Department of mech. Design and prod.

Academic year: September 2022

September
Second year mechanical

Welding Course code: Time all: 2 hrs Total marks= 90

MDP2240
ATTEMPT ALL QUESTIONS ( Assume any missing data)

Question One (10 marks)

1-a: In Shielded Metal Arc Welding Process, discuss the main types of
electrode coatings, fields of application, advantages and limitations of
each type. Write the designation of each type used to weld C-Mn steels
according to AWS E5.1 specification.

1-b: In tabulated form, discuss the main differences between Gas Metal Arc
Welding, and Tungsten Inert Gas (TIG) Welding Processes.

Question Two (15 marks)

2-a: Stainless steels are mainly Cr-Ni alloys, they are grouped according to
their chemical composition. For each group, discuss the main welding
problems to be taken into consideration, and explain how to overcome.

2-b: Two dissimilar metals A&B are welded together. They are in the form of
plates. The thickness of each plate is 15 mm. The chromium equivalent of the
used electrode is 28 with ferrite percent equals 40. The chemical composition
of the two base metals A and B are as follows:-

Elements (Wt%) Cr Ni C Mn Si
Alloy
A 2 1 0.03 0.5 1.3
B 14 20 0.1 2 1.5

From the Schaeffer diagram, answer the following questions

a- Locate the base metals and name their group
b- Calculate the dilution of the filler material (electrode).
(Note: The fused areas ratio of metal B to A = 1.5:1)

Question Three (15 marks)

3-a: In resistance welding process, the heat input H= k.I2.R.t, explain the
effect of welding parameters on the shear strength of the spot welded carbon
steel joints.

3-b: : Discuss the factors affecting the following weld defects and show how
to overcome each: -
1- Lack of fusion 2-Slag inclusion
3- porosity. 4- Heat Affected Zone cold cracking
>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>
Prof. Sr. Rashad elhebeary- Dr. Hassan Megahed
Question (4) 15 points

a. Calculate the resulting chemical composition after melting I ton of grey cast iron using
the following charge:
Charge Pig Iron Cast Iron Scrap I Cast Iron Scrap II Steel Scrap
Weight (kg) 150 300 400 150
The available scrap in the foundry is as following:
Charge Type C% Si% Mn% P% S%
Pig Iron 4 1 0.8 0.08 0.06
Cast Iron scrap I 3.3 2.1 0.5 0.06 0.05
Cast Iron scrap II 3.6 1.8 0.3 0.03 0.02
Steel scrap 0.2 0.3 0.6 0.03 0.02
Take the following in consideration:
Losses: C = 5%; Si=10% and Mn = 15% Gain: S = 5% while phosphorus remain
constant
b. It is required to produce ductile cast iron (0.05%Mg) from the following grey cast iron:

Element C Si Mn P S
% 3.4 2.1 0.4 0.11 0.01

Knowing that: %Mg in nodulizing alloy (FeSiMg) = 10%; 𝛈 = 𝟓𝟎%

𝒂𝒕.𝒘𝒕.𝒐𝒇 𝑴𝒈 𝟏
𝒘𝒕 % 𝒐𝒇 𝒏𝒐𝒅𝒖𝒍𝒊𝒛𝒊𝒏𝒈 𝒂𝒍𝒍𝒐𝒚 = [ ∗ %𝐒 + 𝐌𝐠 𝐫𝐞𝐬𝐢𝐝𝐮𝐚𝐥 ] ∗ ∗
𝒂𝒕.𝒘𝒕.𝒐𝒇 𝑺 𝛈
%𝑴𝒈 𝒊𝒏 𝒏𝒐𝒅𝒖𝒍𝒊𝒛𝒊𝒏𝒈 𝒂𝒍𝒍𝒐𝒚
Atomic Weight S: 32; Atomic Weight Mg: 24
Calculate the weight of nodulizing alloy needed for producing 1 ton from ductile cast iron?

Question (5) 15 points

State true of false with adequate reasons:

1. Pure metals have very defined melting/freezing points while alloys solidify at a range of
temperatures.
2. Permanent molds can be used repeatedly and designed so casting can be removed easily
and mold used for next casting while expendable molds should be broken up to remove
casting.
3. Types of patterns are one-piece for complicated shapes and low quantity production;
Split: two piece for simple shapes.
 4. Shell molding Produces castings with close dimensional tolerances and good surface
finish.
5. Lost-foam casting has the following advantages: simple process, design flexibility,
inexpensive; easily processed into complex shapes and requires minimum finishing.
6. In investment casting, the wax can be recovered and reused.
7. In permanent mold casting; part weight can range from 1 kg to 300 kg but typically
weigh is less than 25 kg.
8. Vacuum casting is used for thin walled (0.75 mm) complex shapes with uniform
properties like gas-turbine components from super-alloys.
9. Hot chamber process is used for low melting point alloys (zinc, tin, and lead) while, cold-
chamber process is used for relatively high melting point alloys (aluminum, magnesium,
and copper).
10. Centrifugal Casting is used for solid cylindrical parts like pipes and can produce parts
over 5 ton casting.

Question (6) 15 points

a. Sketch the necessary core (or cores) and suggest a suitable method for its
manufacturing.
b. Design a suitable gating and risers system; then draw a longitudinal section in the
mold.

All Dimensions in mm