PROBLEMS CHAP.

2
2.1 In one welding experiment, 50-mm-thick steel plates were joined using electro-slag welding. The
current and voltage were 480A and 34V, respectively. The heat losses to the water-cooled copper
shoes and by radiation from the surface of the slag pool were 1275 and 375 cal/s, respectively.
Calculate the heat source efficiency.

2.2 It has been reported that the heat source efficiency in electro-slag welding increases with increasing
thickness of the work-piece. Explain why.

2.3 (a) Consider the welding of 25.4-mm-thick steel plates. Do you prefer to apply Rosenthals two- or
three-dimensional heat flow equation for full-penetration electron beam welds? What about bead-
on-plate gastungsten arc welds?
(b) Suppose you are interested in studying the solidification structure of the weld metal and you wish
to calculate the temperature distribution in the weld pool. Do you expect Rosenthals equations to
provide reliable thermal information in the pool? Why or why not?
(c) In multi-pass welding do you expect a higher or lower cooling rate in the first pass than in the
subsequent passes? Why?

2.4 Large aluminum sheets 1.6 mm thick are butt welded using GTAW with alternating current. The
current, voltage, and welding speed are 100A, 10V, and 2mm/s, respectively. Calculate the peak
temperatures at distance of 1.0 and 2.0 mm from the fusion boundary. Assume 50% arc efficiency.

2.5 Bead-on-plate welding of a thick-section carbon steel is carried out using 200A, 20V, and 2mm/s.
The preheat temperature and arc efficiency are 100C and 60%, respectively. Calculate the cross-
sectional area of the weld bead.

2.6 (a) Do you expect to have difficulty in achieving steady-state heat flow during girth (or
circumferential) welding of tubes by keeping constant heat input and welding speed? Explain
why. What is the consequence of the difficulty?
(b) Suggest two methods that help achieve steady-state heat flow during girth welding.

2.7 A cold-rolled AISI 1010 low-carbon steel sheet 0.6 mm thick was tested for surface reflectivity in
CO2 laser beam welding under the following different surface conditions:
(a) as received;
(b) oxidized in air furnace at 1000C for 20 s;
(c) oxidized in air furnace at 1000C for 40 s;
(d) covered with steel powder.
In which order does the reflectivity rank in these surface conditions and why?

2.8 It was observed in YAG laser beam welding of AISI 409 stainless steel that under the same power
the beam size affected the depthwidth ratio of the resultant welds significantly. Describe and
explain the effect.

2.9 Calculate the thermal cycle at the top surface of a very thick carbon steel plate at 5 mm away from
the centerline of the weld surface. power of the arc is 2kW, the arc efficiency 0.7, the travel speed
2mm/s, and the preheat temperature 100C.

2.10 Is the transverse cross section of the weld pool at a fixed value of x perfectly round according to
Rosenthals three-dimensional heat flow equation? Explain why or why not based on the equation.
What does your answer tell you about the shape of the transverse cross section of a weld based on
Rosenthals three-dimensional equation?