TEST 1 MEM 661

1) Three main different between soldering and brazing are:

Soldering
The melting point for filler metal used in
soldering are less than 427 °C.
Mainly used in electrical industry for
permanent connection of the electrical
component
High temperature and pressure easily
affected the joints
Brazing
The filler metal has melting point more than
427 °C.
Mainly used in to join any kind of metals in
industry
The joints are not affected by high
temperature and pressure

This is because brazing can joint thinner material compared to welding. Since most of car
body part are made up of thin sheet metal it is better to use brazing since it’s operate at
temperature lower than welding. Besides, brazing does not melt the base metal which will
makes the control over tolerance are much easier and does not need finishing process in other
to get the desired dimension.
2) The main reason are because in order to produce much complex shape product. This is
because by having different part of the product it is much easier to create the complex
shape by joining it together. Besides, by having gas welding and SMAW the joint that are
been created are much stronger since during the welding or cutting processes there are
shielding gas that protect the weldment or cutting area which will avoid impurities from
diffuse with the metal and affecting the properties of the metal. Moreover, gas welding
and SMAW are much lower cost compared to other welding and cutting equipment. In
my opinion SMAW are much preferred compared to gas welding. This is because by
using SMAW we only need to buy welding electrode and can cut the cost to by the gas
cylinder to use for cutting and welding. Besides, SMAW are much portable compared to
gas welding since we does not need to carry the gas cylinder when we are performing
welding or cutting in other places.
3) Transformer

Transformer in welding power source converts the moderate voltages and current from
230 VAC into the low voltage around 17 to 45 volts and high current which is from 55 to
590 amperes. The design of the power supply will allow the welders to adjust the output
voltage as desired just by adjusting the primary winding.

Generator and alternator

This is in order to convert the mechanical energy to electrical energy. By having electric
motor or internal combustion engines, the utility power is converted into mechanical
energy and then converted back into electrical energy to have the step down effect as
transformer. Besides the output of the generator can be direct current and can also be a
high frequency AC.

Inverter

Inverter is used to rectify the utility alternate current to direct current and then switch the
direct current to step-down transformer in order for the welders to have its desire voltage
or current.

The latest modern technology of power source can easily sense and give feedback to what
happened in weld pool which then directly control the current which means it will reduce
the excessive losses of the unnecessary current. Besides by having this technologies it
will help to reduce failure of product since the power source will directly control the
current and produce a more stable current for a good fusion to occur which will lead to
the save of cost. Moreover by having generator and alternator inside the power source
will greatly reduce the cost of using utility current since the current can be generated
inside the power source itself.
4) For the tubular shape component it is more preferable to use GTAW. This is because
GTAW use a non-consumable electrode which made the control of the torch much easier
to weld the tubular shape component.
For the railway track the best welding process are the thermite welding. The process are
the rails must be cut into square shape. Then it is pre heated in order to carter the steel
composition. The metal deposition rates must be high and finally check for the acceptable
defect level for the fracture resistance of the steel.

Advantages of GTAW are that it will produce a high-quality welds. Besides the GTAW
can welds a wide range of metals and using GTAW will allow welding in all positions.
The disadvantages are the deposition rates are quite low. Besides it needs a high level of
operator skill and the usage of GTAW will produce higher level of UV rays which will
contribute to health problems.

Advantages of thermite welding are the welds will produce high mechanical strength
which is really important to support the weight of train. Besides it have a good corrosion
resistance compared to other welding type. Moreover thermite welding does not required
external power which will make the welding of railway much easier. The disadvantages
of thermite welding are the cost are much higher compared to other welding processes.
Besides it cannot be used in wet condition or bad weather which will delay the welding of
the railway when rain occurs.
PG
PA/1G/1F

2F/PB PB/2F

PC/2G
2G/PC

4F/PD PD/4F

4G/PE
PF
6) a) 0.35+0.25+0.12=0.72
b) 0.35+0.17+0.34+0.0083= 0.8683
Both result in the CE more than 0.5 which means the material are crack sensitive. In order to
weld this type of material the material require preheating and using low hydrogen welding
procedures.
7) Two primary type of welding groove are single V and double V. Single V groove welding
preparation is made when welders only have access to one side of the material or the
material are not thick enough. Single V groove is a v-shaped formed by combination of
two butting member of the base metal that have single bevel shapes. It can also be formed
between butting and non-butting member that have a planar surfaces arranged to form a
groove or forming the V shape groove in any surface of the member. Double V groove is
welding preparation of the metal that can be access to both side or thicker material in
order to ensure a stronger joint. The V shaped is formed on both side of the metal before
welding process started.
8) Suitable electrode to use are E11013. This is because the yield strength of the material are
between 600-700MPA and when converted it will get 87022.6 psi-101506 psi. Therefore
we pick the E110 which has can support minimum tensile strength of 110000 psi which is
acceptable for the given material. Next we chose 1 as all position weld since the beam
does not only have the flat position but also vertical and overhead welding position and
finally we pick number 3 for rutile 3 covering type which can be used for general welding
application and can even weld an uneven fit.
9) The imperfection that occurs at the weld joint are shrinkage. Shrinkage will cause
distortion to the weld joint which is will make the weldment shrink in between the joint
base metal. In order to handle this imperfection are by not overweld. This is because the
more metal been place in the joint the higher the shrinkage forces which will lead to
induced distortion to occur. Select a proper electrode size, and have a proper weld
preparation before welding procedure. Besides by using intermittent welding can also
reduce the induced distortion. By doing intermittent welding will reduce the weld metal
used for the welding and this will reduce the shrinkage forces to the joint. Finally, by
removing the shrinkage forces after welding. By using peening techniques in order to
reduce the shrinkage forces of the weld bead as it is cool. Peening will stretches the bead
and make it thinner to reduce the stresses induced when metal is cooled.
10) 3 methods to reduce weld induced distortion are by not overweld. This is because the
more metal been place in the joint the higher the shrinkage forces which will lead to
induced distortion to occur. Select a proper electrode size, and have a proper weld
preparation before welding procedure. Besides by using intermittent welding can also
reduce the induced distortion. By doing intermittent welding will reduce the weld metal
used for the welding and this will reduce the shrinkage forces to the joint. Finally, by
removing the shrinkage forces after welding. By using peening techniques in order to
reduce the shrinkage forces of the weld bead as it is cool. Peening will stretches the bead
and make it thinner to reduce the stresses induced when metal is cooled.