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Welding Video
Types of Joints
Welding Definition
Welding is a process by which two materials, usually
metals, are permanently joined together by
coalescence, which is induced by a combination of
temperature, pressure, and metallurgical conditions.
The particular combination of these variables can
range from high temperature with no pressure to high
pressure with no increase in temperature.
Kalpakjian
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A higher ratio, such as 1.5 : 1, produces an oxidizing Excess fuel, on the other hand, produces a carburizing
flame, hotter than the neutral flame (about 3300oC) flame. Carburizing flame can carburize metal also.
but similar in appearance. The excess fuel decomposes to carbon and hydrogen,
Used when welding some nonferrous alloys such as and the flame temperature is not as great (about
copper-base alloys and zinc base alloys but harmful 3000oC).
when welding steel because the excess oxygen reacts Flames of this type are used in welding Monel (a
with the carbon, decarburizing the region around nickel-copper alloy),
the weld. It is also used for high-carbon steels, and some alloy
steels, and for applying some types of hard-facing
material.
Diagram
from 13.8 MPa to 18.2 MPa .
Due to high explosiveness of free acetylene it is stored
in a cylinder with 80-85% porous calcium silicate and
then filled with acetone which absorb upto 420 times
by its volume at a pressure 1.75 MPa .
At the time of acetylene release if acetone comes with
acetylene the flame would give a purple colour.
Another option is acetylene generator.
CaC2 2 H 2O C2 H 2 Ca (OH )2
Ans. (c)
Ans. (a)
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GATE-2003 GATE-2002
In Oxyacetylene gas welding, temperature at the The temperature of a carburising flame in gas
inner cone of the flame is around welding is that of a neutral or an oxidising flame.
(a) 3500C (a) Lower than
(b) 3200C (b) Higher than
(c) 2900C (c) Equal to
(d) 2550C (d) Unrelated to
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800
Eutectoid temperature
723
Austenite
Pearlite
600
T
post heating at higher temperature to temper the
martensite (590-760) required
300
Ms
Mf
100
Martensite
t (s)
When heat is applied (welding) the Carbon reacts with the Chromium to form
IES 2010
Chromium Carbide
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IES-2006 IES-1999
Fabrication weldability test is used to determine The correct sequence of the given materials in
(a) Mechanical properties required for satisfactory ascending order of their weldability is
performance of welded joint (a) MS, copper, cast iron, aluminium
(b) Susceptibility of welded joint for cracking (b) Cast iron, MS, aluminium copper
(c) Suitability for joint design (c) Copper, cast iron, MS, aluminium
(d) Appropriate machining process (d) Aluminium, copper, cast iron, MS
Ans. (a)
Ans. (d)
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Contd
Fig- differences in torch tips for gas welding and gas cutting
Contd
Contd Contd
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The drag lines shows the characteristics of the movement If torch moved too rapidly, the bottom does not get
of the oxygen stream. sufficient heat and produces large drag so very rough
and irregular-shaped-cut edges.
If torch moved slowly a large amount of slag is
generated and produces irregular cut.
Contd Contd
Steels with less than 0.3 % carbon cause no alloys oxidation and cutting is difficult.
problem.
Contd
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IES-1992 IES-2005
The edge of a steel plate cut by oxygen cutting will Consider the following statements:
get hardened when the carbon content is 1. In gas welding, the torch should be held at an angle of
30 to 45 from the horizontal plane.
(a) Less than 0.1 percent
2. In gas welding, the Size of the torch depends upon the
(b) Less than 0.3 percent thickness of metal to be formed.
(c) More than 0.3 percent 3. Drag in gas cutting is the time difference between
(d) Anywhere between 0.1 to 1.0 percent heating of the plate and starting the oxygen gas for
cutting.
Which of the statements given above are correct?
(a) 1, 2 and 3 (b) 1 and 2
Ans. (c)
(c) 2 and 3 (d) 1 and 3
Powder Cutting
Difficult to cut metals by oxy-fuel cutting process are:-
Cast iron, stainless steel,
and others high alloy steels
so we can use powder cutting.
By injecting a finely divided 200-mesh iron powder into
the flame, a lower melting point eutectic oxide is formed
at the cutting interface, where and cutting proceeds in a
similar way of oxy-fuel cutting.
GATE-2009 (PI)
Which of the following powders should be fed for
effective oxy-fuel cutting of stainless steel?
(a) Steel
(b) Aluminum
(c) Copper
(d) Ceramic
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Plasma Cutting
Uses ionized gas jet (plasma) to cut materials resistant to
oxy-fuel cutting,
High velocity electrons generated by the arc impact gas
molecules, and ionize them.
The ionized gas is forced through nozzle (upto 500 m/s), and
the jet heats the metal, and blasts the molten metal away. Free electrons
and ions
More economical, more versatile and much faster (5 to 8
times) than oxyfuel cutting, produces narrow kerfs and
smooth surfaces.
HAZ is 1/3 to th than oxyfuel cutting.
Maximum plate thickness = 200 mm
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Contd
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V I
V1
1
V2
OCV SCC
A
A1 A2 A1 A2
Arc length should be equal to the diameter of the electrode size IES 2010
In arc welding, the arc length should be equal to
(a) 4.5 times the rod diameter
(b) 3 times the rod diameter
(c) 1.5 times the rod diameter
(d) Rod diameter
Ans. (d)
IES-2001 IES-2001
In manual arc welding, the equipment should In arc welding, d.c. reverse polarity is used to bear
greater advantage in
have drooping characteristics in order to maintain (a) Overhead welding
(a) Voltage constant when arc length changes (b) Flat welding of lap joints
(c) Edge welding
(b) Current constant when arc length changes
(d) Flat welding of butt joints
(c) Temperature in the are constant
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IES-1998 IAS-1998
The voltage-current characteristics of a dc Assuming a straight line V-I characteristics for a
generator for arc welding is a straight line dc welding generator, short circuit current as 400A
between an open-circuit voltage of 80 V and short- and open circuit voltage as 400 which one of the
circuit current of 300 A. The generator settings for following is the correct voltage and current setting
maximum arc power will be for maximum arc power?
(a) 0 V and 150 A (b) 40 V and 300 A (a) 400 A and 100 V (b) 200 A and 200 V
(c) 40 V and 150 A (d) 80 V and 300 A (c) 400 A and 50 V (d) 200 A and 50 V
Ans. (b)
Varc=20+5L
GATE -2012 Same Q in GATE -2012 (PI) L=5mm
In a DC arc welding operation, the voltage-arc Varc=20+5X5=45Volt
length characteristic was obtained as Varc = 20 + 5L L=7mm
where the arc length L was varied between 5 mm Varc=20+5X7=55Volt
and 7 mm. Here Varc denotes the arc voltage in Volts.
Y Y1 Y 2 Y1
The arc current was varied from 400 A to 500 A.
Assuming linear power source characteristic, the X X1 X 2 X1
open circuit voltage and the short circuit current for
Y 55 45 45
the welding operation are
(a) 45 V, 450 A (b) 75 V, 750 A X 400 500 400
X Y
(c) 95 V, 950 A (d) 150 V, 1500 A
1
Ans. (C) 950 95
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GATE-1992
GATE 2015 (PI) A low carbon steel plate is to be welded by the manual
Two aluminum alloy plates each 10 mm thick and 1 m metal arc welding process using a linear V - I
long are welded without crowning by multi-pass characteristic DC Power source. The following data are
tungsten inert gas butt welding. The joint
available :
configuration is V-type with 60 angle and root gap is
maintained at 5 mm. If electrode of 5 mm diameter OCV of Power source = 62 V
with 500 mm length is used for welding, then the Short circuit current = 130 A
number of electrodes required is Arc length, L = 4 mm
(A) 7 (B) 9 (C) 11 (D) 13 Traverse speed of welding = 15 cm/s
Efficiency of heat input = 85%
Voltage is given as V = 20 + 1.5 L
Calculate the heat input into the workprice
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Example:
200 Ampere Power Source rated at 60% Duty Cycle
and operated at 250 Ampere (as far as permitted):
I
2
Electrode
IFS-2011 1. Non-consumable Electrodes
What is the maximum output current that can be
2. Consumable Electrodes
drawn at 100% duty cycle from a welding power source
rated at 600A at 60% duty cycle.
[3-Marks] Non-consumable Electrodes
Made of carbon, Graphite or Tungsten.
60
1/ 2 Carbon and Graphite are used for D.C.
100
constant, arc is stable and easy to maintain.
Contd
Contd
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Contd
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Ans. (a)
Arc Length
Low Hydrogen Electrode For good welds, a short arc length is necessary,
The basic coatings contain large amount of because:
calcium carbonate (limestone) and calcium
1. Heat is concentrated.
fluoride (fluorspar) and produce low hydrogen.
2. More stable
But it can absorb moisture therefore coated low
hydrogen electrodes are backed before use to a 3. More protective atmosphere.
temperature of 200oC to 3000C and stored in an
oven at 110oC to 150oC
Other types of electrode release large amount of
hydrogen, which can dissolve in the weld metal
and lead to embrittlement or cracking.
Contd
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GATE-2008 GATE-2006
In arc welding of a butt joint, the welding speed is In an arc welding process, the voltage and current
to be selected such that highest cooling rate is are 25 V and 300 A respectively. The arc heat
achieved. Melting efficiency and heat transfer transfer efficiency is 0.85 and welding speed is 8
efficiency are 0.5 and 0.7, respectively. The area of mm/sec. The net heat input (in J/mm) is
the weld cross section is 5 mm2 and the unit (a) 64
energy required to melt the metal is 10 J/mm3. If (b) 797
the welding power is 2 kW, the welding speed in
mm/s is closest to (c) 1103
(a) 4 (b) 14 (c) 24 (d) 34 (d) 79700
GATE-PI-2014 GATE-2014-SET4
In an arc welding operation carried out with a power A butt weld joint is developed on steel plates having
source maintained at 40 volts and 400 amperes, the yield and ultimate tensile strength of 500 MPa and 700
consumable electrode melts and just fills the gap MPa, respectively. The thickness of the plates is 8 mm
between the metal plates to be butt-welded. The heat and width is 20 mm. Improper selection of welding
transfer efficiency for the process is 0.8, melting parameters caused an undercut of 3 mm depth along
efficiency is 0.3 and the heat required to melt the the weld. The maximum transverse tensile load (in
electrode is 20J/mm3 . If the travel speed of the kN) carrying capacity of the developed weld joint is__
electrode is 4mm/s, the cross-sectional area, in mm2,
of the weld joint is _______________
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Contd
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IES-2001 IES-2001
Arc blow is more common in Pinch effect in welding is the result of
(a) A.C. welding (a) Expansion of gases in the arc
(b) D.C. welding with straight polarity (b) Electromagnetic forces
(c) D.C. welding with bare electrodes (c) Electric force
(d) A.C. welding with bare electrodes (d) Surface tension of the molten metal
Ans. (c)
Ans. (b)
An inert gas is blown into the weld zone to drive away conductivity, is useful for thicker sheets, copper and
Gases are argon, helium, nitrogen, carbon dioxide The arc in carbon dioxide shielding gas is unstable,
Argon ionizes easily requiring smaller arc It is a heavy gas and therefore covers the weld zone
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Contd
GATE 2011
Which one among the following welding processes
used non consumable electrode?
(a) Gas metal arc welding
(b) Submerged arc welding
(c) Gas tungsten arc welding
(d) Flux coated arc welding
Ans. (c)
Fig. TIG
IES 2010
In an inert gas welding process, the commonly used ISRO-2009
gas is
Following gases are used in tungsten inert
(a) Hydrogen
gas welding
(b) Oxygen
(a) CO2 and H2
(c) Helium or Argon
(d) Krypton (b) Argon and neon
(c) Argon and helium
(d) Helium and neon
Ans. (c)
Ans. (c)
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Ans. (b)
Contd
Fig. MIG
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a bare wire consumable electrode, and an arc is carbon steel (< 0.3% carbon).
Deep penetration,
Advantages Limitations
Wire electrodes are inexpensive. Extensive flux handling,
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IES-2006 IES-2005
In which of the following welding processes, flux Which of the following are the major
is used in the form of granules? characteristics of submerged arc welding?
(a) AC arc welding 1. High welding speeds.
(b) Submerged arc welding 2. High deposition rates.
3. Low penetration.
(c) Argon arc welding
4. Low cleanliness.
(d) DC arc welding
Select the correct answer using the code given below:
(a) 2 and 3 (b) 1, 2 and 3
(c) 3 and 4 (d) 1 and 2
IES-2005
In atomic hydrogen welding, hydrogen acts as
(a) A heating agent
(b) One of the gases to generate the flame
(c) An effective shielding gas protecting the weld
(d) A lubricant to increase the flow characteristics of
weld metal
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