Engineering Technical College-Baghdad

Dept. : Welding Eng. MSc. Course

Subject: Welding Procedures Time: 2 hrs
Examiner: Prof. Dr. Adnan N. Abood Date: 14/6/2020
Final Examination

2020/2019

Note: Answer Totally Five Questions

1. Answer Two Questions from the First Three.
Q1. Aluminum alloy AA5050-H112 is to be welded with AA6061-T651 by fusion welding process.
Thickness is 10mm for the two alloys.
A. If TIG is selected for welding;
I. Select the filler metal for welding the above alloys. Why?
II. Select the joint design and all other welding parameter (electrode type, electrode diameter,
nozzle size, electrode taper shape, gas type, gas flow rate and filler diameter).
III. State the current type. Why?
IV. Discuss the important of back stripe and preheating for welding aluminum.
V. If helium + argon as a mixture gas are used instead of pure argon, explain their effect on the
mentioned weldment.
VI. If MIG is used instead of TIG, state the filler metal, protection gas and current type that will
use.
(12 marks)
B. Compute the filler metal weight that required for welding the above aluminum alloys for
length 1m by TIG process.
(8 marks)
C. If the tensile test results for PQR of above aluminum weldments are; (ϭu = 128MPa, ϭy =
44MPa min., 15% Elongation) and standard mechanical properties of the aluminum alloys
are (5050-H112, ϭu = 138MPa min., ϭy = 55MPa min., 12% Elongation) (6061-T651, ϭu =
290MPa min., ϭy = 240MPa min., 10% Elongation) do you accept the WPS producer or not.
Why?
(5 marks)

Q2. A Ferritic nodular cast iron has a fracture is to be repaired by fusion welding process,
thickness 150mm with length of 750mm.
A. If MMAW is to be used;
i. Name all electrodes that may use for welding nodular cast iron by MMAW.
ii. Explain the important of preheating and post heating of welding cast iron.
iii. If MIG/MAG process is used instead of MMAW;
 Select the electrode for good machining to welding zone.
 State the protection gas or gas mixture for welding.
 Select current type and their polarity.
iv. Do you need to procedure qualification tests for the above weldment or not? Why?
(16 marks)
B. By using studding technique, explain the procedure for welding the mentioned cast iron.
(9 marks)
 Engineering Technical College-Baghdad
Dept. : Welding Eng. MSc. Course
Subject: Welding Procedures Time: 2 hrs
Examiner: Prof. Dr. Adnan N. Abood Date: 14/6/2020
Final Examination

2020/2019

Q3. Austenitic stainless steel AISI 304L is to be welded with MIG process, thickness 18mm, and
total length of 2.4m;
A. Name the required electrode for welding with the mentioned process, as well as, current and
polarity. (2 marks)
B. Mainly Oxygen with 2-5% is added to gas protection when welding stainless steel, why?
(3 marks)
C. Copper is employed as a back strip when welding stainless steels .Why?
(3 marks)
D. How we can control delta ferrite in welding zone between 8-10%.
(3 marks)
E. If AISI 304 is to be used instead of AISI 304L, explain the main problem that might appear
in HAZ and how to reduce their effect.
(3 marks)
F. Suppose we need to weld 304L with mild steel ASTM A285 grade C, select the required
electrode. Why?
(3 marks)
G. Select the joint design for 304L and compute the required electrode weight for welding by
MIG process.
(8 marks)
Q4. Answer with a true or false and correct the error, if any.
A. Low coefficient of thermal expansion tends to increase the shrinkage of the weld metal and
the metal adjacent to the weld and thus increases distortion.
B. Electrodes/wires/ rods chemical composition may not be similar to Ni-base alloy being
welded.
C. Using helium instead of argon with TIG or MIG when welding copper will reduce
probability to use preheating.
D. V – Groove weld shows less distortion than X –groove weld.
E. The hot pass should be started after completely finishing the root pass, always within ten
minutes.
F. Stabilizing elements (Ti, Nb…) in a certain types of stainless steels have a stronger affinity
for carbon than does chromium.
G. Hot shortness characteristics of some resultant weld composition; 0.5-1.2%Si, 5-10%Cu, 1.5-2.5%Mn,
2-5%Mg,4-5%Zn, 1-1.5%Fe
H. Weldability of Ferritic st. st. is more than Martensitic st. st.
I. Cellulosic electrodes for vertical down pipe welding (EXXXX-P1) have a thicker coating
than the normal cellulose (EXX10).
J. The effect of Mn/C ≥ 3:1 ratio in any carbon steel is important to reduce toughness.

(10 marks)
 Engineering Technical College-Baghdad
Dept. : Welding Eng. MSc. Course
Subject: Welding Procedures Time: 2 hrs
Examiner: Prof. Dr. Adnan N. Abood Date: 14/6/2020
Final Examination

2020/2019

Q5. Answer with a true or false and correct the error, if any.
A. Nickel alloy joints have wider bevel, narrower root face and wider root opening than steel.
B. MIG process can be used to weld precipitation hardening Ni-alloys.
C. Argon gas gives more penetration than helium when welding Copper with TIG.
D. With the decrease in joint gap, the angular distortion increases.
E. Sensitization is caused by chromium carbide formation and precipitation at grain
boundaries in the heat affected zone when heated in the (200-300o C) temperature range.
F. To minimize grain growth for ferritic stainless steel, weld heat input should be minimized.
G. When carbon equivalent (Ceq) of alloy steel is 0.5% or more, not to be taken into
consideration for pre-heat temperature.
K. Types 308, 309 and 310 austenitic filler metals can be used to weld the martensitic steels to
themselves or to other steels where good as deposited toughness is required.
H. The controlling of Mn/S ≤ 10:1 ratio in any steel is to increase weldability.
I. The heat affected zone HAZ of C-Mn steel that is welded using very low heat input may
show low residual stress.
(10 marks)

2. Answer one question from the two followings.

Q6.
A. Weldability of cast iron has been found to be very poor due to……………
B. In WPS, what is meant by F No. and P No.?
C. Post heat treatment for weldments may be carried out for any of the following reasons;
1)………2)………3)……………..
D. Main Welding Defects when welding aluminum by fusion processes except hot shortness;
1)………….2)………..3)………..4)………..
E. The purpose of the hot pass in pipe welding is primarily to; 1) ………….2)……………….
F. What is meant by 5LX 42………………………………..
G. Normally delta ferrite level ………………. is recommended to avoid hot cracking in
austenite st. st. weldments.
H. In WPS variables, what is meant by ± or φ Backing Gas?
I. In the figure, when GMAW is used, indicate the shielding gas used to weld case-4
1- Helium 2- Argon + Helium 3- CO2 4- Argon 5- Argon + CO2
 Engineering Technical College-Baghdad
Dept. : Welding Eng. MSc. Course
Subject: Welding Procedures Time: 2 hrs
Examiner: Prof. Dr. Adnan N. Abood Date: 14/6/2020
Final Examination

2020/2019

J. Exceeding the maximum inter-pass temperature specified for C-Mn steel weld joint, may
give……
(30 marks)

Q7.
A. Precipitation hardening Ni- base alloys are not preferable for welding with MMAW …………..

B. Identify the correct weld cross section “joint” below:

1- A single V groove weld joint 2- A double V groove weld joint 3- A weld joint
with a bevel depth of ½” 4- A and C 5- B and C

C. Preheating may be carried out for any of the following reasons ……………………………..
D. A stress relief for steel weldments is;
E. In WPS, what is meant by A-No. and group No. ? ……………
F. Solution of Hot Shortness of aluminum alloys are; 1)………2)………3)……..4)…
G. In WPS variables, what is meant by φ Stringer/Weave?.
H. Hot cracking in austenite st. st. weldments can be prevented by; 1)….2)….3)…..4)…..
I. The problems are associated with welds martensitic stainless steels; 1) …..2)… 3)….
J. Flat position is used whenever possible for welding copper by fusion processes because ………

(30 marks)

 There are attached tables may need to use it in the answer.

Good Luck