Example for answering a welding question.

TIG WELDING:
-write the definition of welding.
-TIG welding or Gas Tungsten Arc Welding(GTAW) is a non-pressure arc welding.
-Write principle of arc welding.
-Draw figure.
Welding heat is produced from an electric arc established between the job and bare non-consumable tungsten electrode.A shielded gas(argon, heliumn nitrogen etc) is used as flux.Filler metal if required is fed separately.
ARGON: It requires a lower arc voltage, easier arc starting and provides a smooth arc action.It is economical and heaviest.
HELIUM: Higher arc voltage, hence is used where higher heat input is required.
Sometimes active carbon dioxide is used more economical and requires higher current.Used normally with only DC with +ve electrode.
Argon and helium are used for both AC and DC power sources.
Welding operation is done by striking an arc between the workpiece and tungsten electrode mounted on a special holder.Inert gas is used as flux.The arc is allowed to impinge on the job and a weld pool is created.The welding torch and filler metal are generally kept inclined at angles 70-80 degree and 10-20 degree respectively with the flat workpiece.
-Write advantages and disadvantages.
-Write applications
-Finally precautions.

Welding contd.

Types of electrodes: bare, coated, consumable and non-consumable.
Consumable electrodes: Molen metal from the electrodes and base metal are mixed under the arc provides necessary joint.Electrode is serving the purpose of filler rod as wellas input for heat.
Non consumable electrodes: not consumed during welding.Separate filler rod is used if necessary to fill the gap.These are of carbon & graphite for DC welding.
Tungsten electrodes are used for DC & AC welding and have better control over the heat input because sources are separate.Used in carbon arc & TIG welding.
Bare electrodes are without coating of flux and flux is used separately as non-consumable electrodes.The striking of arc is difficult in such electrodes especially with AC supply.
Coated electrodes are coated with flux and called STICK electrodes.The problem is moisture picked-up by yhe flux and dissociates into oxygen and hydrogen and being absorbed by the liquid metaland released during solidification causing porosity and so advised to keep the electrodes in a dry place.

FLUX:During welding, when metal is heated in air, the oxygen from air combines the metal and forms oxides,which results poor quality, low strength weld and even some cases welding becomes impossible. To protect the weld pool from oxygen of ambient air,flux is used and does not allow the air to come in contact with fused metal.
Thus fluxes may be divided into the following categories.
Gas Forming: Components are organic matters such as starch,wood, pulp etc, which form gas layer, thus isolating the welding zone from the ambient air.
Slag Forming: The slag forming components are chinaclay, felspar, manganese and titanium ores etc and enhance slag formation.Slag covering the molten metal to come in contact with air.

RESISTANCE WELDING

This is a process of welding in which heat is obtained from resistance of the work to the flow of current and then applying pressure. No filler metal or flux is added.
PRINCIPLE OF RESISTANCE WELDING:
In this welding,a low voltage(typically 1 volt) and very high current(typically 15000 A)is passed to the point for a very short time(typically 0.25 sec). This high ampere current heats the joint.The following are the types of resistance welding.
-Spot welding
-Seam welding
-Projection welding
-Resistance butt welding
-Flash butt welding
-Percussion welding
Electrodes for resistance welding: Since electrodes carry large amount of current/ pressure and also help to remove the heat from weld zone. Thus to prevent overheating, the electrodes must have higher electrical conductivity and hardness, hence copper alloys are preferred.
Copper-Cadmium for welding Al and Mg.
Copper-Chromium for welding MS and low alloy steels.

Go through the advantages/ disadvantages and uses for every type of welding.

ARC WELDING

Arc welding is non pressure fusion welding and with or without filler metal depending upon thickness of base plate.
PRINCIPLE OF ARC WELDING:
Arc is generated between anode +ve pole of DC and -ve pole of DC cathode. When these two poles are brought together and separated for a small distance(1.5 to 3 mm)and current flows through a path of ionized particles, called plasma and electric arc is formed.Heat is generated as the ions strike the cathode.Various arc weldings processes are:
-Carbon arc welding
-Flux shielded metal arc welding
-TIG(GTAW) welding
-MIG(GMAW) welding
-Submerged arc welding
-Electroslag welding
-Electrogas welding
-Plasma arc welding
Dear students first four processes are to be studied with making figures(sketch) available on my site.
As explained in the class that for every welding answer first write definition of welding and then type of welding and principle. Make figure and explain.

WELDING

Kindly refer welding contd in my blog of mp course material upto types of flames.

Welding is permanent fastening and process of joining of two metals with pressure or without pressure, by using or without using filler metal by fusion. Fusion takes place by means of heat.Heat is obtained/produced from electric arc,electric resistance,chemical reaction,friction or radiant energy.
Important Terms
Autogenous Welding- Similar metals without adding filler metal.
Homogeneous Welding-Similar metals with adding of filler metal.
Heterogeneous Welding-Dissimilar metals using filler metal.
Base Metal-
Bead or weld Bead-
Weld Pass-
Backing-
Root-
Tack Weld-
Toe of Weld-
Weld Metal-

Classification of Welding:
Make Welding Trees as classification, which is explained in the class and the trees are available on my website.

Difference between Welding, Braze Welding, Brazing and Soldering has been discussed in the class and dictated also.Memorise it thoroughly as instructed.

PATTERN ALLOWANCES

After drawing figures of patterns and writing few lines about patterns.I would like to add about pattern allowances as laid under.

1.Shrikage or contraction allowance
2.Machining or finish allowances
3.Draft or Taper allowance
4.Distortion or camber allowance
5.Shake or rapping allowance
6.Mould wall movement allowance
As explained in the class write few lines with figures.

I have already dictated the following in the class.
Classification of sand.
Preparation of moulding sand.
Preparation of core sand.
Riser,Runner and Gating.
Engineering Materials-Metal, Non-metal, Ferrous & Non-ferrous metals etc.

Plant Layout contd. & Foundry

Dear Students,
Kindly make layouts i.e. Product and Process layouts. The objectives of a good plant layout are laid down.

1.Minimising & efficiently control of material handling and transportation.
2.Bottlenecks and congestion to be eliminated for smooth and continuous flow.
3.Movement of persons to be minimised for effective utilisation of equipment & space.
4.Working place to be safe,well ventilated, and free from dust,noise, fumes & odour.
5.Waiting time for semifinished product should be minimised.
6.Cubic space should be utilised in effective manner.
7.To increase productivity with reduced capital investment.
8.To provide flexibility of manufacturing and management.
9.To allow the movement of material with desired speed and lowest cost.
10.To promote job satisfaction and good relation between management & employees.

FOUNDRY.........FORGING..........FORMING

FOUNDARY: Foundary is a place, where casting is done.Casting is a process of pouring molten metal in a cavity called MOULD.When this mould is filled with molten metal, it solidifies and produces a casting.

PATTERN:Pattern is a model of desired product(casting)i.e. constructed in such a way that it can be used for forming an impression called mould.Pattern is replica of casting.

Pattern Materials:
* Wood
* Metal(Cast Iron, Brass, Aluminium alloys & White Metal etc)
* Plaster
* Plastic Compound
* Wax

The following factors are to be considered for selection of pattern material.
1. Design of casting
2. Quality and quantity of casting
3. Shape and size of casting
4. Types of moulding
5. Types of process of casting
6. Moulding material
7. Possibility of design changes
8. Chances of repeat orders
9. Pattern material should be light in weight, easily worked, shaped and joinable.
10.It should be durable,strong, hard, resistant to wear abrasion, corrosion and chemical reaction.
11. Dimensionally stable,unaffected by variation in temprature and humidity.
12. Low cost, easily repairable and re-usable.
13. Ability to take a good finish.

Refer Casting processes figure at my site 9262k and draw of your own and write basic steps taken in a casting process as explained in the class i.e. from pattern making to dispatch of the cast product.
Main shops in the FOUNDRY.
Pattern Shop, Moulding shop and melting shop( Furnace).
Name the types of patterns and draw the figures. Write why & where are these used.
Types: Solid and single piece, Split(two Pieces), Multi-piece,Match plate, Gated, Skeleton,Sweep, Pattern with loose pieces, Cope & drag pattern, Follow board pattern and Segmental pattern.