Ques.1.

In arc welding, the temperature of the arc is of the order of

1. 100° C
2. 1000° C
3. 3500° C
4. 35000° C

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Answer.3. 3500°C

Explanation:-

Welding is the process of joining metallic parts by bringing them into intimate
proximity and heating the places of contact to the state of fusion or plasticity. This
leads to the interpenetration of atoms of the metals in the weld zone and a strong
inseparable joint is formed after the metals have cooled.

Arc Welding

Arc welding is used to join metals. An electric arc is created between an

electrode and the components being joined in order to melt the components in
the joint area. A filler material is fed into the joint at the same time. Arc-welding
processes include shielded metal arc welding, metal inert gas welding, tungsten
inert gas welding, plasma arc welding, and submerged arc welding.

In this process, an electric arc is produced bat bringing two conductors (electrode
and metal piece) connected to a suitable source of electric current, momentarily
in contact and then separated by a small gap, arc blows due to the ionization and
gives intense heat.
The heat so developed is utilized to melt the part of workpiece and filler metal
and thus forms the weld. For the arc welding, the temperature of the arc
should be 3,500°C. At this temperature, mechanical pressure for melting is not
required. Both AC and DC can be used in the arc welding. Usually, 70-100 V on
AC supply and 50-100 V on the DC supply system is sufficient to strike the arc in
the air gap between the electrodes. Once the arc is struck, 20-30 V is only
required to maintain it.

Ques.2. The arc has

1. Linear resistance characteristics

2. Positive resistance characteristics
3. Negative resistance characteristics
4. Highly inductive characteristics

Hide Explanation

Answer.3. Negative resistance characteristics

Explanation:-
In an ARC WELDING when the supply is given across the conductors separated
by some distance apart, the air gap present between the two conductors gets
ionized, as the arc welding is in progress, the ionization of the arc path and its
surrounding area increases.

As the current is increased, the temperature increases and therefore the

conductivity increases. More ions are formed, so the arc resistance is towered
and the arc voltage is decreased. We say that the arc has a negative resistance
characteristic because the voltage drops with higher currents.

Thus, current increases with the decrease in voltage of the arc. This V-I
characteristic of an arc is shown in fig. It is also known as negative resistance
characteristics of an arc. Thus, it will be seen that this decrease in resistance
with an increase in current does not remain the arc steadily. This difficulty can be
avoided, with the supply, it should fall rapidly with the increase in the current so
that any further increase in the current is restricted.

Ques.3. Arc can be produced by

1. AC current only
2. DC current only
 3. Either AC or DC current
4. All of the above

Hide Explanation

Answer.3. Either AC or DC current

Explanation:-

The arc can be produced by either AC or DC current.

The regular electric power supply (hydel power or thermoelectric) uses high
voltage and low current. It cannot be used directly for welding purposes without a
welding machine, which is specially designed and constructed to change the high
voltage low ampere current into a safe low voltage (which is usually between 50
and 100 volts) and a heavy current supply upto 600 A

The transformer does not have any moving part and as a result, operates with
less maintenance cost and also has higher efficiency. The power used is also
less expensive and there is practically no noise in the operation of the welding
transformer. In AC welding, normally only transformers are used.

Arc welding equipment are of two types:-

1. AC machine
1. Transformer
2. Motor or engine driven alternator
2. DC Machine
1. Transformer with D.C rectifier
2. Motor or engine driven generator

AC machine
An AC generator set comprises an AC generator (alternator) to produce AC
power for welding and a prime mover to run the generator. The prime mover may
be either an AC motor or more often a petrol or diesel engine. AC generator can
deliver current at normal frequency (50 Hz) or high frequency. The electric motor
driven generator sets are those which employ a motor to move at normal
frequency (50 Hz) and drive a generator which produces AC power at some
higher frequency for special welding applications. Engine driven AC generator
sets are used for welding in remote situations where no electric power is
available.

DC arc welding machines:

These are further divided as (i) DC generator set, motor driven or engine driven
and (ii) Transformer rectifier set. One big advantage of a DC welding set is that
either straight or reverse polarity can be used.

DC generator sets consist of a DC generator powered by either an AC electric

motor or an engine (petrol or diesel). The generator set provides DC power in
either straight polarity or reverses polarity using a polarity switch given on the
machine. The generator supplies voltage usually between 15 and 45 volts across
the arc and the open circuit voltage is between 45 and 70 volts and current
supply up to 600 amperes.

DC rectifier sets consist of a transformer to lower down the input AC voltage

and a silicon or selenium rectifier to convert AC into DC. The machine has no
moving part except a moving fan to cool the transformer. The DC rectifier set
gives either straight or reverses polarity. The machine is quite in operation with
low maintenance.

AC/DC arc welding machines: These are basically AC/DC transformers—

rectifier type welding machines which give either AC or DC power for welding
(only one type of power at a time). Rectifier units are designed to provide a
choice of low voltages for MIG welding or submerged arc welding and a high
open circuit voltage with drooping voltage characteristics (constant current type)
for TIG welding, and manual arc welding. The open circuit voltage may be up to
75 volts and arc voltage 25 to 50 volts with current ratings from 200 to 1000
amperes.

Ques.4. The resistance of the arc

 1. Decrease with an increase of the current
2. Increases with increases of the current
3. Does not depends on current
4. None of the above

Hide Explanation

Answer.1. Decrease with an increase of the current

Explanation:-

In an ARC WELDING when the supply is given across the conductors separated
by some distance apart, the air gap present between the two conductors gets
ionized, as the arc welding is in progress, the ionization of the arc path and its
surrounding area increases.

As the current is increased, the temperature increases and therefore the

conductivity increases. More ions are formed, so the arc resistance is towered
and the arc voltage is decreased. We say that the arc has a negative resistance
characteristic because the voltage drops with higher currents.

The resistance of the arc may be increased by:

1. Increasing the Length: The resistance of the arc is directly

proportional to its length. The length of the arc can be increased by
increasing the gap between contacts.
2. Cooling of Arc:– Cooling helps in the deionization of the medium
between the contacts. This increases the arc Resistance. Efficient
cooling Slav, be obtained by a gas blast directed along the arc.
3. Reducing the cross section area of an arc:- If the area of the
cross-section of the arc is reduced, the voltage necessary to
maintain the arc is increased. In other words, the resistance of the
arc path is increased. The cross-section of the arc can be reduced
 by letting the arc pass through a narrow opening or by having the
smaller area of contacts.
4. Splitting of arc:- The resistance of the arc can be increased by
splitting the arc into a number of smaller arcs in the series. Each
one of these arcs experiences the effect of lengthening and cooling.
The arc may be split by introducing some conducting plates
between the contacts.

Ques.5. In arc welding, the voltage on A.C supply system is in the range

1. 1000-1200 V
2. 400-500 V
3. 200-250 V
4. 70-100V

Hide Explanation

Answer.4. 70-100V

Explanation:-

For electric arc welding, both an alternating current (A.C.) and direct current
(D.C.) are used. For A.C. arc welding normally a step-down transformer is
utilized which receives current from the supply mains at 220 volts (in case of
single-phase supply) and 400 to 440 volts (in case of three-phase supply) and
transforms it to the normal open circuit welding voltage (80-100 volts).

In the case of A.C. arc welding, we reduce the incoming voltage to 80-100 volts.
This voltage is actually needed only for striking the arc but for maintaining the
same, we require a still voltage of about 35 to 40 volts. The current regulators
accomplish the desired voltage by adjusting the flow of the current. There is no
fixed polarity at the terminals in case of A.C. welding. So an arc is created by low
voltage, high current supply. In A.C. supply, it does not matter whether the work
or the electrode is positive, or in other words there is no polarity.

Ques.6. In arc welding by dc supply, the voltage required is

1. 10 to 20 V
2. 50 to 60 V
3. 100 to 120 V
4. 200 to 250 V

Hide Explanation

Answer.2. 50-60V

Explanation:-

In the D.C arc welding process, open circuit voltage is 40-60 volts, and the arc
voltage is 18-30 volts. The current for manual arc welding usually ranges from 35
to 500 ampere and for the automatic operation it is from 75 to 600 ampere. The
actual amount of current required depends upon the thickness of the job.

Ques.7. In arc welding, once the arc is struck, the voltage required to maintain
the arc will be

1. 20-30 V
2. 100-120 V
3. 200-220 V
4. 500-1000 V
Hide Explanation

Answer.1. 20-30V

Explanation:-

The voltage required to strike the arc is 40-80 volts but for maintaining the same,
we require a still voltage of about 20 to 30 volts.

Ques.8. A DC generator used for A.C welding should have

1. Rising characteristics
2. Dropping Characteristics
3. Straight characteristics
4. All of the above

Hide Explanation

Answer.2. Dropping Characteristics

Explanation:-

Depending upon the application, A.C. or D.C. machines are used in arc welding,
but in some cases, either of them can be used. D.C. supply is usually obtained
from generators driven by electric motor or if no electricity is available then the
diesel engine can be used. D.C. welding is mostly used for heavy work and at
sites where electricity is not available.

Arc welding requires a power source that can deliver electrical power at low
voltage and high current such that it can establish and sustain an arc plasma
column between the welding electrode and the workpiece. The line voltage in the
mains supply is too high to be used directly in arc welding. Therefore either a
transformer, solid-state inverter/rectifier or a motor-generator set is used to
obtain the required open circuit voltage necessary for arc welding. It is generally
in the range of 20-80 V. At the same time the same power source should be
capable of delivering high current typically ranging from 50 to 1500 A. This
welding power source can have the output of alternating current (AC) or direct
current (DC). These power sources have volt-ampere characteristics typically of
constant current (CC) or constant potential (CP) type. The output may also have
a pulsing mode. A schematic of the basic elements of an arc welding power
source is shown in Fig.

An arc behaves in a totally different manner from a norms resistance. As the

current is increased the potential drop across the arc, instead of increasing as
with an ohmic resistance, decreases up to a current of the order of 50-70 A, and
then become approximately constant. This is because with increasing current arc
increases in size, allowing a larger area for curve flow, and also increases in
temperature becoming thereby more conducting.

The generator used for welding purposes should have high current and low
voltage which can be obtained by the differential compound generator.
Differentially compounded DC generator has drooping characteristics that mean
if load current increases the net flux will decreases(i.e shunt field and series
fields in opposition will increases)due to demagnetization effect hence the
Induced EMF and terminal voltage decreases.

Ques.9. The Polarity of A.C welding sets is

1. Positive
2. Negative
3. No polarity
4. Infinite

Hide Explanation

Answer.3. No polarity

Explanation:-

Polarity in Arc Welding: There is no polarity in A.C. arc welding due to the
reversal of the current, or the heat generated al each pole is the same, and
therefore, changing over the connections of the electrode and job do not have
any effect on the performance of the welding

Ques.10. As the thickness of the part to be welded increases, which of the

following parameter for ac welding should also increase?

1. Voltage
2. Current
3. Frequency
4. All of the above

Show Explanation
Ques.17. Two 3 mm thick mild steel sheets are to be welded. The electrode of
18, 16, 3 and 10 Nos are available which one would you select?

1. No: 10
2. No: 3
3. No: 16
4. No: 18

Hide Explanation

Answer.2. 3

Explanation:-

The welding wire or rod used as filler material in gas welding should have a
chemical composition similar to that of the base metal. The welding rod diameter,
d = t/2 + 1 mm (app.), where t = thickness of the base metal, mm.

d = 3/2 + 1 = 2.5 mm

Note:-

The size of the electrode generally depends on the thickness of the section you
are welding: the thicker the section, the larger the electrode required. In the case
of light sheet, the electrode size used is generally slightly larger than the work
being welded. This means that if a 2.0-mm sheet is being welded, a 2. 5-mm
diameter electrode is the recommended size.

Ques.18. What is an example of plastic welding?

1. Gas Welding
2. Resistance welding
3. Thermit welding without pressure
4. None of these
Hide Explanation

Answer.2. Resistance welding

Explanation:-

There are two main types of the welding process. They are

(a) Plastic weldings

(b) Fusion welding,

In plastic welding & the metal piece are heated to a plastic state. They are
praised together to make the joint. The plastic welding is also known as pressure
welding. Electric resistance welding such as spot welding is an example of plastic
welding.

In the fusion welding, the metal at the joint is heated to the molten state. Then it
is allowed to solidify. Pressure is not applied in this welding process. So it is
known as non-pressure welds. Gas welding and electric arc welding are
examples of fusion welding.

Ques.19. Gray iron is usually welded by

1. Arc welding
2. Gas welding
3. TIG welding
4. MIG welding

Hide Explanation

Answer.1. Arc welding

Explanation:-
Gray cast irons are generally not weldable because they contain a large amount
of carbon and silicon carbon in the range of 2% to 4% and silicon from 0.5% to
2%. These make the weal zone very brittle, which eventually cracks. Weldability
of cast iron also depends on the distribution of the carbon and the kind of
microstructure that develops on cooling. When such casting fractures, repair by
waddling is frequently attempted. This again increases the risk of getting
additional cracks. To minimize this chance, a good welding method such as arc
welding with high nickel filler metal is used. The procedure for arc welding
involves preheating castings to a temperature of about 700°F, then welding with
minimum weld size followed by a slow cool to room temperature and shot
peening of the deposit. It is then tempered room temperature and shot peening of
the deposit. It is then tempered at about 600°F for a sufficient length of time.

Gray iron class 20 is generally easier to weld than class 50. If required, all gray
cast irons can be welded due to the fact that relatively very little is demanded of
this material in terms of mechanical properties after welding. Most gray irons are
brittle and relatively weak, and service stresses are mainly compressive. Hence,
there is no need for high-strength weld deposits.

Ques.20. In ultrasonic welding, the frequency range is generally

1. 100 – 4000 cps

2. 4000-20000 cps
3. 20,000-40,000 cps
4. 80,000-200,000 cps

Hide Explanation

Answer.3. 20,000-40,000 cps

Explanation:-

Ultrasonic metal welding was invented in Germany during the Second World
War. It is a solid-state process in which two parts are welded by the application of
ultrasonic vibrations under moderate pressure. Little or no heat is applied and the
material reaches near to 50 % of its melting temperature. This process permits
welding of thin to thick sections of materials with lower pressures than used in
fused deposition or static press welding.

Every ultrasonic unit contains the following four elements:

● A power supply, which takes line power at 50/60 cycles and

changes it to a high ultrasonic frequency of 20 – 40 kHz or 20,000
cycles per second to 40,000 cycles per second.
● A converter or transducer, which changes the incoming high-
frequency electrical signal to mechanical vibration of the same
frequency
● A booster, which transmits the vibration energy and increases its
amplitude
● An anvil or a nest to support the workpiece; for bonding of textiles,
the pattern wheel replaces the anvil

Applications:-
The success of ultrasonic welding lies in the fact that the process is very fast
(welding times are approximately 1 s), the equipment is compact, the process
can be readily automated, and consistently acceptable weld quality can be
produced. Ultrasonic welding is commonly used to join components in the
automotive, toy, domestic appliance, and packaging industries. It is also the
method of choice when welding many medical plastic components. The only
limitation is that large parts cannot be welded using this method.

Ques.21. Arc blow is a welding defect which is encountered in

1. Arc welding using D.C current

2. Arc welding using A.C current
3. Gas welding
4. Thermit welding

Hide Explanation

Answer.1. Arc welding using D.C current

Explanation:-

ARC BLOW
When electrons flow, they create lines of magnetic force that circle around the
path of flow. These lines of magnetic force are referred to as magnetic lines of
flux. They space themselves evenly along a current-carrying wire. If the wire is
bent, the flux lines on one side are compressed together, and those on the other
side are stretched out, as shown in Figure. The unevenly spaced flux lines try to
straighten the wire so that the lines can be evenly spaced once again. The force
that they place on the wire is usually small, so the wire does not move. However,
when welding with very high amperages, 600 amperes or more, the force may
actually cause the wire to move.
The welding current flowing through a plate or any residual magnetic fields in the
plate results in unevenly spaced flux lines. These uneven flux lines can, in turn,
cause the arc between the electrode and the work to move during welding. The
term arc blow refers to this movement of the arc. Arc blow makes the arc drift like
a string would drift in the wind. Arc blow can be more of a problem when the
magnetic fields are the most uneven such as when they are concentrated in
corners, at the ends of plates, and where the work lead is connected to only one
side of a plate.

The more complex a weldment becomes, tt more likely arc blow will become a
problem. Comply weldments can distort the magnetic lines of flux in unexpected
ways. If you encounter severe arc blow during a weld, stop welding and take
corrective measure to control or reduce the arc blow.

Arc blow can be controlled or reduced by connecting the work lead to the end of
the weld joint and then welding away from the work lead, Another way of
controlling arc blow is to use to work leads, one on each side of the weld.

The best we to eliminate arc blow is to use an alternating current. AC usually

does not allow the flux lines to build long enough to bend the arc before the
current changes direction. If it is impossible to move the work connection or to
change to AC, a very short arc length can help control arc blow. A small tack
weld or a change in the electrode angle can also help control arc blow.
Ques.22. A rectifier for welding has voltage/current characteristic as

1. Drooping
2. Rising
3. Static
4. Variable

Hide Explanation

Answer.1. Drooping

Explanation:-

It consists of a transformer (single-or three-phase) and a rectifier unit as shown in

Fig. Such a unit has no moving parts, hence it has a long life. The only moving
part is the fan for cooling the transformer. But this fan is not the basic part of the
electrical system. Fig. shows a single-phase full-wave rectifier circuit of the
welder. Silicon diodes are used for converting a.c. into d.c. These diodes are
hermetically sealed and are almost ageless because they maintain rectifying
characteristics indefinitely.
Such a transformer-rectifier welding is most adaptable for shied arc welding
because it provides both d.c. and a.c. polarities. It is very efficient and quiet in
operation.

These welders are particularly suitable for the welding of

● Pipes in all positions

● Non-ferrous metals
● Low-alloy and corrosion-heat and creep-resisting steel
● Mild steels in thin gauges.

The open circuit voltage of a constant-current, rectifier type power source ranges
from about 50 to 100 V hence it provides the highest potential voltage when the
welding current circuit is open and no current is flowing. At the start of the weld,
with striking the arc, the sharp drop in voltage takes place from the OCV. A
conducting column of ionized gases is formed along with heating up of the
electrode. As there is a drop in voltage, the simultaneous increase in welding
current takes place. After a certain point, the voltage/current variation becomes
linear following Ohm’s law. The static volt-ampere characteristics of a welding
power source are shown in Fig.
Ques.23. The advantages of welding motor generator is usually in the range of

1. Easily Portable
2. Used for ferrous and Non-ferrous material
3. Can be used for all welding position
4. Less maintenance

Hide Explanation

Answer.4. Less maintenance

Explanation:-

Motor generator power source consisting of an electric motor coupled to a

generator or alternator that produces the desired welding power. These
machines produce superior weld qualities. However, due to the moving parts,
they require frequent maintenance. Welding generators can be of both AC and
DC type.

The electric motor provides a good constant-speed drive for the generator and is
not affected by the load imposed upon it. The generator is specially designed for
welding purposes so that it generates about 60 volts on an open circuit; this
drops to about 20 volts immediately the arc is struck.

Generators are built in various current ratings ranging from about 100 to 600
amperes, and most modern types incorporate means for automatically adjusting
the voltage to meet variations in the demand of the arc Although the arrangement
of the control unit may vary for machines made by different manufacturers, most
consist of a wheel or lever control which selects the correct current for the right
size of electrode and thickness of plate being welded. DC generators usually
have a polarity switch which enables the welder to reverse the polarity, as is
occasionally required when welding with special electrodes.

Such a d.c. the welder has the following advantages:

● It permits portable operation.

● It can be used with either straight or reverse polarity.
● It can be employed on nearly all ferrous and non-ferrous materials.
● It can use a large variety of stick electrodes.
● It can be used for all positions of welding.

Disadvantages

● It has a high initial cost.

● The machine is quite noisy in operation
● Its maintenance cost is higher
● It suffers from an arc blow.

Ques.24. For welding duty rectifier commonly used are

1. Mercury arc rectifier

2. Selenium metal rectifier
3. Any of the above
4. None of the above

Hide Explanation

Answer.2. Selenium metal rectifier

Explanation:-

Welding rectifiers:-

Welding rectifiers change AC current into DC current and may be used as a

power source for various arc welding processes, depending on the machine.
Some Shielded metal arc welding (SMAW) machines have built-in welding
rectifiers so that the welding current output is more stable. Rectifiers have a
constant-current control where the total power output stays the same while the
machine is being used, depending on how the machine has been set. If more
amps are needed, then the power output will change when the controls are reset.

Type of Rectifier used in welding

1. Selenium rectifier
2. Silicon Rectifier

The selenium rectifier is also known as the metal rectifier. The selenium rectifier
is an early type of semiconductor rectifier in which the semiconductor is a copper
oxide or selenium. This device is used in phase controlled converters, inverters,
battery chargers, and cyclo-converters and welding purpose. At the end of the
1950s static welding rectifiers were introduced. Selenium rectifiers were used
initially followed later by silicone rectifiers.

It consists of an Iron or aluminum base disc coated with selenium, which is a

non-metallic element of atomic number 34. A coating of an alloy of tin, cadmium
or bismuth is deposited on to the selenium and forms the counter-electrode

A current will flow from disc to counter-electrode but not in the reverse direction
in which a high resistance is offered so that the unit acts as a rectifier. To
increase the current-carrying capacity the disc is made larger in area and units
are connected in parallel. For higher voltages units are connected in series since,
if the voltage drop across the unit is too high, the reverse current increases
rapidly and the rectifier fails.
Today silicon diode rectifiers are preferred to selenium or germanium rectifiers,
because they have greater rectification efficiency and, are not Rippled by aging
as the latter types are. Silicon diodes are smaller than selenium diodes and are
hermetically sealed and mounted on a suitable fan for cooling.

Note:-

A mercury-arc rectifier or mercury-vapor valve is a type of electrical rectifier

which is used to convert high ac voltage into dc voltage. They were very useful to
provide power for industrial motors, electric railways, and electric locomotives, as
well as big voltage direct current (HVDC) power transmission.

At the lower voltages required for arc welding, the mercury arc rectifier is less
efficient because of its almost constant voltage drop

Ques.25. In resistance welding, aluminum, as compared to steel, requires

1. Larger welding time

2. Smaller welding time
3. Equal welding time
4. Welding time depends upon the value of weld current

Hide Explanation
Answer.2. Smaller welding time

Explanation:-

The resistance welding is applicable to both steel and aluminum. As indicated in

Figure, the dynamic resistance curve for aluminum is entirely different from the
curve for steel. Two facts contribute to this vast difference the oxide on the
surface of the aluminum and the small change in resistivity as a function of
temperature. Upon initial flow of current, resistances are extremely high due to
the oxide layer that has much higher resistivity than the aluminum.

This increases the likelihood of initial expulsion, and will also result in significant
electrode heating. The oxide layer quickly breaks down allowing current to pass
more easily as resistance drops rapidly. However, as compared to the dynamic
resistance curve for steel, there is no significant increase in resistance later in the
cycle. The reason for this is compared to steel, aluminum’s resistivity increases
only slightly with temperature, as shown in Figure (b).
The implication of this difference is that there is limited opportunity to grow the
nugget by taking advantage of the rapid increase in resistivity as is the case with
steel. This is one of the fundamental reasons why aluminum spot weld times
need to be much shorter than those of steel.

Ques.26. Which of the following is not a welding accessory?

1. Electrode holder
2. Work Clamp
3. Cable
4. Gloves

Show Explanation
Ques.27. Chipping hammers are used

1. To remove slag from welding

2. To align the pieces to be welded
3. For tage welding
4. For marking spots to be welded

Hide Explanation

Answer.1. To remove slag from welding

Explanation:-

Chipping hammer and wire brush

A chipping hammer is a chisel-shaped device that is used to remove the slag

formed over the molten weld.

A chipping hammer is necessary for the removal of to protective slag over a

molten welded bead tip. After the weld has solidified and is relatively cooler, you
can remove the slag protection. This is accomplished with a chipping hammer.
The chipping hammer normally has a pointed end and a chisel-like end. The
hammer cracks the slag, thus allowing it to peel away and expose the welded
bead. When using a chipping hammer, you must wear safety glasses to protect
your eyes from the hot slag.
Protective clothing (apron, gloves, etc.) are necessary to protect welder from the
hot spattering particles, against the thermal shocks, etc.

Ques.28. The welding electric circuit is

1. Always earthed
2. Never earthed
3. Through cables only
4. None of the above

Hide Explanation

Answer.1. Always earthed

Explanation:-

General safety in Welding

Generally, welding and thermal cutting operations are not hazardous but a
completely safe workplace. Safety is necessary for welding because electric
current or high voltage current is used in it. The hazards which are more or less
peculiar to welding are:

1. Electric Shock
2. Arc radiation
3. Fumes and dust
4. Compressed Gases
5. Fire and explosions
6. Noise

Electric Shock

Electric shock may occur in welding if current happens to pass through the
welder’s body. The magnitude of the content will depend on the resistance
offered by the body. A current of 0.1 A or above, be it a.c. or d.c. is taken to be
lethal to humans. Since the maximum human body resistance is 600 ohm, the
lethal current will be provided by the voltage of just 60 V (V = i R).

Electric shock results in many accidents the occur during welding. Therefore
necessary precautions must be taken to minimize electric shock. This can best
be done by ensuring proper insulation of cables, and reliable earthing of welding
equipment. The grounding circuit sanitary sewers and water pipes or metallic
structures of buildings and process equipment should never be used as earth or
return for welding circuit.

Ques.29. The eyes of the welding operator must be protected against

1. Ultraviolet radiation
2. Infrared radiations
3. Both (A) and (B)
4. Solar radiation
Show Explanation

Ques30. The danger of electric shock is maximum

1. During arcing
2. After arcing
3. Before welding
4. While inserting an electrode into the holder

Hide Explanation

Answer.4. While inserting an electrode into the holder

Explanation:-

Electric shock is one of the most serious and immediate risks facing a welder.
Electric shock can lead to severe injury or death, either from the shock itself or
from a fall caused by the reaction to a shock.

● When carrying out arc welding work, the two output terminals of the
welding transformer are connected to the electrode holder and
welding workpiece respectively via welding cable and welding return
cable. It is the potential difference between the welding electrode,
which was connected to the electrode holder, and the welding
workpiece that creates an electric arc for the welding work.
● When the hands or other parts of the body of the welding worker
bridge between the output terminals of the welding transformer,
either directly or indirectly, leakage current may flow between the
terminals via the worker and gives him an electric shock.
● Apart from the output terminals, one should also beware of the input
terminals of the welding transformer. The input terminals are
 connected to the mains supply, usually at about 220 V a.c. or 380 V
a.c. Any direct or indirect contact with the energized input terminals
may also cause an electric shock.
● Most electric shock in the welding industry toes not occur from
contact with welding electrode holders but as a result of accidental
contact with bare or poorly insulated conductors.

Causes of electric shock

● Replacing the welding electrode with bare hands without switching

off the welding transformer.
● Accidentally touching the exposed conductor of the electrode holder
or the welding electrode which is connected to the electrode holder.
● Sitting or leaning on the welding workpiece, such as large
machinery, steel structure, and steel tanks, etc. which is connected
with the welding return cable.
● Lying on the floor to weld the underside of the workpiece.

Protection from electric shock

● Avoid making direct contact with any exposed conductor of the

electrode holder, the connected welding electrode and the exposed
metal part of the workplace with the bare hands or the body.
● Always keep the hands and the body dry.
● Do not put the welding transformer too far away from the workplace.
In case of need or accident, the welding transformer can be
switched off in time to disconnect the power source.
 ● Switch off the welding transformer when it stops welding to take
breaks for rest, tea and meal. Also properly dispose of the welding
rod remained on the electrode holder.
● To properly place the electrode holder, in particular when the
welding electrode is in place to avoid accidentally touching the live
parts.
● To stay on a safe working platform when carrying out welding work
at a high level. Otherwise, even a slight electric shock may cause
the welding worker to lose balance and fall down.

Ques.31. The welding transformer used in resistance welding will

1. Step up current
2. Step down current
3. Step up voltage
4. Step up power

Hide Explanation

Answer.1. Step up current

Explanation:-

RESISTANCE WELDING (RW)

In the resistance welding (RW) process the weld is made by clamping the parts
together between the welding machine’s electrodes. Then an electric current is
passed through the parts to heat up the surfaces so they will fuse together.

The welding current required to make a resistance weld must be at a very low
voltage but high amperage. The pressure is applied to ensure a continuous
electrical circuit and to force the heated part together. The parts are usually
joined as a result of her and pressure and are not simply melted together. Flux or
filler metals are not needed for this welding process.

The current for resistance welding is usually supplied by either a transformer or a

transformer capacitor arrangement. The transformer, in both power supplies, is
used to convert the high line voltage (low-amperage) power to the welding high-
amperage current at a low voltage. A capacitor, when used stores the welding
current until it is used. This storage capacity allows such machines to use a
smaller size transformer. The required pressure or electrode force is applied to
the workplace by pneumatic, hydraulic or mechanical means. The pressure
applied may be a little as a few ounces for very small welders to tens of
thousands of pounds for industrial purpose.

Ques.32. In resistance welding, the SCR contactor will close during

1. Squeeze time
2. Hold time
3. Weld time
4. Weld as well as of the time

Hide Explanation

Answer.3. Weld time

Explanation:-

SCR contactors are electronic control devices designed to handle large amounts
of current. SCRs are triggered or turned on by pulses supplied by the timing or
sequencing circuits of the welder. The SCRs are usually cooled by circulating
water.

During the welding process, a large amount of current is required for short
periods of time. Silicon-controlled rectifiers (SCRs) are commonly used to control
the starting and stopping of the large currents associated with electric welders.
The current rating of these devices must be very high, sometimes in the range of
1000 to 100,000 amperes, and the power distribution equipment must be able to
handle these high currents.

The two main function of SCR is in phase control mode with transformers and in
converter configuration.

The common SCR phase-controlled machines are three-phase machines in

either constant current or constant voltage modes. Because of electronic control
of output characteristics, automatic line voltage compensation is easily achieved;
this allows the machine to set the precise welding power, independent from the
variations of input power. An SCR can also serve as a secondary contactor that
allows the welding current to flow only when the control allows the SCRs to
conduct. This is a very useful feature in spot welding and tack welding
operations, in which rapid cycle operation is required. An SCR contactor does not
provide electrical isolation; this requires that a circuit breaker or similar device
would be provided for electrical safety.
Ques.33. In a resistance welder, pneumatic pressure is applied during

1. Squeeze time
2. Weld time
3. Squeeze and weld time
4. Squeeze, weld and hold time

Hide Explanation

Answer.4. Squeeze, weld and hold time

Explanation:-

In resistance welding, the required pressure, or electrode force, is applied to the

workpiece by pneumatic, hydraulic, or mechanical means.

The main welding parameters in electrical resistance spot welding are:

1. Electrode force
2. Welding current
3. Welding time
4. Squeeze time
5. Hold time.

Squeeze Time:- Squeeze time is the amount of time needed to develop the
required electrode force. During the squeeze time, the electrodes clamp the
sheets to be welded under the action of the electrode force, preset by the
welding engineer. The squeeze time should be sufficient to overcome poor fit-up
of the parts to be welded and in practice is similar for both uncoated and coated
steels. Following the period of squeeze time, the welding current flows through
the welding electrodes and the sheets to be welded. It is known that higher
welding currents are required to weld zinc coated steels compared to the same
thickness of uncoated steel.

Weld time:- The weld time is defined as the time during which the current flows
and when weld formation and growth occurs. Longer welding times are generally
required to satisfactorily weld zinc coated steel compared to uncoated steel.

Hold Time:- The hold time is the time during which the electrode force is
maintained, after the welding current flow ends, its purpose is to consolidate the
weld. Pneumatic, hydraulic, or mechanical pressure is applied in all that time
period.

Ques.34. A 10 SWG electrode usually operates in the current range

1. 25 to 45 Amperes
2. 50 to 75 Amperes
3. 95 to 135 Amperes
4. 400 to 600 Amperes
Hide Explanation

Answer.3. 95 to 135 Amperes

Explanation:-

The electrodes are designated by numbers which indicate grade and size of the
core wire.

The sizes are given by absolute sizes (e.g. 1/8″, 5/16″, 7/16″, etc.) or by standard
wire gauge (S.W.G.) sizes. Most common sizes are 4, 6, 8, 10 and 12. The
electrodes with higher SWG size number are thinner.

Although any size electrode can be used for the job, but for quick welding, the
electrode size should be as large as permissible. Larger size electrodes permit
heavier currents to be used hence, the metal deposition is faster and the job is
done quicker. It must be, however, emphasized that choice of the electrode size
does not determine the speed of the work. Good welds come out rapidly if
consistent higher currents are used.

Normally 12 SWG electrodes for welding can be used upto 3 mm plates or

sections, 10 SWG upto 6 mm sections, 8 SWG upto 10 mm, 6 SWG upto 10/15
mm and 4 SWG for sections beyond 20 mm thickness.

Ques.35. TIG welding is

1. Temperature insulated Gas welding

2. Tungsten Inert gas welding
3. Thermally Induced gas welding
4. Thorium Iodine gas welding

Show Explanation
Ques.36. The electrode is not consumed in case of

1. DC arc welding
2. AC arc welding
3. Gas welding
4. TIG welding

Show Explanation

Ques.37. The flux used in TIG welding is

1. Ammonium Chloride
2. Borax
3. Ash
4. None

Hide Explanation

Answer.4. None

Explanation:-

Flux is mainly used for the following purposes

● It prevents the oxidation of the surface of the weld which can

contaminate the welded portion. (Metals at high-temperature forms
oxides which results into the poor surface)
● It helps in forming an alloy at the welded portion which improves the
strength.
 ● In arc welding, the flux coating helps in directing the spark that’s
why the electrode is kept concave in shape so that spark can be
precisely directed towards the cavity where welding has to be
performed.

Flux is not required in TIG since inert gas envelope protects the molten metal
without forming oxides and nitrates so the weld is smooth, uniform, and ductile.
Hence, tungsten arc welding produces very clean welds. No cleaning or slag
removal is required because no flux is used.

Ques.38. Which method would you recommend for the welding of aluminum
alloys?

1. DC arc welding
2. AC arc welding
3. Tungsten Welding
4. Acetylene oxygen gas welding

Show Explanation

Ques.39. Argon is

1. Inactive gas
2. Inert gas
3. Rare gas
4. Oxidizing agent
Show Explanation

Ques.40. With manual arc welding in mild steel, the metal deposition rate will be
nearly

1. 2 to 5 kg per hour
2. 5 to 10 kg per hour
3. 10 to 20 kg per hour
4. 20 to 50 kg per hour

Hide Explanation

Answer.1. 2 to 5 kg per hour

Explanation:-

Manual Metal Arc Welding

The manual metal arc welding also called the Shielded Metal Arc Welding
(SMAW) is the most extensively used manual welding process, which is done
with stick (coated) electrodes. In India, it still, is the most used arc-welding
process. This process is highly versatile and can be used extensively, for both
simple as well as sophisticated jobs. Further, the equipment is the least
expensive than most of the arc-welding processes. Welds by this process can be
made in any position.

The job of any thickness can be welded by shielded metal arc welding. But very
small thicknesses, below 3 mm, may give rise to difficulty in welding because of
their lack of rigidity. Similarly, very large thicknesses, above 20 mm, may take a
long time for filling up the joint groove.

The shielded metal arc welding can be done with either ac or dc power source.
The typical range of the current usage may vary from 50 to SOO A with voltages
from 20 to 40 V.
The main disadvantage of the shielded metal arc welding process is a slow
speed. The typical weld-metal deposition rates may be in the range of 1 to 8
kg/hr in the flat position. This reduces substantially for the vertical and overhead
positions. Further, a lot of electrode material is wasted in the form of an unused
end, slag, and gas. There are more chances of slag inclusions in the bead. Also,
special precautions are needed to reduce moisture pick up so that it would not
interfere with the welding.

The typical shielded metal arc welding set-up with an AC power source. The
electrodes for the welding operation should be selected properly, depending on
the requirements of the welding. The main points to be considered are

1. The composition of the base metal, which determines the electrode

composition
2. The tensile strength of the required joint
3. The thickness of the base metal. For thinner metals, the current
setting should be lower
4. The required metal-deposition rate
5. The type of arc welding equipment used; dc arc welding equipment
would be preferable for overhead welding
6. The weld position: flat, horizontal, vertical or overhead: a flat
position can accommodate a larger size electrode

Also, to increase metal-deposition rate, coatings with iron powder can be used. In
the case of vertical and overhead positions, it is necessary that the weld pool be
smaller for better control. This would necessitate a small size electrode.

Metal deposition rate increases with arc current, as does arc heat and, therefore,
welder discomfort. This, with the limitations on manual welding speed, limits
metal deposition rate to 2-5 kg/hr in the flat position and to 2 kg/hr in other
positions.

Ques.41. Which of the following automatic welding process is likely to give the
maximum rate of metal deposition?
 1. Gas shielded bare wire
2. Submerged arc (single wire)
3. Multiple power submerged arc
4. Continuous flux covered electrode

Show Explanation

Ques.42. The load taken by a welding transformer is

1. Purely resistive
2. Non-inductive
3. Highly-Inductive
4. Highly- Capacitive

Hide Explanation

Answer.3. Highly-Inductive

Explanation:-

Welding Transformers

An AC welding set is nothing but a transformer. A DC rectifier welding set also

comprises essentially of a transformer and a rectifier unit. In both the cases, the
transformer has to perform the two essential functions.

1. Firstly to step down the supply voltage and provide the required
open circuit arc striking voltage.
2. Secondly, once the arc is already struck, to drop the voltage and
provide a voltage just sufficient to maintain that arc.
The first function is the normal function of a transformer. The second requirement
it fulfills either by providing a high leakage reactance in its windings (i.e.,
reducing coupling factor between windings) or bar connecting a reactor in series
with the secondary.

The arc striking voltage is normally between 70 to 100 V in case of AC and 50 to

80 V in case of DC welding for different types of jobs. For welding work in narrow
combined spaces such as tanks the no.load voltage specified may be still lower.

Before the arc is formed i.e., before the air between the electrode and the job is
ionized, there is infinite resistance in the secondary circuit, no current flows, no
drop in the leakage reactances or in the series reactor, so the full secondary emf
induced appears, as the striking voltage between the electrode and the job.

Once the arc is struck, the passage of air between the electrode and the job is ionized the
resistance suddenly falls to the very low value and has −VE characteristics i.e., resistance
goes on falling with increasing arc current. So the voltage across the arc must be reduced
to some value which will stabilize the arc current. This running arc voltage is around 25
to 30 volts in case of AC and 20 to 25 volts in case of DC welding jobs.

The high leakage reactance means the short-circuit impedance, Zsc, is large and
so the short-circuit current is much smaller than in a conventional design. This is
necessary with arc-welding transformers because the arc must be struck with a
relatively high secondary voltage, but when struck the secondary load has low
resistance and the voltage must be considerably reduced. Therefore the welding
transformer is highly inductive in nature and the power factor of welding
transformer is 0.3 to 0.5 lagging

Ques.43. The power factor of the load using the welding transformer is usually

1. Unity
2. Nearly unity lagging
3. Nealy unity leading
4. Very low of the order of 0.3 to 0.5 lagging

Hide Explanation

Answer.4. Very low of the order of 0.3 to 0.5 lagging

Explanation:-

Arc welding transformer is also designed to have a high leakage reactance so as

to stabilize the arc during the welding process. The open-circuit voltage is about
70 V, which facilitates striking the arc when the electrode touches the world,
However, as soon as the arc is established tile secondary voltage falls to about
I5 V, a value that depends upon the length of the arc and the intensity of the
welding current. Due to the high leakage reactance power factor of welding
transformer is 0.3 to 0.5 lagging

Ques.44. Bare type electrodes are

1. Consumable
2. Non-consumable
3. Any of the above
4. None of the above

Show Explanation

Ques.45. For power factor correction of welding transformer, a capacitor is

usually connected on

1. Primary side
2. Secondary side
3. Parallel to arcing electrodes
4. Parallel to mains

Show Explanation
Ques.46. The Position of an arc welding is

1. Flat position
2. Horizontal position
3. Vertical Position
4. All of the above

Hide Explanation

Answer.4. All of the above

Explanation:-

There are four basic positions in which manual arc welding is done.

1. Flat position:- Of all the positions, flat position is the easiest, most
economical and the most used for all shielded arc welding. It
provides the strongest weld joints. Weld beads are exceedingly
smooth and free of slag spots. This position is most adaptable for
welding of both ferrous and non-ferrous metals, particularly for cast
iron.
2. Horizontal Position:- It is the second most popular position. It also
requires a short arc length because it helps in preventing the molten
puddle of the metal from sagging. However, major errors that occur
while welding in the horizontal position are under-cutting and over-
lapping of the weld zone.
3. Vertical Position:- In this case, the welder can deposit the bead
either in the uphill or downhill direction. Downhill welding is
preferred for thin metals because it is faster than the uphill welding.
Uphill welding is suited for thick metals because it produces the
stronger weld.
 4. Overhead Position:- Here, the welder has to be very cautious
otherwise he may get burnt by drops of falling metal. This position is
thought to be the most hazardous but not the most difficult one.

Ques.47. MIG welding is

1. Mild steel inert gas welding

2. Medium inert gas welding
3. Maximum inner depth gas welding
4. Metal inert gas welding

Show Explanation

Ques.48. The advantages of resistance welding is

1. Less skill required

2. Reduced distortion
3. No need of filler material
4. All of the above
Hide Explanation

Answer.4. All of the above

Explanation:-

In the resistance welding (RW) process the weld is made by clamping the parts
together between the welding machine’s electrodes. Then an electric current is
passed through the parts to heat up the surfaces so they will fuse together.

Advantages of resistance welding

● The welding process is rapid and simple.

● Localized heating is possible if required.
● No need of using filler metal.
● Both similar and dissimilar metals can be welded.
● Comparatively lesser skill is required.
● Maintenance cost is less.
● It can be employed for mass production.

Disadvantages of resistance welding

● Initial cost is very high.

● High maintenance cost.
● The workpiece with heavier thickness cannot be welded since it
requires high input current.

Applications of resistance welding

● It is used by many industries manufacturing products made up of

thinned gauge metals.
 ● It is used for the manufacturing of tubes and smaller structural
sections.

Ques.49. Which of the following is not resistance welding?

1. Projection welding
2. MIG welding
3. Seam welding
4. Flash butt welding

Show Explanation

Ques.50. When t is the thickness of the sheet, the tip diameter for spot welding
is usually

1. 2t
2. t
3. √t
4. 1/t

Hide Explanation

Answer.3. √t

Explanation:-

The diameter of the electrode tip. The diameter of the spot weld decreases as
the diameter of the electrode tip increases. Also, if the electrode tip is too small,
the spot weld will not increase in size. The tip diameter must be properly
controlled to obtain the desired welding strength. Before starting opera lion, make
sure that the tip diameter (D) is kept the proper size, and file it cleanly to remove
burnt or foreign matter from the surface of the tip. As the amount of dirt on the tip
increases, the resistance at the tip also increases, which reduces the current flow
through the base metal, which in turn reduces weld penetration resulting in an
inferior weld.

Use the formula to determine the tip diameter two times the plate thickness plus
1/8 inch or 3.2 mm. Usually, the tip diameter is made approximately equal to the
square root of the sheet thickness.

D = 2T + 1/8″

or D = √T

Where

T = thickness of the sheet

Ques.51. In a synchronous welding control, the welding current begins at

1. Later than the power factor angle

 2. Before the power factor angle
3. At the power factor angle
4. None of these

Hide Explanation

Answer.3. At the power factor angle

Explanation:-

Time and sequence control

Weld timers may have a non-synchronous or synchronous form.

A non-synchronous timer starts and stops the current flow by contactor at

instants unrelated to the A.C waveform, as a result, the current may vary, and the
time of repetition of a preset sequence be subject to an inaccuracy of plus or
minus one-half period of the A.C supply.

Synchronous timers:- A synchronous timer provides an accurate timing period in

that it closes and opens the primary of the welding transformer at the same point
of the supply voltage in the making of each weld It reduces or eliminates
electrical transients. Therefore the synchronous control timer operates at the
power factor angle. Where quality is important, and particularly for such materials
as aluminum and its alloys, synchronous timers are usually regarded as
essential. Modern ‘digital solid-state’ controls provide precise and repeatable
control of the welding operation.

This is mostly used with sophisticated spot welding machines. There is a rotating
dial which can very precisely select various lengths of time. The time periods are
selected as per the requirement of a particular weld. This type of timer ensures
that current flows for complete cycles and not for fraction of a cycle. If a particular
weld starts with a positive half-cycle it always ends with the negative half cycle. A
new weld can never start with the same kind of half-cycle that has ended In the
previous weld. This is an essential condition to be fulfilled because, otherwise,
the magnetism retained by the welding transforrner from the final half-cycle of the
previous weld will affect the current and hence will effect the heat of the next
weld.
Ques.52. The function of SCR contactor in resistance welding machine is

1. To provide an accurate weld time for each weld

2. To connect the large power supply to welding by closing a small
switch
3. To provide full wave rectification of the welding current
4. To avoid saturation of transformation core

Hide Explanation

Answer.2. To connect the large power supply to welding by closing a small

switch

Explanation:-

SCR contactors are electronic control devices designed to handle large amounts
of current. SCRs are triggered or turned on by pulses supplied by the timing or
sequencing circuits of the welder. The SCRs are usually cooled by circulating
water.

During the welding process, a large amount of current is required for short
periods of time. Silicon-controlled rectifiers (SCRs) are commonly used to control
the starting and stopping of the large currents associated with electric welders.
The current rating of these devices must be very high, sometimes in the range of
1000 to 100,000 amperes, and the power distribution equipment must be able to
handle these high currents.
The two main function of SCR is in phase control mode with transformers and in
converter configuration.

The common SCR phase-controlled machines are three-phase machines in

either constant current or constant voltage modes. Because of electronic control
of output characteristics, automatic line voltage compensation is easily achieved;
this allows the machine to set the precise welding power, independent from the
variations of input power. An SCR can also serve as a secondary contactor that
allows the welding current to flow only when the control allows the SCRs to
conduct. This is a very useful feature in spot welding and tack welding
operations, in which rapid cycle operation is required. An SCR contactor does not
provide electrical isolation; this requires that a circuit breaker or similar device
would be provided for electrical safety.

Ques.53. Which of the following is the unit for thermal conductivity?

1. W/m °K
2. W/m2 °C
3. W2/m °K
4. W2/m2 °K

Hide Explanation
Answer.1. W/m °K

Explanation:-

Thermal conductivity is the property of a material to conduct heat. In the International

System of Units (SI), thermal conductivity is measured in watts per meter-kelvin
(W/(m⋅K))

Ques.54. Which is not the type of butt welding process?

1. Upset butt Welding

2. Downset butt welding
3. Flash butt welding
4. Percussion butt welding

Hide Explanation

Answer.2. Downset butt welding

Explanation:-

Butt welding

Butt welding is similar to the spot welding; however, the only difference is, in butt
welding, instead of electrodes the metal parts that are to be joined or butted
together are connected to the supply. In this case, the two workplaces are
brought into contact end-to-end and the butted ends a heated by passing a
heavy current through the joint.

This process is useful where parts have to be joined end-to-end or edge-to-edge.

i.e. for welding pipes, wires and rods. It is also employed for making continuous
lengths of chain.

Type of butt welding

The three basic types of the butt welding process are:

(a) Upset butt welding.

(b)Flash butt welding.

(c) Percussion butt welding.

Ques.55. The main purpose of the light coated electrode is to

1. Increase arc stability

2. Reduce Voltage
3. Reduce Current
4. Any of the above

Hide Explanation

Answer.1. Increase arc stability

Explanation:-

Lightly coated electrodes

These electrodes are coated with a thin layer of coating material up to less than 1
mm. This coating usually consists of lime mixed with soluble glass which serves
as a binder. ‘These electrodes are considered as an improvement over bare
electrodes.

The main purpose of using the light coating layer on the electrode is to increase
the arc stability, so they are also called as stabilizing electrodes. The mechanical
strength of the weld increased because the slag layer will not be formed on the
molten weld. For this reason, lightly coated electrodes may only be used for
welding nonessential workpieces.
Ques.56. The highest value of thermal conductivity is for

1. Solid ice
2. Melting ice
3. Water
4. Steam

Hide Explanation

Answer.1. Solid Ice

Explanation:-

In heat transfer, the thermal conductivity of a substance, k, is an intensive

property that indicates its ability to conduct heat.

The thermal conductivity of the ice is highest and it is 0.050–0.250(W·m−1·K−1).

The thermal conductivity of water is 0.5918(W·m−1·K−1).

Ques.57. The type of electrode used in the seam welding is

1. Bare wire Rods

2. Roller electrodes
3. Heavily coated electrode
4. Lightly covered electrode

Hide Explanation

Answer.2. Roller electrodes

Explanation:-

Welding electrode. A component of the welding circuit through v hick current is

conducted and that terminates at the arc, molten conductive slag, or base metal.
See also arc welding

Electrode (arc welding)—a “stick” or ~wire” from which an arc is struck. It may
include the bare metal electrode, carbon electrode, composite electrode, covered
electrode, lightly coated electrode, and the heavy coated electrode.

Electrode (resistance welding)—that part or parts of a machine through which the

welding current and in most cases, pressure, are applied directly to the work. The
electrode may be in the form of a rotating wheel, bar, cylinder, plate, clamp.

Seam Welding
In principle, this process is similar to spot welding except for the shape of the
electrodes. In seam welding, continuously rotating disc type electrodes . are used
whereas in spot welding pointed electrodes are used. In seam, welding pressure
is applied. In seam welding pressure is applied continuously along the whole
length of the lap joint to produce a seam weld. The metallic pieces a held in two
copper disc roller electrodes and are passed through them to complete the joint.

Seam welding is accomplished by using roller-type electrodes in the form of

wheels that are 6 in. (152 mm) to 9 inches. (229 mm) or more in diameter. These
roller-type electrodes are usually copper alloy discs 3/8 inch (10 mm) to 5/8 inch
(16 mm) thick. Cooling is achieved by a constant stream of water directed to the
electrode near the weld.
Welding is done either with the roller electrodes in motion or while they are
stopped for an instant. If the continuous motion is used, the rate of welding
usually varies between 1 ft and 5 ft (30 cm to 152 cm) per minute. The greatest
welding speed is obtained on the thinnest materials. An indexing mechanism can
be used when the wheels are to be stopped for each weld.

Electric timing equipment is used when it is necessary to provide the precise

control required for highest quality welds. Spot welds can be positioned at almost
any interval desired by simply adjusting the timing and rate of electrode motion.

It is possible to change the welding current and electrode pressure to control the
surface condition and width of the weld. The seam width should be about two
times the thickness of the sheet plus 1/16 inch (2 mm).

Types of Resistance Seam Welds

The figure illustrates the type of seams used in most seam welding processes.
The lap seam is the most common of these seams. The tops and bottoms of
containers are usually fastened together with a Hanged seam. For a metal
thickness of 1/16 inch (2 mm), the mash seam is often used. The electrode face
should be wide enough to cover the overlap by approximately one and a half
times the thickness of the sheet.
High-Frequency Resistance Seam Welding

This process is similar to RSEW in some ways. TO major differences are that the
welding current is supplied as supplied frequency, 200 to 500 kHz as opposed to
DC 50-cycle AC. The high-frequency power provides very localized heating. This
heating is a result of the resistant to the current induced in the metal and not to
the resistance between parts. As a consequence of this localizes heating, pipe
and tubing can be welded with little loss of power flowing around the back side of
the joint.

High-Frequency Resistance Seam Welding is used in the production of welded

pipe tubing, and structural shapes. It works very well for tip fabrication of l-
beams, H-beams, channels, and so on. The welded structural shapes are lighter
and stronger than the roll-formed counterparts.

Ques.58. Which of the following outlines the features of D.C welding over A.C
welding?

1.1 The cost of equipment is higher

2. It is less safe as the no-load voltage is high

3. The efficiency is lower due to the presence of the rotating part

2.1. The cost of equipment is higher

2. it is safer

3. The efficiency is higher due to the absence of a rotating part

3.1 The cost of equipment is cheaper

2. It is less safe as the no-load voltage is high

3. The efficiency is higher due to the absence of a rotating part

4.1. The cost of equipment is cheaper

2. It is less safe as the no-load voltage is high

3. The efficiency is lower due to rotating the part

Hide Explanation

Answer.1. The cost of equipment is higher

2. It is less safe as the no-load voltage is high

3. The efficiency is lower due to the presence of the rotating part

Explanation:-

Both D.C. and A.C. equipment are employed in arc welding. D.C. arc welding
machines are D.C. generators driven by an electric motor or an internal
combustion engine. A.C. welding machines are transformers for stepping down
the main supply voltage to the voltage (20 to 40V) and current (150 to 1000 A)
suitable for arc welding. The Comparision between A.C welding and DC welding
are discussed below:-

Comparison Between A.C welding & D.C welding

 A.C Welding D.C Welding

An A.C. welding set

A D.C. welding set using a generator
is cheaper and easy
is costlier and difficult to operate.
to operate.

Maintenance is
economical in view Maintenance is costly due to the
of the absence of presence of moving parts.
moving parts

It is light in weight. The equipment is heavy in weight.

In A.C. arc welding

The heat distribution is different at the
set, the heat
two terminals such as heat developed
distribution is equal
at the positive terminal is 2/3rd and
at the two terminals
that on the negative terminal is 1/3rd
and there is no
of total heat evolved.
polarity.

It is less suitable for

use at low current Better suited for use at low amperage
with small diameter and with small diameter electrodes.
electrodes.

Unsuitable for
Suitable for welding of non-ferrous
welding of non-
metals
ferrous

Striking of an arc is easier.

Striking an arc is
relatively difficult.

This technique is not In view of striking of arc this is easier

preferred for welding and the technique is generally
of sheet metal jobs. preferred.

The efficiency of
A.C. welding system The efficiency of this system is low.
is high.

The system can be utilized anywhere

It can be used only
even in the absence of A.C. mains
when A.C. mains
supply with the help of engine driven
supply is available.
D.C. generator set.

There is always likelihood of an arc

There is no problem
blow unless proper corrective
of arc blow in A.C.
measures are adopted with D.C. arc
welding.
welding.

Only flux-coated
Both bare and flux-coated electrodes
electrodes can be
can be utilized in D.C. arc welding.
used in A.C. arc
Thus, it is cheap.
welding.

The no load
In D.C. arc welding the no load
requirement of A.C.
requirement is very high.
system is low.

The penetration Due to low arc voltage, the penetration

obtained in A.C. arc obtained in D.C. arc welding is
welding is good
giving strong joints
relatively poor.
due to high arc
voltage.

Ques.59. The quantity of heat required to change the temperature of 1 gm of ice from
−6°C to −5°C is known as

1. Latent heat of fusion

2. Temperature coefficient
3. Specific heat
4. Latent heat of vaporization

Hide Explanation

Answer.3. Specific heat

Explanation:-

Specific Heat:- The specific heat is the amount of heat per unit mass required to raise the
temperature by one degree Celsius. Here the temperature is increasing from −6°C to
−5°C i.e +1° C.

The latent heat of fusion (or meltings) of a substance the heat energy required to
convert a unit mass of the substance from the solid to the liquid state, without
chant of temperature.

The latent heat of vaporization (or boiling) of substance is the heat energy
required to convert a unit mass of the substance from the liquid to the gaseous
stats without change of temperature.

A temperature coefficient describes the relative change of a physical property

that is associated with a given change in temperature
Ques.60. A body at the temperature T K radiates heat in proportion to

1. T2
2. 1/T2
3. T4
4. 1/T4

Hide Explanation

Answer.3. T4

Explanation:-

According to Stephen’s Law, the total rate at which a black body emits heat
radiation is proportional to the 4th power of its absolute temperature. If E is the
rate of emission of heat radiations T is the absolute temperature, then

E ∝ T4

or

E = σT4

Here σ is the proportionality constant and known as Stefan’s constant and its
value is 5.672×10−2 W/m2/K4.

Ques.61. If a body reflect entire radiation incident on it, then it is known as

1. Black body
2. Gray body
3. White Body
4. Transparent Body
Hide Explanation

Answer.1. Black body

Explanation:-

A body which absorbs all the radiation incident on it would then appear ‘perfectly
black’ to us. This is because we observe a body due to ‘reflection’ of radiation
incident on it; and if a body absorbs all the radiation incident on it, then it would
reflect no radiation. So, a body would be invisible to us or appear black to us.
Such a body was called by Kirchhoff as a black body.

● As perfectly black body neither reflect nor transmits any radiation,

therefore absorptance of a perfectly black body is unity.
● As the black body reflects no wavelength, it appears black,
whatever be the color of the radiation incident on it.
● When black body heated to a suitable high temperature, it emits
radiation of all possible wavelengths. The radiation given out by a
perfect black body is called black body radiations or total radiations.

A body whose absorptive power is unity at all the wavelengths or that absorbs all
incident electromagnetic radiation, regardless of frequency or angle of incidence
is termed as the black body

Ques.62. A digital timer in a resistance welding machines provides

1. Accurate timing
2. Identical welds
3. Synchronous operation
4. All of these
Show Explanation

Ques.63. Which of the following generators are used in arc welding

1. Shunt generators
2. Series Generator
3. Cumulative compound generators
4. Differential compound generators

Hide Explanation

Answer.4. Differential compound generators

Explanation:-

Arc welding is the widely used method of joining the metal parts. Here the source
of heat is an electric arc. Arc welding is a group of welding processes wherein
heating is produced with an electric arc or arcs, mostly without the application of
pressure and with or without the use of fillet metal, depending upon the base
plate thickness.

ARC Welding Principle

In arc welding, the ARC is generated between the positive pole of D.C. (direct
current) called anode and the negative pole of D.C. called cathode. When these
two poles are brought together, and separated for a small distance (1.5 to 3 mm)
such that the current continues to flow through a path of ionized particles, called
plasma, an electric arc is formed. Since the resistance of this ionized gas column
is high, so more ions will flow from anode to the cathode. Heat is generated as
the ions strike the cathode.

A.C. or D.C. Machines in ARC Welding

Depending upon the application, A.C. or D.C. machines are used in arc welding,
but in some cases, either of them can be used. D.C. supply is usually obtained
from generators driven by electric motor or if no electricity is available then the
diesel engine can be used. D.C. welding is mostly used for heavy work and at
sites where electricity is not available.

Arc welding requires a power source that can deliver electrical power at low
voltage and high current such that it can establish and sustain an arc plasma
column between the welding electrode and the workpiece. The line voltage in the
mains supply is too high to be used directly in arc welding. Therefore either a
transformer, solid-state inverter/rectifier or a motor-generator set is used to
obtain the required open circuit voltage necessary for arc welding. It is generally
in the range of 20-80 V. At the same time the same power source should be
capable of delivering high current typically ranging from 50 to 1500 A. This
welding power source can have the output of alternating current (AC) or direct
current (DC). These power sources have volt-ampere characteristics typically of
constant current (CC) or constant potential (CP) type. The output may also have
a pulsing mode. A schematic of the basic elements of an arc welding power
source is shown in Fig.

An arc behaves in a totally different manner from a norms resistance. As the

current is increased the potential drop across the arc, instead of increasing as
with an ohmic resistance, decreases up to a current of the order of 50-70 A, and
then become approximately constant. This is because with increasing current arc
increases in size, allowing a larger area for curve flow, and also increases in
temperature becoming thereby more conducting.
The generator used for welding purposes should have high current and low
voltage which can be obtained by the differential compound generator.
Differentially compounded DC generator has drooping characteristics that mean
if load current increases the net flux will decreases(i.e shunt field and series
fields in opposition will increases)due to demagnetization effect hence the
Induced EMF and terminal voltage decreases.

Ques.64. Which of the following is of high value in case of induction heating?

1. Voltage
2. Current
3. Frequency
4. All of the above

Hide Explanation

Answer.3. Frequency

Explanation:-
Induction heating is defined as the process of heating an electrically conducting
object (usually a metal) by electromagnetic induction, through heat generated in
the object by eddy currents.

Induction heating occurs when an electrical current (eddy current) is induced into
a workpiece. For the induction heating process to be efficient and practical,
certain relationships of the frequency of the electromagnetic field that produces
the eddy currents, and the properties of the workpiece, must be satisfied. The
basic nature of induction heating is that the eddy currents are produced on the
outside of the workpiece in what is often referred to as “skin effect” heating.
Because almost all of the heat is produced at the surface, the eddy currents
flowing in a cylindrical workpiece will be most intense at the outer surface, while
the currents at the center are negligible. The depth of heating depends on the
frequency of the ac field, the electrical resistivity, and the relative magnetic
permeability of the workpiece.

Frequency is one of the most critical parameters in these applications. If the

frequency is too low, an eddy current cancellation within the heated body will
take place, resulting in poor coil efficiency.

However, when the frequency is too high, the skin effect will be highly
pronounced, resulting in a current concentration in a very thin surface layer
compared to the diameter/thickness of the heated component. In this case, a
lengthy heating time will be required to provide sufficient heating of the internal
areas and the core. Prolonged heat time results in an increase of the radiation
and convection heat losses that, in turn, reduce the thermal efficiency of the
induction heater and diminish the main advantage of induction heating.
Frequency is always a reasonable compromise.
Ques.65. Induction heating process is based on

1. Electro-magnetic induction principle

2. Resistance heating principle
3. Thermal ion release principle
4. Nucleate heating principle

Hide Explanation

Answer.1. Electro-magnetic induction principle

Explanation:-

Induction heating is defined as the process of heating an electrically conducting

object (usually a metal) by electromagnetic induction, through heat generated in
the object by eddy currents.

In induction heating when an alternating voltage applied to an induction coil (e.g.,

solenoid coil) will result in an alternating current in the coil circuit. An alternating
coil current will produce in its surroundings a time-variable magnetic field that has
the same frequency as the coil current. That magnetic field strength depends on
the current flowing in the induction coil, the coil geometry, and the distance from
the coil. The changing magnetic field induces eddy currents in the workpiece
located inside the coil. These induced currents have the same frequency as the
coil current; however, their direction is opposite to the coil current.

Alternating eddy currents induced in the workpiece produce their own magnetic
fields, which have opposite directions in the direction of the main magnetic field
of the coil. Therefore, the total magnetic field of the induction coil is a result of the
source magnetic field and induced magnetic fields. Alternating eddy currents
produce heat by the Joule effect (I2R). A conventional induction heating system
that consists of a cylindrical load surrounded by a multiturn induction, the coil is
shown in Figure.
In a narrow sense, induction heating is similar to the Joule heating effect, but with
one important modification. The currents that heat the material are induced via
electromagnetic induction. Therefore, it could be a non-contact heating process.
Accordingly, only those with high electric conductivity, such as copper, gold, and
aluminum, can be directly heated via induction. Food items are then heated by
the metals.

Induction heating works better on specific metals due to additional heating

mechanisms. For instance, induction can heat ferrous metals better than other
materials. That is because the iron crystals in ferrous metals can be repeatedly
magnetized and demagnetized by the alternating magnetic field. This will lead to
hysteresis losses in addition to the normal induction heating.

Ques.66. In case of induction hardening

1. Heating occurs uniformly in the part to be heated

2. Heating occurs in the core of the part to be heated
3. Heating occurs in the center of the part to be heated
4. Heating is more at the core and less on the surface of the part to be
heated
Hide Explanation

Answer.1. Heating occurs uniformly in the part to be heated

Explanation:-

Induction Hardening

Because the heating is done by induction, this process is known as induction

hardening. In induction hardening, rapid heating is generated by electromagnetic
induction when a high-frequency current is passed through a coil surrounding the
part. The depth to which the heated zone extends depends on the frequency of
the current and the duration of the heating cycle. Because of an electrical
phenomenon called “skin effect,” the depth of the heated area is inversely
proportional to the frequency used.

The time required to heat the surface layers to above the material transformation
range is surprisingly brief, a matter of a few seconds. Selective heating and
therefore hardening is accomplished by the suitable design of the coils or
inductor blocks. At the end of the heating cycle, the steel is usually quenched by
water jets passing through the inductor coils. Precise methods for controlling the
operation, such as the rate of energy input, duration of heating, and rate of
cooling, are thus necessary. These features are incorporated in induction
hardening equipment, which is usually operated entirely automatically.

Induction heating is an extremely versatile heating method that can perform

uniform surface hardening, localized surface hardening, through hardening and
tempering of hardened pieces. Heating is accomplished by placing a steel part in
the magnetic field generated by high-frequency alternating current passing
through an inductor, usually a water-cooled copper coil. The depth of heating
produced by induction is related to the frequency of the alternating current: the
higher the frequency is, the thinner or more shallow the heating. Therefore,
deeper case depths and even through hardening are produced by using lower
frequencies.

Induction hardening offers a number of advantages over other heat treatment

methods. The most important advantages are short heat treatment times, good
repeatability concerning the hardened-layer quality, small or negligible
subsequent distortion, and a minimum subsequent product surface oxidation.
Ques.67. Induction heating, the depth upto which the current will penetrate is
proportional to

1. Frequency
2. (Frequency)2
3. 1/(Frequency)
4. 1/(Frequency)1/2

Hide Explanation

Answer.4. 1/(Frequency)1/2

Explanation:-

In induction heating, the heat in the electrically conducting workpiece is produced

by circulating currents caused by electromagnetic induction. Induction heating is
clean quick and efficient. It allows a defined section of the workplace to be
heated accurately.

The depth to which the heated zone extends depends on the frequency of the
current and on the duration of the heating cycle. Because of an electrical
phenomenon called “skin effect,” the penetration depth of the heated area is
inversely proportional to the square root of frequency and directly proportional to
the square root of the workplace resistivity p

δ = K.√ρ/√f

Where K is constant

Therefore, the induction frequency is selected based on the application. A low

frequency such as the utility frequency may be used for induction melting of large
workpieces. High frequencies of up to a few hundred kilohertz are used for
forging, soldering, hardening, and annealing.

Ques.68. The method of heating used in an electric room heat convector is

 1. Resistance heating
2. Induction heating
3. Dielectric heating
4. Arc heating

Hide Explanation

Answer.1. Resistance heating

Explanation:-

RESISTANCE HEATING

When the electric current is made to pass through a high-resistive body (or)
substance, a power loss takes place in it, which results in the form of heat
energy, i.e., resistance heating is passed upon the I2R effect. This method of
heating has wide applications such as drying, baking of potteries, commercial
and domestic cooking, and the heat treatment of metals such as annealing and
hardening. In an oven where wire resistances are employed for heating,
temperature up to about 1,000°C can be obtained.
Electric resistance heaters all operate on the same principle as resistance
heating method. Current passes through a wire with high electrical resistance,
generating heat in the process. The amount of heat generated depends on the
wire resistance and the voltage.

The resistance heating is further classified as:

1. Direct resistance heating,

2. Indirect resistance heating, and
3. Infrared (or) radiant heating.

Ques.69. Highest power factor can be expected in which method of heating?

1. Electric arc heating

2. Dielectric heating
3. Induction heating
4. Resistance heating

Hide Explanation

Answer.4. Resistance heating

Explanation:-

Electric resistance heating converts nearly 100% of the energy in electricity to

heat.

Resistance heating works equally well with low voltage and low-frequency
supply. It works even on d.c. supply. In this method, all Be energy given to the
resistance which acts as a heating element is converted to heat. The loss of
energy occurs while transferring this heat from the element to the substance to
be heated. Compared to other high-frequency methods this loss is less thus
overall efficiency of the resistance heating is high. One more advantage of
resistance heating is it almost works on unity power factor since it does not
contain any inductive part.

The resistance heating can be achieved in two ways direct resistance heating
and indirect resistance heating.

Ques.70. Which of the following heating elements can give the highest
temperature in resistance heating?

1. Copper
2. Nickel Copper
3. Nichrome
4. Silicon’s carbide

Hide Explanation

Answer.4. Silicon’s carbide

Explanation:-

Electrical heating elements in industrial furnaces are used in a variety of

industries such as heat treatment of metals, electronic components, ceramics,
and chemicals.

● Furnaces operating in air at temperatures up to 1300° C usually use

wire-wound Cr alloys.
● For higher temperatures in air, either precious metal or SiC rods arc
used.
● For very high temperatures requiring an oxidizing environment
ceramic elements, most commonly Zirconium dioxide (ZrO2) are
used.
 ● In cases in which reducing atmospheres can be tolerated, graphite
or refractory metals such as Molybdenum and Tungsten can be
used.

Major Heating Elements

⇒ Ni-Cr-Based Heating Elements

The Ni-Cr-based heating elements are typical metallic heating elements and are
the most popular because they are inexpensive and easy to manufacture. Two
types, one is composed of Ni 80% and Cr 20%, whereas the other is composed
of Ni 60% and Cr 17% (plus Fe), are most widely used. The oxide film (Cr2O3)
formed on the surface of the heating element functions as a protective film.

⇒MoSi2 (Molybdenum disilicide) Based Heating Element

The MoSi2 (Molybdenum disilicide)based heating elements are made by forming

a SiO2 (glass) film on the surface of MoSi2, a metallic material. The SiO2 film
functions as a protective film, which enables usage of the element at high
temperatures. Therefore, this metallic heating element can be used at high
temperatures of up to 1,900°C under normal atmospheric conditions. However,
the service temperature is lower under reducing atmospheres and high-vacuum
conditions, in which the SiO2 film is degraded. The disadvantages of this element
include brittleness at room temperature, low thermal shock and
softening/deformation at high-temperature ranges.

⇒Silicon Carbide-Based Heating

Element Non-metallic heating elements are represented by the silicon carbide-

based heating elements, which feature high thermal resistance and corrosion
resistance. As for the electrical properties, they have negative characteristics
upto approximately 600°C and positive characteristics at higher temperatures.
The heating elements, with the maximum service temperature of 1,600°C, can be
used over a versatile temperature range. The silicon carbide-based heating
elements also have a SiO2 film that functions as a protective film generated on
the surface, as in the case of MoSi2,-based heating elements. However, the
resistance increases over time approaching the end of service life.
⇒Graphite Heating Element

This heating element has the maximum service temperature of approximately

2,600°C in a non-oxidizing atmosphere such as in an inert gas. However, the
elements cannot be used in an oxidizing atmosphere because they react with
oxygen and water vapor at temperatures above 400°C. The purity can be
improved, allowing for the application to semiconductors. Furthermore, graphite-
based heating elements are used not only for resistance heating but also for arc
heating, and the demand for them as electrodes in steel manufacturing is high.

Ques.71. If the temperature coefficient of silver is 0.0038, the temperature

coefficient for Manganin may be expected to be

1. 0.001
2. 0.00002
3. 0.0038
4. 0.0001

Hide Explanation

Answer.2. 0.00002
Explanation:-

The temperature coefficient of silver is 0.0038 at 20°C so the temperature

coefficient for manganin for 20°C is .000002

Ques.72. Nichrome wire can be safely used for heating upto

1. 2000 °C
2. 1600 °C
3. 1450 °C
4. 1150 °C

Hide Explanation

Answer.4. 1150 °C

Explanation:-

Nichrome (NiCr, nickel-chrome, chrome-nickel, etc.) is any of various alloys of

nickel, chromium, and often iron (and possibly other elements).

The Ni-Cr-based heating elements are typical metallic heating elements and are
the most popular because they are inexpensive and easy to manufacture. Two
types, one is composed of Ni 80% and Cr 20%, whereas the other is composed
of Ni 60% and Cr 17% (plus Fe), are most widely used. The oxide film (Cr2O3)
formed on the surface of the heating element functions as a protective film.

Heating elements made of Nichrome can be used for continuous operation at a

temperature up to 1200oC.

Ques.73. If a furnace is to be heating to temperatures around 1500°C which of

the following material for heating elements should be selected?
 1. Eureka
2. Kanthal
3. Platinium molybdenum carbo compound
4. Nichrome

Hide Explanation

Answer.3. Platinium molybdenum carbo compound

Explanation:-

● The melting point of Eureka is 1221 to 1300 °C

● The melting point of Kanthal is 1,425 °C
● The melting point of Nichrome is 1400 °C
● Molybdenum compounds (about 14% of world production of the
element) are used in high-pressure and high-temperature
applications as pigments and catalysts. The melting point of
platinum-molybdenum carbon compound is around 3000°C

Ques.74. Which of the following elements will have the least range of
temperature?

1. Eureka
2. Nichrome
3. Silicon carbide
4. Kanthal

Hide Explanation
Answer.1. Eureka

Explanation:-

● The melting point of Eureka is 1221 to 1300 °C

● The melting point of Kanthal is 1,425 °C
● The melting point of Nichrome is 1400 °C
● The melting point of Silicon Carbide is 2,730 °C

Hence Eureka has the least range of temperature.

Ques.75. Which of the following device is necessarily required for automatic

temperature control in a furnace?

1. Thermocouple
2. Thermostat
3. Autotransformer
4. Heating elements of variable resistance material

Hide Explanation

Answer.2. Thermostat

Explanation:-

For the heat treatment process to be in control it essential that the furnace is in
control. If a furnace is out of control the heat treatment process is bound to be
out of control. It’s like driving a car which is out of control; you don’t know
whether or not you will reach your destination safely. An example of the need for
critical temperature control is the solution heat treatment of titanium alloys which
is performed at a temperature only slightly below (50 -150 °F). If the temperature
is exceeded, tensile properties, especially ductility, are reduced and cannot be
fully restored by subsequent heat treatment.

The automatic controls used in an electric heating system are designed to ensure
its safe and efficient operation. In a central heating system, the wall-mounted
room thermostat is the control that governs the normal operation of the furnace.
The operating principle is simple. The temperature selector on the thermostat is
set for the desired temperature. When the temperature in the room falls below
this setting, the thermostat will call for heat and cause the first heating circuit in
the furnace to be turned on. There is generally a delay of about 15 seconds
before the furnace blower starts. This prevents the blower from circulating cool
air in the winter. After about 30 seconds, the second heating circuit is turned on.
The other circuits are turned on one by one in the timed sequence.

Note:- A thermocouple is a device used to measure the temperature, a

thermostat is a control device which measures the temperature (could be using a
thermocouple to do that) and comparing the measured temperature with the
required temperature (setpoint) and based on these data control a heating and/or
cooling device.

Ques.76. Furnaces used for cremation use

1. Resistance heating
2. Induction heating
3. Dielectric heating
4. Arc heating

Hide Explanation

Answer.1. Resistance heating

Explanation:-

Cremation is the combustion, vaporization, and oxidation of human bodies to

basic chemical compounds, such as gases, ashes, and mineral. Cremation
reduces the body to its basic elements through a process that exposes it to open
flames, intense heat and evaporation. This is done in a specially designed
furnace called a cremation chamber or retort.

Temperature up to 3000°C can be obtained in the furnace chamber hence direct

resistance heating are preferred for cremation.

Ques.77. Induction heating is possible

1. On ferrous material only

2. On magnetic material only
3. On dc supply only
4. On AC supply only

Hide Explanation

Answer.4. On AC supply only

Explanation:-

Induction heating is defined as the process of heating an electrically conducting

object (usually a metal) by electromagnetic induction, through heat generated in
the object by eddy currents.

Frequency is one of the most critical parameters in these applications. If the

frequency is too low, an eddy current cancellation within the heated body will
take place, resulting in poor coil efficiency.

However, when the frequency is too high, the skin effect will be highly
pronounced, resulting in a current concentration in a very thin surface layer
compared to the diameter/thickness of the heated component.

Since in DC current the frequency is Zero hence the induction heating is

applicable for AC power supply only.
Ques.78. A piece of steel is to be heated to a predetermined temperature. In
which of the following furnace it will attend the desired temperature in the
shortest possible time?

1. Oil fired furnace with the heat exchanger

2. Electric resistance furnace
3. Induction heating furnace
4. Electric arc furnace

Hide Explanation

Answer.3. Induction heating furnace

Explanation:-

Induction heating is an extremely versatile heating method that can perform

uniform surface hardening, localized surface hardening, through hardening and
tempering of hardened pieces. Heating is accomplished by placing a steel part in
the magnetic field generated by high-frequency alternating current passing
through an inductor, usually a water-cooled copper coil. The depth of heating
produced by induction is related to the frequency of the alternating current: the
higher the frequency is, the thinner or more shallow the heating. Therefore,
deeper case depths and even through hardening are produced by using lower
frequencies.

Induction hardening offers a number of advantages over other heat treatment

methods. The most important advantages are short heat treatment times, good
repeatability concerning the hardened-layer quality, small or negligible
subsequent distortion, and a minimum subsequent product surface oxidation.

Ques.79. In a domestic cake baking oven, the temperature is controlled by

1. Series-parallel operation
 2. Autotransformer
3. Thermostat
4. Voltage variation

Hide Explanation

Answer.3. Thermostat

Explanation:-

Practically all ovens are now temperature controlled; failing a built-in thermostat,
use a small portable oven thermometer.

The thermostat used ovens where it controls the flow of electricity or gas to the
oven’s burner. If the oven temperature rises above the desired value, the
thermostat’s switch turns the burner off. When the oven temperature falls back
below the desired value, the switch turns the burner back on. In this manner, the
thermostat keeps the oven temperature within a narrow range.

Note:- A thermocouple is a device used to measure the temperature, a

thermostat is a control device which measures the temperature (could be using a
thermocouple to do that) and comparing the measured temperature with the
required temperature (setpoint) and based on these data control a heating and/or
cooling device.

Ques.80. If the supply frequency is reduced from 50 Hz to 1 Hz, which of the

following method of heating will be least affected

1. Resistance heating
2. Dielectric heating
3. Induction heating
4. None of above
Hide Explanation

Answer.1. Resistance heating

Explanation:-

When the electric current is made to pass through a high-resistive body (or)
substance, a power loss takes place in it, which results in the form of heat
energy, i.e., resistance heating is passed upon the I2R effect. Since this heating
process is purely resistive in nature i.e it does not have any capacitor or inductor
part hence resistance heating method is free from frequency variation

Ques.81. Thermal conductivity is least for

1. Air
2. Water
3. Glass
4. Copper

Hide Explanation

Answer.4. Copper

Explanation:-
Thermal conductivity is the property of a material to conduct heat.

The thermal conductivity of air at 25°C is 0.0262 W/(m K)

The thermal conductivity of water at 25°C is 0.606 W/(m K)

The thermal conductivity of glass at 25°C is 1.05 W/(m K)

The thermal conductivity of copper at 25°C is 401 W/(m K)

Hence Copper has the highest thermal conductivity

Ques.82. Which method of heating is likely to give leading power factor?

1. Electric arc heating

2. Induction heating
3. Dielectric heating
4. Resistance heating

Hide Explanation

Answer.3. Dielectric heating

Explanation:-
Dielectric heating

Dielectric heating, also known as electronic heating, RF (radio frequency)

heating, and high-frequency heating, is the process in which a high-frequency
alternating electric field, or radio wave or microwave electromagnetic radiation
heats a dielectric material.

Dielectric heating (also called High-frequency capacitive heating) is employed for

heating insulators like wood, plastics, and ceramics etc.

A non-conducting material generates heat when subjected to an alternation

electric field. This process wherein heating takes place due to dielectric loss is
known as dielectric heating. The amount of heat produced depends on the value
of the dielectric strength of the material. The non-conducting material acts as the
job which is to be heated. This method is extensively used in plastic and wood
industries. It is especially of immense utility where multiple woods are to be
heated and glued. The heat supplied by this method is applied even] throughout
the whole body. This method is also employed in the textile, rubber, chemical,
and food industries.

The phenomenon of the dielectric loss taking place in insulating materials is just
analogous to the hysteresis loss taking place in the magnetic materials. Just as
there is no perfect conductor, so there is no perfect insulator too.
If an ac voltage is applied across a piece of an insulator, an electric current i
flows as shown in Fig. The total current i can be supposed to be made up of two
components ic and iR as shown in Fig. , where ic is the capacitive current leading
the applied voltage Vin by 90° and iR is the resistive current in phase with the
applied voltage Vin, as shown in Fig. The resulting dielectric loss appears in the
form of heat in the dielectric of the capacitor. It is convenient to regard this i2R
current as flowing through a leakage resistance R placed in parallel with the
capacitance C as shown in Fig.

The current flowing in the circuit is given by

Ic = E/Xc

Where Ic =Current flowing through the capacitor in Amp

E = High-frequency supply voltage

Xc = Capacitive reactance in Ohm

During charging and discharging of the capacitor, the molecular arrangement of

the job changes because of continuous stress created by the electric. field. This
change in molecular arrangement results in the generation of heat.

When a solid dielectric material (Insulating) is subjected to an alternating electric

field, it is not supposed to carry any current. However, in practice, some leakage
current passes through it and power loss is takes place. This loss is called the
dielectric loss and result in heating of the dielectric material.
Ques.83. Direct resistance Heating is used in

1. Electrode Boiler
2. Salt-Bath furnace
3. Resistance Welding
4. All of the above

Hide Explanation

Answer.4. All of the above

Explanation:-

Direct resistance heating (or ohmic heating) is based on the flow of an electrical
current through the body to be heated, which is directly connected to an electrical
supply. The heating can be realized by DC or AC currents, but the industrial
applications are mostly done with the alternating ones.
Materials with fairly high electrical resistivity, such as carbon and low alloy steels
and nickel alloys, are readily heated by direct resistance. With low resistivity
materials such as copper and aluminum, the process is often not cost-effective.

Direct resistance heating is used in the iron and steel industry: for heating rods
and billets prior to rolling and forging for ferrous and non-ferrous annealing; either
alone or i^l combination with other fuels for melting glass; in electrode boilers, for
water heating and steam raising; and in salt baths for the surface heat treatment
of metallic components.

Ques.84. Which of the following method is suitable for heating of conduction

medium?

1. Radiant heating
2. Eddy current heating
3. Induction heating
4. Indirect arc heating
Hide Explanation

Answer.3. Induction heating

Explanation:-

Induction heating is defined as the process of heating an electrically conducting

object (usually a metal) by electromagnetic induction, through heat generated in
the object by eddy currents.

In induction heating when an alternating voltage applied to an induction coil (e.g.,

solenoid coil) will result in an alternating current in the coil circuit. An alternating
coil current will produce in its surroundings a time-variable magnetic field that has
the same frequency as the coil current. That magnetic field strength depends on
the current flowing in the induction coil, the coil geometry, and the distance from
the coil. The changing magnetic field induces eddy currents in the workpiece
located inside the coil. These induced currents have the same frequency as the
coil current; however, their direction is opposite to the coil current.

Alternating eddy currents induced in the workpiece produce their own magnetic
fields, which have opposite directions in the direction of the main magnetic field
of the coil. Therefore, the total magnetic field of the induction coil is a result of the
source magnetic field and induced magnetic fields. Alternating eddy currents
produce heat by the Joule effect (I2R). A conventional induction heating system
that consists of a cylindrical load surrounded by a multiturn induction, the coil is
shown in Figure.
Ques.85. In dielectric heating, current flows through

1. Metallic conductor
2. Ionic discharge between dielectric medium and the metallic
conductor
3. Dielectric
4. Air

Hide Explanation

Answer.3. Dielectric

Explanation:-
Dielectric heating, also known as electronic heating, RF (radio frequency)
heating, and high-frequency heating, is the process in which a high-frequency
alternating electric field, or radio wave or microwave electromagnetic radiation
heats a dielectric material.

A non-conducting material generates heat when subjected to an alternation

electric field. This process wherein heating takes place due to dielectric loss is
known as dielectric heating. The amount of heat produced depends on the value
of the dielectric strength of the material. The non-conducting material acts as the
job which is to be heated. This method is extensively used in plastic and wood
industries.

The phenomenon of the dielectric loss taking place in insulating materials is just
analogous to the hysteresis loss taking place in the magnetic materials. Just as
there is no perfect conductor, so there is no perfect insulator too.

Ques.86. Which of the following is the desirable property of resistance heating

elements materials?

1. High resistivity
 2. High melting point
3. Low-temperature coefficient
4. All of the above

Hide Explanation

Answer.4. All of the above

Explanation:-

Property of resistance heating

Indirect resistance furnaces use many different types of heating elements for
producing heat. A good heating element should have the following properties:

1. High Specific Resistance:-When specific resistance of the material

of the wire is high, only short length of it will be required for a
particular resistance (and hence heat) or for the same length of the
wire and the current, heat produced will be more.
2. High Melting Temperature:- If the melting temperature of the heating
element is high, it would be possible to obtain higher operating
temperatures.
3. Low Temperature Coefficient of Resistance:- In case the material
has low temperature coefficient of resistance, there would be only
small variations in its resistance over its normal range of
temperature. Hence, the current drawn by the heating element
 when cold (i.e., at the start) would be practically the same when it is
hot.
4. High Oxidising Temperature:- Oxidisation temperature of the
heating element should be high in order to ensure longer life.
5. Positive Temperature Coefficient of Resistance:- If the temperature
coefficient of the resistance of the heating element is negative, its
resistance will decrease with rising in temperature and it will draw
more current which will produce more wattage and hence heat. With
more heat, the resistance will decrease further resulting in instability
of operation.
6. Ductile:- Since the material of the heating elements has to have
convenient shapes and sizes, it should have high ductility and
flexibility.
7. Mechanical Strength:- The material of the heating element should
possess high mechanical strength of its own. Usually, different
types of alloys are used to get different operating temperatures.

Ques.87. Which of the following is the ideal method of heating plastics?

1. Oil fired furnace

2. Resistance furnace heating
3. Dielectric heating
4. Coal-fired furnace
Hide Explanation

Answer.3. Dielectric heating

Explanation:-

If non-magnetic materials, i.e. insulators such as China glass, ceramics, etc. are
subjected to high voltage alternating current, their temperature will increase after
some time. The increase in temperature is due to the conversion of dielectric loss
into heat. For obtaining the adequate heating effect, the high voltage at about 20
kV and frequency in the range of 1 and 50 MHz are usually employed. The
phenomenon of the dielectric loss taking place in insulating materials is just
analogous to the hysteresis loss taking place in the magnetic materials.

The amount of heat produced depends on the value of the dielectric strength of
the material. The non-conducting material acts as the job which is to be heated.
This method is extensively used in plastic and wood industries.

Ques.88. If f be the frequency then the dielectric loss is proportional to

1. f
2. f2
3. 1/f
4. 1/f2

Hide Explanation
Answer.1. f

Explanation:-

The expression of the dielectric loss is given as

Ploss = 2π.f.C.V2.δ

Where

f = frequency

C = Capacitance of the capacitor

V = applied voltage

δ = Phase angle
This power is converted into heat. Since for a given insulator material, C and δ
are constant, the dielectric loss is directly proportional to V2f. That is why the
high-frequency voltage is used in dielectric heating. Generally, A.C voltage of
about 20 kV at a frequency of 10-30 MHz is used.

Ques.89. When E is the voltage impressed on the dielectric, the dielectric loss
will be proportional to

1. E
2. E2
3. 1/E
4. 1/E2

Hide Explanation

Answer.1. E

Explanation:-

The expression of the dielectric loss is given as

Ploss = 2π.f.C.E2.δ

Where
f = frequency

C = Capacitance of the capacitor

E = applied voltage

δ = Phase angle

This power is converted into heat. Since for a given insulator material, C and δ
are constant, the dielectric loss is directly proportional to E2f. That is why the
high-frequency voltage is used in dielectric heating. Generally, A.C voltage of
about 20 kV at a frequency of 10-30 MHz is used.

Ques.90. Mica is a:-

1. Insulating and dielectric material

2. Dielectric material but not an insulator
3. Insulating material but not dielectric
 4. Magnetic Material

Hide Explanation

Answer.1. Insulating and dielectric material

Explanation:-

When two conducting plates are brought closer and are separated by another
plate that is made up of insulating material leads to the formation of the
capacitor. The insulating material used in it is balled dielectric material.

The main function of a dielectric material is to store electrical energy. Thus

dielectric materials are used in capacitors. There are four types of capacitors
available depending on the dielectric material used in them.

1. Capacitors with air and gases as dielectric:- Such capacitors are used in
circuits where energy loss in them should be low as well as the value of
capacitance should be small. Thus, these types of capacitors are used in circuits
where accuracy is the prime concern, for example, radio frequency circuits.

2. Capacitors with mineral oil as dielectric:- These capacitors give a large value
of capacitance with a small amount of dielectric loss.

3. Capacitors with a combination of solid and liquid as dielectricsPaper, glass,

mica, mineral oil, caster oil, etc. are used in these types of capacitors. Oil
impregnated paper dielectric is used for making capacitors that should have the
large value of capacitances. These type of capacitors are used in power
distribution systems.
4. Capacitors with only solid as dielectric such as glass, mica, etc. These
capacitors are used in laboratories. Mica has a high dielectric constant, high
dielectric strength and low dielectric loss. Further, the dielectric constant of mica
does not change much with temperature. Most of the capacitors are constructed
as sealed components.

Ques.91. The advantages of dielectric heating are

1. Pollution free
2. Uniform Heating
3. Non-metallic heating
4. All of the above

Hide Explanation

Answer.4. All of the above

Explanation:-

Advantages of Dielectric heating

1. Since heat is generated within the dielectric medium itself, it results

in uniform heating.
2. Heating becomes faster with increasing frequency.
3. It is the only method for heating bad conductors of heat. Heating is
fastest in this method of heating.
4. Since no naked flame appears in the process, inflammable articles
like plastics and wooden products etc. can be heated safely.
5. Heating can be stopped immediately as and when desired.
Ques.92. For arc heating, the electrodes are made of

1. Copper
2. Aluminum
3. Graphite
4. ACSR conductor

Hide Explanation

Answer.3. Graphite

Explanation:-

Electrodes used in an arc furnace

The following three types of electrodes are used in arc furnaces:

(i) Carbon electrodes:

● These electrodes are used with small furnaces for the manufacture
of ferro-alloys, aluminum, calcium carbide, phosphorus etc.
● These are made of anthracite coal and coke.
● These are very cheap and cost less than one half as much for same
weight ah graphite electrodes.
● The large area of carbon electrodes allows for more uniform
heating.

(ii) Graphite electrode :

● These electrodes are obtained by heating the carbon electrodes to

a very high temperature.
 ● Owing to lower resistivity of graphite (one fourth that of carbon),
graphite is required half in size for the same current resulting in
easy replacement.
● Graphite begins to oxidize at about 600°C whereas carbon at about
400°C. Under average conditions, the consumption of graphite
electrodes is about one half that of the carbon electrode.

(iii) Self-baking electrodes:

● These electrodes are employed in ferro-alloys and electrochemical

furnaces and the electrolytic production of aluminum.
● These electrodes are made of special paste, whose composition
depends upon the types of process for which it is used, it is
contained in the thin steel cylinder. The flow of current produces
heat and the paste is baked and formed into an electrode.

Features of carbon and graphite electrodes are:

● Resistivity: The graphite electrodes have low-specific resistance

than the carbon electrodes, so the graphite required half in size for
the same current resulting in easy replacement.
● Oxidation: Graphite begins to oxides at 600°C whereas carbon at
400°C.
● Electrode consumption: For steel-melting furnaces, the consumption
of the carbon electrodes is about 4.5 kg of electrodes per tonne of
steel and 2.3-to 6.8 kg electrodes per tonne of steel for the graphite
electrodes.
● Cost: The graphite electrodes cost about twice as much per kg as
the carbon electrodes. The choice of electrodes depends chiefly on
 the question of the total cost. In general, if the processes requiring
large quantities of electrode, carbon is used but for other processes,
the choice depends on local conditions.

Ques.93. For Gluing of wood, which method will be suitable for the purpose?

1. Induction heating
2. Resistance heating
3. Dielectric heating
4. Any of the above

Hide Explanation

Answer.3. Dielectric heating

Explanation:-

Gluing of wood

Dielectric heating is used for gluing of woods, In a number of wooden furniture

items and other articles such as desk tops, table tops, corners of cots, drawing
boards, etc. wooden panels are made by gluing boards together edgewise.
Sometimes veneers (to cover with a thin layer of finer wood) are laid over glued
panels. The main difficulty in the use of animal glues is of a long curing time and
the parts to be joined have to be kept under mechanical pressure after
application of the glue for a period of 24 hours in order to let the glue dry up.

Dielectric heating in the region of the glue between adjacent wood parts permits
a strong bond with a stay-in-press time of only about 30 seconds. This dielectric
heating may also be used for binding boards edgewise for making large panels.
The glue used should be one which hardens quickly when heated to the desired
temperature.
Ques.94. Which of the following will happen if the thickness of the refractory wall
of the furnace is increased?

1. Energy consumption will be decreased

2. The temperature inside the furnace will fall
3. The temperature on the outer surface of the furnace wall will drop
4. Heat loss through furnace wall will be increased

Hide Explanation

Answer.3. The temperature on the outer surface of the furnace wall will drop

Explanation:-

In a furnace we want to have high heat transfer inside the furnace; however, we
do not want any heat loss through the furnace wall. Thus to prevent the heat
transfer from the furnace to the atmosphere a bad heat conductor or a very good
heat insulator is required. In the case of the furnace, the wall is prepared by
multiple layers of refractory materials to minimize the heat losses. Therefore, wall
insulation is required to minimize the heat loss from the system to the
environment or heat gain from the environment to the system (like cryogenic
systems).

Furnace Design

The furnace chamber provides space to conduct the activity in the furnace. This
chamber design has many issues like shape, size, the ratio of various
dimensions, refractory lining thickness, and nature, furnace casing material with
proper ports, etc. These factors are briefly discussed below:

Chamber shape

The furnace chamber shape could be closed rectangular (e.g. reheating furnace),
narrow rectangular (e.g. coke oven), closed trough (e.g. open hearth furnace),
closed hemispherical shape (e.g. electric arc furnace), open cylindrical shape
(e.g. cupola), one end closed cylindrical shape (e.g. induction melting furnace),
etc. The shape depends on the process activity and the mode of heat

Chamber size

The dimensions of rectangular shape furnace (length, width and height),

cylindrical shaped (height and diameter) furnace or hemispherical shaped
(section diameter and center height) furnace depend on the scale of operation
and process constraints. In case of reheating furnace, the length of the furnace
will depend on the object size to be heated and burner design. The width of the
furnace will be decided on the number of pieces to be heated (load) at a time,
while the height will be decided by the aerodynamics of the furnace for good gas
flow and heat transfer. The coke oven chamber dimensions are decided by
operating factors. The coke oven length depends on the oven capacity and
availability of pusher arm length, the height is decided by selection of heating
chamber flue design and the minimum desired width is decided by the ability of a
man to enter for construction and repair. In each case, there are compelling
parameters to fix the dimensions depending on the furnace capacity.

Refractory thickness and nature

The nature of refractory is decided by the maximum temperature requirements

and other working conditions like the chemical nature of materials in contact,
working load, erosion and corrosion parameters, etc. Once the nature of
refractory is decided, then the thickness of the refractory layer would depend on
the inner working temperature, the thermal conductivity of the refractory and
maximum temperature sustainable by the outer metallic casing.

Thermal conductivity and heat capacity:

in practical applications, refractory materials processing high thermal capacity as

well as low thermal conductivity are required, depending upon (of course) the
functional requirements. In most situations, a refractory that serves as a furnace
wall should have a low thermal conductivity in order to retain as much as heat as
possible. However, a refractory used in the construction of the walls of muffles or
retorts or coke ovens should have a high thermal conductivity in order to transmit
as much heat as possible to the interior. The charge remains separated from the
flame in these specific examples of installations.

The heat transferred or conducted by a refractory at a rate Q is given by the

relationship:
Q = K.(T1 − T2) A ⁄ ΔX

Where

T1 = Temperature on the hotter surface

T2 = Temperature on the colder surface

A = Area of refractory

K = Thermal conductivity

ΔX = Thickness

From this relationship, it follows that if the refractory wall is made thicker, the
heat loss will be decreased. Alternatively, if the refractory brick is backed by an
insulating layer, the same result ensues. These provisions tend to cause the
refractory material to be at a higher average temperature. The increased
temperature tends to soften the refractory and to enhance the chemical attack on
it. In this scenario, a choice must be made between increased heat savings and
a reduction in the life of the refractory material. This particular problem has drawn
considerable attention to the design of open-hearth furnaces for steel making.
The question of insulating the roofs of these furnaces has been the subject of a
great deal of deliberation.

The porosity of refractory bricks has a direct bearing on the thermal conductivity.
The densest and the least porous bricks have the highest thermal conductivity
owing to the absence of air voids. On the other hand, in porous bricks, the
entrapped air in the pores acts as a nonconducting material.

The heat capacity of a furnace unit at a given temperature depends on bulk

density, specific heat and thermal conductivity of the refractory. The heat
capacity and thermal conductivity of a refractory increase with increasing bulk
density, and decrease with increasing porosity. A refractory with a high bulk
density and a high thermal conductivity is desirable from the point of view of
certain applications. With refractories used for heat storage and transmission,
such as checker bricks, no conflict between properties arises, since high density
is a desirable criterion both for stability and for increased heat storage and
conductivity.
Furnace casing material

The furnace is generally encased in steel structure for stability, support, and
handling. The steel selected is generally common structural steel unless some
furnace demand heat resisting steel for special applications. The steel casing
thickness depends on the furnace size and loads subjected. The steel casing is
made sufficiently strong to sustain rough working conditions of the furnace. This
casing has ports for the burner, gas exit, material charging and discharging door,
etc.

Burners

The burners are necessary to combust the fuel for generating thermal energy for
its efficient utilization in the furnace. The suitable burners are selected based on
the type of fuel (coal, oil or gas) best suited for the furnace.

Ques.95. High frequency for induction heating can be generated by

1. Motor generator set

2. Spark gap oscillator
3. Vacuum tube oscillator
 4. Any of the above

Hide Explanation

Answer.4. Any of the above

Explanation:-

Sources of high frequency for induction heating

Basically, there are three types of equipment used for converting the electrical
energy at a low frequency to one at a high frequency suitable for induction
heating

1. The motor generator set

2. The spark gap converter
3. The vacuum tube oscillator.

Motor generator Set:- The motor generator set consists of an induction motor
coupled to a specially designed generator having both the armature and field
windings on the stator. The change in reluctance produces a corresponding
change in the magnetic flux flowing in the iron circuit which induces a voltage in
the armature winding. The voltage is proportional to the rate of change of total
flux and the frequency is determined by the number of complete flux reversals
per second.
Spark Gap Converter:- The basic principle of operation of a spark gap converter
is the alternate charging and discharging of a capacitor.

Although no longer produced commercially, the spark-gap converter was one of

the earliest means of providing high-frequency ac power in the radio frequency
region. It was used primarily in metal melting, in particular for precious metals.

In its simplest form, the spark-gap converter includes a step-up transformer (T1)
which increases the line voltage to a higher level, which is subsequently
impressed across the spark gap. The spark gap is in parallel with a capacitor (C1)
and the primary of transformer T2. This is an output transformer; its secondary is
connected to the work coil.

In operation, as the primary voltage rises in each half-swing of the 60-Hz line
current, the voltage across the gap also rises until it exceeds the breakdown
level. This voltage is also equal at that instant to the voltage impressed across
the series circuit formed by the capacitor and the output transformer primary. The
capacitor charges to this peak voltage. When the voltage exceeds the breakdown
level of the gap, the low-resistance arc that has formed discharges the capacitor
through the gap, passing an oscillating current through the combination of the
capacitor and the transformer primary. As the capacitor discharges, the voltage
across the gap decreases until the arc can no longer be sustained. On the
reverse half-cycle of the 60-Hz line current, the cycle is repeated with the current
in the circuit going in the reverse direction.

In later developments of the system, vacuum tubes were used to increase

stability, and the gaps were contained in a hydrogen atmosphere to reduce the
need for constant maintenance.

Frequencies generated by this system are generally in the range of 80 to 200

kHz. However, many frequency components are produced simultaneously so that
the output is not purely sinusoidal. The efficiency of these systems is rather low
—on the order 15 to 50% line-to-load.

Vaccum tube Converter:- The vacuum tube oscillator or electronic heater as it is

sometimes called. produces large power outputs at the higher frequency of the
order of 600 KHz.The 50 HZ supply is first converted into d.c. and then inverted
into high frequency currents.

Ques.96. The advantages of High-frequency heating is

1. Uniform heating
2. More economical
3. Less space requirement
4. All of the above

Hide Explanation

Answer.4. All of the above

Explanation:-

Advantages of High-Frequency Heating

The advantages of high-frequency heating are as follows:

● It is possible to control the quantity of heat with the help of electrical

clocks and photoelectric clock devices.
● As the heat is developed in the material to be heated, it reduces the
heating time.
● Heat is uniformly and evenly distributed, and there is no chance of
oxidation.
● There is no flue gas, smoke, and dirt. This improves the working
condition.
● The space required is limited.
● It is easy to maintain high-frequency heating equipment.
● The operation of high- frequency heating is simple to control.
● The high-frequency heating is automatic and it can even be
operated by semi-skilled labor.
● It is economical.
● With high-frequency inductive heating, electrodes in the vacuum
tube, which is beyond reach, can be heated.
● Non-conductors are heated economically with high-frequency
dielectric heating

Ques.97. The heating elements of an electric iron is composed of_____

1. Aluminium
2. Copper
 3. Nichrome
4. Constantan

Hide Explanation

Answer.3. Nichrome

Explanation:-

We know that metals contain a large number of free electrons and thus electric
current can pass through them easily. For example, metals offer a little
resistance to the flow of free electrons through them, i.e., they have low
resistance. Substances like manganin, constantan, nichrome, tungsten, etc.,
offer high resistance to the flow of electric current through them. Hence, they
have high resistance. Constantan (or Eureka) is an alloy of copper (55%) and
nickel (45%). It is used in the construction of pyrometer and thermocouple.
Manganin is an alloy of copper (83%), manganese (13%) and nickel (4%). It is
used in the construction of rheostats and resistor. Nichrome is an alloy of nickel
(60%) and chromium (40%). It is used in the construction of the heating element.

The heating elements (or heating coils) of electrical heating appliances such as
electric iron and toaster, etc., are made of an alloy rather than a pure metal
because

(i) the resistivity of an alloy is much higher than that of pure metal

(ii) an alloy does not undergo oxidation (or burn) easily even at high temperature
when it is red hot.

For example, nichrome alloy is used for making the heating elements of electrical
appliances such as electric iron, toaster, electric kettle, room heaters, water
heaters (geysers, and hair dryers, etc., because:

(i) Nichrome has very high resistivity (due to which the heating element made of
nichrome has a high resistance and produces a lot of heat on passing current).
(ii) Nichrome does not undergo oxidation (or burn) easily even at high
temperature. Due to this nichrome wire can be kept red-hot without burning or
breaking in the air.

The resistivity of conductors (like metals) is very low. The resistivity of most of
the metals increases with temperature. On the other hand, the resistivity of
insulators like ebonite, glass, and diamond is very high and does not change with
temperature. The resistivity of semiconductors like silicon and germanium is in-
between those of conductors and insulators and decreases on increasing the
temperature.

Ques.98.A freshly painted layer may be dried electronically by_______.

1. Emissive Heating
2. Induction Heating
3. Infrared heating
4. Convection heating

Hide Explanation

Answer.3. Infrared heating

Explanation:-

Infrared heating:- Infrared heating is generated by i^2R losses in heating lamps

or devices, and this is a special case of resistance heating. The difference,
however, is that infrared energy can be generated in a narrow bandwidth. This
can be applied more efficiently in some cases than combustion energy that
spans a broader bandwidth. To be most efficient, infrared heaters should
concentrate their output at the peak of the absorption spectrum for the material
being heated.

It can transfers energy to a body with a lower temperature through

electromagnetic radiation. Depending on the temperature of the emitting body,
the wavelength of the peak of the infrared radiation ranges from 780 nm to 1 mm.
No contact or medium between the two bodies is needed for the energy transfer.
Infrared heaters can be operated in vacuum or atmosphere. There are
applications in papermaking, drying paints and enamels, and production of
chemicals and drugs.

Ques.99. Choice of frequency for induction heating depends upon

1. Size of object
2. Depth of penetration
3. Resistivity of material
4. All of the above

Show Explanation

Ques.100. In induction heating, the skin depth of penetration is proportional to

1. √Frequency
2. 1/√Frequency
3. 1/√Frequency
4. Frequency

Hide Explanation

Answer.4. 1/(Frequency)1/2

Explanation:-

In induction heating, the heat in the electrically conducting workpiece is produced

by circulating currents caused by electromagnetic induction. Induction heating is
clean quick and efficient. It allows a defined section of the workplace to be
heated accurately.
The depth to which the heated zone extends depends on the frequency of the
current and on the duration of the heating cycle. Because of an electrical
phenomenon called “skin effect,” the penetration depth of the heated area is
inversely proportional to the square root of frequency and directly proportional to
the square root of the workplace resistivity p

δ = K.√ρ/√f

Where K is constant

Therefore, the induction frequency is selected based on the application. A low

frequency such as the utility frequency may be used for induction melting of large
workpieces. High frequencies of up to a few hundred kilohertz are used for
forging, soldering, hardening, and annealing.