spherical fusion zone extending up to the full thickness of each sheet is formed. The properties of the
metallic sheets are given as:
Density =7500 kg/ , Latent heat of fusion=350 kJ/kg
Assume: (i) contact resistance along sheet-sheet interface is 300 micro-ohm and along electrode-sheet
interface is zero; (ii) a spherical spot is formed to the full thickness, and (iii) the complete weld fusion
zone is at the melting temperature.
Calculate:
i. Amount of conductive heat loss through the bulk sheet material
ii. Melting efficiency of the process

Q7. What is 'Friction Welding'? What are the various types of friction welding processes? Discuss
them briefly.

Q8. Explain the following welding techniques:

i Explosive welding
ii Diffusion welding
iii Resistance spot welding and Resistance seam welding
iv Laser beam welding