TWO MARKS Awt-1

ADVANCED WELDING TECHNOLOGY SMVEC
MEE 81 ADVANCED WELDING TECHNIQUES - TWO MARKS
UNIT - I (Introduction to Welding and Gas welding )
1. Define welding process.

Welding is a process of joining two similar or dissimilar metals with the help of heat or pressure by
some other means. The cost of welding is very less as compared to other processes and forms a strong
joint.
2. What is the reasons welding largely used in field of Engineering?

 Manufacturing of machine tools, auto parts, cycle parts.
 Fabrication of farm machinery and equipment.
 Fabrication of buildings, bridges and ships.
 Construction of boilers, furnaces, railways, cars, aeroplanes, rocket and missiles.
 Manufacturing of television sets, refrigerators, kitchen cabinet.
3. Define Arc welding process.

In Arc welding process, the weld is produced by the extreme heat of an electric arc drawn between an
electrode and the work piece, or in some cases, between two electrodes. Welds are made with or
without the application of pressure and with or without filler materials.
4. State the merits and demerits of welding.

Merits:
 Welding is more economical and is much faster process as compared to other processes (riveting,
bolting, casting etc).
 Welding, if property controlled results permanent joints having strength equal or sometimes
more than base metal.
 Large number of metals and alloys both similar and dissimilar can be joined by welding.
 General welding equipment is not very costly.
 Portable welding equipment’s can be easily made available.
Demerits:
 It results in residual stresses and distortion of work piece.
 Welded joint needs relieving and heat treatment.
 Welding gives out harmful radiations, fumes and spatter,
 Edges preparation of the welded jobs are required before welding.
 Skilled welder is required for production of good welding.
5. Classify the welding processes.

 Oxy-fuel gas welding process.
 Arc welding process.
 Resistance welding.
 Solid state welding.
 Thermit welding.
 Radiant energy welding.
6. Define pressure and Non pressure welding.

 Pressure welding is a joining process under pressure without additional filler metal.
 Fusion or non-Pressure welding is a joining process that uses fusion of the base metal to make
the weld.
DEPT. OF MECHANICAL ENGG.

7. State that Gas welding process.

Gas welding process is a one type of fusion welding process which joint metals, using the heat of
combustion of an oxygen/air and fuel gas (i.e. acetylene, hydrogen, propane or butane) mixture is
usually referred as “Gas welding” the intense heat (flame) thus produced melts and fuses together the
edges of the parts to be welded, generally with the addition of a filler metal.
8. List out the Gas welding equipment.

 Oxygen cylinder.  Torch tips.
 Acetylene cylinder.  Goggles.
 Regulator.  Lighter.
 Torch.  Fire extinguishers.
9. Define oxy-acetylene welding.

Oxy acetylene welding process, acetylene is mixed with oxygen in correct proportions in the welding
torch and ignited. The flame resulting at the tip of the torch is sufficiently hot to melt and Joint the
parent metal.
The oxy-acetylene flame reaches a temperature of about 3300°C and thus can metal most of the ferrous
and Non-ferrous metals in common use.
10. Classify the flames of oxy-acetylene.

 Neutral welding flame (Acetylene and oxygen in equal proportions).
 Carburizing welding flame (Excess of Acetylene).
 Oxidizing welding flame (excess of oxygen).
11. Classify the gas welding techniques.

There are two types of gas welding techniques
 Leftward welding.
 Rightward welding.
12. Define flux and main functions.

The chemicals which deoxidize the metal surface and provide inert atmosphere around the molted
metal are known as fluxes.
The main function of flux is given below:
 To prevent oxide on the hot surfaces.
 To reduce the viscosity of molted metal.
 It maintains a steady arc in case of arc welding.
13. List out the advantages and disadvantages of gas welding.

Advantages:
 Equipment is cheap as compared to other welding process.
 Maintenance of equipment is very less.
 It is specially used for sheet metal work.
 It is a portable process.
Disadvantages:
 It takes long time for heating the job as compared to the arc welding
 The heat affected area is more.
 This is prone to corrosion and brittleness.
 Gases are expensive and difficult to store.

14. Define welded joint and its types.

Welded joint is a permanent joint which is obtained by the fusion of the edges of the two parts to be
joined together, with or without the application of pressure and a filler material. They are two types
 Lab joint or fillet joint  Edge joint

 Butt joint  T-joint
 Corner joint
15. Define lab joint and butt joint.

 The lab joint or fillet joint is obtained by overlapping the plates and then welding the edges of the
plates. The cross section of the fillet is approximately triangular.
 Butt joint is obtained by placing the plates edge to edge. In butt welds the plate edges do not
require bevelling is the thickness of plate is less than 5mm.
16. Classify the butt joint.

 Square butt joint  Double V-butt joint
 Single V-butt joint  Double U-butt joint
 Single U-butt joint
17. Write down the elements of a welding symbol.

 Reference line  Supplementary symbols
 Arrow  Finish symbols
 Basic weld symbols  Tail and
 Dimensions and other data  Specification, process or other references.
18. What are two types of stresses are induced in eccentric loading of welded joint?
 Direct shear stress (t)
 Bending or torsional shear stress (cr)
19. Define Eccentric loaded welded joint.

An eccentric load may be imposed on welded joints in many ways. The stresses induced on the joint
may be of different nature or of the same nature. The induced stresses are combined depending upon
the nature of stresses.
UNIT - II ( Arc welding )
1. State Arc welding process and types.

Arc welding process, in which an electric arc between an electrode and a work piece or between two
electrodes is utilized to weld base metals. The various arc welding processes are.
 Carbon Arc welding  Gas metal arc welding
 Shielded metal arc welding  Gas tungsten arc welding
 Flux cored arc welding  Electro slag welding
 Plasma arc welding  Stud arc welding
2. Define carbon arc welding and types.

Carbon arc welding is a process in which the joining of metals is produced by heating with an arc
between a carbon electrode and the work. No shielding is used. Pressure and/or filler metal may or may
not be used. They are classified into two types.
 Single electrode arc welding

 Twin carbon electrode arc welding.

3. Write down the advantages and disadvantages of carbon arc welding.

Advantages:
 Low cost of equipment and welding operations.
 High level of operator skill is not required.
 The process is easily automated.
 Low distortion of workpiece.
Disadvantages:
 Unstable quality of the weld (porosity).
 Carbon of electrode contaminates weld material with carbides.
4. Define shielded metal arc welding (SMAW).

Shielded metal Arc welding (SMAW) is one of the oldest, simplest and most versatile joining
processes. About 50% of all industrial and maintenance welding currently is performed by this process.
The electric arc is generated by touching the tip of a coated electrode against the work piece and with
drawing it quickly to a distance sufficient to maintain the arc. The electrodes arc in the shapes of thin
long rods that arc held manually.
5. List out the shielded metal Arc welding equipment’s.

 Constant current welding power supply  Ground clamp.
 Electrode holder.  Work lead and its terminals.
 Electrode lead and its terminals.  Welding electrodes.
6. Define electrode and types.

An electrode is a piece of wire or a rod of a metal or alloy, with or without coatings. An arc is set up
between electrode and work piece. There are two types of electrodes.
(a) Consumable electrodes (b) Non-consumable electrode
 Bare electrode  Carbon or graphite electrode
 Coated electrodes  Tungsten electrode
7. List the merits and demerits of shielded metal Arc welding.

Merits:
 Low cost equipment.
 Welds many different metals and alloys.
 Relatively portable and can be used in confined spaces.
 Welds can be performed in any position.
Demerits:
 Not suitable for metal sheets under 1/8" thick.
 Operator duty cycle and overall deposition rate arc usually lower with SMAW than with wire fed
processes.
 The frequent stops and starts caused by changing electrodes can result in weld defects.
8. Define submerged Arc welding.

In submerged Arc welding (SMAW), the weld arc is shielded by a granular flux consisting of lime,
silica, manganese oxide, calcium fluoride and other components. The flux is fed into the weld zone
from a hopper by gravity flow through nozzle.
The thick layer of flux completely covers the molten metal. It prevents spatter and sparks and
suppresses the intense ultraviolet radiation and fumes characteristics of the SMAW process.

9. What are the advantages of submerged Arc welding process?

 High quality of the weld metal.
 Extremely high deposition rate and speed.
 Smooth, uniform finished weld with no spatter.
 Little or no smoke.
 No arc flash, thus minimal need for protective clothing.
 High utilization of electrode wire.
10. State Tungsten inert gas welding (TIG).

Gas tungsten arc welding (GTAW) or Tungsten inert Gas (TIG) welding is a process in which the
joining of metal is produced by heating there with an arc between a tungsten electrode and work. A
shielding gas is used, normally argon TIG welding is normally done with a pure tungsten or tungsten
alloy rod, but multiple electrodes are sometimes used.
11. State the applications of TIG welding.

 Gas tungsten arc welding is the most popular method for welding aluminium stainless steels, and
nickel based alloys.
 It produces top quality welds in almost all metals and alloys used by industry.
 TIG welding process is very good for joining thin base metals because of excellent control of
heat input.
 Visibility is excellent because no smoke or fumes are produced during welding, and there is no
slag or spatter that must be cleaned between passes or on a completed weld.
12. Write down the advantages and disadvantages of TIG welding.

Advantages:
 No weld cleaning is necessary, No flux is required.
 The welding speed is high.
 It produces high quality weld and produces weld without contamination.
Disadvantages:
 The process is slower than consumable electrode arc welding processes.
 Transfer of molten tungsten from the electrode to the weld causes contamination.
 Exposure of the hot filler rod to air using improper welding techniques causes weld metal
contamination.
 Inert gases for shielding and tungsten electrode costs add to the total cost of welding compared
to other processes.
13. Define metal inert gas (MIG) welding.

Metal inert gas (MIG) welding or gas metal Arc welding (GMAW) is an electric arc welding process
which joins metals by heating them with an arc established between a continuous filler metal electrode
and work. Shielding of the arc and molted weld pool is obtained entirely from an externally supplied
gas or gas mixture. This process is sometimes referred to as MIG or C02 welding.
14. Write down the advantages of MIG welding.

 This welding produce high quality welds can be produced much faster than with SMAW or TIG
welding.
 Since a flux is not used, there is no chance for the entrapment of slag in the weld metal.
 The gas shield protects the arc so that there is very little loss of alloying elements as the metal
transfers across the arc.
 This process can be operated in several ways including semi and fully automatic.

UNIT - III ( Plasma Arc welding, Solid state welding )
1. Define plasma Arc welding (PAW).

Plasma Arc welding (PAW) is a process in which coalescence or joining of metals is produced by
heating with a constricted arc between an electrode and the work piece (transfer arc) or the electrode
and constricting (nozzle non transfer arc).
Shielding is obtained from the hot ionized gas issuing from the orifice, which may be supplemented
by an auxiliary source of shielding gas. Shielding gas may be an inert gas or mixture of gases. Pressure
may or not be used, and filler metal may or may not be supplied.
2. List down the equipment’s of plasma Arc welding (PAW).

 Power source  Control console
 Welding torch  Wire feeder
3. Write the advantages of plasma Arc welding.

 The torch to work distance from the plasma arc is less critical than for gas tungsten arc welding.
This is important for manual operation, since it gives the welder more freedom to observe and
control the weld.
 In this operation, the heat affected zone and the form of the weld arc more desirable.
 The higher heat concentration and the plasma jet allow for higher travel speeds. The plasma arc
is more stable and is not as easily deflected to the closest point of base metal.
 Greater variation in joint alignment is possible with plasma Arc welding
4. Write the disadvantages of plasma Arc welding.

 The torch is more delicate and complex than a gas tungsten arc torch
 Even the lowest rated torches must be water cooled
 The tip of the tungsten and the alignment of the orifice in the nozzle is extremely important and
must be maintained within very close limits
5. State the Electro slag welding (ESW).

Electro slag welding (ESW) is similar to electro gas welding. The main difference is that the arc is
started between the electrode tip and bottom of the part to be welding. Flux is added which than melts
by the heat of the arc.
After the molten slag reaches the tip of the electrode, the arc is extinguished Heat is produced
continuously by the electrical resistance of the molten slag. Because the arc is extinguished, ESW is
not strictly an arc welding process.
6. State the Flux cored Arc welding.

Flux cored Arc welding (FCAW) is an arc welding process in which the heat for welding is provided
by an arc between a continuously fed tubular electrode '& and the work piece. Shielding is obtained by
a flux contained within the tubular electrode wire or by the flux and a supplied shielding gas.
7. Define Electro gas welding.

Electro gas welding (EGW) is used primarily for welding the edges of sections vertically and in one
pass with the pieces placed edge to edge (butt joint). The weld metal is deposited into a weld cavity
between the two pieces to be joined.
The space is enclosed by two water cooled copper dams (shoes) to prevent the molten slag from running
off: mechanical drives move the shoes upward, circumferential (such as those in pipes), also are
possible, with the work piece rotating.

8. Define filler.
The rod which provides additional metal in completing the welding is known as filler. The
composition of filler metal should be the same as that metals to be welded.
9. Define solid state welding

Solid state welding is a joining process in which time, temperature and pressure individually or in
combination produce coalescence of the base metals without melting of the base metals. Hence it is
often termed as cold welding. Hence the thermal stress related problems are eliminated.
10. Write down the types of solid state welding

There are various types of solid state welding:
 Friction welding
 Friction stir welding
 Forge welding
 Diffusion welding
 Ultrasonic welding
 Explosive welding
11. State the advantages of solid state welding

 Weld (bonding) is free from microstructure defects (pores, non-metallic inclusions, segregation of
alloying elements)
 Mechanical properties of the weld are similar to those of the parent metals.
 No consumable materials (Filler material, Fluxes, Shielding gases) and required.
 Dissimilar metals may be joined (Steel - Aluminum alloy, steel - copper alloy)
12. State the disadvantages of solid state welding.

 Through surface preparation is required (degreasing, oxides removal, brushing/sanding).
 Expensive equipment.
13. State that cold welding

Cold welding is a solid state welding process in which two work pieces are joined together at room
temperature and under a pressure, causing a substantial deformation of the welded parts and providing
an intimate contact between the welded surfaces. The cold welding also known as cold pressure
welding.
14. List out cold welding equipment’s.

The cold welding machine has following components Punch presses, Punch tool or die, Rollers (as in
rolling) and Static load (Manual or power)
15. Write down the applications of cold pressure welding.

 The cold pressure welding technique is used when welding wires of non-ferrous metals such as
aluminum, copper or aluminum alloys.
 It is used in assembly of small transistors where heating is not allowed.
 It is used to join wires when they break during operations.
 It can be used to joint dis-similar metals.
16. Write the advantages of cold pressure welding.

 This process does not involve any heat and flux and hence smooth joint is produced.
 This process is suitable to weld almost all metals from A1 to Cu.

17. Write the disadvantages of cold pressure welding

 Cold welding is not suitable for high strength (Fe) metals and alloys as they require greater
pressure to produce deformation.
 The joint can fail in a reactive environment or a high oxygen environment.
 It is suitable for buried pipes and for components deployed in spaces, where there is no risk of
oxygen contact.
 For the cold welding to be effective, the surfaces need to be brushed and cleaned effectively.
18. Define diffusion welding

Diffusion welding is a solid state joining process in which the strength of the joint results primarily
from diffusion. This process requires temperature of about in order to have a high diffusion rate
between the parts being joined. The strength of the welding depends on pressure, temperature, time of
contact and the cleanliness of the metal.
19. Write the various stages of mechanism of diffusion bonding

 Deformation and interfacial boundary deformation
 Grain boundary migration and pore elimination
 Volume diffusion pore elimination.
20. Write down the various factors influencing diffusion welding

 Temperature – D = Do e-Q.KT
 Time - X = C(Dt)1/2
 Pressure
21. Write down the advantage* of diffusion welding.

 This solid state process avoids pitfalls of fusion welding
 Dissimilar materials welds are possible.
 Properties and microstructures remain similar to these of base metals,
 Multiple welds can be made in one setup at the same time.
 Highly automated process does not need skillful workforce.
22. List out the limitations of diffusion welding

 Costly equipment especially for large weldments.
 Costly preparation with smooth surface finish and exceptional cleanliness.
 Protective atmosphere or Vaccum required
 Lone time to completion.
23. List out the applications of diffusion welding

 Application in titanium welding for Aero-Space vehicles.
 Diffusion welding of Nickel alloys include Inconel 600, wrought udimet 700 and Rene 41.
 Dissimilar metal diffusion welding applications include cu to II, cu top A1 and cu to cb - 1 % Zr.
Brittle intermetallic compound formation must be controlled in these applications.
24. State that explosion welding

Explosion welding (EXW), pressure is applied by detonating a layer of explosive that has been placed
over one of the components being joined called the flyer plate.
The contact pressure developed are extremely high, and the kinetic energy of the plate striking the
mating component causes a wavy interface. As a result, the bond strength from explosion welding is
very high.

25. Write down the various parts of explosive welding.

 Detonator  Flyer plate
 Base plate  Constant interface.
 Cladding metal or cladder
26. Write down the types of explosive waves

 There are two types of waves generated during explosive welding.
 Deflagration
 Detonation
27. List out the applications of explosive welding

 Joining of pipes and tubes
 Major areas of the use of this method are heat exchanger tube sheets and pressure vessels.
 Tube plugging
 Remote joining in hazardous environment
 Other applications are in chemical process vessels, ship building industry, cryogenic industry, etc.,
28. Write the advantages of explosive welding

 Can bond many dissimilar, normally unweldable metals.
 Simplicity of the process
 Extremely large surfaces can be bonded.
 Wide range of thickness can be explosively clad together
 Small quantity of explosive used.
29. List the demerits of explosive welding

 The metals must have high enough impact resistance and ductility.
 Noise and blast can require operator protection, Vaccum chambers, buried in sand/water.
 The use of explosives in industrial areas will be restricted by the noise and ground vibrations
caused by the explosion.
 The geometries welded must be simple-flat, cylindrical conical
30. Define Thermit welding.

Thermit welding is the application of a filler material or the joining of two pieces of metal, usually
steel, through the use of heat supplied by a chemical reaction. Usually large parts, such as locomotive
rails, large gears and general fractures on large pieces of equipment were repaired by thermit welding.
The thermit welding also called as Alumino-thermic welding.
31. Give chemical reaction in Thermit welding.

8A1 + 3Fe304 = 9Fe + 4 A1203 + heat.
32. What are the types of thermit welding?
 There are two types of thermit welding
 Plastic (or) Pressure thermit welding.
 Fusion (or) Non-pressure thermit welding.
33. Define pressure and Non-pressure thermit welding.

In pressure thermit welding is mainly used for butt welding thick pipes, raults, rails. In weld pressure
is used instead of fusion to join the metal. The process uses the thermit reaction only as a heat source.
Non-pressure welding process is completely different. In this process the workpieces are lined up,
leaving a space between the ends that are to be welded.

34. What are the advantages of thermit welding?

 For restore broken teeth on big gears.
 For welding frames of machines.
 Used for welding large broken crankshaft.
 For welding new necks to rolling mill rills with pinion.
 Used for building up damaged wobblers.
35. What are the limitations of thermit welding?

 Its cannot weld for low melting point.
 It has slag inclusion.
 Low deposition rate with operation factor.
 Extremely high level of fume.
36. State the applications of thermit welding.

 It is mainly used in repair and welding of large forging and castings, pipes, mill housing and heavy
rail section.
 It is used to repair heavy sections.
 Often used to join rail tracks.
 Field welding of truck.
37. Define electron beam welding.

Electron beam welding (EB W) is a fusion welding process in which a beam of high velocity electrons
is applied to two materials to be joined. The workpieces melt and flow together as the kinetic energy
of the electrons is transformed into heat upon impact.
38. What are the components of EBW?

 Electron gun.
 Working chamber.
 Workpiece manipulator.
 Power supply, control and monitoring electronics.
39. Mention the advantages of EBW.

 High depth to width ratio eliminates multiple part welds.
 Welds upto 95% of the strength of base material.
 Minimizes shrinkage and distortion and allows welds in close proximity to heat sensitive
components.
 Vacuum environment eliminates impurities such as oxides and nitrides.
 Precise control and repeatability at speeds from 1 to 200 inch/min.
40. Write down the limitation of EBW.

 Cost of the equipment is very high.
 It is not suitable for large workpieces.
 Skilled operators are required to operate the machine.
 It is applicable for thin materials.
41. Write down the application of EBW.

 EBW is used for automobile, aerospace, medical and other industrial parts.
 Assembly of conventional production parts; partial processing of parts such as gears, valves and
bearings are other common applications.

42. Define underwater welding.

Underwater welding is the process of welding at elevated pressures, normally underwater. Under water
welding can either take place wet in the water itself or dry inside a specially constructed positive
pressure enclosure and hence a dry environment. It is predominantly referred to as "hyperbaric
welding" when used in a dry environment and underwater welding when in a wet environment.
42. Classify underwater welding.

The underwater welding classified into two types they are
 Wet underwater welding.
 Dry underwater welding.
43. Write the various components of wet underwater welding.

 Diving equipment.
 Welding power sources.
 Safety switch.
 Communication system.
 Welding cables, welding and cutting holders.
44. Write down the advantages of wet underwater welding.

 It is less cost compared to dry welding.
 Fast method.
 The welder can reach portions of offshore structure that could not be welded using other methods.
45. Mention the limitation of wet underwater welding.

 There is rapid quenching of the weld metal, it decreases the ductility and impact strength of the
weldment.
 Large amount of hydrogen present in the weld region which causes embrittlement, cracks and
microscopic fissures.
 Poor visibility the welder some times is not able to weld properly.
46. Write down various types of dry underwater welding.

 Dry habitat welding.
 Dry chamber welding.
 Dry spot welding.
47. What are the advantages of dry underwater welding?

 Better quality welds.
 Better driver safety.
 No build-up of hydrogen and oxygen pockets.
 Surface monitoring possible.
48. Write down the applications of underwater welding.

 Offshore construction for tapping sea sources.
 Temporary repair work caused by ships collisions (or) unexpected accidents.
 Repair and maintenance of ships.
 Salvaging vessels sunk in the sea.
 Repair and maintenance of underwater pipelines.
 Construction of large ships beyond the capacity of existing docks.

49. Write down abbreviation of LASER.

LASER stands for "Light Amplification of Stimulated Emission of Radiation". Laser being coherent
in nature has a specific geometry if it is focused by conventional optical lenses can generate high power
density.
50. Write down the principle of LBM.

LBM uses the light energy of a laser beam to remove material by vapourization and ablation. In this
process the energy of coherent light beam is focused optically for predicated longer period of time. The
beam is pulsed so that the released energy results in as impulse again the work surface that does melting
and evaporation.
51. Write the advantages of LBM.

 Materials which cannot be machincd by conventional are machined by LBM
 There is no tool so no tool wear.
 Drills very fine and precise holes & cavities.
 Making of complex components.
52. Mention the applications of LBM.

 It is used to perform different machining operations like drilling, slitting, slotting, scribing
operations.
 It is used for drilling holes of small diameter of the order of 0.025 mm.
 Making complex profiles in thin and hard materials like integrated circuits and printed circuit
boards (PCB).
 Machining of mechanical components of watches.
53. Define atomic hydrogen welding.

Atomic hydrogen welding is a non-pressure fusion welding process. It is an arc welding technique that
uses an arc which is located between two tungsten electrodes and a hydrogen shielding gas. This
welding technique was discovered by Irving langmuir while he has studying atomic hydrogen
molecules which latter recombine and produce an extensive amount of heat that can reach temperature
between 3400°C to 4000°C. This process also known as "Arc atom welding".
54. Mention the various components of atomic hydrogen welding.

 Welding torch.  Hydrogen cylinder.
 Two tungsten electrodes.  AC power supply.
 Trigger.
55. Mention the advantages of atomic hydrogen welding.
 Welding is faster.
 Intense flame is obtained which can be concentrated at the joint. Hence less distortion.
 Workpiece do not form a part of the electric circuits. Hence, problems like striking the arc and
maintaining the arc column are eliminated.
 Separate flux/shielding gas is not required. The hydrogen envelope itself prevents oxidation of the
metal and tungsten electrode. It also reduces the risk of nitrogen pick-up.
56. Define friction stir welding.

Friction stir welding (FSW) is a solid state joining process that uses a non- consumable tool to join two
facing workpieces without melting the workpiece material. Heat is generated by friction between the
rotating tool and the workpiece material, which leads to a softened region near the FSW tools.

57. Write down various steps in FSW.

 Star of joining.
 Insert joining tool.
 Joining.
 Pull away joining tool (end).
58. What are the various materials can be joined FSW.

 Aluminium and aluminium alloys
 Steel and steel alloys.
 Castiron materials
 Copper and bronze
 All ferrous materials and their alloys.
59. What are the stages in welding cycle?

 Dwell.
 Transient heating.
 Pseudo steady state.
 Post steady state.
60. Mention the advantages of FSW.

 Good mechanical properties in the as welded conditions.
 No consumables, a threaded pin made of conventional tool steel.
 Easily automated on simple milling machines-Low setup cost and less training.
 Can operate in all positions (horizontal, vertical) as there is no weld tool.
 Improved safety due to the absence of toxic fumes (or) spatter of molten material.
 General performance and cost benefits from switching from fusion to friction.
61. Write the disadvantages of FSW.

 Less flexible than manual and Arc processes.
 Exit hole left when tool is withdrawn.
 Large down forces required with heavy duty clamping necessary to hold the plates together.
 Often slower transverse rate than some fusion welding techniques, although this may be offset if
fewer welding passes are required.
62. Write the applications of FSW.

 Friction stir welding used for various  Automotive
fields they are  Railways
 Ship building and offshore  Robotics
 Aerospace  Fabrication
63. What are the various welding method used for Aerospace industry.
 Friction welding  Gas metal arc welding
 Friction stir welding  Gas tungsten arc welding
 Flash welding  Plasma Arc welding
 Resistance spot welding  Laser beam welding
 Electron beam welding  Diffusion welding
64. What are the various welding automation in nuclear reactor?

 Remote welding in nuclear sites.  Narrow gap welding

37. Write down the advantage of Narrow gap welding?

 The process offers better economy for welding of thick materials [Generally over 50 mm thick]
and shorter welding times.
 There is low angular distortion because the joint preparation is almost parallel sided.
UNIT - IV ( Resistance welding, Plastic welding )
1. Define Resistance welding.

Resistance welding processes are a fast and reliable means of joining thin applying pressure on the two
parts to be joined. Once the correct amount of pressure is applied current is passed between the two
(or) more overlapped sheets. Resistive heating results in melting and the formation of a "Weld nugget"
or "Weld seam".
2. List down the various types of resistance welding.

The various types of resistance welding are as follows
 Spot welding  Resistance butt welding
 Seam welding  Flash butt welding
 Projection welding  Percussion welding
3. Write down the various process parameters of resistance welding.

 Welding current.  Electrode force.
 Welding time.  Welding speed.
 Electrode geometry and dimension.
4. What are the advantages of resistance welding?

 Heat concentration, heating time is short, small welding deformation.
 Easily automated.
 No filler metal.
 High speed <0.1 seconds in automotive spot welds.
 Suitable for high rate production.
 Economical.
5. List down the demerits of resistance welding.

 Lower tensile and fatigue strengths.  Not portable. Electrode wear.
 Higher equipment coot than arc welding.  Lap joint requires additional metal
6. Write down the application of resistance welding.

 This type of welding is used where long production runs and consistent conditions can be
maintained.
 The automotive industry is the major user of the resistance welding processes, following by the
appliance industry.
 This type of welding is also used in the steel industry for manufacturing pipe, tubing and smaller
structural sections.
7. State that spot welding (or) resistance spot welding (RSW).

Spot welding is a process in which faying surfaces arc joined in one or more spots by resistance to the
flow of electric current through work pieces that are held together under force by electrodes. The
contacting surfaces in the region of current concentration are heated by a short time pulse of low
voltage, high amperage current to form a fused of weld metal.

8. Classify spot welder.

There are three types of spot welders
 Rack arm spot welder.
 Press type spot welder.
 Portable type spot welder.
9. Define resistance seam welding (or) seam welding.

Resistance seam welding (RSW) is a modification of spot welding where in the electrodes are replaced
by rotating wheels or rollers. Using a continuous AC power supply, the electrically conducting rollers
produce a spot weld whenever the current reaches a sufficiently high level in the AC cycle.
10. Write the advantages of spot welding.

 Comparatively low cost.
 This method doesn't need highly skilled worker.
 The joint made is highly uniform.
 Automatic or semi-automatic operation both can be done.
 There is no need for edge preparation.
11. State the resistance projection welding (RPW).

In resistance projection welding (RPW), high electrical resistance at the joint developed by embossing
one or more projections on one of the surfaces to be welded. The projections may be round or oval for
design or strength purposes.
12. List down the applications of spot welding.

 Spot welding of thick steel plates has been done and it has replaced the need for riveting.
 The welding of two or more sheet metals can be joined by mechanic means more economically
by using the spot welding methods. We don't need gas tight joints.
 Spot welding can be used for attaching braces, pads (or) clips with cases, bases and covers which
are mainly product of sheet metal forming.
 Automobile and aircraft industries relies greatly of spot welding these days.
13. Write down the advantages and disadvantages of seam welding.

Advantages:
 Gas tight as well as light tight joints can be made.
 The overlap is less than spot or projection welding.
 The production of single seam weld and parallel seams can be got simultaneously.
Disadvantages:
 The welding process is restricted to a straight line or uniformly curved line.
 The sheet metals having thickness more than 3mm can cause problems while welding.
 The design of the electrodes may he needed to change to weld sheet metals having obstructions.
14. List out the applications of resistance seam welding (RSEW).

 Girth weld is possible in rectangular or square or even in circular shapes.
 Most of the metals can be welded [except copper and some high percentage copper alloys].
 This welding used for making petrol tanks for automobile seam welding tubes, drums and other
components of domestic applications.
 Seam welding is relatively fast method of welding producing quality welds.

15. Write down the advantages and disadvantages of resistance projection welding.
Advantages RPW
 Projection welding electrodes have a longer life when compared to spot welding electrodes.
 Simultaneous operation can be done (i.e) more than one welds can be made.
 It is not limited to sheet to sheet joints.
 It can be done in specific points which arc desired to the welded.
Disadvantages of RPW
 All types of metals cannot be welded using projection method.
 All the metals are not strong enough to support projections. Some brasses and coppers cannot be
welded satisfactorily using projection welding.
 There is an extra operation which is called forming of projection.
 Projections need to have same heights for a appropriate welding.
16. List out the applications of projection welding.

 Projection welding is used in Automobile sector.
 It is used in refrigeration works (mass production of condensers, gratings, racks...)
17. State that percussion welding.

Percussion welding is one type of resistance welding method. In this welding process where a united
body is made over the entire area of butt positional work surfaces by heating is obtained from an arc
produced by a rapid discharge of electric energy and the pressure is applied same time of electrical
discharge.
18. Define resistance butt welding.

It stays one kindly of resistance welding are two types of resistance welding.
 Upset butt welding.
 Flash butt welding.
19. List out the advantages and disadvantages of flash butt welding.
Advantages:
 It is much quicker.
 Current consumption is less.
 The weld joint stronger.
 The end faces of workpieces need not be prepared, which is a primal requirement in butt
welding.
Disadvantages:
 These method needs periodic maintenance of machine and replacement of insulation.
 Operator has to take enough care against possible fire hazard due to flashing.
 Addition stock has to be provided to compensate the loss of metal during flashing and upsetting.
This adds to the cost of product.
20. List out the advantages and disadvantages of percussion welding.

Advantages:
 Parts with different thermal conductivities can be easily welded.
 Very quick process time, usually takes less than 0.1 second.
 Without any danger of annealing, hardened surfaces may be welded.

Disadvantages:
 The process is limited to butt welded joint only.
 The joint used in limited to about 1.5 to 3 cm because of control of paths of arc is difficult.
 The process cannot be used for welded heavy sections larger than 600 mm2.
21. Mention the applications of percussion welding.

 This process joints similar or dissimilar metals.
 This process is used for welding fine wire leads to filaments in lamps and terminals.
 This welding is useful to make large contact assemblies for relays etc.
 It can join wires and rods by butt joints. This process is used to attach metal tips.
22. Define high frequency resistance welding.

High frequency welding is a welding process in which the heat source used to melt the joining surfaces
is obtained form high frequency (HF) alternating current resistance heating. High frequency current
has certain characteristics that make it useful for welding.
23. State that stud welding.

The stud welding is part of an arc welding process where a united body is produced by heating with an
electric arc between the metal studs or similar parts and base metals. The heating process is running
till the base metal getting molten stage, after certain time the arc is stopped and stud is feed into the
molten zone.
Molten metal is shielded with a ferrule and flux or shielding inert gas. The argon inert gas is used for
joining the aluminium stud and flux is used for steel stud welding.
24. List out the advantages and disadvantages of stud welding.

Advantages:
 It produces a full cross sectional weld, forming a bond that is stronger than the surrounding metal.
 Arc stud welding produces a strong, one sided weld. The welds are vibration proof and resist
breaking, loosening or weaking.
 Where quality is measured in part by attractive appearance, arc stud welding offers excellent
cosmetic appear because the reverse side is not marred
Disadvantages:
 The action can alone be acclimated to bend almost baby apparatus (such as studs or plugs).
 Which ca be rotated at aerial speed, assimilate a assignment piece.
 The systems acclimated are bound to studs upto about 25mm bore and plugs for bushing holes
upto about 25mm bore (plug welding)
25. Write down the applications of stud welding.

 In automotive industry, the process is used to assemble heat shields, power steering and dashboard
components, instrument panels, insulation, lights system.
 In farm equipment industry, it's used to assemble fenders, brackets, cabs, spreaders, thresher teeth,
wiring and hose management parts.
 In construction equipment industry, it's used to make cover plates, non skid devices and wiring &
hose management parts.
 In industrial equipment industry, arc stud welding is used to assemble inspection cover plate
attachments, enclosures, flow indicators, material handling equipment and controls. It is also used
for power transformer tanks and transducers.
 Ship builders use it to attach insulation, wire management devices and hatch covers.

26. State that low frequency Electrical resistance welding.

Electrical resistance welded (ERW) pipe manufactured by cold forming a sheet of steel into a
cylindrical shapes. Current is then passed between the two edges of the steel to heat the steel to a point
at which the edges are forced together to form a bond without the use of welding filler material. Initially
this manufacturing process used low frequency AC current to heat the edges.
27. State the merits and demerits of low frequency resistance welding.
Merits:
 Low frequency electrical resistance welding process which produced a higher quality weld.
 Over time, the welds of low frequency process.
Demerits:
 The high frequency process is still being used to manufacture pipe for use in new pipeline
construction.
 ERW pipe stayed found to be subject to selective seam corrosion, hook cracks and inadequate
bonding of the seams.
28. Write the disadvantages of spot welding.

 The equipment cost is high so it can has an effect on the initial cost.
 Skilled welders are needed for the maintenance and controlling.
 Some metals need special surface preparation for making the RSW a success
 The thick jobs are easy to weld.
29. Write down the various metal joining processes.

 Bolting  Arc welding
 Riveting  Resistance welding.
 Soldering
30. Write formula for heat generation in resistance welding.

E = P.T.t
Where,
E - Heat energy I - Current
R - Electrical resistance T - Time at current is applied
31. Define Ultrasonic welding

Un Ultrasonic welding (USW), the faying surfaces two components are subjected to a static normal
forces and oscillating shearing (tangential) stresses. The shearing stresses are applied by the tip of a
transducer, which is similar to that used for ultrasonic machining. The frequency of oscillation is
generally in the range from 10 to 75 KHz, although a lower or higher frequency can be employed.
32. Write down the various components of ultrasonic welding.

 Generator  Booster
 Machine press  Welding horn
 Welding stack  Support tooling
 Transducer
33. List out the advantages of ultrasonic welding

 Ultrasonic welding has advantages over resistance sport welding such that it requires a little heat
application during joining without melting of the material.
 Consequently, no cast nuggets or brittle inter metallic are formed in ultrasonic welded parts.

 There can be no arc and hence no tendency to expel molten metal from the joints.
 The process permits welding thin to thick sections and a wide variety of dissimilar materials.
34. Write the applications of ultrasonic welding.

 Medical equipment (Filters, face, Mask, Valves, cardiometry reservoir)
 Automotive components (glove boxes doors, Filters, valves)
 Appliance (Vacuum cleaner, steam iron, dishwasher components)
 Electrical equipment (switches, terminal blocks, connectors)
 Electronic and computer components.
35. List the limitations of ultrasonic welding.

 Ultrasonic welding is restricted to the lap joint. Welding of thin materials sheet, foil and wires and
attaching of thin sheets to heavier structural members.
 The maximum thickness of welds is about 2.5 mm for "Al" and 1 mm for harder materials.
 Only small and thin parts may be welded.
 Tool design is required, Work pieces may bone to the anvil.
37. State Friction welding

Friction welding (FRW) is a solid state welding process in which coalescence is achieved by frictional
heat combined with pressure. The friction is induced by mechanical rubbing between the two surfaces,
usually by rotation of one part relative to the other, to raise the temperature at the joint interface to the
hot working range for the metals involved. Then the parts are driven toward each other with sufficient
force to form a metallurgical bond.
38. Write the various types of friction welding.

 Continuous drive friction welding  Linear friction welding
 Inertia friction welding
39. Write the various process parameters in friction welding

 Power  Time of duration
 Axial pressure  Peripheral speed.
40. Write the advantages of friction welding.

 No filler metal is needed
 Flux and shielding gas are not required
 The process is environmentally clean; no arcs, sparks, smoke or fumes are generated by clean
parts.
 Surface cleanliness is not as significant, compared with other welding processes, since friction
welding tends to distrupt and displace surface films.
41. Write the limitations of friction welding

 In general, one work piece must have an axis of symmetry and be capable of being rotated about
that axis.
 Capital equipment and tooling cost are high.
 Dry bearing and no forgeable materials cannot be welded.
 If both parts are longer than 1 m (3 ft) special machines are required.
42. State the applications of friction welding

 Machine production and spare part industry - cog wheels piston rods, hydraulic cylinders, crank
shaft, drill bits.

 Automotive industry - valves, clack valve, drive shafts gear levers, axle fasteners.
 Aviation and space industry - repulsion Jets, spindles combustion chambers, turbines, piper, rotors,
fitting.
 Work set industry - spiral - spiral drills, milling cutter, borers’ reamers, cutting tools.
43. State Forge Welding

Forge Welding is a welding process in which components to be joined are heated to hot working
temperatures and then forged together by hammer or other means. Considerable skill was required by
the craft men who practiced it in order to achieve a good weld by present - day standards.
44. Stat the advantages of forge welding

 It is simple and easy
 It does not required any costly equipment for weld small pieces.
 It can weld both similar and dissimilar metals.
 No filler material required.
45. State the limitations of forge welding

 Only small objects can be weld. Larger objects required large press and heating furnaces, which
are not economical.
 High skill required because excessive hammering can damage the welding plates.
 High welding defects involve
 It cannot use as mass production
 Mostly suitable for iron and steel
46. Define Roll Welding

Roll welding is a solid state cold welding process, obtained through flat rolling of sheet metals. In roll
bonding two or more layers of different metals are passed through a pair of flat rollers under sufficient
pressure to bond the layers. The pressure in high enough to deform the metals and reduce the combined
thickness of the clad material.
47. Write the merits and demerits of roll welding Merits of roll welding
 No filler metal required
 High production rates possible
 Lends itself to mechanization and automation.
 Lower operator skill level than for arc welding
 Good repeatability and reliability. Demerits of rill welding
 High initial equipment cost
 Limited to lap joints for most roll welding process
48. Write the applications of roll welding

 Cladding stainless steel to mild or low alloy steel for corrosion resistance.
 Bimetallic strips for measuring temperature.
 "Sandwich" coins for U.S mint.
49. State the hot pressure welding

Hot pressure welding is a solid state process that produces joints between the faying surfaces of two
bodies. It is done by application of heat and pressure. Fusion temperature is not reached. Filler metal
is not needed and substantial plastic deformation is generated.

50. Write the advantages of hot pressure welding.

 Simple process  Quick weld production
 Simple joint preparation  High quality joints
 Relatively low cost equipment
52. State the limitations of hot pressure welding.

 Not all metals are weldable
 Not easily automated
 Length of cycle dependent on time for heating
 Removal of flash and bulge required after welding
 Only simple sections readily butt weldable.
UNIT - V ( Testing of Welds, NDT)
1. State that destruction test.

Destructive testing method damage the test piece to more or less extent. The extent of damage on
(destructive) tested specimens sometime can be up to complete fracture (like in tensile or fatigue
testing) thus making it un-useable for the intended purpose. This find out the mechanical properties
such as strength, toughness and hardness of the materials.
2. List out the various type of destruction testing.

 Tensile testing  Nick break testing
 Bend testing  Hardness testing
 Impact testing
3. Write the benefits of destruction testing.

 Verifies properties of a material
 Determines quality of welds
 Helps you to reduce failures, accidents and costs.
 Ensures compliance with regulations.
4. List out the applications of destructive testing.

 Sampling inspection
 Research inspection
 Welding procedures qualification
 Welder performance qualification testing
 Failure analysis work.
5. Define bend test.

Bend test is one of the most important and commonly used destructive tests to determine the ductility
and soundness [for the presence porosity, inclusion, penetration and other macro size internal weld
discontinuities] of the weld joint produced using under set of welding conditions.
6. State that hardness test.

Hardness is defined as resistance to indentation and is commonly used as a measure of resistance to
abrasion or scratching. For the formation of a scratch or causing abrasion, a relative movement is
required between two bodies and out of two one body must penetrate/indent into other body.
Indentation is the penetration of a pointed object (harder) into other object (softer) under the external
load.

7. List out the various types of hardness testing.

 Brinell hardness test
 Rockwell hardness test
 Vickers hardness test
8. State that Non-destruction testing.

 Non destruction testing (NDT) can be performed on metals, plastics, ceramics, composites,
cermets and coatings in order to detect cracks, internal voids, surface cavities, delamination,
incomplete defective welds. This testing does not affect the material future usefulness.
9. Classify non-destructive testing (NDT).

 Visual inspection test  Ultrasonic test
 Microscopy test  Magnetic particle test
 Radiograph test  Eddy current test
 Dye penetrate test (or) Liquid penetration  Acoustic emission test.
test.
10. Define liquid penetrate testing and magnetic particle testing.
 Liquid penerant testing is a method which can be employed for the detection of open-to-surface
discontinuities in any industrial product which is made from a non- porous material. This method
is widely used for testing of non-magnetic materials
 Magnetic particle testing is used for the testing of materials which can be easily magnetized. This
method is capable of detecting open to surface and just below the surface flaws.
11. List out merits and demerits of liquid penetrant testing. Merits:
 Relatively low cost
 Highly portable NDT method
 Highly sensitive to find, tight discontinuities
 Can be used on a variety of materials. Demerits:
 Detects surface discontinuities only.
 Cannot be used on porous specimens
 Only surface breaking detects can be detected
 Test surface must be free of all contaminants.
12. List the advantages of ultrasonic testing.

 It can be used to determine mechanical properties and microstructure.
 It can be used for imaging and microscopy
 It is portable and cost effective
 It is not affected by optical density.
13. State Radiographic testing.

Radiographic testing is method of inspecting materials for hidden flaws by using the ability of short
wavelength electromagnetic radiation (high energy photons) to penerate various materials. The
intensity of the radiation that penerates and passes through the material is either captured by a radiation
sensitive film (film radiography) or by a planer array of radiation sensitive sensors (Real time
radiography).
14. List out the advantages of radiographic testing.

 Useful for thin sections.
 Suitable for any material.

 Both surface and internal discontinuities can be detected.

 Significant variations in composition can be detected.
15. Lint out the disadvantages of radiographic testing.

 Generally an inability to scope with thick sections,
 Possible health hazard.
 Not suitable for surface defects.
 No indication of depth of a defect below the surface.
 The process is generally slow.
16. List out the welding defects.

 Spatter  Crater cracks
 Deformation  Under cut
 Arc blow  Porosity
 Solidification crack  Slag inclusion
 Lack of fusion defects  Lack of root penetration.
17. Define weldability.

The capability of a material to be welded under the imposed fabrication conditions into a specific,
suitably designed structure and to perform satisfactory in the intended surface. Weldability depends on
various factors such as nature of metals, weld design, welding technique, and skills.
18. Write down the physical properties of stainless steel.

 The co-efficient of thermal expansion
 The thermal conductivity
 The electrical resistivity
 The melting temperatures
19. Write down the applications of liquid penetrant testing.

 The inspection of tools and dies.
 The inspection of tanks, vessels, reactors, piping, dryers and pumps in the chemical,
petrochemical, food, paper and processing industries.
 The inspection field drilling rigs, drill pipe, casting and drilling equipment.
 The inspection of aircraft engine parts, propellers, wing fitting and casting.
20. List out the advantages of magnetic particle testing.

 Best method for the detection of fine, shallow surface cracks in ferromagnetic material.
 Fast and relatively simple NDT method
 Generally inexpensive
 Will work through thin coating.
21. Write down the demerits of magnetic particle testing.

 Materials must be ferromagnetic
 Orientation and strength of magnetic field is critical.
 Defects surface and near to surface discontinuities only.
 Burning of test parts a possibility.
22. State the limitations of ultrasonic testing.

 Manual operation requires careful attention by experienced technicians.
 Extensive technical knowledge is required for the development of inspection procedures.

 Parts that is rough, irregular in shape, very small or thin, or not homogeneous are difficult to
inspect.
 Surface must be accessible to transmit ultrasound.
23. Write the applications of ultrasonic testing.

 Wall thickness measurements in pressure vessels, pipelines, gas holders, storage tanks for
chemical and accurate estimate of the effect of wear and corrosion without having to dismantle
the plant.
 Measurement of the thickness of ship hulls for corrosion control.
 Control of machining operations, such as final grinding of hollow propellers.
 Inspection of heat exchanger tubing in nuclear reactors.

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ADVANCED WELDING TECHNOLOGY SMVEC

MEE 81 ADVANCED WELDING TECHNIQUES - TWO MARKS

UNIT - I (Introduction to Welding and Gas welding )

1. Define welding process.

2. What is the reasons welding largely used in field of Engineering?

3. Define Arc welding process.

4. State the merits and demerits of welding.

5. Classify the welding processes.

6. Define pressure and Non pressure welding.

DEPT. OF MECHANICAL ENGG.

7. State that Gas welding process.

8. List out the Gas welding equipment.

9. Define oxy-acetylene welding.

10. Classify the flames of oxy-acetylene.

11. Classify the gas welding techniques.

12. Define flux and main functions.

13. List out the advantages and disadvantages of gas welding.

DEPT. OF MECHANICAL ENGG.

14. Define welded joint and its types.

 Lab joint or fillet joint  Edge joint

15. Define lab joint and butt joint.

16. Classify the butt joint.

17. Write down the elements of a welding symbol.

19. Define Eccentric loaded welded joint.

UNIT - II ( Arc welding )

1. State Arc welding process and types.

2. Define carbon arc welding and types.

 Single electrode arc welding

DEPT. OF MECHANICAL ENGG.

3. Write down the advantages and disadvantages of carbon arc welding.

4. Define shielded metal arc welding (SMAW).

5. List out the shielded metal Arc welding equipment’s.

6. Define electrode and types.

7. List the merits and demerits of shielded metal Arc welding.

8. Define submerged Arc welding.

DEPT. OF MECHANICAL ENGG.

9. What are the advantages of submerged Arc welding process?

10. State Tungsten inert gas welding (TIG).

11. State the applications of TIG welding.

12. Write down the advantages and disadvantages of TIG welding.

13. Define metal inert gas (MIG) welding.

14. Write down the advantages of MIG welding.

DEPT. OF MECHANICAL ENGG.

UNIT - III ( Plasma Arc welding, Solid state welding )

1. Define plasma Arc welding (PAW).

2. List down the equipment’s of plasma Arc welding (PAW).

3. Write the advantages of plasma Arc welding.

4. Write the disadvantages of plasma Arc welding.

5. State the Electro slag welding (ESW).

6. State the Flux cored Arc welding.

7. Define Electro gas welding.

DEPT. OF MECHANICAL ENGG.

9. Define solid state welding

10. Write down the types of solid state welding

11. State the advantages of solid state welding

12. State the disadvantages of solid state welding.

13. State that cold welding

14. List out cold welding equipment’s.

15. Write down the applications of cold pressure welding.