Name: Lakshya Khanna
Branch:Just write like a conventional question-
IT-1
Shift: Morning form.
answer
Enrolment no: 02513203125
Roll No.: 25
conventional question-answer format:
Question 1
Define welding and classify welding processes based on the state of metal during
welding. Explain the advantages of welding over other joining methods like riveting and
bolting. Why is welding considered the most versatile joining process in modern
manufacturing?
Answer:
Welding is a process of joining two or more metal parts by heating their surfaces to
a suitable temperature and applying pressure or using a filler material to form a
permanent joint.
Welding processes can be classified based on the state of the metal during welding:
Solid-state welding: Metals are joined without melting (e.g., friction welding).
Fusion welding: Metals are melted at the joint to form a pool and then solidify
(e.g., arc welding).
Advantages of welding over riveting and bolting include:
Provides a continuous joint with better strength and leak-proof
properties. Requires less weight and space compared to
mechanical fasteners.
Faster production and reduced material cost.
No holes or disassembly needed, preserving material integrity.
Welding is considered the most versatile joining process because it can join
different types and thicknesses of metals with various techniques, can be
automated, and is widely used in industries like automotive, aerospace, and
construction.
Question 2
Calculate the heat generated in resistance spot welding with the following parameters:
Welding current I = 12,000 A, Contact resistance R = 150 μΩ, Welding time (t) = 0.8
seconds, Overall efficiency = 75%. Also, find the actual heat utilized for welding and
explain why efficiency is less than 100% in resistance welding.
Answer:
Given:
$ I 12000 , A $, $ R 150 \times 10^ 6 , \Omega $, $ t = 0.8 , s $, $ \eta =
75% 0.75 $ Heat generated,
Actual heat utilized,
Efficiency is less than 100% because some heat is lost due to radiation, conduction
to the surrounding parts, and heat dissipation to electrodes. Not all electrical
energy is converted into useful heat at the weld spot.
Question 3
Explain the oxy-acetylene gas welding process with a neat labeled diagram. Describe the
three types of flames produced and specify which flame is used for welding different
materials (mild steel, cast iron, copper, aluminum).
Answer:
Oxy-acetylene welding is a gas welding process where a flame is produced by
burning a mixture of oxygen and acetylene gas. The flame melts the base metal,
and a filler rod is added to join the metals.
Flame types:
Neutral flame: Equal oxygen and acetylene, used for
mild steel. Carburizing flame: Excess acetylene, used
for cast iron.
Oxidizing flame: Excess oxygen, used for copper and brass.
For aluminum, inert gas welding is commonly preferred instead of oxy-
acetylene. The flame heats the metal to melting without oxidizing or
carburizing the metal.
Question 4
Compare Shielded Metal Arc Welding SMAW) and Gas Tungsten Arc Welding GTAW/TIG)
processes in terms of electrode type, shielding method, weld quality, skill requirement,
productivity, and cost.
Parameter SMAW GTAW/TIG
Electrode Type Consumable covered electrode Non-consumable tungsten
electrode
Shielding Method Flux coating on electrode generates External inert gas shield (argon)
gas
Weld Quality Good, but slag removal needed Excellent, clean with no slag
Skill Requirement Moderate High skill required
Productivity Moderate Lower due to slower welding
speed
Cost Lower initial equipment cost Higher initial equipment cost
SMAW is good for general purpose welding, while GTAW is preferred for critical,
thin, or exotic metals.
Question 5
An arc welding operation has these parameters: V 28 V, I 200 A, S 5 mm/s, arc
efficiency = 85%. Calculate: a) Power input to arc b) Heat input per unit length c) Heat
input if speed increases to 8 mm/s.
Answer:
a)Power,
b)Heat input per unit length,
c)For S 8 mm/s,
Effect: Increasing welding speed decreases heat input per unit length.
Question 6
Explain submerged arc welding SAW) with sketch, discuss granular flux functions,
advantages and limitations, and why itʼs unsuitable for overhead welding.
Answer:
SAW is a continuous arc welding process where the arc is submerged under a layer
of granular flux. The flux protects the molten weld pool and stabilizes the arc.
Flux functions:
Protects weld from oxidation.
Provides slag formation to protect cooling
weld. Stabilizes arc and improves weld
quality.
Advantages:
High deposition
rate. Deep
penetration.
Automated and clean process.
Limitations:
Limited to flat or horizontal welding positions.
Not suitable for overhead welding because flux and molten metal can fall.
Question 7
Classify welding electrodes as per AWS and explain: E6013, E7018, E308 16. Discuss
storage requirements for low hydrogen electrodes and consequences of improper
storage.
Answer:
AWS classification:
The first letter 'E' means electrode.
The first two digits indicate tensile strength 60
60,000 psi). The third digit indicates welding
position.
The last digit indicates type of coating and current .
E6013 General purpose, rutile coating, AC/DC, medium
penetration. E7018 Low hydrogen, DC , high strength,
used for critical welds.
E308 16 Stainless steel electrode for 18/8 stainless steel.
Low hydrogen electrodes need to be stored in dry, heated cabinets to prevent
moisture absorption. Improper storage causes hydrogen embrittlement and weld
cracking.
Question 8
Resistance seam welding of 2 mm thick sheets, I 8000 A, R 200 μΩ, t=0.5 s,
spots/min=120. Calculate: a) Heat per spot b) Total energy per minute c) Actual heat
utilized if efficiency = 60%.
Answer:
a)Heat per spot,
b)Total energy per minute,
c)Actual heat utilized,
Question 9
List and explain six common welding defects with causes and remedies, classified
as external and internal defects.
Answer:
External
defects:
Porosity: Gas trapped; remedy - improve shielding.
Undercut: Excessive melting; remedy - reduce
heat input. Spatter: Droplets around weld; remedy
- adjust arc length.
Internal defects:
Incomplete penetration: Weld not full depth; remedy - correct
parameters. Slag inclusion: Flux trapped inside weld; remedy -
clean between passes. Cracks: Thermal stress; remedy -
preheat and control cooling.
Question 10
Explain three NDT methods for weld inspection: Dye Penetrant Testing DPT , Radiographic
Testing RT , Ultrasonic Testing UT . Recommend a method for detecting surface cracks
in aerospace welds.
Answer:
DPT Dye seeps into surface cracks, then developer reveals defects. Simple and
low cost, but only surface cracks.
RT Weld irradiated with X-rays, defects show as dark areas on film. Good
for internal defects, permanent record but costly and safety concerns.
UT High-frequency sound waves reflect off defects. Portable and detects surface
and internal flaws.
Recommendation: DPT for surface cracks in aerospace components due to its
sensitivity and
ease for surface defects.
If you want, sketches for processes like oxy-acetylene welding and submerged arc
welding can
be added to complete the answer. Let me know if you want that included. This
completes the assignment in standard question-answer format as requested.