DEPARTMENT OF MECHANICAL ENGINEERING

ME3393 MANUFACTURING PROCESSES

TWO MARK QUESTION WITH ANSWERS
UNIT II METAL JOINING PROCESSES
1. List out any four arc welding equipment.
The most commonly used equipments for arc welding are as follows:
A.C or D.C. machine
Wire brush
Cables and connectors
Ear thing clamps
Chipping hammer
2. What are the special features of friction welding?
Friction welding is a solid state welding process where coalescence is produced by t he
heat obtained from mechanically induced sliding motion between rubbing surfaces.
The work parts are held together under pressure.
Its operating is simple.
Power required for the operation is low.
It is used for joining steels, super alloys, non-ferrous metals and combinations of m etals.
3. Define resistance welding process.
Resistance welding is a process where coalescence is produced by the heat obtained from
resistance offered by the workpiece to the flow of electric current in a circuit of which the
work piece is a part and by the application of pressure.
4. What is weld porosity? How is it caused?
Porosity is the formation of small holes or pores in the weld.
Porosity is caused by entrapment of gases during the solidification process
The gases so entrapped mostly consists of hydrogen, oxygen and nitrogen of which
hydrogen is most prominent for causing porosity
5. How can slag inclusions in welding be an of small voided?
• Avoid multi layer welding
• Reduce arc length
• Increase electrode angle
• Avoid using large electrode
6. How does brazing differ from braze welding?
Brazing Braze Welding
The filler alloy is fed to one or more points in the assembly and it is drawn into the rest of the
joint by capillary action.
The filler alloy is deposited directly at the point where it is desired.
7. Why flux is coated on filler rods?
The coating improves penetration and surface finish.
Suitable coating will improve metal deposition rates.
8. What is the application of carburizing flame?
Carburizing flame is generally used for:
➢ Welding of low alloy steel rods
➢ Non-ferrous metals
➢ High carbon steel
9. What are the diameter and length of the electrodes available in the market?
• Standard length of electrodes is 250 mm, 300 mm and 450 mm.
• Standard diameters of electrodes are 1.6,2 ,2.5, 3.2, 4,5,6,7,8, and 9 mm.
10. Define weld ability.
Weld ability is defined as the capacity of a material to be welded under fabrication conditions
imposed in a specific and suitably designed structure and to perform satisfactorily in the
intended service.
11. State requirement of a good weldability.
A metallic material with adequate weld ability should fulfill the following requirements:
i. Have full strength and toughness after welding.
ii. Contribute to good weld quality even with high dilution.
iii. Have unchanged corrosion resistance after welding.
iv. Should not embrittle after stress relieving.
12. How is welding classified?
Gas welding
Arc welding
Resistance welding
Solid state welding
Thermo-chemical welding processes
 Radiant energy welding processes
13. Name the types of flames.
The generated flames are classified into following three types
(a) Neutral flame (Acetylene and oxygen in equal proportion)
(b) Oxidizing flame (Excess of oxygen)
(c) Reducing flame or carburizing flame (Excess of acetylene)
14. Where is oxdizing flame used?
i. Copper-base metals
ii. Zinc-base metals
iii. Ferrous metals such as manganese steel, cast iron, etc.
15. Explain the function of flux in welding.
While welding, if the metal is heated in air then the oxygen from air combines with the metal
to form oxides. This results in poor quality, low weld strength hence, to avoid this difficulty a
flux is employed during welding. It prevents the oxidation of molten metal.
16. Give the applications of gas welding.
Gas welding is most widely used for the following purposes:
Joining thin materials.
Joining most ferrous and non-ferrous metals.
In automobile and aircraft industries.
In sheet metal fabricating plant.
17. What is arc welding?
Electric arc welding is a fusion welding process in which welding heat is obtained from an
electric arc between an electrode and the workpiece.
18. Define arc length and arc crater.
The distance between the centre of arc of the electrode tip and the bottom of arc crater is
called as arc length. A small depression is formed in the base of the metal which is called as
arc crater.
19. Define SMAW.
It is an arc welding process where coalescence is produced by heating the workpiece with an
electric arc set up between the flux coated electrode and the workpiece.
20. What is submerged arc welding ?
It is an arc welding process where coalescence is produced by heating, with an electric arc set
up between bare metal electrode and workpiece.
21. Explain in short plasma arc welding.
It is an arc welding process where coalescence is produced by the heat obtained from a
constricted arc set up between a tungsten electrde and the water cooled nozzle or the
workpiece. The process employs two inert gases i.e. one forms the plasma arc and the second
shields the plasma arc. Filler rod may or may not be added and pressure is not required for
welding.
22. Write about special feature of flux cored welding.
The electrode is flux cored i.e. flux is contained within the hollow electrode. The flux cored
electrode is coiled and supplied to the arc as a continuous wire. The flux inside the wire
provides the necessary shielding of the weld pool.
23. What are the factors affecting resistance welding?
Four factors are involved in operation of resistance welding:
i. Amount of current passing through the work piece.
ii. The pressure that electrodes transfer to the work piece.
iii. Time during which current flows.
iv. Area of electrode tip in contact with the work piece.
24. What is adhesive bonding?
Adhesive bonding is the process of joining materials by using adhesives. The term adhesive
includes substances such as glues, cements and other bonding agents. Main steps in adhesive
bonding are
(1) Surface Preparation (2) Applying the primer
(3) Applying the adhesive (4) Assembling adhesive coated components
(5) Curing the assembly (6) Testing of the joints
25. Explain thermoplastic adhesives.
Thermoplastic type adhesives soften at high temperature. They are easy to use and are
employed as, air drying dispersions, emulsions or solutions that achieve their strength
through the evaporation of the solvent
26. Explain thermosetting adhesives.
Thermosetting adhesives, once hardened cannot be remelted and a broken joint cannot be
rebounded by heating also. These types of adhesives cure or harden by chemical reactions
like polymerisation, condensation, vulcanisation or oxidation caused by the addition of a
catalyst; heat, pressure, radiations, etc.
27. What is brazing?
It is defined as a group of joining processes where coalescence is produced by heating to a
suitable temperature and by using a filler metal having a liquid us above 4700 C and below
the solids of the base metal.
28. What is thermit welding?
Thermit welding is a fusion welding process that makes use of the intense heat produced
when a mixture containing iron oxide and powdered aluminium is ignited. It reduces iron
oxide to thermit steel and slag.
29. Name different defects in weld.
(a) Cracks (b) Distortion (c) Inclusions
(d) Porosity and blow holes (e) Undercutting (f) Overlapping
(g) Spatter (h) Poor fusion
(i) Poor weld bead appearance (j) Incomplete penetration