King Fahd University of Petroleum & Minerals

Mechanical Engineering Department

ME 322: MANUFACTURING PROCESSES

Semester (202)
Homework # 3
Assigned February 28

Due on Sunday, March 7, on BB (before 11:59 pm).

Late submission or submission by email will not be considered

Name: ID#:

Problems Marks Grades

1 20
2 20
3 20
4 20
5 20

Total 100

IMPORTANT
 Write your name and ID# on this cover page and include it with the
solution file and save it as PDF file.
 Name the PDF file as “HW#-ID#.pdf” (e.g. HW1-202012345.pdf).
1. Upload the PDF file on Black Board under Assignments section.
 You will have 2 attempts to upload your file.
 (IMPORTANT: Plagiarism, i.e. copying HW from others work, will
grant you ZERO in the HW).
Problem 1
It takes 3021 J to melt the amount of metal of a weld bead with a cross-sectional area of 4.5 mm2 and
150.0 mm long. (a) Using Table 25.2, what is the most likely metal? (b) If the heat transfer factor is
0.82 and the melting factor is 0.63 for the welding process, how much heat must be generated at the
welding source to accomplish the weld?

Problem 2
A single U-groove weld is used to join two pieces of 6.0-mm-thick austenitic stainless steel plate using
an arc welding operation. The radius of the groove is 2.5 mm; however, during welding the
penetration of the weld causes an additional 1.25 mm of metal to be melted. The length of the weld =
250 mm. The melting factor of the setup = 0.65, and the heat transfer factor = 0.90. Assuming the
resulting top surface of the weld bead is flush with the top surface of the plates, determine (a) the
amount of heat (in joules) required to melt the volume of metal in this weld (filler metal plus base
metal), (b) the welding time if the source power is 2500 W?

Problem 3
A gas tungsten arc-welding operation is performed on low carbon steel. Voltage = 24 volts, current =
165 amps, heat transfer factor = 0.72, and melting factor = 0.63. Filler metal wire of 4.0-mm diameter
is added to the operation, so that the final weld bead consists of 65% filler and 35% base metal. If the
travel speed in the operation is 6.0 mm/sec, determine (a) cross sectional area of the weld bead and (b)
feed rate (mm/sec) at which the filler wire must be supplied.

Problem 4
The unit melting energy for a certain sheet metal is 9.04 J/mm3. The thickness of each of the two
sheets to be spot welded is 3.75 mm. To achieve required strength, it is desired to form a weld nugget
that is 5.65 mm in diameter and 3.6 mm thick. The weld duration will be set at 0.45 sec. If the
electrical resistance between the surfaces is 140 micro ohms, and only one third of the electrical energy
generated will be used to form the weld nugget (the rest being dissipated), determine the minimum
current level required in this operation.

Problem 5

An oxyacetylene welding (OAW) operation is used to weld a corner joint formed by two 4.25-mm
thick low carbon steel plates. A fillet weld is made at the joint, and the cross-sectional area of the
weld bead =
13.5 mm2. Travel speed at which the bead is formed = 5 mm/s. The unit melting energy of the steel =
10.32 J/mm3. From previous OAW operations, it is known that only 40% of the energy generated by
the torch is used for melting the metal; the rest is dissipated. Determine the volume flow rate (m 3/hr)
of acetylene required to perform this OAW operation. An equal volume flow rate of oxygen will be
used.