Roll Number:

Thapar Institute of Engineering & Technology, Patiala

Department of Mechanical Engineering
End Semester Examination, December, 2019

BE- (VII'`' Semester)

UPE702: Metal Casting and Joining
05 th December, 2019
Time: 03 Hours; MM: 100
Name of Faculty: Dr. Dheeraj Gupta
Note:
Do all questions in sequence; assume suitable missing data, if any, draw schematic
diagram wherever is required.

Q.1 (a) A cylindrical riser must be designed for a sand-casting mold. The casting 10
itself is a steel rectangular plate with dimensions 7.5 cm x 12.5 cm x 2.0
cm. Previous observations have indicated that the total solidification time
(TST) for this casting = 1.6 min. The cylinder for the riser will have a
diameter-to-height ratio = 1.0. Determine the dimensions of the riser so
that it's TST = 2.0 min.
Q.1 (b) The voltage-length characteristic of a D.C. arc is given by V=20+40L, 10
where 'V' is the arc voltage and I,' is the length of arc in cm. Determine
the open circuit voltage and short circuit current for arc length ranging
from 3 mm to 5 mm and current ranging from 400 to 500 Amp during
welding operation.
Q.2 (a) What are the different methods used in arc initiations in case of GTAW 05+05
process and what are the features of pulse TIG welding and also draw the
schematic of the pulse current and time.
Q.2 (b) How the maintenance of the arc is achieved during arc welding process. 05+05
Why pure tungsten electrode is not recommended for GTAW process and
how to overcome with those associated problems with this material as
electrode with proper explanations.

Q.3 (a) What is the significance of arc forces in arc welding process and discuss 10
various forces acting with suitable schematic diagram
Q.3 (b) Write the comparison of AC and DC welding power sources in capacity 05+05
of the following; arc stability, distribution of arc heat, efficiency, power
factor and cleaning action. At what duty cycle need a 300 A welding

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 power source rated at 60% duty cycle be operated to get an output current

of 400 A?
06+04
What are the common problems associated while welding of aluminum
Q.4 (a)
and carbon steel and also describe the tffm weldability.
10
Discuss the different modes of metal transfer during consumable arc
Q.4 (b)
welding processes, with schematic diagrams.
05+05
Discuss the working principles of plasma arc welding process, with
Q.5 (a)
suitable schematic diagram and also compare transferred and non

transferred PAW process.

10
What are the causes of the following sand casting defects; show them
Q.5 (b)
schematically; (i) miss run; (ii) cold shuts, (iii) penetration, (iv) pin holes,

(v) shrinkage cavities

th December, 2019 at 04:00 PM

Note: Students can see their evaluated answer script on 10
in Sand Testing Laboratory (Workshop).

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