TUGAS

(Home Work) 2
Welding processes
1.1 Welding processes
[Q1]
Comparing to riveting, welding has various advantages and disadvantages. Pick out
three (3) advantages and three (3) disadvantages of welding respectively.

Advantages:
Welding provide maximum efficiency
Welding process takes less time than riveting
Welding has more strength than riveting
Disadvantages:
Requires a good welding skill
The inspection of welding is more difficult than riveting

[Q2]
Welding processes are able to be classified into the category of (a) fusion welding,
(b) pressure welding or (c) soldering. What the following welding processes should
be classified into the category of (a), (b) or (c). Put a category mark (a), (b) or (c) for
each welding process.
. (1) Friction welding ( b )
. (2) Electron beam welding ( a )
. (3) Electro slag welding ( a )
. (4) Thermit (Almino-thermic) welding ( a )
. (5) CO2 gas shielded metal arc welding ( a )
. (6) Soft soldering ( c )
. (7) Submerged arc welding ( a )
. (8) Resistance spot welding ( b )
. (9) TIG welding ( a )
. (10) Ultrasonic welding ( b )

[Q3]
Welding processes may be classified according to the type of energy source used
directly for welding. Choose the welding processes from Group B that belong to the
energy sources in Group A, and put the corresponding marks in the parentheses.
[Group A]
(1) Electric energy

( d, b, a, e )

(2) Mechanical energy

( h, j, c )

(3) Chemical energy

( I, g )

(4) Light energy

( f )

[Group B]
(a) Submerged arc welding x
(c) Explosion welding x

(b) Electro-slag welding x

(d) Plasma arc welding x

(e) SMAW (Manual metal arc welding) x

(f) Laser welding x

(g) MAG welding x

(i) Oxy-flame (gas) welding x

(h) Resistance welding x

(j) Friction welding x

[Q4]
Welding processes may be classified according to the types of energy source utilized
directly for welding. Choose the energy source in [Word group] that is applied in
each welding process, and put its alphabet into each ( ).
1. MAG welding



2. Aluminothermic welding

3. Electron beam welding


4. Oxy-fuel gas welding


5. Friction stir welding


6. Laser welding



7. Manual metal arc welding (SMAW)
8. Explosion welding


9. TIG welding (GTAW)


10. Electroslag welding

(a)
(c)
(d)
(c)
(b)
(d)
(e)
(b)
(a)
(a)

[Word group]

(a) Electric energy

(b) Mechanical energy

(c) Chemical energy

(d) Light energy

[Q5]
Regarding the features of the following welding and cutting processes, choose the
relevant one from among the words in the word group given below and enter its
alphabetic symbol into each parenthesis.
(1) MAG welding

(a)

(2) Laser welding and cutting

(d)

(3) Submerged arc welding

(a)

(4) Friction welding

(b)

(5) Gas welding

(c)

[Word group]
(a)Electrical energy

(b) Mechanical energy

(c) Chemical energy

(d) Light energy

[Q6]
Regarding the classification of welding encircle their alphabets choose five (5) gas-
shielded arc welding processes and encircle their alphabets.
(a) stud welding

(b) TIG welding

(d) submerged arc welding

(e) self-shielded arc welding

(f) MAG welding

(g) shielded metal arc welding

(h) electro-slag welding

(i) brazing

(j) electro-gas arc welding

(k) resistance spot welding

(l) MIG welding

(m) electron beam welding

(n) plasma arc welding

(c) laser welding

[Q7]

In case of using 100% CO2 gas as shielding, droplet size is becoming larger than that
in case of using CO2 Argon gas mixture. Explain the reasons.
[Q8]
The following sentences describe the metal transfer modes. Choose the relevant one
and put its alphabet into each parenthesis.
(1) The molten metal droplet, which is detached from the tip of the electrode by the
arc force, transfers along the cavity wall in the flux covering around the electrode.
This metal transfer mode can be observed in submerged arc welding. ( )
(2) The molten metal droplet is punctured by rapid expansion of the internal gases
generated in the droplet. This metal transfer mode can be observed in shielded
metal arc welding. ( )
(3)The molten metal droplet grows in size as large as the electrode diameter or
larger to transfer. This metal transfer mode can be observed in shielded metal arc
welding with low-hydrogen type electrodes and CO2-shielded arc welding with high
currents. The both amount and size of the spatter increases in general. ( )
(4) The molten metal droplet whose diameter is as small as the electrode diameter
or smaller transfers in free flight in the arc column. This metal transfer mode can be
observed in MAG welding with high currents and Ar-rich shielding gas (Ar: 80% or
larger) and MIG welding. In general, spatter decreases, and the arc is likely to
become stable. ( )
(5) The molten metal droplet, which is developed on the tip of the electrode, makes
a contact to the weld pool and is transferred with the aids of the electromagnetic
pinching effect and the surface tension of the droplet. This metal transfer mode can
be observed in MIG and MAG welding with low current, low arc voltage, and short
arc length. This transfer mode is suitable for sheet metal welding and all-position
welding. ( )
[Word group]
(a) spray transfer

(c) short-circuiting transfer

(e) globular transfer

(b) flux-wall-guided transfer

(d) explosive transfer;

[Q9]

Regarding the metal transfer modes, choose the relevant one in the word group and
enter its each parenthesis.
(1) CO2-shielded arc welding with low currents.

(a)

(2) Pulsed MAG welding with low average currents.

(c)

(3) CO2-shielded arc welding with medium currents.

(b)

(4) MAG welding with high currents and a mixed shielding gas (c)
of 80%Ar+20%CO2.
(5) MIG welding with high currents.

(d)

[Word group]
(a) short-circuiting transfer

(c) spray transfer

(b) globular transfer

(d) explosive transfer

[Q10]
The following sentences are describing electrode wire melting and metal transfer
modes in MAG welding with solid wire. Choose the relevant one and circle its
alphabet.
(1) Wire melting rate is given mainly by the heat from the arc and also the following
due to the current flow in the wire.
(a) Electromagnetic force
(b) Radiation heat
(c) Resistance heat
(d) Convection heat
(2) When the wire melting rate (or wire feeding speed) is kept constant, welding
current may change if the following parameter is changed.
(a) Torch angle
(b) Wire extension

(c) Welding speed

(d) Flow rate of shielding gas
(3) In MAG welding using 100% CO2 gas for shielding gas, when higher arc voltage is
applied, the arc is becoming unstable. In that case at lower welding current, usually
the following metal transfer mode is adopted at lower arc voltage.
(a) Short circuiting transfer (Dip transfer)
(b) Globular transfer
(c) Spray transfer
(d) Explosive transfer
(4) In MAG welding with Argon base mixture shielding gas (Ar + CO2) spray transfer
mode may be obtained by increasing the following parameter more than a certain
critical value.
(a) Arc voltage
(b) Welding current
(c) Wire extension
(d) Flow rate of shielding gas
(5) In spray transfer mode, the force which acts to detach the droplet from the wire
tip is mainly the following.
(a) Plasma stream
(b) Surface tension
(c) Stiffness of the arc
(d) Electric magnet force

[Q11]
Pick out a non-consumable electrode gas-shielded arc welding process using DC
power source with constant current characteristics. And then give the kind of
shielding gas, the material of electrode and the polarity of electrode, when the
process is applied on welding of stainless steel.
Welding process ( )

Shielding gas ( )
Material of electrode ( )
Polarity of electrode ( )
[Q12]
Pick out at least three (3) advantages and three (3) disadvantages of TIG arc welding
process.

Advantages:
o Non-Consumable Electrode
o Filler metal is optional
o Good for non-ferrous metals
Disadvantages
o Complicated (Requires skills)
o Time consuming ( Slow method)
o Producing smoke screen

[Q13]
Give four (4) advantages and four (4) disadvantages of SAW, comparing with the
SMAW (Manual metal arc welding).

Advantages:
o Good for thick sessions welding
o Minimum of welding radiation
o Suitable for welding carbon, low alloy and alloy steels
o High metal deposition rates
Disadvantages:
o Flat/horizontal position welding only
o The electrode needs certain care
o Higher cost
o More complicated equipment

[Q14]
Pick out five (5) features of submerged arc welding process, comparing to manual
metal arc welding (shielded metal arc welding) process.

Features:
o Simple Equipment
o Low Cost
o Used for maintenance, repair & field construnction
o Portable

[Q15]
The sentences below, describing MAG welding, have error(s) in the parentheses.
Correct them.
(1) In the case of shielding gas-containing argon mixed with 20% of CO2 gas, the
metal transfer mode become spray transfer (when the welding speed is higher than
a certain critical value).
(2) Comparing with 100% CO2 gas shielded arc welding under the same welding
parameters, MAG welding with using mixed gas of 80% argon and 20% of CO2 has
(wider bead, but easily gets more spatter).
[Q16]

Pick out at least three (3) features of TIG welding (GTAW), comparing with MMA
welding (SMAW).

Features:
o Filler metals is optional
o Suitable for joining thin section
o Can be used for welding reactive metals

[Q17]
Pick out three (3) advantages and three (3) disadvantages of MAG welding
comparing to SAW (submerged arc welding) respectively.
[Q18]
Pick out three (3) advantages and three (3) disadvantages of FCAW welding
comparing to MAG (metal active gas) welding respectively.

Advantages:
o Versatility
o Capable of high deposition rates
o Good for non-ferrous metals
Disadvantages
o Wrong selection of consumables may lead to lower weld toughness
o Potential of lack of fusion type defects
o Fume extraction may be required