WELDING:

1. Aluminum <copper <cast iron<ms.

2. Reduce dimensional stability, weld cracking, effect on fatigue strength,reduction in the
creep strength are residual stresses in welding.
3. Heat affected zone will increase with increased starting temp, increased thermal
conductivity of the base metal.
4. The magnitude of residual stresses in welding depends upondesign of weldment, support
of clamping components, welding process used.
5. Aluminium is poor absorber of laser light.
6. Friction welding and TIG welfing is good for aluminium.
7. For aluminum AC current plus high frequency is must.
8. CI is difficult to weld because it has high carbon % and brittleness (poor ductility).
9. High carbon martensite tends to form in the heat affected zones.
10.CI are joined by Oxyacetylene brazing process.
11.SS difficult to weld because it contains (nickel &chromium).
12.TIG,MIG, shielded metal arc and Plasma weldings are used for SS steel
13.Gray iron is usually welded using Gas welding.
14.Preheating before welding is done t prevent cold cracks.
15.Mild steel, cast iron, low carbons steel, aluminium-----neutral flame.
16.Medium carbon steel, nickel-------carburising flame.----(29000c)
17.Brass bronze,zinc base material-------oxidising flame.----(33000c)
18.In neutral flame the ratio of volume of acetylene and oxygen is same.
19.Oxyacetylene reducing flame is used while carrying out the welding on high carbon steel.
20.Neutral flame----------(31000c).
21.Carburizing flame (2900c) < neutral flame (31000c) < oxidizing flame (33000c).
22.Oxyacetylene welding ---the joint is heated to state of fusion, no pressure is used, o2 is
stored in steel cylinder at a pressure of 14 mpa, when there is an excess of acetylene used
there is a decided change in the appearance of flame.
23.In oxy-acetylene gas welding for complete combustion the volume of o2required per unit
of acetylene is 2.5.
24.In gas welding the torch should be held at 30 to 45 from horizontal plane.
25.In gas welding the size of the torch depends upon the thickness of metal to be formed.
26.Drag in gas cutting is the time difference btw heating of plate and starting the oxygen gas
for cutting.
27.Thick steel plate cut with oxygen normally shows signs of cracking this tendency for
cracking can be minimized by slow speed cutting.
28.Oxygen is stored in a cylinder at a pressure ranging from 13.8 to 18.2 Mpa.
29.Ratio b/w oxygen and acetylene gases for neutral flame in gas welding is 1:1.
30.Final micro structure depends upon cooling rate.
31.In dc welding the straight polarity (electrode negative ) results in lower penetration rate.
32.Air blow is more common in dc welding with bare electrodes.
33.Pinch effect in welding is the result of expansion of gases in the arc.
34.In manual arc welding the equipment should have dropping charecterstics in order to
maintain current constant when arc length changes.
35.In arc welding d.c reverse polarity is used to greater advantage in flat welding of lap
joints.
36.Gas tungsten arc welding (TIG) process does not use consumable electrodes.
37. Weld spatter occurs due to high welding current, too small an electrode, arc except
wrong polarity.
38.Coating material of an arc welding electrode contains deoxidizing agent, arc stabilizing
agent, slag forming agent.
39.In arc welding 65 to 75 % heat is generated at the anode.
40. The electrodes used in arc welding are coated this coating isnot expected to prevent
electrode from contamination.
41.Two plates of the same metal having equal thickness are to be butt welded with electric
arc when the plate thickness changes welding is achieved by adjusting the duration of
current.
42.Mig welding process uses consumable electrode and d.c power supply.
43.Ac and dc may be used in tig depending upon material
44.Dc is used in mig for all materials.
45.TIG welding process uses non consumable electrodes.
46.In MIG welding the metal is transferred into the form of molten drops.
47.DC with reverse polarity is used in MIG welding and used of dc with reverse polarity
enables deeper penetration and clean surgace.
48.The welding process in which bare wire is used as electrode granular flux is used and the
process is characterized by its high speed welding is known as submerged arc welding.
49.In submerged arc welding process flux is used in the form of granules.
50.High welding speeds ,high deposition rates are major charectsticts of sub merged arc
welding.
51.For maximum metal deposition submerged arc welding is most preffered.
52.Laser beam welding process consists of minimum heat affected zone.
53.Increasing order of heat affected zones: LASER BEAM < MIG < SUBMERGEDARC <
ARC WELDING.