ADVANCED WELDING TECHOLOGY

UNIT 1 1. 2. 3. 4. 5. 6. 7. 8. 9. Explain importance and applications of welding. How welding processes are classified Name some joining process other than welding. List the criteria for selection of welding process. Discuss the requirements of formation of ideal metallurgical bond . Discuss the variation of joint strength with gap thickness in solid\ liquid bonding process . Give the relative advantages and limitations of various welding process . Explain gas welding process. Why oxy-acetylene gas is used ? Give a short note on chemistry of oxy-acetylene flame. Explain different types of flames .Give commonly used materials and types of flame used . Show typical oxy-acetylene flame with temp. variation . With reference to gas welding explain gas cylinders, pressure regulators, welding torch, welding rods and flux. the list of some

10. Explain various welding techniques used in welding . 11. Show the basic circuit for arc welding and explain it. 12. Explain mechanism of arc with arc structure ,and arc force . 13. Explain V-I and V-L characteristics in detail . 14. Explain D.C.S.P. and D.C.R.P.in detail and compare with A.C. . 15 Discuss various types of electrodes .Compare carbon and graphite electrodes. 16 Discuss various ingredients of combustible electrodes. Explain effect of polarity also. 17 Discuss single and twin carbon electrode arc welding process. 18. Explain constant current and constant voltage characteristics of welding machines. 19 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Discuss the functions of electrode coating. Discuss operating parameters of metal arc welding . Discuss flux shielded metal arc welding method (S.M.A.W.) . Explain Tungsten Inert Gas (T.I.G.) Welding method . With reference to TIG welding ,explain Balanced & Unbalanced wave form, Rectification and methods to overcome unbalanced wave form . Explain arc initiation mechanism and gas shielding methods . Explain M.I.G. Welding method . discuss advantages and limitations . Draw the neat figure and discuss various modes of metal transfer in arc welding. Explain resistance spot and seam welding process with neat figure. Draw current and pressure cycle for resistance welding. Show the effect of current ,pressure and time on weld strength in resistance spot welding process. Explain high frequency resistance welding (HFRW) and high frequency induction welding. Explain projection ,flash and percussion welding process. Explain electro slag and electro gas welding . Explain operational steps of friction welding ,also discuss the effects of variables on it. Discuss the steps of inertia welding. Give the sketch of fiber flow line in friction and inertia welding . Discuss the submerged arc welding (SAW) and flux cored arc welding (FCAW). 20. Discuss arc blow in d.c. arc welding. Suggest some methods to reduce severity of arc blow problem.

ADVANCED WELDING TECHOLOGY

36 37 38 39 40 Comment on cold and hot pressure welding. Give a note on diffusion bonding, stud welding and thermit welding. What do you mean by fusion arc welding.? Comment on manual, semi-automatic, automatic and automated welding process. Give the list of various welding process along with A .W .S. designation.

ADVANCED WELDING TECHOLOGY

UNIT 2 41 Discuss plasma arc welding .Compare it with T.I.G. welding. applications of cold welding. 43 Explain theory of diffusion (bonding) welding. Give the name of various diffusion welding methods. 44 Discuss general features of welding techniques using radiation energy. What do you mean by power density? 45 Explain key hole techniques .Discuss various forces tending to form and maintain key hole. 46 Explain electron beam welding (E.B.M.) Discuss effect of vacuum on E.B.M. .Compare vacuum and atmospheric welding system. 47 Comment on electron beam gun , vacuum pumping system ,process variables and applications Of E.B.M. 48 Explain principle and operation of LASER beam welding with its advantages and limitations. 49 What do you mean by ultrasonic welding. Discuss metallurgy of this welding. 50 Explain atomic hydrogen welding with its applications and limitations.

42 Discuss mechanism of cold welding. Give the name of some materials which are welded by cold welding. Give the

ADVANCED WELDING TECHOLOGY

UNIT 3 51 Discuss the metallurgy of explosive welding (E.X.W.) Write the name of some explosives used .discuss Limitations and applications of E.X.W. 52 Give the characteristics of under water welding . discuss some common problems encountered in under water welding. What do you mean by hyper baric and cavity welding . 53 Explain cladding process in detail with advantages and limitations. 54 Explain thermal spray coating (metalizing) . Give advantages and limitations also. 55 Discuss with neat figure (a) flame spraying (b) electric arc spraying (c) plasma arc spraying 56 Discuss characteristics and applications of sprayed metals. 57 Explain objectives of hard facing .Discuss various surfacing methods with neat figure. 58 Explain soldering and brazing process in detail. 59 Give the soldering and brazing recommendations for some commonly used engineering materials. 60 Comments on welding of plastics.

ADVANCED WELDING TECHOLOGY

UNIT 4 61 Give the list of some common welding defects, there causes and remedial measures taken to minimize them. 62 Discuss general sources of weld defects in detail. 63 How do you classify cracks . Discuss various factors which may promote hot cracking. 64 Comment on weld decay ,dilution ,porosity and blow hole in welding joints. 65 Comment on spatter, inclusion, incomplete penetration and corrosion of welding. 66 Give the short note on - liquation cracking, crater cracking , reheating cracking and stress corrosion cracking. 67 Explain distortion and shrinkages in welding joints .Discuss various measures taken to control distortion . 68 Explain following tests used to test welding joints tensile test , bend test and impact test. 69 Explain liquid dye penetration test ,fluorescent-penetration test and eddy current test . 70 Explain radiography , ultra sonic test and magnetic particle inspection test used to inspect welding joints.

ADVANCED WELDING TECHOLOGY

UNIT 5 71 What do you mean by weldability? Discuss various tests performed to check weldability. 72 Comment on various problems associated with welding of stain- less steel. 73 Explain various zones of welding joint. Discuss main features of H.A.Z. 74 Discuss various causes of the development of residual stresses in welding joints. 75 Discuss longitudinal and transverse residual stresses in welding joints with neat figure showing variation of these stresses. 76 Discuss various defects produced due to residual stresses in welding joints. 77 Explain various methods of controlling welding residual stresses. 78 Comment on welding sequence, peening ,preheating and post welding heat treatment(PWHT). 79 What do you mean by vibratory stress relief (V.S.R.) Discuss its procedure and uses. 80 Draw a figure showing standard identification and symbols for weld. 81 What are the objectives of pre-heating? Give advantages and limitations. 82 Comment on heat input of welding process. 83 Calculate melting efficiency in case of arc welding of steel at 20 V,200 amp. Current. The travel speed is 5 mm/s and cross-section area of joint is 20 sq mm . Heat required to melt steel is taken as 10 J/ cubic mm and heat transfer efficiency is taken as 0.85. 84 Two steel sheets 1 mm thick are resistance welded in lap joint with a current of 10,000 amperes and 0.1 s . The effective resistance is 100 micro-ohm . The joint may be considered as cylinder of 5 mm diameter and 1.5 mm height. Density of steel is 0.00786 g/cubic mm and heat required for melting steel is 10 J/cubic mm . Calculate the heat loss. 85 Give the expression for preheating temperature and peak temp. 86 Explain brittle coat and photo-stress methods . 87 Discuss principles of sound welding design. 88 Comment on allowable strength of various welded joints . 89 Comment on eccentric loaded joint with neat figure. 90 Comment on design of tubular joint , pipe and pressure vessels. 91 Discuss thermal considerations and temp. distribution in butt weld. 92 Discuss heat flow in fillet weld and resistance butt weld. 93 Comment on heat flow in under water welding. 94 Discuss metallurgical effects of heat flow in welding. 95 Comment on residual life assessment of welded structure. 96 Show in figure different zones of a steel weldment as represented on an iron carbon diagram. 97 Discuss effects of thermal gradient on weld metal structure. 98 Discuss toughness and other properties of H.A.Z.. Define grain growth and grain refined zone of H.A.Z. 99 Discuss effect of welding speed on grain structure. 100 Comment on epitaxial solidification and fusion boundary zone.