Welding assignment questions

1. A fillet weld is used to join 2 medium carbon steel plates each having a thickness of 5.0
mm. The plates are joined at a 90o using an inside fillet corner joint. The velocity of the
welding head is 6 mm/s. The cross-section of the weld bead approximates a right isosceles
triangle with a leg length of 4.5 mm, the heat transfer factor is 0.80, and the melting factor
is 0.58. The heat required to melt steel may be taken as 10 J/mm3. Determine the rate of
heat generation required at the welding source to accomplish the weld.

2. In a resistance welding of a lap joint of two mild steel sheets 1.5 mm thick, a current of
10000 A is passed for a period of 0.1 seconds. The effective resistance of the joint is 120
micro ohms. The density of steel is 0.00786 g/mm3 and the heat required to melt is 1381
J/g. The joint can be considered as a cylinder of 5 mm in diameter and 2.25 mm in height.
Calculate the percentage of heat distributed to the surroundings.

3. The arc welding of cold rolled steel plates having a thickness of 6 mm in butt welding is
being carried out under an ambient temperature of 30 °C and a welding speed of 9 mm/s.
The welding transformer is set at 25 V and the current flowing is 300 A. Taking the arc
efficiency as 0.85, calculate the temperature to which the plates should be preheated such
that a satisfactory metallurgical quality is obtained. Take ρc = 0.0044 J/mm3 °C, k = 0.028
J/mm.s.°C

4. Calculate the size of the heat-affected zone obtained for the same welding in problem 3
under preheating, and discuss the likely metallurgical structure in HAZ. Take the melting
temperature of the steel as 1510 °C.

5. A full penetration weld pass is made on steel of thickness 20 mm at ambient temperature

(30 °C) using the following welding parameters. Calculate the size of the heat-affected
zone.
Melting Temperature = 1510 °C
Austenisation temperature = 730 °C
Thermal conductivity = 0.028 J/mm.s.°C
Volumetric specific heat = 0.0044 J/mm3 °C
Current = 200 A
Arc voltage = 50 V
Travel speed = 7 mm/s
Preheat = 25 °C
Heat-transfer efficiency = 0.9