AkhilBharatiya Maratha ShikshanParishad's

Anantrao Pawar College of Engineering & Research

Record No.: ADM/D/036B DoI: 21/01/2019
Revision: 00
Internal Correspondence For Department

Department: Mechanical Engineering Subject: Advanced Manufacturing Processes

Multiple Choice Questions

Unit 2 Advance Joining Processes

1. Friction welding produces welds due to ______
a) electrode melting
b) workpiece melting
c) relative motion between work pieces
d) adhesive force between workpiece particles

Answer: c
Explanation: Friction Welding (FRW) is a solid state welding process which produces welds
due to the compressive force contact of work pieces which are either rotating or moving relative
to one another.

2. In friction welding, material is deformed due to_____

a) elastic deformation
b) plastic deformation
c) ductile deformation
d) brittle deformation

Answer: b
Explanation: In friction welding the heat required to produce the joint is generated by friction heating at
the interface. This heat displaces material plastically from the faying surfaces.

3. Which of the following is true about friction welding?

a) One workpiece is held stationary while the other is moving
b) Both the workpieces are moving
c) Both the workpieces are stationary and filler is added in the space between them
d) The material is deformed elastically

Answer: a
Explanation: The components to be joined are first prepared to have smooth, square cut surfaces. One
piece is held stationary while the other is mounted in a motor driven chuck or collet and rotated against
it at high speed.

4. During friction welding, initially low pressure is applied. Why?

a) For slowly increasing the surface temperature
b) For melting the surface coating on the materials

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c) To check weldabilty of two materials
d) For initial cleaning of the surface

Answer: d
Explanation: A low contact pressure may be applied initially to permit cleaning of the surfaces
by a burnishing action. This pressure is then increased and contacting friction quickly generates
enough heat to raise the abutting surfaces to the welding temperature.

5. After the welding temperature is reached _____

a) rotation is stopped
b) speed of rotation is increased
c) rotation of first workpiece is stopped and second workpiece starts rotating
d) filler material is added

Answer: a
Explanation: As soon as the welding temperature is reached, rotation is stopped and the pressure is
maintained or increased to complete the weld. The softened material is squeezed out to form a flash. If
desired, the flash can be removed by subsequent machining action.

6. By friction welding, steel bars upto _____ mm diameter can be welded.

a) 10
b) 50
c) 100
d) 210

Answer: c
Explanation: During friction welding, a forged structure is formed in the joint. Friction welding
has been used to join steel bars upto 100 mms in diameter and tubes with outer diameter upto
100 mm.

7. Inertia welding is a modified form of friction welding.

a) True
b) False

Answer: a
Explanation: Inertia welding is a modified form of friction welding, where the moving piece is attached
to a rotating flywheel. The flywheel is brought to a specified rotational speed and is then separated from
the driving motor.

8. Which of the following is not true about inertia welding?

a) Weld is formed when the flywheel stops

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b) The process is difficult for automation
c) Weld quality is consistent
d) Parts remain in contact even after the weld is completed

Answer: b
Explanation: The weld is formed when the flywheel stops its motion and the pieces remain
pressed together. Since the conditions of the inertia welding are easily duplicated, welds of
consistent quality can be produced and the process can be easily automated.

9.Which of the following materials cannot be welded by friction welding?

a) Aluminium
b) Copper
c) Stainless steel
d) Non-forgeable materials

Answer: d
Explanation: Dry bearing and non-forgeable materials cannot be welded by a friction welding
process, i.e., one of the components must be ductile when hot, to permit deformations.
Preparation and alignment of the workpieces of the workpieces may be critical for developing
for developing uniform rubbing and heating, particularly for pieces having diameters larger
than 50mm.

10.Aluminium is difficult to friction weld because of _____

a) ductility
b) softness
c) micro porosity
d) heat reflectivity

Answer: c
Explanation: The basic problems with friction welding of aluminium and its alloys are that they
possess:
• Cast brittle dendritic structure
• Micro porosity
• Loss of strength in heat affected zone

11. Which of the following processes can be used as alternative technique for joining
aluminium and its alloys?
a) Tungsten inert-gas welding
b) Metal inert-gas welding

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c) Friction stir welding
d) Oxy-Acetylene flame technique

Answer: c
Explanation: The following alternate techniques are being used for joining of aluminium and its
alloys:
• Electron beam welding
• Laser beam welding
• Variable polarity plasma arc welding
• Friction stir welding.

12. All metallic engineering materials which are _____ can be friction welded.
a) soft
b) weldable
c) forgeable
d) metamaterials

Answer: c
Explanation: As a rule, all metallic engineering materials which are forgeable can be friction
welded, including automotive valve alloys, maraging steel, tool steel, alloy steels and tantalum.
In addition, many castings, powder metals and metal matrix composites are weldable.

13.Friction welding produces quality joints, with a 100% _____ weld.

a) lap joint
b) tee-joint
c) butt joint
d) edge joint

Answer: c
Explanation: Friction welding produces forged quality joints, with a 100% butt joint weld
through the contact area. Furthermore, in friction welding heat affected zone is much narrower
as compared to other welds, which indeed reduces the cost of post-weld heat treatments (stress
relieving processes).

14._____ generated during friction welding is coherent.

a) Burr
b) Molten metal
c) Flash curl
d) Fly ash

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Answer: c
Explanation: The flash curl generated during welding is coherent, will not flake off, and can
often be left intact if design and engineering considerations allow. Alternately, parts can
frequently be designed to accommodate the flash curl in a recess (flash trap).

15. Which of the following is not the advantage of friction welding?

a) No smoke generation during the process
b) Less sparks are produced during the process
c) Applicable for all metals
d) Time saving process

Answer: c
Explanation: The advantages of this process such as no smoke, fumes or gases, or few sparks
produced, and the fact that the process is machine-controlled, make it suitable for use in
potentially explosive or hazardous environments. The machine can be fully automated so the
operator can be safely located out of harm’s way. This process is not applicable to non-
forgeable metals.

16.From given below which one is not the processes parameter of FSW.

a)Rotation Speed b)Tilting angle c)Material used d)Down force

Ans:- c

17.In FSW small change in shape of tool can cause significance change in ____________ and
quality of weld.

a)Operational Speed b)tool quality c)feed d)removed chips

Ans:- Operational Speed

18._____________ is the period of the starting stage of welding process in FSW.

a)Transient stage b)Dwell c)Pseudo Steady State d)none of these

Ans:-Dwell

19.________ is the constant eat generation starts in the beginning of the process.

a) Transient heat b)Dwell c)Pseudo Steady State d)none of these

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ANS:-a

20._____________- is the stage in which the thermal zone around the tool becomes steady.

a)Transient stage b)Dwell c)Pseudo Steady State d)none of these

Ans:-c

21.In electron beam welding the tungsten filament heated upto high temperature at _______
degree Celsius.

a)2500 b)2200 c)3000 d)1800

Ans:-2500

22..In electron beam welding the ______ filament heated upto high temperature at 2500 degree
Celsius.

a)Titanium b)Carbide tool c)Tungsten d)steel alloy

Ans:-Tungsten

23.From the following image one D shows ___________ zone.

a)Parent Metal b)Heat Affected c)Thermo Mechanical Effected d)Weld Nugget

Ans:-d

24.From the following image one C shows ___________ zone.

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a)Parent Metal b)Heat Affected c)Thermo Mechanical Effected d)Weld Nugget

Ans:-c

25.From the following image one B shows ___________ zone.

a)Parent Metal b)Heat Affected c)Thermo Mechanical Effected d)Weld Nugget

Ans:-b

26.From the following image one A shows ___________ zone.

a)Parent Metal b)Heat Affected c)Thermo Mechanical Effected d)Weld Nugget

Ans:-a

27.In electronic beam welding depth of penetration is depending upon ________.

a)Electronic beam power b)acceleration voltage c)beam current d)None of these.

Ans:-b

28.In Laser Beam Welding ______________- used to emit light.

a)cadmium lamp b)florescent lamp c)Flash lamp d)None of these

Ans:-c

29.Laser beam welding is a ______ joining process.

a) fission b) fusion c) coherent d) plastic

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Answer: b
Explanation: Laser is an acronym for light amplification by stimulated emission of radiation.
Laser Beam Welding (LBW) is a fusion joining process that produces coalescence of materials
with the heat obtained from a concentrated beam of coherent, monochromatic light impinging
on the joint to be welded.

30.Which of the following is used to direct laser beam?

a) glass apertures b) perforated glass sheets c) flat optical elements
d) electro-magnetic coils

Answer: c
Explanation: In the LBM process, the laser beam is directed by flat optical elements, such as
mirrors and then focused to a small spot (for high power density) at the workpiece using either
reflective focusing elements or lenses.

31.In case of laser welding, heat input is _____ to fuse the weld metal.
a) equal to the required amount b) close to the minimum required
c) greater by 200 J than required d) approximately higher by atleast 320 J

Answer: b
Explanation: Following are the few advantages of Laser Beam Welding:
• Heat input is close to the minimum required to fuse the weld metal
• Reduced heat affected zones
• Workpiece distortions are minimized due to smaller heat affected zones.

32..In LBW the atoms of ____________ absorb the energy and electron of those atoms get
excited.

a)Ruby crystal b)Quarts Crystal c)Swiss quartz crystal d) diamond crystal

Ans:-a

33. Tool in USM is generally made from which of the following materials?
a) Glass b) Ceramic c) Carbides d) Steel

Ans:-d

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Explanation: The tool material should be such that indentation by the abrasive grits does not
lead to brittle failure. Thus the tools are made of tough, strong and ductile materials like steel,
stainless steel and other ductile metallic alloys.

34. In ultrasonic machining, the abrasive particles act as the __________

a) chip carriers b) intenders c) finishing particles

d) thickening agent for the slurry

Answer: b
Explanation: During ultrasonic machining, as the tool vibrates over the workpiece, the abrasive
particles act as the indenters and indent both the work material and the tool.

35. During USM, cracks are produced due to _____

a) von-mises stresses b) hertzian stresses c) principal stresses
d) episodic acute stresses

Answer: b
Explanation: During USM, as the tool vibrates, it leads to the indentation of the abrasive grits.
During indentation, due to hertzian contact stresses, cracks would develop just below the
contact site then as indentation progresses the cracks would propagate due to increase in stress
and ultimately lead to brittle fracture of the work material under each individual interaction site
between the abrasive grits and the workpiece.

36. Increasing volume concentration of abrasive in slurry would affect MRR in which of the
following manner?
a) increase MRR
b) decrease MRR
c) would not change MRR
d) initially decrease and then increase MRR

Answer: a
Explanation: The concentration of abrasive grits in the slurry is related as follow
n = (6AC)/ πdg2,
where n= number of grits
A= total surface area of the tool facing the workpiece
C= concentration of abrasive grits in the slurry
dg= diameter of a grit
Thus above relation shows that any increase in ‘C’ will increase ‘n’ and hence material removal
rate (MRR).

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37. Which of the following material is not machined by USM?
a) Brittle metals b) Glass c) Ceramics d) Ductile materials

Answer: d
Explanation: USM is used for machining;
• hard metallic alloys • brittle metallic alloys • semiconductors • glass • ceramics
• carbides.

38. The development of USM was started in _____

a) 1920 b) 1927 c) 1947 d) 1980

Ans:-b

Explanation: The development of USM was started in 1927. It was accidentally discovered
during investigating the ultrasonic grinding of abrasive powders.

39. Which of the following is not a part of the ultrasonic machine used in USM?
a) Generator b) Acoustic head c) Slurry pump d) Lead-screw

Answer: d
Explanation: The basic ultrasonic equipment consists of, a generator for high frequency
oscillations; an acoustic head, consisting of a transducer and a horn also known as shank or
trunk; also, tool and abrasive slurry elements like pump and tank for slurry.

40. The tool is joined to the trunk by _____

a) riveted joint b) welded joint c) brazing d) honing

Answer: c
Explanation: The tool is attached to the trunk or the horn by silver brazing process. At times it
is fasten or the screwed to the trunk also. The commonly used tool materials are brass, high
speed steel, mild steel, silver, stainless steel, tungsten carbide and monel metal.

41.Which of these are(is) Not the thermal spray coating processes?

a)Wire frame spray b)Electric arc wire spray c)Plasma Spray

d)carbide coat Spray

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Ans:-d

42.The following figure shows the _________________ process.

a)Wire frame spray b)Electric arc wire spray c)Plasma Spray

d)High velocity oxy fuel Spray

Ans:-a)

43.In plasma spray coating the temperature of plasma is as much as ________degree Celsius

a)12000 b)14000 c)10000 d)16000

Ans:-16000

44.The __________ process utilizes a combination of oxygen with various fuel gases hydrogen,
propane, propylene.

a)Plasma Spray b)Electric arc wire spray c)Plasma Spray

d)High velocity oxy fuel Spray

Ans:-d

45.The following diagram shows______________ Process.

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a)Ultrasonic welding b)Electric arc wire spray c)Plasma Spray

d)High velocity oxy fuel Spray

Ans:-a

46.Material like Pentaerytritol Tetranitrate and Trinitrotoluene is used in __________

a)Electric Welding b)High Velocity oxy fuel spray c) Explosive welding

d)None of these

Ans:-c

47.In cryogenic welding the cryogenic phenomenon includes the material processing under
_______ degree Celsius temperature.

a)-500 b)-50 c)-150 d)-300

Ans:- c

Descriptive Question for 1 and 2 Mark .

What are the different parameters of FSW.?

What are the metallurgical Advantages of FSW?

What are safety precaution in Underwater welding?

What are the applications of Thermal Spray coating?

Which area ultrasonic welding is applicable?

What are the applications of Laser Beam Welding?

Which are the tool materials applicable in FWS?

What is principle of Electronic Beam Welding?

State different welding zones.

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What are the methods available for welding polymer?

Which gases are uses in cryogenic application?

What are the temperatures of the gases used in cryogenic applications?

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