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Active Learning 1 (Ans)

This document contains details about an active learning assignment for a Metal Processing Technologies course. It includes questions about welding processes and metal joining techniques. Specifically, it asks students to define terms like fusion welding and autogenous welding, discuss the advantages and disadvantages of welding, explain the differences between fusion and solid-state welding, name types of joints, and describe the microstructure of welded joints. It provides background information and asks students to analyze welding concepts.

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tira
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© © All Rights Reserved
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30 views

Active Learning 1 (Ans)

This document contains details about an active learning assignment for a Metal Processing Technologies course. It includes questions about welding processes and metal joining techniques. Specifically, it asks students to define terms like fusion welding and autogenous welding, discuss the advantages and disadvantages of welding, explain the differences between fusion and solid-state welding, name types of joints, and describe the microstructure of welded joints. It provides background information and asks students to analyze welding concepts.

Uploaded by

tira
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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FACULTY OF MANUFACTURING ENGINEERING

SEM I 2020/2021

4BMFG-1

BMFS 4513 METAL PROCESSING


TECHNOLOGIES

ACTIVE LEARNING 1

LECTURER’S NAME : PROFESOR MADYA DR NUR IZAN SYAHRIAH


BINTI HUSSEIN

STUDENT NAME : NUR ATIRAH ASNA BINTI MOHAMAD RAUS

MATRICS NUMBER : B051710149

SECTION : 4BMFG-1/1
BMFS 4513
METAL PROCESSING TECHNOLOGIES
CHAPTER 1

ACTIVE LEARNING 1

1. Discuss the advantages and disadvantages of welding compared to


other types of assembly.

Advantages
- Welding provides a permanent joint which the welded components
become a single entity
- Welding usually the most economical way to joint parts in terms of
material usage and fabrication cost.
- Welding process does not restrict to a factory environment and can be
accomplished “in the field”.

Disadvantages
- Most welding operations are performed manually and are expensive in
the terms of labor cost
- Most welding processes utilize high energy and are inherently
dangerous
- Welded joints do not allow for convenient disassembly
- Welded joints can have quality defects that are difficult to detect.

2. Define the term fusion welding.


Fusion welding is the joining processes that melt the base metals. In many
fusion welding operations, a filler metal is added to the molten pool to facilitate
the process and provide bulk and added strength to the welded joint while a
fusion welding operation in which no filler metal is called an autogenous weld.
3. Explain the difference between fusion welding and solid-state welding.
Fusion welding is the joining processes that melt the base metals while solid-
state welding is the joining processes in which coalescence results from
application of pressure alone or a combination of heat and pressure.

4. Define the term autogenous weld.


Autogenous weld is a fusion welding operation in which no filler metal is added.

5. Discuss the reasons why most welding operations are inherently


dangerous.
- Welding operations require high temperature of molten metals
- In gas welding, fuels (e.g. acetylene) are a fire hazard
- Many welding processes use electrical power so electrical shock is a hazard.

6. Name and sketch five (5) types of joint.


7. Draw schematic diagrams showing how the part edges would be
prepared and aligned with each other and also showing the weld cross-
section for the following welds:
a. Single fillet weld for tee joint
b. Double U-groove weld for a butt weld
8. Explain the formation of microstructure in fusion zone, heat affected
zone and unaffected base plate of a fusion-welded joint.

- Fusion zone has central zone is composed of the base and the filler
metal.
- Application of heat and introduction of filler material (if any) into weld
zone allows the weld joint to cool to ambient temperature.
- Solidification process is similar to casting which begins with the
formation of columnar (dendritic) grains. These grains are relatively long
and form parallel to the heat flow.
- Due to metals are much better heat conductors than surrounding air, the
grains lie parallelly to welded plane of two components. Shallow weld of
grains perpendicular to their interface with base metal and the growing
grain is parallel to the direction of heat flow.
- Heat affected zone (HAZ) is within the base metal itself.
- Metal experiencing temperatures below melting point but high enough to
cause microstructural changes in solid metal.
- Its chemical composition similar to base metal but this region has been
heat treated so its properties and structure have been altered.
- Effect on mechanical properties in HAZ is usually negative and welding
failures often occurred.
- The properties and microstructure of HAZ depends on (a) the rate of
heat input and cooling and (b) the temperature to which this zone was
raised.
- Strength and hardness of HAZ de[end partly on how original strength
and hardness of base metal developed prior to the welding.
- Heat applied during welding recrystallizes the elongated grains of cold
worked base metal and the grains away from weld metal recrystallized
into fine and turns equiaxed grains.
- Grains close to weld metal subjected to elevated temperatures for a
longer time. Grains will grow in size and become softer and lower
strength region. Joint will be weakest at its HAZ.
- Portions of base metal that far enough away from heat source doe not
undergoes any microstructural changes during welding because of far
lower temperature to which they subjected.
- The structure becomes wrought.

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