SECOND SEMESTER MID TERM THEORY EXAMINATION:

SHEET METAL AND WELDER COURSE

(DATE - _______MAR 2024)

Instructions (Read Carefully)

• Attempt all the questions in question 1 to 3 Maximum Marks -
• No overwriting/ cutting/ use of correction pen is allowed. Time Allotted -
• Only blue ball pen will be used.
• Circle the correct answer in question No 3.
• No extra sheet will be provided for rough work.
• The tables given in the question paper are to be drawn in the answer sheet.

Student No _________________ Rank ___________ Name ___________________________________

Question 1. Fill in the blanks. (5 x 1 = 5 Marks)

(a) The ______________ is use to connect the earth cable firmly to the job or welding table and the same is
made of copper or its alloy.
(b) The distance to be maintained between the work piece and nozzle in oxy-acetylene gas welding
is________.
(c) Oxy-acetylene cutting torch is used to cut MS plate above_______________thickness.
(d) Identify of the Part name of X and Y____________

(e) In SMAW, while depositing the beads on the MS plate, advance the bead on each weave by not more than
_______ mm to keep the molten slag away from the molten pool of metal.

Question 2. State True or False. (5 x 0.5 = 2.5 Marks)

(a) The size of nozzle to be selected for gas welding process varies according to the thickness of the metal to
be welded.
( )
(b) In OAW, rubber hose-pipe is used for carrying oxygen is maroon colour while those for acetylene are black.
( )
(c) Brazing is a metal joining process which is done at a temperature of above 450°C as compared to soldering
which is done at below 450°C. ( )
(d) Blow hole and porosity in a weld are caused by the presence of contaminants/impurities on the job surface
or on electrode flux. ( )
(e) Electrode holder is a clamping device used to grip and manipulate the electrode during arc welding.
( )
Question 3. Choose the correct answer. (5 x 0.5 = 2.5 Marks)
(i) Identify the Name of the welding defect this figure

(a) Spatter (b) Undercut

(c) Overlap (d) Blowhole and porosity
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(ii) In Ohm’s law, what does “R” represent?

(a) Current in amperes (b) Voltage in Volts
(c) Resistance in Ohms (d) None of the above

(iii) Identify the types of welding joint given below in the picture?

(a) Corner joint (b) Edge joint

(c) Lap joint (d) Tee joint
(iv) In the following figure, the symbols “X” refers to-

(a) Root Gap (b) Root Face

(c) Root Run (d) Root Penetration
(v) When brass is welded using oxy-acetylene welding, we use __________ flame
(a) Oxidizing (b) Neutral
(c) Carburising (d) None of the above
Question 4. Answer any two (2 x 5=10 Marks)
(a) Your supervisor has asked you to make a square butt joint of size 150x50x2mm. You have a MS steel
sheet of 180x120x2mm?
(i) State, how you will carry out setting and tacking.
(ii) Make a diagram to indicate the root gap you will maintain, What are the reason for keeping such a
root gap
(b) One refrigerator with damage in copper pipe line has arrived to MTTS welder workshop. Your supervisor
inspected the damage and found out that you have to weld using OAW.
(i) Why will you use oxy-acetylene welding and not shield metal arc welding?
(ii) State the types of flames employed in `oxy-acetylene welding? Mention details in the table given
below.

Ser No Type of Description Combustion Ratio of Uses

Flame Gases

(c) Which faults were commonly observed in arc welding? Explain the under mentioned five defects of arc
welding in the table format given below.
S/ Defect Causes Preventive Action Annotated Figure
No to be drawn here
(aa Undercut
)
(ab Overlap
)
(ac) Blowhole
(ad Spatter
)
(ae Crack
)
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SECOND SEMESTER MID TERM PRACTICAL EXAMINATION:

SHEET METAL AND WELDER COURSE (BATCH II)
(DATE ____ MAR 2024)

Instructions (Read carefully)

• Attempt all the practical tasks. Maximum Marks -
• Only blue ball pen is used in writing any calculation.
• Neat diagrams to be made duly annotated.
• Use the space given for rough work.

Question 1. Practical Tasks. (120min)

(a) Construct fillet “T” joint on 10mm thick M.S plate in flat position using SMAW welding procedure. (40 min)
(b) Construct deposit straight line bead on MS plate in flat position. (20 min)
OR
(c) Construct weaving beads on MS Plate 10mm thick in flat position using SMAW welding procedure. (20 min)
(d) Construct edge joint on M.S sheet 2mm thick in flat position without filler rod using oxy-acetylene welding.
(40 min)

Question 2. Viva Voce and Identification of Tools and Instruments. (Additional time)