Code No: R05311805 Set No.

1
III B.Tech I Semester Supplimentary Examinations, February 2008
WELDING METALLURGY
(Metallurgy & Material Technology)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
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1. Explain TIG welding with respect to:

(a) Principle
(b) Operation and
(c) Equipment [4+6+6]
2. (a) With the aid of a simple outline sketch show the crystal structure in a cross-
section of a single ‘V’ butt weld in an un-alloyed non-ferrous metal.
(b) What is meant by post heating? Explain why welded assemblies may be
subjected to post heating? [8+8]
3. (a) What are the advantages and disadvantages of submerged arc welding with
two to three electrodes each having its independent power sources over that
with single electrode?
(b) What are the advantages and limitations of spray arc MIG welding process
over pulsed arc process? [8+8]
4. (a) What are the two types of electron beam guns? Give their individual advan-
tages?
(b) Explain why a vacuum chamber is used with the electron beam? [10+6]
5. Name different electrodes that are used for the welding of grey cast-iron and explain
oxy-acetylene welding of grey cast-iron? [16]
6. (a) Describe the factors affecting weldability of copper and its alloys.
(b) Copper and high copper alloys are very difficult to join by resistance spot
welding, whereas flash welding technique gives good results. Justify. [8+8]
7. (a) Define burning in the heat affected zone of a fillet weld and explain its causes
and remedies?
(b) Describe the phenomenon hydrogen induced cracking occurring in the welding
of high strength steels. [8+8]
8. Write short notes on:
(a) Soldering of carbon and low alloy steels
(b) Soldering of copper and its alloys [8+8]

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Code No: R05311805 Set No. 2
III B.Tech I Semester Supplimentary Examinations, February 2008
WELDING METALLURGY
(Metallurgy & Material Technology)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. (a) Explain the variables affecting the strength of a weld joint.

(b) Explain the characteristics of Butt joints. [8+8]

2. Write short notes on:

(a) Metallurgical effects of heat flow in welding

(b) Heat flow in fillet welds [8+8]

3. (a) What are the advantages and limitations of standard MIG process over mag-
netic flux MIG process?
(b) Give the important applications of plasma torches? [8+8]

4. (a) What are the variables encountered in spot welding?

(b) Explain diffusion bonding and give the important applications of diffusion
welding? [8+8]

5. (a) Give the causes of porosity in the deposit, when hard facing is carried out on
low carbon steel?
(b) How does the welding of high carbon steels differ from that of medium and
low carbon steels? Explain. [10+6]

6. (a) Differentiate semi-automatic welding of aluminum with machine welding?

(b) What are the different solid state welding processes used for joining aluminum
alloys? [8+8]

7. (a) What are the causes and remedies for stress corrosion cracking in the welding
of austenitic stainless steels?
(b) What are the factors which promote hot cracking in weldments? [8+8]

8. (a) What are the advantages of furnace brazing over other methods of brazing?
(b) What are the furnaces used for brazing purposes?
(c) Explain infrared brazing process? [6+5+5]

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Code No: R05311805 Set No. 3
III B.Tech I Semester Supplimentary Examinations, February 2008
WELDING METALLURGY
(Metallurgy & Material Technology)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. With a neat sketch describe the principle of operation of any welding fixture with
which you are acquainted and state the factors that must be considered for the
effective operation of a welding fixture. [16]

2. (a) What are the effects of thermal stresses in welds?

(b) What are the different methods used to reduce welding stresses to a minimum?
Explain any one of them. [8+8]

3. (a) Give the advantages and limitations of submerged arc welding.

(b) What are the applications of submerged arc welding. [10+6]

4. (a) What are the two types of electron beam guns? Give their individual advan-
tages?
(b) Explain why a vacuum chamber is used with the electron beam? [10+6]

5. (a) For a plain carbon steel containing 0.4% Carbon give three typical metal-
lurgical states which might exist in the material in the vicinity of a fusion
weld?
(b) Austenitic heat resisting steels containing higher nickel and chromium contents
are used for fabricating structures for high temperature service. Give reasons?
[8+8]

6. Write short notes on:

(a) Welding of dissimilar metals

(b) Welding of copper and its alloys. [8+8]

7. (a) What are the causes and remedies for stress corrosion cracking in the welding
of austenitic stainless steels?
(b) What are the factors which promote hot cracking in weldments? [8+8]

8. (a) Describe brazing of copper and its alloys?

(b) Explain the ultrasonic condensation methods of soldering? [8+8]

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Code No: R05311805 Set No. 4
III B.Tech I Semester Supplimentary Examinations, February 2008
WELDING METALLURGY
(Metallurgy & Material Technology)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. (a) Square butt joint is limited by metal thickness. Why?

(b) It is poor practice to weld only one side of a double bevel joint. Explain why?
(c) How the diameter of the electrode determine the current requirement?
(d) Why do different shielding gases yield different weld bed shapes? [4+4+4+4]

2. (a) Expalin the effect of gases which are absorbed during welding and give the
prevention methods of gaseous contamination.
(b) Define porosity in welds? Explain how to minimize porosity. [8+8]

3. (a) What are the fuel gases used in metal cutting? Give their advantages?
(b) What are the advantages and limitations of oxygen lance cutting over plasma
cutting? [8+8]

4. Draw a neat sketch of electron beam welding system and describe the working of
electron beam gun? [16]

5. (a) What are the welding characteristics of cast-irons?

(b) Describe the methods of reinforcing welds in cast-iron with neat sketches.
[4+12]

6. (a) Describe the advantages and limitation of joining copper and its alloys by gas
welding process over arc welding process.
(b) Why is flux used when welding aluminum? [10+6]

7. (a) What are the commonly encountered defects in spot welding?

(b) What are the causes and remedies of the defects excessive electrode indentation
and metal expulsion? [8+8]

8. (a) What are the factors to be considered in soldering joint design? Name different
soldering joints?
(b) What are the factors to be considered in selecting a solder alloy? Name any
two soldering alloys. [8+8]

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