Module 4

Explain the Working principle of Arc welding with neat sketch.

Describe the construction & working of Arc welding process with neat sketch

Arc welding: It is a type of fusion welding. It operates under the principle that when two
conductors of an electric circuit are touched together momentarily and then
instantaneously separated slightly, assuming that there is sufficient voltage in the circuit
to maintain the flow of current, an electric arc is formed. Concentrated heat is produced
throughout the length of the arc at a temperature of about 5000 to 6000 oC. In arc
welding, usually the parts to be welded are wired as one pole of the circuit, and the
electrode held by the operator forms the other pole. When the arc is produced the
intense heat quickly melts the work piece metal which is directly under the arc, forming
a small molten metal of the electrode is carried over by the arc to the molten metal pool
of the work piece. The molten metal in the pool is agitated by the action of the arc,
thoroughly mixing the base and the filler metal. A solid joint will be formed when the
molten metal cools and solidifies. The flux coating over the electrode produces an inert
gaseous shield surrounding the arc and protects the molten metal from oxidizing by
coming in contact with atmosphere.
Explain the different types of flames used in Gas welding.

(i) Neutral flame:

With the help of a neat sketch explain the working of Gas welding
Oxy-acetylene welding: It is a fusion welding, in which a strong gas flame is used to
raise the temperature of the work piece to melt them. As in the arc welding, a filler metal
is used to fill the joint. The gases that can be used for heating are (i) Oxygen and
acetylene (ii) Oxygen and hydrogen. Oxy-acetylene gas mixture is most used in gas
welding. When right proportions of oxygen and acetylene are mixed in the welding torch
flame produced is called as the oxy-acetylene flame. The temperature attained in 3200o
C, hence has an ability to melt all commercial metals.

Enumerate the Difference between Soldering, Brazing and Welding.

Comparison between Welding, Soldering and Brazing:

What is Soldering? Explain the process of soldering

Soldering
• Soldering is a method of joining similar or dissimilar metals by the application of heat
and using a filler metal or alloy called solder, whose liquidus temperature is below 450o
C.
• The molten filler metal is made to flow between the two closely placed adjacent
surfaces by the capillary action.
• Though soldering obtains a good joint between the two plates, the strength of the joint
is limited by the strength of the filler metal used.
Sequence of operations: The following operations are required to be performed
sequentially for making soldered joints.
• Shaping and fitting of metal parts together: The two parts to be joined are shaped to fit
closely so that the space between them is extremely small and filled completely with
solder by capillary action. If a large gap is present, capillary action will not take place,
and the joint will not be strong.
• Cleaning of surfaces: In order to obtain a sound joint, the surfaces to be soldered are
cleaned to remove dirt grease or any other foreign material.
• Application of flux: The flux is applied when the parts are ready for joining.
• Application of heat and solder: The parts are held in a vice or with special work holding
devices so that parts do not move while soldering.
Advantages:
• Simple and economical process.
• Relatively low temperature process, there is no metallurgical damage to base
metal.
• The soft soldered joints can easily be dismantled by simple heating.
Disadvantage:
• The strength of joint relatively low.
• Flux must be thoroughly cleaned off after soldering, as it is often corrosive.
What is Brazing? Explain the process of soldering

Brazing is a process of making joints where in coalescence is produced by

heating to suitable temperatures above 500o C and by using a non-ferrous filler metal
having a melting point (up to 900o C) below that of the base metal, the filler metal being
distributed between the closely fitted surfaces of the joint by capillary action. Brazing
gives a much stronger joint than soldering
The principal difference is the use of a harder filler material commercially known as
spelter. Filler metals used in this process may be divided into copper base alloys and
silver base alloys. The spelter is usually an alloy of copper, zinc and tin. Both similar and
dissimilar metals can be joined. • The flux along with spelter (filler metal) is applied to
remove oxides from the surfaces. Borax is the most widely used flux. It will dissolve the
oxides of most of the common metals. Other fluxes used are mixtures of borax, boric
acid, fluorides and chlorides.
Advantages:
• Dissimilar metals, such as stainless steel to cast iron can be joined by
brazing. Almost all metals can be joined by brazing except aluminium and magnesium
which cannot easilybe joined by brazing.
• Because of the lower temperatures used there is less problems due to heat.
• The joint can be quickly finished without much skill.
• Because of the simplicity of the process it is often an economical joining
method with reasonable joint strength.
• The brazed joints are reasonably stronger, depending on the strength of the
filler metal used.
Disadvantages:
• Flux material required to prevent the corrosion.
• Large section cannot be joined.
• Fluxes and filler materials may toxic.
• Filler materials are expensive
Describe the following Materials i) Ceramics ii) Shape memory Alloys

Describe the three types of carbon steels with applications

Low Carbon Steel: It is also called Mild steel and the most common type of carbon
steel. It contain 0.03-0.25%off carbon and rest is iron It is soft, ductile and it has good
machinability, good weldability, good toughness, good impact resistance.
Applications: It finds applications in nails, rivets, bolts, nuts, beams, boiler
plates, shafts, gears and axles.

Medium Carbon Steel: It has 0.25-0.59% of carbon and rest is iron

Properties: like good toughness, high hardness, high tensile strength, good
bending strength, wear resistance and good machinability.
Applications: It is used in transmission shafts, axles, gears, connecting rods
Alloy Steel : An alloy can be defined as a homogeneous mixture of two or more metals.
Alloy steel include iron and carbon.

Stainless Steel • It is an iron-carbon alloy with chromium content of 11.5%-

25%depending upon the properties • Chromium helps to resist corrosion in steels. •
They get the name because they do not corrode or stain easily.
Applications: Manufacturing of kitchen utensils, sinks, food processing equipment,
chemical plant and equipment, knife blades, surgical instruments etc.,

Chromium Steel • In this type of steel chromium is the alloying element • It improves
toughness, resistance to heat, corrosion
Applications: application in balls, rollers, cutting tools
Write a short note on Shape Memory Alloys

Shape-memory alloy: • Shape-memory alloy (SMA) is an alloy that can be deformed

when cold but returns to its predeformed ("remembered") shape when heated. • It may
also be called memory metal, memory alloy, smart metal, smart alloy, or muscle wire. •
Parts made of shape-memory alloys can be lightweight, solid-state alternatives to
conventional actuators such as hydraulic, pneumatic, and motor-based systems. • They
can also be used to make hermetic joints in metal tubing.

Types of Shape-memory alloy • The two most prevalent shape-memory alloys are
copper-aluminium-nickel and nickeltitanium (NiTi), but SMAs can also be created by
alloying zinc, copper, gold and iron. • Although iron-based and copper-based SMAs,
such as Fe-Mn-Si, Cu-Zn-Al and Cu-Al-Ni, are commercially available and cheaper than
NiTi, NiTi-based SMAs are preferable for most applications due to their stability and
practicability as well as their superior thermo-mechanic performance.

Applications of Shape-memory alloy:

• Recent research of SMA has been applied in the field of Aerospace, Automotive,
Biomedical, and Robotics. • This memory effect is due to the presence of austenite and
martensite crystalline structures. These alloys are bio-compatible, lightweight, and also
possess a high force-to-weight ratio.

Defrine the following terms:

i. Ceramic ii. Graphite iii. Polymers
Ceramics
• Ceramics are inorganic solid materials containing compounds of metallic and non-
metallicelements most frequently oxides, nitrides and carbides • Ceramics are good for
high temperature applications mainly because of their unique mechanical, chemical,
structural and functional properties • Example: Clay, Bricks, Tiles, Glass, Cement
Graphite:
• Graphite is a crystalline form of the element carbon. It consists of stacked layers of
graphene. • Graphite occurs naturally and is the most stable form of carbon under
standard conditions. • Synthetic and natural graphite are consumed on large scale for
uses in pencils, lubricants, and electrodes. • Under high pressures and temperatures, it
converts to diamond. It is a weak conductor of heat and electricity.

Polymers: • These are the organic materials with carbon as a element in their formation
• Ploymers are composed of large number of small molecules called manomers •
Examples: Polyethylene, polyvinyl chloride, Nylon, Polypropylene, Polythene

Properties: • They have low density • They exhibit good corrosion resistance • They
process good mouldability • They have low coefficient of friction • They give excellent
surface finish • Low mechanical properties

Define rhe engineering materials? Explain the classifications of Ferrous and Non
ferrous materials

Explain the different types of Ferrous materials with applications.

Explain the different types of Nonferrous materials with applications

OR
Recite the classification of metals

Engineering materials are defined as solid substances which are manufactured and
used for various engineering applications.

Pig Iron: It is the first stage of iron directly extracted from the ore through blast furnace.
It Contain high percentage of carbon and other impurities.
Properties: High hardness and Vey brittle
Applications: It is used in making wrought iron, cast iron and steel

Wrought iron: Wrought iron is an iron alloy with a very low carbon content
Properties: Low carbon content, Soft, Highly Ductile in nature, High toughness,
Good machinability, Corrosion resistance, High elasticity.
Applications: Due to corrosion resistance it is used in making steam and water
pipes. Decorative applications like fences, gates and railings, balconies, bars, engine
bolts, rivets, railway couplings, chain links and crane hooks.

Cast Iron: Is a ferrous material that is produced when pig iron is remelted in a cupola
furnace .
 Properties: Very strong but brittle, Low melting point, Good fluidity, Castability,
Goodmachinability, wear resistance
Applications: Manufacture of machine frames, columns, beds and plates,
housing, flywheels, manhole covers, engine block, cylinder head, gearbox case,
machine parts etc,

Grey Cast: Iron It is produced when the molten pig iron in the mould is allowed to cool
and solidify slowly. Carbon here is mainly in the form of graphite
Properties: Good castabality, High fluidity, easy Machinability, high strength and
ductility under compressive loads. It is named as Grey cast iron because of its freshly
fractured surface has a grey appearance
Applications: Base structures of machinery, Automotive engine blocks, gears,
flywheels, brake discs and drums and machine bases.

STEEL
Low Carbon Steel: It is also called Mild steel and the most common type of carbon
steel. It contain 0.03-0.25%off carbon and rest is iron It is soft, ductile and it has good
machinability, good weldability, good toughness, good impact resistance.
Applications: It finds applications in nails, rivets, bolts, nuts, beams, boiler
plates, shafts, gears and axles.

Medium Carbon Steel: It has 0.25-0.59% of carbon and rest is iron

Properties: like good toughness, high hardness, high tensile strength, good
bending strength, wear resistance and good machinability.
Applications: It is used in transmission shafts, axles, gears, connecting rods

Alloy Steel : An alloy can be defined as a homogeneous mixture of two or more metals.
Alloy steel include iron and carbon.

Stainless Steel • It is an iron-carbon alloy with chromium content of 11.5%-

25%depending upon the properties • Chromium helps to resist corrosion in steels. •
They get the name because they do not corrode or stain easily.
Applications: Manufacturing of kitchen utensils, sinks, food processing equipment,
chemical plant and equipment, knife blades, surgical instruments etc.,

Chromium Steel • In this type of steel chromium is the alloying element • It improves
toughness, resistance to heat, corrosion
Applications: application in balls, rollers, cutting tools

Non-Ferrous Metals
These are metals without iron content. These materials are preferred due to • Good
strength to weight ratio • Good resistance to corrosion • Light weight • High electrical
and thermal conductivity • Ease fabrication

Aluminium • It is extracted from Bauxite • The mechanical properties can be

improved by mixing aluminium with silica, copper,zinc

Properties: • Light weight, high ductility, good electrical and thermal conductivity, good
resistance tocorrosion
Application: • Used in making aircraft parts • Used in automobile for making cylinder
block, piston and other engine componenets • Used in domestic application for making
cooking utensils • Electrical industry- cables, induction motor, conductors rotors

Alloys of Aluminium- Duralumin, Magnalumin

Copper • Reddish brown colour, extracted from PYRITE • It is soft, malleable, ductile,
light weight, high thermal conductivity, good corrosionresistance, good electrical and
thermal conductivity
Applications: • Used to make door knobs • Used in electrical wires, cable,
conductors • Used to make alloy of brass and bronze • In the form of tubes used in
refrigerator, air conditioner and radiator due to high thermalconductivity

Alloys of Copper: Brass, Bronze, Gun Metal

Lead
Alloys of Lead • Solder: Lead and tin used for joining less fusible metals Lead foil: is
made sandwich of lead between two sheets of tin,. Lead foils are used inradiation
shielding • Lead-antimony alloy: are used in storage batteries grid Zinc • Is heavy bluish
white metal which can be extracted from Zinc Sulphide or Zinc blend • It is fair conductor
f electricity • It has low melting point and boiling point • It is resistance to corrosion and
good castability Application • Galvanizing: To protect iron and steel form corrosion, they
are immersed in a bath ofliquid zinc or electroplated with zinc, this is called galvanizing
• Galvanised steels is used in produce automobile parts Alloy of Zinc • Cadmium zinc
alloy • Magnesium zinc alloy • Copper zinc alloy • Lead zinc alloy • Iron zinc alloy