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    Mid Sem Solution A

    Uploaded by

    Tilakraj Baghel
    The document provides a summary of questions that will be included on an exam for a course on joining materials. It includes 10 subquestions across 2 main questions. The subquestions cover topics like welding processes for aluminum alloys, thermal cycles during welding, weld pool geometry, microstructure of the fusion zone, and minimizing distortion during welding. Calculations of cooling rate and identifying conditions for a planar solid-liquid interface in the fusion zone are asked. Processes discussed include gas tungsten arc welding and oxyacetylene welding.

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    Mid Sem Solution A

    Uploaded by

    Tilakraj Baghel
    17 views4 pages
    The document provides a summary of questions that will be included on an exam for a course on joining materials. It includes 10 subquestions across 2 main questions. The subquestions cover topics like welding processes for aluminum alloys, thermal cycles during welding, weld pool geometry, microstructure of the fusion zone, and minimizing distortion during welding. Calculations of cooling rate and identifying conditions for a planar solid-liquid interface in the fusion zone are asked. Processes discussed include gas tungsten arc welding and oxyacetylene welding.

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    The document provides a summary of questions that will be included on an exam for a course on joining materials. It includes 10 subquestions across 2 main questions. The subquestions cover topics like welding processes for aluminum alloys, thermal cycles during welding, weld pool geometry, microstructure of the fusion zone, and minimizing distortion during welding. Calculations of cooling rate and identifying conditions for a planar solid-liquid interface in the fusion zone are asked. Processes discussed include gas tungsten arc welding and oxyacetylene welding.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    17 views4 pages

    Mid Sem Solution A

    Uploaded by

    Tilakraj Baghel
    The document provides a summary of questions that will be included on an exam for a course on joining materials. It includes 10 subquestions across 2 main questions. The subquestions cover topics like welding processes for aluminum alloys, thermal cycles during welding, weld pool geometry, microstructure of the fusion zone, and minimizing distortion during welding. Calculations of cooling rate and identifying conditions for a planar solid-liquid interface in the fusion zone are asked. Processes discussed include gas tungsten arc welding and oxyacetylene welding.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 4

    Joining of Materials

    (Course Code: FMD518)


    (Exam date: 22/09/2023)
    All questions are compulsory
    Total marks - 50, Time: 2 hr

    1) You are supposed to do the welding of heat-treated 2xxx series Aluminium alloy. The
    alloy is going to be used in aerospace applications. Answer the below questions
    regarding the welding process.
    a) Explain the possible welding modes during Arc and electron beam welding. Draw
    the transverse cross-section of weld bead geometry in both processes. (5 marks)

    Ans: Melt-in and Keyhole modes explanation (3 marks) with images (2 marks)

    b) Assume you have selected the GTAW process for the Al alloy; what polarity will
    you be using for welding? Why? (3 marks)

    Ans: Reverse polarity (DCEP) (1.5 mark), cleaning action or removal of oxide layer (1.5 mark)

    c) During the GTAW process, the Al alloy is subjected to various thermal cycles at
    different locations. Assume the above welding process is carried out with a current
    of 150 A and voltage of 15V with a welding speed of 2 mm/s. Calculate the cooling
    rate along the X axis of the workpiece for 100 and 250 oC preheating conditions.
    (Take necessary assumptions if needed.) (thermal conductivity of Al is 35 W/moC)
    (6 marks)

    Ans: Use either Rosenthal 2D or 3D with suitable assumptions, and solve at a location of y=z=0

    d) In the same diagram, Draw the thermal cycle for the above GTAW process at the
    fusion zone, heat-affected zone, and unaffected material. (3 marks)

    Ans: Draw a Temperature vs. time diagram for FZ, HAZ and unaffected material on the same
    diagram. The peak temperature order is FZ>HAZ>unaffected material

    e) The 2xxx Al alloy has Cu as the primary alloying element if the liquidus
    temperature of the alloy is 650 oC, solidus temperature is 560 oC, and the Diffusion
    coefficient of Cu in liquid aluminium is 3 x 10-5cm2/s. Identify the condition for a
    planar solid-liquid interface in fusion zone solidification and explain how the
    microstructure modifies with the cooling rate. (3 marks)
    Ans: Use the below equation and calculate the condition to get a planar interface

    (2 marks)

    Cooling rate increases, the finer microstructure will form in the fusion zone. (1 mark)

    f) What shielding gas will you prefer for the above GTAW processes? Why? (2
    marks)

    Ans: Argon, a greater oxide cleaning action, is heavier than helium, it offers more effective
    shielding, is easier to ionize, and is less cost.
    g) Write the procedure to measure the heat source efficiency of the GTAW of
    Aluminium alloy. ( 4 marks)

    Ans: Use the below equation and explain any calorimeter procedure

    h) Draw and explain how the electrode tip angle affects the weld pool geometry. (3
    marks)

    Ans:
    i) Draw the distribution of Cu from the dendritic centre to the inter-dendritic region.
    Explain the assumptions (3 marks)

    Ans:

    Draw any of these figures with the assumption

    j) Draw the hot ductility curve and explain the nil strength temperature (NST), nil
    ductility temperature (NDT) and ductility recovery temperature (DRT). How will it
    affect the welding process? (5 marks)

    Ans: NST/NDT/DRT explanation with figure


    (4 marks), explain the effect of temperature range on weld solidification cracking (1 mark)

    2) Consider the repair welding of a high-carbon steel component using the Oxyacetylene
    welding process. While starting the welding torch, different types of flames are
    possible.
    a) What flame will you prefer for the above welding process? Justify your answer. ( 2
    marks)

    Ans: carburising or reducing flame (1 mark) and writing its justification related to carbon
    escape from the surface (1 mark)

    b) How can you visually identify the selected flame? (2 marks)

    Ans: Write about acetylene feather and its colour.

    c) Write the advantages and disadvantages of the oxyacetylene welding process. (3


    marks)

    Ans: Any three advantages and disadvantages

    3) Write a short note on epitaxial and competitive growth during weld microstructure
    formation. (3 marks)

    Ans: with the explanation of epitaxial and competitive


    growth

    4) Write a short note about the distortion of welded components and suggest possible ways
    to minimise distortion. (3 marks)

    Ans: Write about distortion (1 marks) and at least two ways to minimise it (2 marks)

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