GANADIPATHY TULSIS JAIN ENGINEERING COLLEGE

Department of Mechanical Engineering

IMPORTANT QUESTIONS AND ANSWERS

SUBJECT CODE : ME 8351

SUBJECT NAME : MANUFACTURING TECHNOLOGY - I

Regulation: 2017 Year and Semester: II and III

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UNIT II - METAL JOINING PROCESSES

PART-A

1. What is meant by Nuggest in Electrical Resistance welding?

(Nov/Dec 2014)
The point at which the molten metal is created for short period of time
due to maximum heat generation is called nuggest.

2. Write short notes on thermit welding. (Nov/Dec 2012,13)

It is a fusion welding process in which the weld is effected by pouring
superheated liquid thermit steel around the parts to be united.

3. What is meant by “carburising flame” in gas welding?

(Nov/Dec 2012)
Gas welding is done by burning a combustible gas with air or oxygen in a
concentrated flame of high temperature. In which there is an excess of
acetylene is needed the flame produced is called carburising flame.
4. Write the difference between brazing and soldering.(May/Jun 2014,15)
Brazing Soldering
The process of joining two metals by The process of joining two metals by
using filler metal (fusible alloy) is using a harder filler metal (spelter) is
known as brazing. The filler metal known as soldering. The filler metal
having liquid temperature is above having liquid temperature is below
4270 C. 4270 C.

5. What are the functions of flux in welding electrode?

(May/Jun 2010, 12, Nov/Dec 2013, 14)
The functions of flux are

 To remove the impurities and oxides present on the surfaces of

metal.
 To obtain a satisfactory bond.
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6. Name various causes for the defect porosity in welding. (May/Jun 2015)

 Presence of gases in the metal

 Moisture in the flux
 Rust on the welded edges or filler material

7. Differentiate fission welding from fusion welding. (May/Jun 2010)

Fusion welding Fission welding

The metals at the joint is heated to a
molten state and allowed to solidify.
It is also called non pressure welding.
E.g: Gas welding , Arc welding
The metal parts are heated to a plastic
state and are pressed together to make
the joint. It is also called pressure
welding.
E.g: Solid state welding

8. Sketch the different types of oxyacetylene flames. (May/Jun 2014)

Types of flame Sketch of flame

Neutral flame

Oxidizing flame
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Carburizing flame

9. What is the minimum distance maintained between two successive spot

welds made by resistance welding? Why? (May/Jun 2013)
The minimum distance 150 mm and maximum distance between two
securing points 300 mm should be maintained two successive spot welds or the
acceptable distance is 16 times of thickness of metal to be welded because the
shunt current flowing through already formed weld spot reduces the efficiency
of the welding process.

10. Write short notes on transferred and non transferred in plasma arc
welding. (May/Jun 2013)
Transferred type:

In transferred type, the tungsten electrode is connected to the negative

terminal and the work piece is connected to the positive terminal. An electric
arc is maintained between the electrode and the work piece heats a co-axial
flowing gas and maintains it in a plasma state.

Non- Transferred type:

In this type, the power is directly connected with the electrode and the
torch of nozzle. The electrode carries the same current. Thus the ionizing is at
high velocity gas that is strewing towards the work piece.
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11. Mention the application of friction welding. (May/Jun 2010)

 Aerospace industry.
 Automobile industry.
12. Define the term “electrode” and mention its major classifications.

(Nov/Dec 2011)

Electrode is a solid rod in arc welding process to produce electric arc by

passing the current through the work piece and electrode for melting the
surfaces or edges are joined without applying external force.

Types of Electrode:

(i) Consumable electrodes

 Bare electrodes
 Lightly coated electrodes
 Heavily coated electrodes
(ii) Non -Consumable electrodes
13. What is the principle of resistance welding? (Nov/Dec 2009)

The two metal parts to be joined are heated to a plastic state by their
resistance to the flow of electric current and the mechanical pressure is used to
complete the weld.

14. How can slag inclusions in welding be avoided? (May/Jun 2008)

 Avoid multi layer welding

 Reduce arc length
 Increase electrode angle
 Avoid using large electrode
15. What are the diameters and length of electrodes available in the
market? (Nov/Dec 2009)
 Standard lengths of electrodes are 250 mm, 300 mm and 450 mm.
 Standard diameters of electrodes are 1.6, 2, 2.5, 3.2, 4, 5,6,7,8 and 9mm
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PART - B

1.Explain with neat sketch the components of oxy acetylene gas welding
equipment. (Nov/Dec 2014)
Gas cylinders:
Gas welding, ahead of oxygen and acetylene are used. These two gases
are stored in separate cylinders. The standard colour for oxygen cylinder is
black. The oxygen is stored in the cylinder at a pressure of 125 to 140 kg/cm2.
The standard colour for acetylene cylinder is maroon. The acetylene is stored in
the cylinder at a pressure of
16 kg/cm2. Acetylene cylinder is fitted with a fusible plug to avoid explosion.
Pressure regulators:
Each cylinder is fitted with a pressure regulator. These regulators are
used to reduce and control the working pressure of the gases. The working
pressure of oxygen is 0.7 to 2.8 kg/cm2. The working pressure of acetylene is
0.07 to 1.03 kg/cm2.
Pressure gauges:
There are four pressure gauges provided in which two are placed on the
oxygen cylinder regulators and two on acetylene cylinder regulators. Among
two pressure gauge, one is for showing the cylinder pressure. The other one is
for showing the working pressure for welding.
Hoses:
The regulator of each cylinder is connected to the torch through two
long hoses. It should be flexible, strong, desirable, non-process and light.
Welding torch:
Oxygen and acetylene gases enter the torch through the hose in separate
passages. Both the gases are mixed in the mixing chamber of the torch. When it
is ignited, a flame will be produced at the tip of the torch called nozzle. There
are two control valves on the welding torch. They are used to control the
quantity of oxygen and acetylene gases to adjust the flame.
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Goggles:
The welding goggles are used to protect eyes from the flame heat, and
ultraviolet and infrared rays.
Welding gloves:
Gloves are used to protect hand from the injury causing by heat and
metal splashes.

2. Describe the process of Electro slag welding and identify their major
applications. (Nov/Dec 2014)
Electro slag welding process which produces coalescence through
electrically melted flux which melts both the filler metal and the surface of the
work piece to be melted. Welding is initiated on a starting block at the bottom
of the vertically positioned joint. Flux poured around the electrode is converted
to slag that floats on a layer of molten metal confined in the joint by water
cooled copper shoes that slides on the sides. The heat of the fusion is provided
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by resistance heating in the slag. The welding dams and head move upward as
weld metal solidifies and new metal is fed in by the wire electrodes.

The consumable wire electrode may be solid or flux coated but most of
the shielding is provided by an argon and CO2 gas mixture injected into the
gap. The heat is furnished by an electrical arc between the electrode and metal
pool. It is used particularly for thick plates and structures for turbine shafts,
boiler parts.
Advantages of Electro slag welding:
 High deposition rate.
 Low slag consumption
 Low distortion
 Unlimited thickness of work piece

Disadvantages of Electro slag welding:

 Coarse grain structure of the weld

 Low toughness of the weld
 Vertical position possible only
Applications:
 Construction of bridges, pressure vessels,
 Construction of thick walled and large diameter pipes
 Construction of thick storage tanks and ships.
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3. What is the principle of thermit welding? Explain the same with a neat
sketch of the welding arrangement. (May/Jun 2012& 2017)
It is a fusion welding process in which the weld is effected by pouring
superheated liquid thermit steel around the parts to be united. The thermit
process for welding metal is based on the chemical reaction between finely
divided aluminium and iron oxide.
8Al + 3Fe3O4 = 4Al2 O3 + 9Fe
During the reaction, the oxygen leaves the iron oxide and combines with
aluminum, producing aluminum oxide, or slag, and superheated thermit steel.
The thermit is a mixture of finely divided aluminium and iron oxide, the
ratio by weight being approximately three parts of iron oxide to one part of
aluminium. The mixture placed in a refractory – lined crucible, is ignited with
the aid of a highly inflammable powder composed largely of barium peroxide.
The temperature produced by the thermit reaction is approximately 3000 0 C or
about twice the temperature of the melting point steel.

In making pressure welds by the thermit process, a pattern of wax is

shaped around the parts to be welded. A sheet iron box is placed around the
wax pattern and the space between the pattern and box is filled and rammed
with sand. Pouring and heating gates, and risers, are cut in the sand and a flame
is directed into the heating opening. The wax pattern melts and drains out but
the heating is continued to raise the temperature of the parts to be welded. This
preheating is done before the liquid metal is poured into the mould in order to
prevent chilling of the steel. Then the burner or torch is removed, and the
preheating gate is plugged with sand. The superheated metal produced by the
thermit reaction in a crucible is poured into the mould surrounding the surfaces
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to be welded. After the welding temperature is reached mechanical pressure is

applied to complete the weld.
Applications:
 Joining of railroad rails.
 Repair of cracks in large steel castings and forgings.
 Weld surface is often smooth enough that no finishing is
required.
Advantages of thermit welding:
 No external power source is required.
 Very large heavy section parts may be joined.
Disadvantages of thermit welding:
 Only ferrous parts may be welded.
 Slow welding rate
 It causes distortion in the weld region.

4. Explain Resistance seam welding with neat sketch. (Nov/Dec 2013)

Seam welding is a method of making a continuous joint between two

over lapping pieces of sheet metal. The normal procedure for making seam
welding is to place the work between the wheels which serve as conductors for
producing continuous welds. As pressure is applied, the drive started and the
welding current switched on. Then at the same time, the over lapping surfaces
of metal are forced together as fast as they are heated.
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A coolant is applied to conserve the electrodes and cool the work rapidly
to speed the operation. The materials that may be seam welded include most of
those that may be spot welded. Steel plates 10 mm thick have been seam
welded to hold about 200 kg/cm2 pressure.
Advantages of Resistance seam welding:
 No filler metal required
 High production rates possible
 Lends itself to mechanization and automation
 Lower operator skill level than for arc welding
 Good repeatability and reliability
Disadvantages of Resistance seam welding:
 High initial equipment cost
 Limited to lap joints for most seam welding processes

5. Explain Friction stir welding with neat sketch. (Nov/Dec 2013& 2016)
The frictional energy generated when two bodies slide on each other is
transformed into heat; when the rate of movement is high and the heat is
contained in a narrow zone, welding occurs.

In practically one part is firmly held while the other is rotated under
simultaneous application of axial pressure. The temperature rises, partially
formed welded spots are sheared, surface films are disrupted, and the rotation is
suddenly arrested when the entire surface is welded. Some of the softened
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metal is squeezed out into a flash, but it is not fully clear whether melting takes
place. The heated zone being very thin, dissimilar metals are easily joined.
Limitations:
 At least one of the parts must be rotational
 Flash must usually be removed
 Upsetting reduces the part lengths (which must be taken into
consideration in product design)
Applications:
 Shafts and tubular parts
 Industries: automotive, aircraft, farm equipment, petroleum
and natural gas

6. Explain the arc welding process with neat sketch. (May/Jun 2015)
In arc welding process, the heat is developed by an electric arc. The arc
is produced between an electrode and the work. It is the process of joining two
metal pieces by melting their edges by an electric arc. In this welding, the
electrical energy is converted into heat energy. The electrode and work piece
are brought near to each other with a small gap of 3mm approximately. Then
the current is passed through the work piece and electrode to produce an
electric arc.

The work piece is melted by the arc. The electrode is also melted and
hence, both the work pieces become a single piece without applying external
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pressure. The temperature of arc is about 50000 C to 60000 C. the electrode

supplies additional filler metal into the joints and is deposited along the joint. A
transformer is used for supplying the current. To obtain better depth of fusion,
the electrode is kept at 700 inclinations to the vertical.
Advantages:
 Most efficient way to join metals
 Lowest-cost joining method
 Affords lighter weight through better utilization of materials
 Joins all commercial metals
 Provides design flexibility
Disadvantages:
 Manually applied, therefore high labor cost.
 Need high energy causing danger
 Not convenient for disassembly.
 Defects are hard to detect at joints.
Part - C
1. Describe the ultrasonic welding process with neat diagram.
(May/Jun 2015)
Ultrasonic welding is the joining or reforming of thermoplastics through
the use of heat generated from high-frequency mechanical motion. It is
accomplished by converting high-frequency electrical energy into high-
frequency mechanical motion. That mechanical motion, along with applied
force, creates frictional heat at the plastic components' mating surfaces (joint
area) so the plastic material will melt and form a molecular bond between the
parts.
The two thermoplastic parts to be assembled are placed together, one on
top of the other, in a supportive nest called a fixture. A titanium or aluminum
component called a horn is brought into contact with the upper plastic part. A
controlled pressure is applied to the parts, clamping them together against the
fixture. The horn is vibrated vertically 20,000 Hz (20 kHz) or 40,000 Hz (40
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kHz) times per second, at distances measured in thousandths of an inch

(microns), for a predetermined amount of time called weld time. Through
careful part design, this vibratory mechanical energy is directed to limited
points of contact between the two parts.

The mechanical vibrations are transmitted through the thermoplastic

materials to the joint interface to create frictional heat. When the temperature at
the joint interface reaches the melting point, plastic melts and flows, and the
vibration is stopped. This allows the melted plastic to begin cooling. The
clamping force is maintained for a predetermined amount of time to allow the
parts to fuse as the melted plastic cools and solidifies. Once the melted plastic
has solidified, the clamping force is removed and the horn is retracted. The two
plastic parts are now joined as if molded together and are removed from the
fixture as one part.
Advantages:
 Fast, economical and easily automated.
 Mass production can be made.
 Increased flexibility and versatility.
 Possibility to join large structures.
Disadvantages:
 Large joints cannot be weld in a single operation.
 Specifically designed joints are required.
 Tooling costs for fixtures are high.
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2. What is meant by welding defect? Explain any five welding defects.

(May/Jun 2010 & 2017)
The defects in the weld can be defined as irregularities in the weld metal
produced due to incorrect welding parameters or wrong welding procedures or
wrong combination of filler metal and parent metal. Weld defect may be in the
form of variations from the intended weld bead shape, size and desired quality.
1. Cracks
Cracks may be of micro or macro size and may appear in the weld metal
or base metal or base metal and weld metal boundary. Different categories of
cracks are longitudinal cracks, transverse cracks or radiating/star cracks and
cracks in the weld crater. Cracks occur when localized stresses exceed the
ultimate tensile strength of material. These stresses are developed due to
shrinkage during solidification of weld metal.

2. Porosity
Porosity results when the gases are entrapped in the solidifying weld
metal. These gases are generated from the flux or coating constituents of the
electrode or shielding gases used during welding or from absorbed moisture in
the coating. Rust, dust, oil and grease present on the surface of work pieces or
on electrodes are also source of gases during welding. Porosity may be easily
prevented if work pieces are properly cleaned from rust, dust, oil and grease.
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3. Solid Inclusion

Solid inclusions may be in the form of slag or any other nonmetallic

material entrapped in the weld metal as these may not able to float on the
surface of the solidifying weld metal. During arc welding flux either in the
form of granules or coating

after melting, reacts with the molten weld metal removing oxides and other
impurities in the form of slag and it floats on the surface of weld metal due to
its low density.

4. Lack of Fusion and Inadequate or incomplete penetration:

Lack of fusion is the failure to fuse together either the base metal and
weld metal or subsequent beads in multipass welding because of failure to raise
the temperature of base metal or previously deposited weld layer to melting
point during welding. Lack of fusion can be avoided by properly cleaning of
surfaces to be welded, selecting proper current, proper welding technique and
correct size of electrode.

5. Imperfect Shape : Imperfect shape means the variation from the desired
shape and size of the weld bead. During undercutting a notch is formed either
on one side of the weld bead or both sides in which stresses tend to
concentrate and it can result in the early failure of the joint. Main reasons for
undercutting are the excessive welding currents, long arc lengths and fast
travel speeds.