NPTEL Online Certification Course

Advances in Welding and joining technologies

A-1: Detailed Solution
Indian Institute of Technology Guwahati

1. Following welding processes comes under the pressure welding process because
pressure is also applied during these processes.
i. Resistance welding
ii. Diffusion welding
iii. Explosive welding

2. This statement is false since complete melting of material is not required for solid-state
welding. The electroslag welding process is homogeneous since filler material has the
same metallurgical composition as base metal; hence this statement is true. Statement
(iii) is also true because the temperature should be above the melting point to create a
fusion welding process. Brazing is a type of permanent joining process.
3. In straight polarity, the electrode is connected to the negative terminal while the
workpiece is connected to the positive terminal. Hence, 2/3rd of the heat will be
generated at the workpiece and 1/3rd at the electrode. So, more heat at the workpiece
results in a higher penetration depth and less deposition rate.
4. In the shield metal arc welding process, flux produces shielding gas. In the gas tungsten
arc welding process, shielding is provided by the inert gases. In submerged arc welding,
shielding is provided by the flux granules.
5. In oxy-acetylene gas welding, the ratio of oxygen to acetylene in a neutral flame is
exactly one-to-one. Hence, both cylinders (same capacity) will be emptied at the same
time. In an oxidizing flame, the flame contains more oxygen than the neutral flame.
Hence, the oxygen cylinder will be emptied first in case of oxidizing flame.
6. The voltage-current characteristic of a constant voltage power source for arc welding
must be a downward linear negative slope. In contrast, the voltage-current characteristic
of a constant current power source must be sharply drooping.
7. Gas tungsten arc welding and plasma arc welding use a non-consumable electrode for
joining the workpiece.
8. In thermit welding, the molten metal is produced due to heat generated by the
exothermic chemical reaction between aluminum powder and iron oxide components.
𝟖𝐀𝐥 + 𝐅𝐞𝟑 𝐎𝟒 = 𝟗𝐅𝐞 + 𝟒𝐀𝐥𝟐 𝐎𝟑

9. In brazing and soldering:

• In soldering, the joining process wherein metals are bonded together using a non-
ferrous filler metal with a melting temperature lower than 450 °C.
• In brazing, the melting point of the filler metal or alloy is greater than 450 °C.
• In soldering, the filler metal is made of lead and tin
• Tin promotes the wetting action required for making the joint

10. Given:
Welding current = 250 A
Welding voltage = 20 V
Welding speed = 4 mm/s
Arc Power = Welding current X Welding voltage
= 250 X 20
5 kW.