MENG3209: Fundamentals of Manufacturing Processes

Assignment # 4 (Due Date: Thursday December 14th 2017)

Welding

Instructor: Dr. Mohamed Emara

1) Explain the following welding operations:

a. Electrogas welding
b. Electroslag welding
c. Carbon welding
d. Stud welding
e. Roll spot welding
f. Percussion welding
g. High frequency resistance welding
h. Induction welding
i. Pressure gas welding
j. Friction stir welding

2) Differentiate between Plug and Slot welds.

3) What are the advantages and disadvantages of welding compared to other types of assembly
operations?

4) A heat source can transfer 3500 J/sec to a metal part surface. The heated area is circular, and the
heat intensity decreases as the radius increases, as follows: 70% of the heat is concentrated in a
circular area that is 3.75 mm in diameter. Is the resulting power density enough to melt metal?

5) Compute the unit energy for melting for the following metals: (a) aluminum, (b) plain low
carbon steel, (c) copper and (d) titanium . Use Table 27.2
6) A U-groove weld is used to butt weld 2 pieces of 7.0-mm-thick titanium plate. The U-groove is
prepared using a milling cutter so the radius of the groove is 3.0 mm. During welding, the
penetration of the weld causes an additional 1.5 mm of material to be melted. The final crosssectional
area of the weld can be approximated by a semicircle with a radius of 4.5 mm. The length
of the weld is 200 mm. The melting factor of the setup is 0.57 and the heat transfer factor is 0.86.
(a) What is the quantity of heat (in Joules) required to melt the volume of metal in this weld (filler
metal plus base metal)? Assume the resulting top surface of the weld bead is flush with the top
surface of the plates. (b) What is the required heat generated at the welding source?
Use Table 27.2

8) The welding power generated in a particular arc-welding operation = 3000 W. This is transferred to
the work surface with a heat transfer factor = 0.9. The metal to be welded is copper whose melting
point is given in Table 29.2. Assume that the melting factor = 0.25. A continuous fillet weld is to be
made with a cross-sectional area = 15.0 mm2. Determine the travel speed at which the welding
operation can be accomplished.
Use Table 27.2
9) A welding operation on an aluminum alloy makes a groove weld. The cross-sectional area of the
weld is 30.0 mm2. The welding velocity is 4.0 mm/sec. The heat transfer factor is 0.92 and the
melting factor is 0.48. The melting temperature of the aluminum alloy is 650C. Determine the rate
of heat generation required at the welding source to accomplish this weld.

10) The power source in a particular welding operation generates 125 Btu/min, which is transferred to
the work surface with heat transfer factor = 0.8. The melting point for the metal to be welded =
1800F and its melting factor = 0.5. A continuous fillet weld is to be made with a cross-sectional
area = 0.04 in2. Determine the travel speed at which the welding operation can be accomplished.

11) A spot weld was made using an arc-welding process. In a spot-welding operation, two 1/16-in-thick
aluminum plates were joined. The melted metal formed a nugget that had a diameter of in. The
operation required the power to be on for 4 sec. Assume the final nugget had the same thickness as
the two aluminum plates (1/8 in thick), the heat transfer factor was 0.80 and the melting factor was
0.50. Determine the rate of heat generation that was required at the source to accomplish this weld.
Use Table 27.2

12) A shielded metal arc-welding operation is performed on steel at a voltage = 30 volts and a current =
225 amps. The heat transfer factor = 0.85 and melting factor = 0.75. The unit melting energy for
steel = 10.2 J/mm3. Determine (a) the rate of heat generation at the weld and (b) the volume rate of
metal welded.

13) A GTAW operation is performed on low carbon steel, whose unit melting energy is 10.3 J/mm3.
The welding voltage is 22 volts and the current is 135 amps. The heat transfer factor is 0.7 and the
melting factor is 0.65. If filler metal wire of 3.5 mm diameter is added to the operation, the final
weld bead is composed of 60% volume of filler and 40% volume base metal. If the travel speed in
the operation is 5 mm/sec, determine (a) cross-sectional area of the weld bead, and (b) the feed rate
(mm/sec) at which the filler wire must be supplied.

14) flux-cored arc-welding operation is performed to butt weld two austenitic stainless steel plates
together. The welding voltage is 21 volts and the current is 185 amps. The cross-sectional area of
the weld seam = 75 mm2 and the melting factor of the stainless steel is assumed to be 0.60. Using
tabular data and equations given in this and the preceding chapter, determine the likely value for
travel speed v in the operation.
Use Table 28.1

15) The unit melting energy for a certain sheet metal is 9.5 J/mm3. The thickness of each of the two
sheets to be spot welded is 3.5 mm. To achieve required strength, it is desired to form a weld nugget
that is 5.5 mm in diameter and 5.0 mm thick. The weld duration will be set at 0.3 sec. If it is
assumed that the electrical resistance between the surfaces is 140 micro-ohms, and that only
one-third of the electrical energy generated will be used to form the weld nugget (the rest being
dissipated), determine the minimum current level required in this operation.

17) A resistance seam-welding operation is performed on two pieces of 2.5-mm-thick austenitic

stainless steel to fabricate a container. The weld current in the operation is 10,000 amps, the weld
duration = 0.3 sec, and the resistance at the interface is 75 micro-ohms. Continuous motion welding
is used, with 200-mm-diameter electrode wheels. The individual weld nuggets formed in this
RSEW operation have diameter = 6 mm and thickness = 3 mm (assume the weld nuggets are
disc-shaped). These weld nuggets must be contiguous to form a sealed seam. The power unit
driving the process requires an off-time between spot welds of 1.0 s. Given these conditions,
determine (a) the unit melting energy of stainless steel using the methods of the previous chapter,
and (b) the proportion of energy generated that goes into the formation of each weld nugget.
Use Table 27.2

18) The voltage in an EBW operation is 45 kV. The beam current is 60 milliamp. The electron beam is
focused on a circular area that is 0.25 mm in diameter. The heat transfer factor is 0.87. Calculate the
average power density in the area in watt/mm2.

19) An electron-beam welding operation is to be accomplished to butt weld two sheet-metal parts that
are 3.0 mm thick. The unit melting energy = 5.0 J/mm3. The weld joint is to be 0.35 mm wide, so
that the cross section of the fused metal is 0.35 mm by 3.0 mm. If accelerating voltage = 25 kV,
beam current = 30 milliamp, heat transfer factor f1 = 0.85, and melting factor f2 = 0.75, determine
the travel speed at which this weld can be made along the seam.