Diploma Manufacturing technology 1 N Scheme important Questions and answers
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Dept: Mechanical Engineering Scheme: N
Subject: Manufacturing Technology 1
Unit – 2 – Joining Processes
- Define List out its uses.
- Welding is the process of joining similar or different metal by
- Welding is used in the fabrication of automobile bodies, air craft, machine frames, boilers, ship building, railway wagons,
- What are the types of welding? Give
- Plastic welding or pressure welding
Example : Electric resistance welding.
- Fusion welding or non – pressure welding/
Example ; Electric arc welding, gas welding.
- List out the equipment needed for arc
- Welding generator(D.C) 6) Protective shield or transformer(A.C) 7) Gloves
- Electrode holder 8) Apron
- Electrode 9) Chipping hammer
- Welding cables 10) Wire brush
- Earthing clamps
- What are the uses of electrode holder and earth
- The electrode holder connects to the welding cable and conducts the welding current to the electrode.
- The Earthing clamp is used to connect the earth cable to the work
- Name the two basic types of electrode?
- Consumable electrode 2) Non-consumable electrode
- What are the types of consumable electrodes?
- Bare electrodes: They are not coated with
- Lightly coated electrodes: A light layer of flux is coated on the
- Heavily coated electrodes: Flux is coated on the electrodes to a thickness of 1 mm to 3
- List out the various methods of arc
- Metal arc welding
- Metal Inert Gas (MIG) welding
- Tungsten Inert Gas (TIG) Welding
- Submerged arc welding
- Electro slag welding
- Give the expansion of MIG and TIG
- MIG – Metal Inert Gas welding
- TIG – Tungsten Inert Gas welding
- State the difference between MIG and TIG
| MIG welding | TIG welding |
| Consumable electrode is used | Non-consumable electrode is used. |
| Electrode is used as filler metal. | Filler metal is supplied separately. |
| Efficiency is more. | Efficiency is less. |
- What is plasma? List out the advantages of plasma arc
Ionised gas jet is called plasma. It produces high heat and is used for joining metal together.
Advantages of plasma arc welding :
- All metals can be welded by this
- No filler rod is
- Welding speed is
- High quality welding joint can be
- Write the applications of submerged arc welding.
Submerged arc welding is used for welding low carbon steel and alloy
- What is electro slag welding? Give its
Electro slag welding is a process of joining two thick metal plates by the heat generated when electric current is passed through molten slag.
Boiler plate, turbine shaft, stainless steel and carbon steel can be welded by this method.
- What is gas welding? Name the gases used in gas
Gas welding is a process of joining metals by the heat of the flame formed when oxygen burns with another gas
The following gases are used to produce flame in gas welding.
- Oxygen – acetylene
- Oxygen – hydrogen
- Air- acetylene
- List out the equipment needed for gas
- Gas cylinders 2) Pressure regulators 3) Pressure gauge 4) Hoses 5) Welding torch
- How do you differentiate oxygen and acetylene cylinders in gas welding?
The cylinder painted with black colour has oxygen. The cylinder painted with maroon colour has acetylene.
- What is the function of a pressure regulator fixed on a gas cylinder?
The pressure regulator is used to control the working pressure of oxygen and acetylene.
- What are the three types of flames in gas welding?
- Neutral flame 2) Carburising flame 3) Oxidising flame
- What is neutral flame? Give its
The neutral flame is produced when equal quantity of oxygen and acetylene gases are used.
Neutral flame is used for welding steel, cast iron, aluminium, copper and stainless steel.
- When carburising flame is produced? State its
Carburising flame is produced when the quantity of acetylene is more than oxygen.
Carburising flame is used for welding steel, alloy steels, non-ferrous metals, nickel and monel metal.
- How oxidising flame is produced? List out its
Oxidising flame is produced when the quantity of oxygen is more than acetylene.
Oxidising flame is used for welding brass, bronze, manganese and steel.
- What is resistance welding? List out the types of resistance
In resistance welding, the metal is heated to plastic stage due to the heat generated by the electric resistance.
The types of resistance welding are :
- Butt welding 3) Seam welding
- Spot welding 4) Projection welding
- What is spot welding? Give its
Spot welding is a type of resistance welding which is used for joining overlapping sheet metals by making weld at regular interval.
Boxes, cans, automobile frames and air conditioners can be welded by spot welding.
- Give the difference between upset butt welding and flash butt
In upset butt welding, the metals to be welded are clamped in copper jaws so that there is a light contact at the ends of metals.
In flash but welding, the metals to be welded are clamped in jaws so that there is a small air gap between the ends of metals.
- What is seam welding? List out its
Seam welding is a process of making weld continuously
between two overlapping sheet metals.
Seam welding is used for welding radiators, drums, leak proof tanks, automobile silencers, etc.
- Give the applications of flame
Steel and iron plates having thickness up to 100 mm can be cut by this method.
- What is hard facing?
Hard facing is a process of coating a hard metal powder on the surface of soft metals.
- What is bronze welding? Give its
- It is a welding technique, in which the edges of work pieces to be welded are heated to the melting temperature of filler
- It is used for welding cast iron, steel, copper, bronze and
- Differentiate between soldering and
- Soldering is the process of joining two similar or dissimilar metals by using a low melting alloy called
- Brazing is the process of joining two similar or dissimilar metals by using a high melting alloy called
- What is solder and spelter?
- Solder is an alloy of tin and
- Spelter is a mixture of copper and zinc
- List out the types of
- Torch brazing 2) Dip brazing
3) Furnace brazing 4) Induction brazing
- What is thermit? Give the applications of thermit
- Thermit steel is a mixture of aluminium powder and iron oxide in the ratio of 1:3.
- Thermit welding is used for joining heavy parts, rails, pipes, shafts, cables and worn out machine
- Define solid state Give its types.
Solid state welding is the process of joining metals in solid state without melting them. In this method, welding is done by the inter atomic bonds developed when the atoms of two surfaces are brought very close to each other.
Types of solid state welding.
- Friction welding 2) Ultrasonic welding
3) Diffusion welding 4) Explosive welding
- List out the applications and advantages of friction
Applications :
Friction welding is used for welding aero engine parts and gas turbine shafts. It is also used for welding pinions to shafts, rods to yokes, flanges to pipes, etc.
Advantages :
- The initial cost is low.
- Dissimilar metals can be
- It is a simple and fast
- High quality weld can be
- The power consumption is
- List out the applications of ultrasonic
- It is used for welding metals up to 3 mm
- Thin sheets can be joined with thick
- Electrical and electronic components can be
- Plastic components can also be
- It is used for welding in nuclear reactor and aircraft
- What is the principle involved in electron beam welding? Give its
In this method, welding is done by the heat produced when the high velocity electron beams are focused on the object.
Application :
- It is used for welding automobile and aero plane
- It is used for welding high temperature metals like tungsten, molybdenum and
- Pressure vessel and turbine parts can be
- What is LASER? List out the advantages of laser beam
LASER means Light Amplification by Stimulated Emission of Radiation. It is a beam of light having a single wave length.
Advantages :
- The temperature can be controlled
- Welding can be accurately
- No distortion
- Heat treated components can be welded without affecting its
- The weld is not affected by
- What are the types of welded joints?
- Butt joint 2) Lap joint 3) ‘T’ joint
4) Corner joint 5) Flange joint
- List out the non-destructive and destructive methods for welded
Non destructive testing methods :
- i) Magnetic particle test ii) X-ray test iii) Ultrasonic test
Destructive testing methods :
- i) Nick brake test ii) Bend test iii) Tensile test
39. What are the applications of magnetic particle test, X-ray test and ultrasonic
🟆 Magnetic particle test is used to find out cracks and slag inclusions.
🟆 X-ray test is used to fine out defects like porosity, blow holes and cavities.
🟆 Ultrasonic test is used to find out defects like cracks, blow holes and porosity by using ultrasonic waves.
- List out the various defects in welding
1) Incomplete fusion 2) Slag inclusion 3) Crack 4) Undercut 5) Porosity and blow holes
| Check N Scheme Mechanical Department Study Materials | |
| Strength of Materials | Click here |
| Manufacturing Technology – 1 | Click here |
| Thermal Engineering – 1 | Click here |
| Metrology & Measurements | Click here |
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