Part A

1. What are the functions of runner in a casting?

In the casting process, the runner plays a vital role in delivering molten metal to the mold

cavity and ensuring a high-quality cast. Here are its key functions:

Delivering Molten Metal:

 The runner acts as a channel or passage that efficiently carries the molten metal from

the pouring cup or sprue (where the metal is initially poured) to the mold cavity where

the final casting shape is formed.

 By providing a designated pathway, the runner ensures a smooth and controlled flow

of metal, minimizing turbulence and air entrapment within the mold. This helps

prevent defects in the cast product.

Regulating Flow Rate:

 The size and design of the runner system, including the runner itself, can be

strategically adjusted to control the speed at which the molten metal fills the mold

cavity.

 A well-designed runner system ensures an optimal flow rate. This is crucial because:

 Too slow a flow can lead to premature solidification before the mold cavity is filled

completely, resulting in incomplete casting.

 Excessively rapid flow can cause turbulence and erosion of the mold walls, creating

surface imperfections in the cast.

Facilitating Slag Separation:

 During the pouring process, impurities like oxides, slag, and dross can be present in

the molten metal.

 The runner, designed with a larger cross-sectional area compared to some other parts

of the gating system, can act as a settling chamber for these impurities.
  Since the runner solidifies after the mold cavity due to its larger size, these lighter

impurities tend to float up and get trapped within the runner. This allows for cleaner

molten metal to flow into the mold and produce a higher quality casting.

By performing these functions, runners contribute significantly to the success of the casting

process. They ensure efficient metal delivery, proper flow rate control, and cleaner metal

filling the mold cavity, ultimately leading to a well-formed and high-quality cast product.

2. What are the functions of a riser?

In metal casting, a riser, also known as a feeder, plays a crucial role in ensuring the quality of

the final cast product. Here are its key functions:

Compensates for Shrinkage:

 Most metals shrink in volume as they cool and solidify from their molten state.

 This shrinkage can create cavities or voids inside the casting, compromising its

strength and integrity.

 The riser acts as a reservoir of molten metal.

 As the casting cools and shrinks, the molten metal in the riser feeds the solidifying

metal, preventing voids from forming within the desired cast shape.

Gas Escape:

 During the casting process, trapped gases like air or mold cavity gases can become

embedded in the molten metal.

 These gases can create pockets or porosity within the casting, affecting its properties.

 The riser acts as a collection point for these gases.

 Since the riser solidifies last due to its larger size and positioning, the gases tend to

rise and get trapped there instead of within the casting itself.

Improves Feeding Efficiency:

  The ideal scenario is for the entire casting to solidify uniformly, starting from the

outermost sections and progressing inwards.

 However, some areas, particularly thicker sections, tend to cool slower and solidify

later.

 By strategically placing the riser near these thicker sections, the molten metal in the

riser can flow and feed them effectively during solidification, minimizing shrinkage

defects.

Allows for Slag Removal:

 During casting, impurities like oxides or slag can form on the surface of the molten

metal.

 The riser, due to its larger size and slower solidification, acts as a trap for these

impurities.

 As the metal in the riser solidifies last, these impurities tend to concentrate there,

making it easier to remove them from the final casting after it cools.

By performing these functions, risers ensure the production of high-quality castings with

minimal defects and improved mechanical properties.

Additional Points:

 Riser design is crucial for its effectiveness. Factors like size, shape, and placement are

carefully calculated to ensure it feeds the casting efficiently and solidifies last.

 After the casting cools, the riser is removed from the final product. The metal from

the riser can often be recycled and reused in subsequent casting processes.

3. What is meant by mould cavity?

In the casting process, the mold cavity is the heart of the operation. It's the very space within
the mold that defines the final shape, size, and intricacies of the cast product. Here's a

breakdown of its significance:

The Blueprint for the Casting:

 The mold cavity is essentially a negative impression created inside the mold.

 This impression replicates the exact shape and form of the desired cast component.

 It's formed by the absence of material in the mold where the molten metal will

eventually be poured.

Creating the Cavity:

 There are several ways to create the mold cavity, depending on the casting method

and complexity of the part being produced.

 In sand casting, a common technique, a pattern with the desired shape is used to press

a cavity into the sand. After removing the pattern, the remaining void becomes the

mold cavity.

 In other methods, like permanent mold casting or die casting, metal molds with pre-

machined cavities are used.

Factors Affecting Cavity Design:

The design of the mold cavity is crucial for achieving a successful casting.

Important considerations include:

 Part Geometry: The cavity needs to accurately reflect the dimensions and features of

the final cast component.

 Draft Angles: Slight tapers on the cavity walls are incorporated to facilitate easier

removal of the casting after solidification.

 Wall Thickness: The thickness of the cavity walls needs to be appropriate to allow for

proper metal filling and solidification without premature freezing or cracking.

  Gating System Design: The design of the channels that deliver molten metal to the

cavity (runners, sprues, etc.) needs to be integrated with the cavity design for optimal

filling and solidification.

Overall Significance:

A well-designed mold cavity is essential for producing castings that meet the desired

specifications in terms of:

 Shape and Accuracy: The cavity ensures the cast part replicates the intended form

precisely.

 Dimensional Control: The cavity dimensions dictate the final dimensions of the

casting.

 Surface Quality: The smoothness and integrity of the cavity walls influence the

surface finish of the cast product.

By carefully designing and creating the mold cavity, manufacturers can achieve high-quality

castings that meet their functional and aesthetic requirements

4. What is the use of core in a casting process?

In casting processes, a core acts as an internal insert placed within the mold cavity to form the

desired hollow sections, cavities, or recesses within the final cast product. Here's a closer

look at the use of cores:

Creating Internal Features:

Unlike the mold cavity that defines the overall external shape of the casting, cores are used to

shape the internal features. These features can include:

Hollow sections (think pipes, engine blocks)

 Holes of various shapes and sizes

 Undercuts (recessed features with overhanging edges)

 Internal pockets or cavities

Since a standard mold cavity cannot be formed around these internal features, cores are

strategically positioned inside the mold to create the necessary voids during casting.

Material and Placement:

Cores are typically made from sand similar to the molding material. However, they can also

be made from other materials depending on the casting process and desired core properties.

Examples include:

 Shell Molds: Offer better strength and collapsibility for intricate cores.

 Cold-Box Cores: Use chemical binders for faster setting times.

 Metal Cores: Used in some specialized casting processes for permanent or reusable

cores.

Cores are positioned and secured within the mold cavity using various techniques:

 Core Prints: These are extensions of the core that integrate with the mold walls,

providing support and alignment.

 Core Pastes or Adhesives: These can be used to hold cores in place, especially for

smaller cores.

Benefits and Considerations:

Using cores offers several advantages:

 Complex Geometry: Enables the creation of intricate internal features that wouldn't be

possible with just the mold cavity.

 Weight Reduction: Hollow sections created by cores can significantly reduce the

weight of the cast component.

 Material Savings: Less metal is required compared to a solid casting, leading to cost

savings.

However, using cores also comes with considerations:

  Increased Complexity: Core production and placement add complexity to the casting

process.

 Core Removal: Cores need to be removed from the solidified casting, which can be

challenging and may require additional processing steps.

 Core Strength: Cores need to be strong enough to withstand the molten metal pressure

during pouring.

In conclusion, cores are a valuable tool in casting processes, enabling the creation of complex

internal features and offering benefits like weight reduction and material savings. However,

their use adds complexity and requires careful consideration of core strength, placement, and

removal methods

5. Distinguish between shot blasting and sand blasting?

Both shot blasting and sand blasting are abrasive cleaning techniques that utilize a stream of

pressurized air to propel a blasting media against a surface. However, they differ in the type

of media used, the propulsion method, and their applications.

Media:

 Shot Blasting: Employs round or spherical metallic abrasive media like steel shot,

chilled iron grit, or aluminum oxide. These provide a more controlled cleaning action

with less potential for surface damage.

 Sand Blasting: Traditionally used silica sand as the abrasive media. Sand is a cheaper

option but can be aggressive and leave a rougher surface finish. Due to health

concerns related to silica dust inhalation, alternative media like glass beads, crushed

coal slag, or organic materials are becoming more common in sand blasting.

Propulsion Method:
  Shot Blasting: Uses centrifugal force generated by a rotating wheel to propel the

abrasive media at high velocity towards the target surface. This method offers more

precise control over the blasting intensity.

 Sand Blasting: Relies on compressed air to forcefully push the abrasive media through

a nozzle. This method can be less precise and more prone to variations in blasting

intensity.

Applications:

 Shot Blasting: Preferred for cleaning and preparing metal surfaces for processes like

painting, coating, or welding. It's also used for peening, a process that strengthens the

surface of a metal by inducing compressive stress. Due to the controlled nature of the

process and the reusability of metallic shot, shot blasting can be a more cost-effective

solution in the long run for frequent use.

 Sand Blasting: Often used for cleaning various surfaces, including concrete, stone,

and brick, in addition to metals. It can be effective for removing rust, paint, graffiti,

and other contaminants. Sand blasting can also be used for texturizing surfaces or

creating decorative finishes. However, due to the potential for aggressive cleaning and

health risks associated with silica sand, alternative media and techniques are

increasingly preferred.

6. State the applications of cores.

As discussed earlier, cores play a vital role in casting processes by enabling the creation of

various internal features within the cast product. Here's a breakdown of their key

applications:

Forming Hollow Sections:

Cores are essential for creating hollow sections in castings. This is particularly beneficial for

components like:
  Pipes

 Engine blocks

 Pump housings

 Valves

 Bores and cylinders

By using cores, manufacturers can achieve these hollow features, leading to weight reduction,

improved material efficiency, and creation of functional internal passages within the casting.

Creating Holes and Recesses:

Cores are not limited to just simple hollow sections. They can also be used to form various

shapes and sizes of holes within the casting. This includes:

 Round holes

 Square or rectangular holes

 Elliptical or irregular shaped holes

 Undercuts (features with overhanging edges that cannot be formed by the mold cavity

alone)

Cores provide the flexibility to create these internal features, expanding the design

possibilities for cast components.

Internal Pockets and Cavities:

In some cases, castings may require internal pockets or cavities for specific functionalities.

Cores can be strategically placed to form these features precisely within the cast product.

Overall Benefits of Using Cores:

 Enables Complex Geometry: Cores allow for the creation of intricate internal features

that wouldn't be possible with just the mold cavity. This expands design possibilities

and functionality of cast components.

  Weight Reduction: Hollow sections formed by cores significantly reduce the weight

of the final casting. This is crucial for applications where weight is a critical factor,

such as in aerospace or automotive parts.

 Material Savings: By utilizing cores for hollow sections, less metal is required

compared to a solid casting. This translates to cost savings on material usage.

However, it's important to remember that using cores also introduces some complexities:

 Increased Complexity: Core production, placement, and removal add extra steps to

the casting process, requiring more planning and potentially increasing production

time.

 Core Strength: Cores need to be strong enough to withstand the molten metal pressure

during pouring without breaking or collapsing.

 Core Removal: After solidification, cores need to be removed from the casting, which

can be challenging and may require additional processing steps like mechanical

breaking or chemical leaching.

In conclusion, cores are a valuable tool in casting processes, enabling the creation of complex

internal features, weight reduction, and material savings. But, their use requires careful

consideration of the additional complexity, core strength, and removal methods involved

7. Name the various pattern types.

In casting processes, various pattern types are used to create the mold cavity that defines the

final shape of the cast product. Here's a breakdown of some common pattern types:

Single-Piece Pattern:

 The simplest type, a single-piece pattern represents the entire final cast shape in one

solid piece.

 Suitable for simple, non-complex geometries.

  Easy and inexpensive to manufacture.

Two-Piece Pattern (Split Pattern):

 Consists of two or more sections that fit together to form the complete mold cavity.

 Used for objects with features like undercuts (areas with overhangs that a single piece

can't create).

 Dowel pins or other alignment features ensure proper positioning of the split sections.

Multi-Piece Pattern:

 Similar to a two-piece pattern but with more than two sections for even more complex

geometries.

 Each section is designed to create a specific portion of the mold cavity.

 Requires careful assembly and alignment of all sections for accurate casting.

Match Plate Pattern:

 A two-piece split pattern mounted on a single board (match plate).

 Both halves of the pattern are permanently attached to the opposite sides of the match

plate, ensuring perfect alignment.

 Enables faster and more consistent mold making compared to a regular two-piece

pattern.

Cope and Drag Pattern:

 A specific type of split pattern used in sand casting.

 The "cope" section forms the top part of the mold, and the "drag" section forms the

bottom part.

 The mold cavity is created by placing the pattern halves in their respective cope and

drag flasks (containers for molding sand).

Sweep Pattern:

 Used for creating cylindrical or profiled shapes.

  A two-dimensional template (the sweep) is swept along a defined path to generate the

mold cavity.

 Often used for parts like pipes, columns, or wheels.

Skeleton Pattern:

 An internal framework representing the outer dimensions of the cast part.

 Used for large, simple shapes where the internal details are not critical.

 Less material is required compared to a solid pattern, reducing cost and weight.

Loose-Piece Pattern:

 A base pattern with separate inserts for creating specific features like holes or cavities.

 The loose pieces are inserted into the base pattern before mold creation and removed

afterwards.

 Offers flexibility for creating variable features within the cast product.

Shell Pattern:

 A thin shell made from resin-bonded sand that conforms to the shape of a master

pattern.

 Used for high-volume production runs and creating intricate shapes.

 Offers good surface finish and dimensional accuracy.

Follow Board Pattern:

 A contoured board that guides the molder in creating the mold cavity by hand in sand.

 Used for one-off or prototype castings where the cost of a more complex pattern is not

justifiable.

 Requires skilled molders for achieving accurate results.

Segmental Pattern:
  Similar to a multi-piece pattern but specifically used for symmetrical or repetitive

features.

 A single segment is used to create multiple identical features in the mold cavity.

 Reduces pattern complexity and cost for castings with repeating elements.

8. State any two casting defects.

Here are five common casting defects:

Shrinkage Cavity: As mentioned earlier, this defect occurs due to the contraction of metal

during solidification. The solidifying metal leaves behind voids or cavities within the cast

product, weakening it and affecting its performance. These cavities are more prominent in

thicker sections that solidify slower.

Gas Porosity: Trapped gases like air or mold cavity gases become entrapped within the

molten metal during pouring. These gases solidify as pockets or porosities within the cast,

reducing its strength, ductility, and pressure resistance. Improper venting, slow pouring rates,

and moisture in the mold can contribute to gas porosity.

Mold Material Defects: These defects arise from issues with the mold material itself.

Examples include:

 Cut and Washes: Erosion of the mold cavity due to molten metal washing away the

mold material. This can lead to uneven surfaces or protrusions on the casting.

 Scabs: Formation of loose or fused pieces of mold material on the casting surface

caused by weak bonding or improper ramming (compacting) of the mold material.

Pouring Metal Defects: Issues during the pouring process can also cause defects. Examples

include:

 Cold Shut: Occurs when two streams of molten metal fail to fuse completely, leaving

a visible weld line or incomplete weld on the casting surface. This can be caused by

low pouring temperature, improper gating design, or turbulence during pouring.

  Slag Inclusions: Non-metallic impurities like oxides or slag become trapped within

the cast product during pouring. These inclusions can weaken the casting and create

imperfections on the surface.

Hot Tears: These are cracks that develop in the cast product as it cools and solidifies. Hot

tears are caused by stresses induced due to uneven cooling rates within the casting. Thicker

sections cool slower and shrink at a different pace compared to thinner sections, leading to

these cracks.

9. Define Moulding

Moulding (Manufacturing Process): This refers to the process of shaping a liquid or pliable

material into a desired form using a rigid frame called a mold or matrix. The molten material

is poured or injected into the mold cavity, and it solidifies or cures, taking on the shape of the

mold. This is a widely used manufacturing technique for creating objects from various

materials, including:

 Metals (casting)

 Plastics (injection molding, blow molding)

 Glass

 Ceramics

 Rubber

Moulding (Decorative Trim): This refers to decorative strips made from various materials

like wood, plaster, or plastic that are used to add ornamentation or finishing touches to walls,

ceilings, furniture, or other architectural elements. These mouldings come in various profiles

and styles, offering aesthetic appeal and functional purposes like:

o Covering gaps between walls and ceilings

o Creating transitions between different materials

o Adding visual interest and detail to a space

10. Define Casting

Casting is a fundamental manufacturing process used to create objects by shaping molten

metal (or other materials) using a mold cavity. Here's a breakdown of the key aspects:

Process:

 Mold Creation: A mold is prepared using a pattern, which replicates the desired final

shape of the cast product. The mold cavity is the negative impression of the desired

shape within the mold. Different materials like sand, metal, or ceramic can be used for

mold creation, depending on the casting process and desired part characteristics.

 Molten Metal Preparation: The metal chosen for the casting is melted in a furnace to

reach a high-temperature liquid state.

 Pouring: The molten metal is poured into the mold cavity, filling it completely.

 Solidification: The poured metal cools and solidifies within the mold cavity, taking on

the shape of the cavity.

 Mold Removal: Once the metal solidifies, the mold is broken or dismantled to remove

the cast product.

 Finishing: The casting may undergo further processing like cleaning, heat treatment,

or machining to achieve the final desired dimensions and surface finish.

Advantages of Casting:

 Versatility: Casting can be used with a wide range of metals and alloys, allowing for

the creation of parts with diverse properties.

 Complex Shapes: The process can produce intricate and complex shapes that would

be difficult or expensive to create using other methods.

 High-Quality Products: Casting can produce parts with good dimensional accuracy,

surface finish, and mechanical properties.

  Mass Production: Casting is suitable for both small and large-scale production runs.

Disadvantages of Casting:

 Dimensional Limitations: Mold shrinkage and other factors can introduce slight

dimensional variations in castings.

 Surface Imperfections: Casting defects like porosity or surface roughness can occur.

 Material Waste: Depending on the casting process, there can be some leftover

material or scrap from the mold or gating system.

 Environmental Impact: Melting metals can require high energy consumption and may

have environmental concerns.

Applications of Casting:

Casting is a widely used process across various industries for creating a vast array of

products. Here are some examples:

 Automotive Parts: Engine blocks, cylinder heads, pistons, brake calipers, etc.

 Machine Tools: Gears, housings, frames, etc.

 Construction: Pipes, valves, fittings, ornamental elements, etc.

 Consumer Goods: Pots, pans, tools, furniture hardware, etc.

 Aerospace: Engine components, landing gear parts, etc.

Part B

1. Sketch and Explain Sand Casting Process. Also state the advantages and limitations of it.

Step 1. Pattern Preparation:

 The process begins with the creation of a pattern, which is a replica of the desired

final product. This pattern is typically made of wood, metal, or plastic.

Step 2. Flask Setup:

 A flask, which consists of two parts, the cope (upper) and drag (lower), is prepared.

The pattern is placed inside the drag, and the cope is placed over it.

Step 3. Sand Filling:

 Green sand (a mixture of sand, clay, water, and sometimes additives) is tightly packed

around the pattern within the flask. This creates a mold cavity, replicating the shape of

the pattern.

Step 4. Pattern Removal:

 Once the sand is packed, the pattern is carefully removed from the mold, leaving

behind a cavity that matches the shape of the desired part.

Step 5. Core Placement (if necessary):

 If the final product requires internal features, such as holes or hollow sections, sand

cores are placed within the mold to create these voids.

Step 6. Flask Assembly:

 After core placement (if needed), the cope is placed back onto the drag, forming a

complete flask assembly.

Step 7. Pouring Basin and Sprue Formation:

 Channels for pouring molten metal, called the pouring basin and sprue, are created in

the cope. These channels allow the molten metal to flow into the mold cavity.

Step 8. Venting and Gating System:

 Additional channels called vents and gates are created to allow gases to escape and to

control the flow of molten metal into the mold cavity.

Step 9. Pouring of Metal:

 Molten metal is poured into the pouring basin, allowing it to flow through the sprue

and gating system and fill the mold cavity.

Step 10. Cooling and Solidification:

 After pouring, the molten metal cools and solidifies inside the mold cavity, taking the

shape of the desired part.

Step 11. Shakeout:

 Once the metal has solidified, the flask is opened, and the sand mold is broken apart

to reveal the cast metal part. Any excess sand is removed through shaking or other

methods.

Step 12. Finishing:

 The final cast part may undergo additional finishing processes such as grinding,

machining, or surface treatment to achieve the desired specifications and surface

quality.

This line diagram illustrates the sequential steps involved in the sand molding process, from

pattern preparation to finishing of the cast part.

2. With the aid of a neat sketch explain permanent mold casting process. Discuss its various
industrial applications

Sketch:

Explanation:

Permanent mold casting is a metal casting process that utilizes a reusable mold made of metal

(usually cast iron or steel) to create castings. Here's a breakdown of the steps involved,

illustrated in the accompanying sketch:

 Mold Preparation:

o Mold Manufacturing: A permanent mold is created in two halves (cope and

drag) using machining or casting techniques. The mold cavity precisely

replicates the desired shape of the final casting.

o Preheating: The mold halves are preheated to a specific temperature (typically

between 150-300 °C) to improve metal flow and reduce thermal shock during

pouring.
 o Mold Coating: A ceramic coating may be applied to the mold cavity to

enhance metal flow, promote easier casting removal, and extend mold life.

 Core Setting (Optional): If the casting requires internal features, sand cores or metal

cores are placed within the mold cavity before closing.

 Mold Assembly: The cope and drag are securely clamped together to form a complete

mold cavity.

 Metal Melting: The chosen metal for the casting is melted in a furnace to a high-

temperature liquid state.

 Pouring: The molten metal is poured into the mold cavity through a sprue, filling it

completely. Due to the preheated mold, faster solidification at the mold interface can

occur.

 Solidification: The poured metal cools and solidifies within the mold cavity, taking

the shape of the cavity.

 Mold Opening: Once the metal solidifies, the mold is opened, and the casting is

removed.

 Gating System Removal: The solidified metal from the sprue and runners (gating

system) is cut or broken away from the casting.

 Finishing: The casting may undergo further processing like heat treatment, shot

blasting, or machining to achieve the final desired dimensions and surface finish.

Industrial Applications of Permanent Mold Casting

Permanent mold casting offers several advantages over sand casting, making it suitable for

various industrial applications. Here are some key areas where it's used:

 Automotive Industry: Engine blocks, cylinder heads, pistons, brake calipers, and other

engine components benefit from the good surface finish, dimensional accuracy, and

faster production rates achievable with permanent mold casting.

  Consumer Goods: Pots, pans, cookware, tools, and various hardware components can

be efficiently produced using permanent mold casting due to its suitability for

medium-volume production runs.

 Aerospace Industry: Engine components, landing gear parts, and other aerospace

components can be cast using permanent mold casting, especially when good

mechanical properties and dimensional accuracy are required.

 Electronics Industry: Heat sinks, enclosures, and other electronic components can be

cast with permanent molds, particularly for applications requiring good thermal

conductivity and precise dimensions.

 Medical Equipment: Certain medical equipment components, such as instrument

housings or prosthetic parts, can be produced using permanent mold casting due to its

ability to handle a variety of metals and create complex shapes.

Overall, permanent mold casting is a valuable process for producing medium-volume

castings with good surface finish, dimensional accuracy, and a wider range of material

options compared to sand casting. However, the initial cost of the permanent mold can be

higher compared to sand molds.

Part A(Welding)

1. How is an arc obtained in arc welding?

In arc welding, an electric arc is formed between two electrical conductors separated by a

small gap. Here's a breakdown of the key steps involved:

 Electrical Circuit: An electric arc welding machine acts as the power source,

supplying an electric current. This current can be direct current (DC) or alternating

current (AC) depending on the specific welding process.

 Electrode: One of the conductors is an electrode, which can be consumable or non-

consumable.
 o Consumable Electrode: In processes like Shielded Metal Arc Welding

(SMAW) or Flux-Cored Arc Welding (FCAW), the electrode is a

continuously fed solid wire that melts and contributes filler material to the

weld pool.

o Non-Consumable Electrode: In processes like Gas Tungsten Arc Welding

(GTAW) or Tungsten Inert Gas (TIG) welding, the electrode is usually a

tungsten rod that doesn't melt during welding but provides the path for the

current to flow.

 Workpiece: The other conductor is the workpiece, which is the metal you are welding.

 Initiating the Arc: The gap between the electrode and the workpiece creates initial

resistance to the current flow. When the welding machine is activated, a high voltage

is momentarily applied to ionize the gas in the gap (typically air) and create a

conductive path. This allows the current to start flowing.

 Sustaining the Arc: Once the initial ionization occurs, the intense heat generated by

the high current further ionizes the gas in the gap, maintaining a low-resistance path

for current flow. This creates a continuous, bright plasma arc between the electrode

and the workpiece.

 Shielding Gas (Optional): In some processes like GMAW or FCAW, an inert or active

shielding gas is used to protect the molten metal from contamination by atmospheric

gases like oxygen and nitrogen. This shielding gas is typically delivered through a

nozzle surrounding the electrode.

Additional Notes:

 The temperature within the arc can reach extremely high values, typically exceeding

5,000°C (9,032°F). This intense heat melts the base metal and the electrode (if

consumable) to form a molten weld pool.

  The specific properties of the electrode material, welding current, and shielding gas (if

used) influence the characteristics of the arc and the resulting weld.

Overall, the arc formation in arc welding is a combination of electrical current, ionization of

gas in the gap, and intense heat that creates a sustained path for current flow and allows for

melting the metals to be joined.

2. what is oxy-acetylene welding?

Oxy-acetylene welding, also commonly referred to as oxy-fuel welding (OFW) or gas

welding, is a joining process that utilizes a high-temperature flame to melt the edges of

workpieces for fusion. Here's a breakdown of the key aspects of oxy-acetylene welding:

Equipment:

 Gas Cylinders: Separate high-pressure cylinders store oxygen and acetylene gas.

 Regulators: Regulators attached to each cylinder control and reduce the pressure of

the gas delivered to the torch.

 Welding Torch: A hand-held welding torch mixes the oxygen and acetylene gas in a

controlled ratio before they exit through a nozzle, creating the flame.

 Fillers: For some applications, additional filler metal may be fed into the weld pool to

create a stronger joint.

Process:

 Preparation: The surfaces to be welded are cleaned to remove dirt, grease, or rust that

can hinder a good weld.

 Gas Flow Adjustment: The welder adjusts the oxygen and acetylene flow rates at the

regulators to achieve the desired flame characteristics.

 Ignition: The exiting gas mixture is ignited with a spark lighter.

 Heating and Melting: The welder directs the flame towards the joint, heating the base

metal until it melts.

  Filler Metal (Optional): If using a filler rod, the welder dips it into the molten pool to

add material and bridge the gap between the workpieces.

 Weld Pool Manipulation: The welder controls the torch angle and movement to create

a proper weld bead size and penetration.

 Cooling and Solidification: Once the desired weld length is achieved, the welder

removes the heat source, allowing the molten metal to cool and solidify, forming a

strong joint.

Flame Types:

 Neutral Flame: An ideal flame for most welding applications, with an equal balance

of oxygen and acetylene, resulting in a clean and slightly carburizing flame cone.

 Oxidizing Flame: Achieved with an excess of oxygen, this flame is hotter but can

cause excessive metal oxidation, leading to weak welds.

 Carburizing Flame: Contains excess acetylene, resulting in a cooler and softer flame

that may be suitable for specific applications but can lead to brittle welds in some

metals.

Advantages of Oxy-Acetylene Welding:

 Versatility: Can weld various metals, including mild steel, stainless steel, cast iron,

copper, and brass.

 Portability: The equipment is relatively portable, allowing for welding in various

locations.

 Simple Equipment: The basic setup is less complex compared to some arc welding

machines.

 Brazing: The same oxy-fuel torch setup can be used for brazing applications, which is

a joining process for dissimilar metals or thin sheet metal.

 Disadvantages of Oxy-Acetylene Welding:

  Heat Control: Precise heat control can be challenging compared to arc welding

methods.

 Slower Welding Speeds: Generally slower than arc welding processes.

 Safety Concerns: Both oxygen and acetylene are flammable gases, requiring proper

handling and safety precautions.

Applications of Oxy-Acetylene Welding:

 Repair and Maintenance: Commonly used for repair work on pipes, boilers, and other

metal structures.

 Fabrication: Can be used for various fabrication projects involving different metals.

 Cutting: With appropriate tips, the oxy-fuel torch can also be used for cutting metals.

 In conclusion, oxy-acetylene welding is a traditional and versatile metal joining

process offering portability and the ability to weld various metals. However, for some

applications, arc welding methods might be preferred due to their faster welding

speeds and potentially better heat control.

3. Define welding.

Welding is a fabrication process that joins materials, typically metals or thermoplastics, by

using high heat to melt the parts together and allowing them to cool, causing fusion. This

creates a strong bond at the joining interface. Here are some key points about welding:

 Heat Source: Welding relies on a concentrated heat source to melt the materials being

joined. This heat source can come from various sources, such as an electric arc (arc

welding), a gas flame (oxy-fuel welding), or friction (friction welding).

 Fusion: The intense heat melts the base metals (the parts being joined) along the joint.

In some cases, a filler metal may also be added to create a molten pool that fills the

gap and solidifies to form the weld.

  Joint Strength: Upon cooling, the molten metal solidifies, creating a strong

metallurgical bond between the joined parts. The strength of the weld can be as strong

as, or even stronger than, the base metal itself.

 Applications: Welding is a widely used process in various industries for applications

like construction, shipbuilding, automotive manufacturing, and pipeline fabrication.

Here are some additional points to consider:

 There are different types of welding processes, each with its own advantages and

limitations. The choice of welding method depends on factors like the type of

material, thickness of the parts being joined, desired joint strength, and portability

requirements.

 Welding requires proper training and safety precautions. Welders need to wear

personal protective equipment to shield themselves from heat, sparks, and fumes

generated during the welding process.

Overall, welding is a fundamental metal joining technique that plays a crucial role in various

fabrication and construction applications.

4. State the application of thermit welding.

Thermit welding finds applications in various industries due to its unique capabilities. Here

are some of the key applications of Thermit welding:

 Joining Thick Sections: Thermit welding excels at joining very thick and heavy metal

sections where other welding methods might struggle. This includes applications like:

o Railway Tracks: Thermit welding is a traditional and trusted method for

joining railroad rails. It creates strong and reliable joints that can withstand

heavy loads from locomotives and freight trains.

 o Ship Hulls: Thermit welding is used for welding thick steel plates used in ship

hulls. The aluminium oxide slag produced during the reaction acts as a

protective layer against corrosion, which is beneficial for seafaring vessels.

o Pipes and Boilers: Large diameter pipes and thick-walled boilers can be joined

using Thermit welding.

 Repair Applications: Thermit welding is valuable for repair work on heavy castings

and machinery components. Here are some examples:

o Cracked Engine Blocks: Cracked engine blocks in large engines or generators

can be repaired using Thermit welding.

o Broken Gears: Fractured or broken gear teeth can be rebuilt and repaired using

Thermit welding techniques.

 Other Applications: Beyond thick sections and repairs, thermit welding finds uses in:

o Welding Cables: Thermit welding can be used to join large copper cables for

electrical applications.

o Construction and Mining: Thermit welding can be used for joining crane rails,

structural steel components, and other heavy metal elements used in

construction and mining industries.

Here are some additional points to consider about thermit welding applications:

 Remote Locations: Since thermit welding utilizes a relatively simple setup and doesn't

require external power sources, it can be suitable for welding in remote locations

where electricity might be unavailable.

 Cost-Effectiveness: For thick sections, thermit welding can be a cost-effective

alternative to other joining methods due to its simple equipment requirements.

  Limitations: Thermit welding can be a slow process compared to other techniques,

and the exothermic reaction generates significant heat, requiring proper precautions.

Additionally, it's generally less suitable for joining thin materials.

Overall, Thermit welding remains a valuable technique for joining thick metal sections,

repairs, and specific applications where its portability and cost-effectiveness outweigh its

limitations.

5.Define “under water welding”

Under water welding is a specialized welding process used to join metals while submerged

underwater. Here's a breakdown of its key aspects:

Environment:

 Underwater welding takes place in aquatic environments, such as oceans, lakes, rivers, or

even pools. The welder may be situated in a pressurized chamber filled with air (dry

welding), or operate directly in the water (wet welding).

Challenges:

 Water Barrier: The presence of water creates a significant barrier compared to

traditional welding in air. Water conducts heat away from the weld zone rapidly,

requiring more heat input to achieve proper melting and fusion.

 Limited Visibility: Underwater environments can have limited visibility due to factors

like turbidity or depth. Welders rely on special helmets or cameras to see the weld

pool clearly.

 Electrocution Risk: The combination of electricity and water poses an increased risk

of electrical shock. Special precautions and equipment are necessary to ensure welder

safety.

Techniques:
  Wet Welding: The most common method, utilizing waterproof electrodes and a direct

electrical current in the water. Limited to shallow depths and often used for low-

carbon equivalent steels.

 Dry Welding: Performed inside a specially designed chamber filled with an inert gas

mixture, creating a dry environment around the weld zone. Offers superior weld

quality and can be used for greater depths but is more complex and expensive to set

up.

Applications:

 Ship Building and Repair: Underwater welding is crucial for construction,

maintenance, and repair of ships, submarines, and offshore oil rigs.

 Pipeline Construction and Repair: Used for joining and repairing pipelines laid

underwater for transporting oil, gas, or other materials.

 Salvage Operations: Underwater welding plays a role in salvaging shipwrecks or

repairing underwater structures damaged by accidents.

Safety:

 Underwater welding requires specialized training and certification for welders due to

the unique challenges and increased risks involved.

 Strict safety protocols and equipment are essential to ensure welder safety from

electrical hazards, pressure changes, and potential hazards like marine life.

In conclusion, underwater welding is a demanding but essential skill for various underwater

construction, repair, and salvage operations. It requires specialized techniques, equipment,

and safety protocols to overcome the challenges of the underwater environment and create

strong, reliable welds.

6. List out any four methods used in weld cleaning.

Here are four methods commonly used in weld cleaning:

  Wire Brushing: This is a simple and versatile method for removing spatter, slag, and

light oxidation from the weld area. Stainless steel or carbon steel wire brushes can be

used depending on the application and desired cleaning intensity. Wire brushing is

effective for initial cleaning but may not be sufficient for removing heavier slag or

discoloration.

 Grinding: Angle grinders with various grinding wheels offer a more aggressive

cleaning method compared to wire brushing. Grinding wheels come in different

abrasiveness levels, allowing selection based on the material and amount of material

removal required. Grinding is effective for removing heavy slag, weld beads, and

oxides but needs to be controlled to avoid excessive base metal removal.

 Chemical Cleaning: Chemical cleaning solutions can be applied to the weld zone to

dissolve or loosen slag, oxides, and contaminants. This method is particularly useful

for removing stubborn oxides or heat tint that might be difficult to remove by

mechanical methods. It's important to choose the appropriate chemical solution for the

specific base metal and to follow safety precautions for handling chemicals.

 Sandblasting: This method utilizes a pressurized stream of abrasive material like sand

or glass beads to clean the weld area. Sandblasting is effective for removing heavy

scale, rust, and stubborn contaminants but can be quite aggressive. Care needs to be

taken to avoid damaging the base metal or surrounding areas. Sandblasting is often

used for industrial applications where a high degree of cleaning is required.

 These are just a few of the common methods used in weld cleaning. The choice of

method depends on factors like the type of weld, the amount of cleaning required, the

desired surface finish, and safety considerations

7. What are various weld positions?

There are various positions used in welding, each requiring specific techniques and welder

skill to achieve a good quality weld. Here's a breakdown of some common weld positions:

a. Flat Position (1G/1F): This is the simplest and most comfortable position for the

welder. The work piece is placed flat and horizontal, allowing the welder to deposit

the weld metal with gravity assisting in filling the weld pool. This position is ideal for

beginners and for creating high-quality welds. It's denoted as 1G for Groove welds

and 1F for Fillet welds according to American Welding Society (AWS) standards.

b. Horizontal Position (2G/2F): The work piece is positioned horizontally, but the weld

joint itself is in a horizontal plane. This position requires more skill than the flat

position because the welder needs to control the molten metal to prevent it from

dripping. Techniques like stringer beads or weaving can be used to maintain proper

weld pool size and penetration. It's denoted as 2G for Groove welds and 2F for Fillet

welds according to AWS standards.

c. Vertical Position (3G/3F): The work piece is vertical, and the weld joint is also

vertical. This position is more challenging than the previous two as the molten metal

tends to run downwards due to gravity. Welders need to use a whipping technique or

special electrodes to control the weld pool and achieve proper penetration. It's denoted

as 3G for Groove welds and 3F for Fillet welds according to AWS standards.

d. Overhead Position (4G/4F): The work piece is positioned overhead, and the weld joint

is also overhead. This is the most difficult position for welding because the molten

metal falls due to gravity. Welders need exceptional skill and specialized techniques

like stitch welding or backhand welding to create a good quality weld. It's denoted as

4G for Groove welds and 4F for Fillet welds according to AWS standards.

e. Inclined Position: This is a general term for any position where the weld axis is at an

angle between horizontal and vertical. Inclined positions can be further categorized
 based on the angle of inclination, such as 45 degrees or 60 degrees. Welding in

inclined positions requires techniques similar to horizontal or vertical welds

depending on the inclination angle.

Additional Notes:

 The choice of welding position depends on the accessibility of the weld joint and the

overall geometry of the work piece. Some joints may be easier to weld in a flat

position by rotating the work piece, while others may necessitate welding in a vertical

or overhead position.

 Welders typically practice and qualify themselves for welding in different positions to

demonstrate their skill and ability to create strong and reliable welds in various

welding scenarios.

By understanding these different weld positions and the techniques involved, welders can

approach various welding tasks with the appropriate skills and ensure the quality and

integrity of their welds.

8. What are the typical applications of soldering?

Soldering finds applications in various industries due to its versatility and ability to create

strong electrical and mechanical connections. Here are some typical applications of soldering:

Electronics:

 Printed Circuit Boards (PCBs): Soldering is the primary method for attaching

electronic components like resistors, capacitors, and integrated circuits (ICs) to PCBs.
 It creates a reliable electrical connection and ensures proper signal transmission

between components.

 Wire Connections: Soldering is used to join electrical wires for various applications.

This can involve connecting wires to terminals on circuit boards, power supplies, or

other electrical components.

Plumbing:

 Sweat Soldering: This technique uses a solder with a lower melting point than

traditional soldering alloys. It's commonly used to join copper pipes by heating the

fitting and inserting the pipe to create a watertight seal.

Metalwork and Jewelry:

 Joining Sheet Metal: Soldering can be used to join thin sheets of metal for various

applications like creating decorative items, enclosures, or small parts.

 Jewelry Making: Soldering is a fundamental technique in jewelry making for joining

different metal components, attaching findings like jump rings or clasps, and repairing

broken pieces.

Other Applications:

 Heat Sinks: Soldering is used to attach heat sinks to electronic components to improve

heat dissipation and prevent overheating.

 Food Canning: While not soldering in the traditional sense, some can seams in food

cans are sealed using a soldering technique to create an airtight container.

Here are some additional factors that contribute to the widespread use of soldering:

 Relatively Low Melting Point: Solders typically have lower melting points compared

to welding materials, making them suitable for applications where using high heat

might damage components.

  Good Electrical Conductivity: Many solder alloys offer good electrical conductivity,

ensuring efficient current flow in electrical connections.

 Strength and Durability: Soldered joints can provide strong and durable connections

that can withstand mechanical stress and vibrations.

 Relatively Simple Process: Soldering is a relatively simple process compared to some

welding techniques, making it suitable for various applications and skill levels.

Overall, soldering remains a widely used technique across various industries due to its

versatility, affordability, and effectiveness in creating strong electrical and mechanical

connections.

9. What are welding Defects?

Welding defects are imperfections or irregularities that occur in a weld joint and can

compromise its strength, functionality, or appearance. These defects can arise from various

factors during the welding process. Here's a breakdown of key points about welding defects:

Types of Defects:

Welding defects can be classified in different ways, but some common categories include:

 Incomplete Fusion: Occurs when the base metal doesn't fully melt and fuse together,

creating a weak spot in the weld.

 Porosity: Small gas pockets trapped within the weld metal, reducing its strength and

creating potential corrosion points.

 Cracks: Fractures in the weld metal or heat-affected zone (HAZ) due to stresses or

shrinkage during cooling.

 Undercut: A groove melted into the base metal adjacent to the weld bead, reducing

the effective weld throat thickness.

 Overcut: Excessive melting of the base metal beyond the intended weld zone,

potentially weakening the surrounding material.

  Spatter: Small droplets of molten metal that scatter around the weld zone, causing

aesthetic issues and potential rework.

 Warping: Distortion of the work piece due to uneven heating and cooling during the

welding process.

Causes of Defects:

Several factors can contribute to welding defects, such as:

 Incorrect Welding Parameters: Improper settings for current, voltage, travel speed, or

wire feed rate can lead to incomplete fusion, porosity, or excessive spatter.

 Poor Joint Preparation: Dirty, rusty, or improperly prepared surfaces can hinder weld

metal adhesion and cause defects like lack of fusion or cracks.

 Incorrect Electrode Selection: Choosing the wrong electrode type or size for the

material and application can lead to various defects.

 Welding Technique: Improper torch angle, manipulation, or travel technique can

affect weld penetration, cause undercut or overheating, and lead to defects.

 Environmental Factors: Wind, rain, or excessive humidity can affect shielding gas

coverage and potentially cause porosity or weld contamination.

Effects of Defects:

The severity of a welding defect depends on its type, size, location, and the application. Some

minor defects might be acceptable in non-critical applications, while others can significantly

weaken the weld and compromise the structural integrity of the joint. Defects can also lead to

leaks in pressure vessels, premature failure under stress, or aesthetic imperfections in

cosmetic welds.

Prevention and Inspection:

 Following proper welding procedures as recommended by welding codes and

standards helps to minimize the risk of defects.

  Welders need to be qualified for the specific material, joint configuration, and

welding process being used.

 Visual inspection is a common method to identify surface defects like cracks,

undercut, or spatter.

 Non-destructive testing (NDT) techniques such as X-ray radiography or ultrasonic

testing can be used to detect internal defects like porosity or cracks.

By understanding the different types of welding defects, their causes, and methods for

prevention and inspection, welders can create high-quality welds that are strong, functional,

and meet the required standards for the application.

10.What are the testing methods for welding?

There are two main categories of testing methods for welds: destructive and non-destructive

testing (NDT). Each category has its own advantages and applications.

Destructive Testing:

 Involves physically breaking or damaging the weld to assess its properties.

 Provides detailed information about the weld's internal structure and mechanical

strength.

 Not ideal for finished products or critical welds where destroying the joint is

unacceptable.

Here are some common Destructive Testing methods for welds:

 Tensile Test: A weld sample is pulled until it breaks, measuring its tensile strength

(force required to break it) and elongation (amount of stretching before breaking).

 Bend Test: A weld sample is bent to a specific angle or until it fractures, evaluating its

ductility (ability to deform without breaking).

  Impact Test: A weld sample is struck with a weighted pendulum to measure its

toughness (resistance to fracture under sudden impact).

 Macroetch Test: A polished weld cross-section is etched with acid to reveal the weld

grain structure, penetration depth, and potential defects like cracks or porosity.

Non-Destructive Testing (NDT):

 Evaluates the weld quality without damaging the joint itself.

 Essential for inspecting finished products and critical welds to ensure their integrity.

 Different NDT methods are sensitive to different types of defects.

Here are some common Non-Destructive Testing (NDT) methods for welds:

 Visual Inspection (VT): The most basic method, using the naked eye or with

magnifying tools to examine the weld surface for cracks, undercuts, spatter, or other

visible defects.

 Radiographic Testing (RT): X-rays are passed through the weld, and an image is

captured on film or a digital detector. This can reveal internal defects like porosity,

cracks, or incomplete fusion.

 Ultrasonic Testing (UT): High-frequency sound waves are introduced into the weld,

and their reflections are analyzed to detect internal defects based on variations in the

sound wave propagation.

 Liquid Penetrant Testing (PT): A colored liquid is applied to the weld surface, then

removed. Penetrant seeps into surface-breaking cracks and becomes visible under

ultraviolet light, revealing their location.

 Magnetic Particle Testing (MT): A strong magnetic field is applied to the weld area.

Fine magnetic particles are sprinkled on the surface, and they are attracted to areas of

discontinuity or cracks in the weld.

Choosing the Right Testing Method:

 The selection of the most appropriate testing method depends on several factors, including:

 Material type: Different NDT methods may be more effective for certain materials.

 Weld type and application: The criticality of the weld and the type of defects being

inspected will influence the choice of test.

 Cost and complexity: Some NDT methods are more expensive or require specialized

equipment and expertise compared to others.

By employing a combination of destructive and non-destructive testing methods, welders and

inspectors can ensure that welds meet the required quality standards and provide the

necessary strength, functionality, and reliability for their intended application.

Part B (Welding)

1. Electric Arc Welding: Joining Metals with Intense Heat

Electric Arc Welding (EAW) is a versatile and widely used metal joining process that utilizes

the intense heat generated by an electric arc to melt and fuse together separate pieces of

metal. Here's a detailed breakdown of the process, accompanied by sketches for better

understanding:

Components:

1. Power Supply: Provides electric current to the welding circuit. It can be either Direct Current

(DC) or Alternating Current (AC) depending on the specific process and material being

welded.

2. Electrode: A conductive rod that can be consumable (melts and becomes part of the weld) or

non-consumable (conducts current but doesn't melt).

3. Work piece: The metal pieces being joined together.

4. Ground Clamp: Connects the power supply's return path to the workpiece.

5. Shielding Gas (Optional): Protects the molten metal from contamination by the atmosphere.

Can be delivered from a gas cylinder or generated by the flux coating on the electrode.

Sketch 1: Basic Arc Welding Setup

Electric Arc Welding Setup Diagram

Process:

 Preparation: The joint area on the workpiece needs to be clean and free of any

contaminants like rust, paint, or oil. Beveling the edges (cutting them at an angle) can

be done for thicker plates to improve weld penetration.

 Initiating the Arc: The welder touches the tip of the electrode to the workpiece

momentarily and then lifts it slightly to create a gap. This gap allows the current to

flow, ionizing the air and creating a highly concentrated electric arc.

 Melting Metal: The intense heat from the arc (reaching temperatures around 3500°C

to 4000°C) melts the base metal at the joint and the tip of the consumable electrode (if

used).
 Weld Pool: A molten pool of metal forms at the point of contact. This molten pool

consists of melted base metal and, in the case of consumable electrodes, melted

electrode material.

 Shielding (Optional): In processes that use a consumable electrode with a flux

coating, the flux decomposes during welding, releasing a shielding gas that protects

the molten metal from contamination by oxygen and nitrogen in the atmosphere. This

improves weld quality and prevents defects. For non-consumable electrodes, a

separate shielding gas may be used.

 Weld Bead Formation: As the welder moves the torch along the joint, the molten

metal in the pool solidifies behind the arc, forming a weld bead that joins the two

pieces of metal.

 Slag Removal (For Consumable Electrodes): The flux coating on the electrode also

produces a glassy material called slag, which floats on top of the weld pool. After

completing a weld run, the welder needs to chip away the slag with a chipping

hammer to expose the underlying clean metal.

 Multiple Passes (For Thick Plates): For thicker plates like 10mm or more, achieving

full weld penetration might require multiple weld passes. Each pass deposits weld

metal on the previous one, building up the weld thickness.

Sketch 2: Electric Arc Welding Process

Electric Arc Welding Process Diagram Electrode melting, weld pool formation,

solidification, slag layer

Advantages of Electric Arc Welding:

 Versatile: Can join a wide variety of metals, including steel, stainless steel, aluminum,

and more.

 Strong Welds: Produces strong and durable welds when done correctly.

 Portable: Many EAW machines are portable, making them suitable for field welding

applications.

 Cost-Effective: A relatively cost-effective welding process compared to some other

methods.

Disadvantages of Electric Arc Welding:

 Skill Required: Requires practice and skill to produce high-quality welds.

 Smoke and Fumes: Generates smoke and fumes during welding, requiring proper

ventilation.
  Safety Concerns: Electric shock, arc rays, and molten metal spatters pose safety

hazards. Welders need to wear proper Personal Protective Equipment (PPE).

Types of Electric Arc Welding:

There are several variations of EAW, each with its own advantages and applications. Some

common types include:

 Shielded Metal Arc Welding (SMAW): The process described above, using a

consumable electrode with a flux coating.

 Gas Tungsten Arc Welding (GTAW): Uses a non-consumable tungsten electrode and

a separate shielding gas.

 Flux-Cored Arc Welding (FCAW): Similar to SMAW but uses a continuously fed

electrode with internal flux.

 Submerged Arc Welding (SAW): Automated process for high-quality

2. Two 100x50x10 mm Mild steel plates to be welded .Suggest a suitable welding

method.Skecth and explain the same.

Shielded Metal Arc Welding (SMAW), also commonly called Stick Welding, is a highly

suitable method for joining your two 100x50x10 mm mild steel plates. Here's why SMAW is

a good choice:

 Versatility: SMAW is a versatile process that can weld a wide variety of metals,

including mild steel.

 Simplicity: The equipment is relatively inexpensive and user-friendly, making it

suitable for various applications.

 Portability: The welding machine and consumables (electrodes) are portable, allowing

for welding in different locations.

  Good Penetration: SMAW offers good weld penetration, which is important for

creating strong welds in mild steel plates.

SMAW Welding Process:

1. Preparation:

 Cleaning: Clean the surfaces of the plates where the weld will be made to

remove any dirt, grease, or rust. This ensures good electrical contact and a

clean weld.

 Positioning: Securely clamp or tack weld the plates together in the desired

position to maintain proper alignment during welding.

 Electrode Selection: Choose an electrode suitable for mild steel welding, such

as E6013 for general-purpose applications. Consider factors like electrode

diameter and weld thickness when selecting the electrode.

2. Welding:

 Connect the Machine: Connect the welding machine according to the

manufacturer's instructions. Typically, the electrode holder connects to the

 positive (DC) terminal, and the ground clamp connects to the workpiece (the

metal plates).

 Adjust Settings: Set the welding current according to the electrode diameter

and plate thickness. Refer to the electrode manufacturer's recommendations

for appropriate current settings.

 Strike the Arc: Gently tap the electrode tip on the workpiece to establish an

electric arc. Maintain a slight gap between the electrode tip and the workpiece

as you weld.

 Travel Angle: Maintain a proper travel angle (typically 10-15 degrees)

between the electrode and the joint as you move along the weld seam.

 Welding Technique: Use a weaving or zig-zag motion with the electrode to

ensure proper weld penetration and bead width.

 Electrode Consumption: As you weld, the electrode tip will melt and be

consumed. Adjust the electrode holder as needed to maintain a proper

electrode stickout length.

3. Weld Completion and Finishing:

 Crater Fill: Once you reach the end of the weld, momentarily hold the arc at

the stopping point to fill the crater and prevent cracking.

 Chip Slag: After completing the weld, allow it to cool slightly. Then, use a

chipping hammer and chipping gun to remove the slag (molten flux coating

from the electrode) covering the weld bead.

 Inspection: Visually inspect the weld for any cracks, porosity, or other defects.

Grinding may be required to smooth the weld bead if necessary.

Advantages of SMAW for this application:

 Cost-Effective: Relatively inexpensive equipment and consumables.

  Good Weld Strength: Can create strong and reliable welds in mild steel.

 Works in Various Positions: Welding can be done in flat, horizontal, vertical, or

overhead positions.

Disadvantages of SMAW:

 Spatter: The process can generate some spatter (molten metal droplets) during

welding.

 Slower Compared to Other Methods: May be slower than some other welding

methods like GMAW (Gas Metal Arc Welding).

 Requires Skill: Learning proper technique takes practice to produce good quality

welds.

Overall, SMAW is a well-suited and practical choice for welding your two mild steel plates.

It offers a good balance of cost, weld quality, and versatility for this application.

Submerged Arc Welding:

Absolutely, submerged arc welding (SAW) is another viable option for welding your two

100x50x10 mm mild steel plates. Here's a breakdown of SAW and why it can be a good

choice for your application:

 Process Explanation:

SAW is an automatic or semi-automatic arc welding process that utilizes a continuously fed

consumable solid electrode and a blanket of granular, fusible flux. Here's a closer look:

1. Continuous Electrode: A solid electrode wire is continuously fed through the welding head

towards the joint.

2. Flux Layer: Submerged arc welding, as the name suggests, involves submerging the arc and

the weld zone beneath a layer of powdered flux. This flux performs several functions:

 Shields the arc: The flux creates a protective gas shield around the arc and

molten metal, preventing contamination from atmospheric gases like oxygen

and nitrogen.

 Provides additional metal: Some fluxes contain alloying elements that are

deposited into the weld pool, enhancing certain properties.

  Slags formation: The flux melts and forms a molten slag layer on top of the

weld pool. This slag protects the weld from oxidation during solidification and

helps improve bead shape.

3. Automatic/Semi-Automatic Operation: SAW is typically an automatic or semi-automatic

process. In automatic SAW, the welding head travels along the weld seam, feeding the

electrode and maintaining the flux layer. In semi-automatic SAW, the operator may manually

manipulate the welding head.

4. High Welding Speeds: SAW offers high welding speeds due to the continuous electrode feed

and automatic operation.

Advantages of SAW for Mild Steel Plates:

 High Welding Speeds: Faster welding compared to SMAW, leading to increased

productivity.

 Deep Penetration: Excellent weld penetration, which can be beneficial for thicker

plates.

 Good Weld Quality: Can produce high-quality, clean welds with minimal spatter.

 Reduced Operator Exposure: The submerged arc protects the operator from the arc

and fumes.

Disadvantages of SAW for this application:

 Higher Initial Cost: SAW equipment typically has a higher initial investment

compared to SMAW.

 Less Portability: SAW machines tend to be larger and less portable than SMAW

machines.

 Limited Visibility: The operator has limited visibility of the weld pool due to the flux

layer.
  Less Suitable for Thin Plates: SAW may not be ideal for very thin plates due to its

deep penetration characteristics.

Choosing Between SAW and SMAW:

For welding your two 100x50x10 mm mild steel plates, both SAW and SMAW can be

suitable options.

3. Two 100x50x5 mm Mild steel plates to be welded .Suggest a suitable welding

method.Skecth and explain the same.

Given the smaller size (5 mm thickness) of your mild steel plates, Gas Metal Arc Welding

(GMAW), also commonly called MIG (Metal Inert Gas) welding, is a highly suitable method.

Here's why GMAW is a good choice:

 Precise Control: GMAW offers precise control over the heat input due to the

continuous wire feed and controllable current settings. This is crucial for welding thin

plates to minimize the risk of burn-through.

 Good Weld Quality: Can produce clean and strong welds with minimal spatter.

 Versatility: GMAW can weld various metals, including mild steel, with proper

shielding gas selection.

 Faster Welding Speeds: Offers faster welding speeds compared to SMAW, especially

for thinner materials.

 GMAW Welding Process:

1. Preparation:

 Cleaning: Clean the surfaces of the plates where the weld will be made to

remove any dirt, grease, or rust. This ensures good electrical contact and a

clean weld.

 Positioning: Securely clamp or tack weld the plates together in the desired

position to maintain proper alignment during welding.

 Shielding Gas Selection: Choose an appropriate shielding gas for mild steel,

such as a mixture of argon and carbon dioxide (e.g., 70% Ar / 30% CO2). The

gas selection can influence factors like weld penetration and bead profile.

2. Welding:

 Connect the Machine: Connect the welding machine according to the

manufacturer's instructions. Typically, the welding torch connects to the

positive (DC) terminal, and the ground clamp connects to the workpiece (the

metal plates).

 Adjust Settings: Set the welding current, wire feed speed, and voltage

according to the material thickness and desired weld characteristics. Refer to

the equipment manual and manufacturer recommendations for appropriate

settings.

 Trigger Control: Pull the trigger on the welding torch to initiate wire feeding

and establish the arc.

 Travel Angle: Maintain a proper travel angle (typically 10-15 degrees)

between the torch and the joint as you move along the weld seam.

 Torch Manipulation: Use a steady and consistent torch manipulation technique

to achieve proper weld width and penetration.

3. Weld Completion and Finishing:

 Crater Fill: Once you reach the end of the weld, momentarily hold the arc at

the stopping point to fill the crater and prevent cracking.

 Wire Trimming: After completing the weld, allow it to cool slightly. Then,

trim the excess solid wire electrode protruding from the torch.

 Inspection: Visually inspect the weld for any cracks, porosity, or other defects.

Grinding may be required to smooth the weld bead if necessary.

Advantages of GMAW for Thin Mild Steel Plates:

 Precise Heat Control: Minimizes the risk of burn-through in thin plates.

 Good Weld Quality: Clean welds with minimal spatter.

 Fast Welding Speeds: Improves productivity.

 Versatility: Welds various metals with proper gas selection.

Disadvantages of GMAW:

 Wind Sensitivity: Wind can affect the shielding gas coverage, potentially leading to

weld porosity. Requires proper shielding from wind outdoors.

 Cost of Consumables: Solid wire electrode and shielding gas are consumable items

that add to the operating cost.

 Requires Practice: Learning proper technique takes practice to produce good quality

welds.

Overall, GMAW is a well-suited choice for welding your two thin mild steel plates. It offers a

good balance of precision, weld quality, speed, and versatility for this application.

4. Two 100x50x1 mm Mild steel plates to be welded .Suggest a suitable welding

method.Skecth and explain the same.

Gas welding, also known as oxy-fuel welding (OFW), might be possible for welding your

two 100x50x2 mm mild steel plates under certain conditions, but it's not generally the most

recommended method. Here's why:

Limitations of Gas Welding for Thin Plates:

 Heat Control: OFW relies on a flame for heating, which can be challenging to control

precisely. For thin plates like 2 mm, achieving the right heat input to create a good

weld without burning through the material can be difficult.

 Slow Welding Speed: Gas welding is generally slower than other methods like

GMAW. This can be a disadvantage, especially for repetitive welds on multiple

plates.
  Limited Penetration: While skilled welders can achieve some penetration with OFW,

it may not be as deep compared to processes like SMAW or GMAW. For some

applications, deeper penetration might be desired for a stronger joint.

 Possible Scenario for Gas Welding Thin Plates:

 Experienced Welder: An experienced welder skilled in gas welding techniques might

be able to achieve good results with proper torch manipulation and heat control.

 Non-Critical Application: If the application is non-critical and high weld strength is

not a major concern, then gas welding could be an option.

Advantages of Gas Welding:

 Simple Equipment: OFW equipment is relatively simple and often less expensive

compared to other welding machines.

 Versatility: Gas welding can weld various metals, including mild steel, copper, and

brass.

 Brazing: The same oxy-fuel torch setup can be used for brazing applications, which is

a joining process for dissimilar metals or thin sheet metal.