9-Casting & Welding Theory & Questions Altogethre 2013 PDF

Sand casting
y The molten metal is p p

poured into the sprue hole, flows
y Sand
S d casting
i uses ordinary
di sand
d as the
h primary
i through the runners, and enters the mold cavity
mould material. through an opening called a gate.
y The sand grains are mixed with small amounts of y Gravity flow is the most common means of
other materials,
materials such as clay and water,
water to improve i t d i the
introducing th metalt l into
i t the
th mold.
ld
Metal Casting mouldability and cohesive strength, and are then

packed around a pattern that has the shape of the
desired casting.
y After solidification, the mold is broken and the
finished casting is removed.
y The casting is then “fettled”
fettled by cutting off the ingate
y The pattern must be removed before pouring, the
and the feeder head.
mold is usually made in two or more pieces.
y Because the mold is destroyed, a new mold must be
y An opening called a sprue hole is cut from the top of
made for each casting.g
By S K Mondal th mold
the ld through
th h the
th sand d andd connected
t d to
t a
system of channels called runners. Contd…. Contd…
Sequential steps in making a sand casting y The mold is opened, the pattern board is drawn

y A pattern board is placed between the bottom (drag) (removed), and the runner and gate are cut into the
and top (cope) halves of a flask, with the bottom side up.
p( p ) , p surface of the sand.
y Sand is then packed into the drag half of the mold.
S d i h k d i h d h lf f h ld y The
Th mold
ld is
i reassembled
bl d with
ith the
th pattern
tt b d
board
removed, and molten metal is poured through the
sprue.
y A bottom board is positioned on top of the packed sand,
and the mold is turned over, showing the top (cope) half
and the mold is turned over showing the top (cope) half
of pattern with sprue and riser pins in place. y The contents are shaken from the flask and the metal
segment is
i separated
d from
f the
h sand,
d ready
d for
f further
f h
processing.
y The cope half of the mold is then packed with sand.
The cope half of the mold is then packed with sand
Contd…
Casting Terms
y Flask: A moulding flask is one which holds the sand
mould intact. It is made up of wood for temporary
applications or metal for long‐term use.
y Drag: Lower moulding flask.
y Cope: Upper moulding flask.
y Cheek:
h k Intermediate
d moulding
ld fl k used
flask d in three‐
h
piece moulding.
moulding
For-2013 (IES, GATE & PSUs) Page 1 Contd…
y Moulding sand: The freshly prepared refractory
y Pattern: Pattern is a replica of the final object to be y Pouring basin: A small funnel‐shaped
funnel shaped cavity at the top
material used for making the mould cavity. It is a
made with some modifications. of the mould into which the molten metal is poured.
p
mixture of silica, clay and moisture in appropriate
y Parting
g line: This is the dividing
g line between the two y Sprue: The passage through which the molten metal
proportions.
i
moulding flasks that makes up the sand mould. from the pouring basin reaches the mould cavity.
y Backing
B ki sand:
d This
Thi is
i made
d up off used
d and
d burnt
b t
y Runner: The passage ways in the parting plane through
y Bottom board: This is a board normally made of wood,
sand.
sand which
hi h molten
l metall flow
fl i regulated
is l d before
b f they
h reach
h
which is used at the start of the mould making.
y Core: Used for making hollow cavities in castings.
castings the mould cavity.
cavity
y Gate: The actual entry
y p
point through
g which molten
Contd… metal enters the mould cavity in a controlled rate. Contd…
Padding IES‐2001
y Chaplet: Chaplets are used to support cores inside the y Tapering of thinner section towards thicker section
mould cavity.
cavity is known as 'padding'
padding . Th main
The i purpose off chaplets
h l t isi
y This will require extra material.
y Chill: Chills are metallic objects, which are placed in (a) To ensure directional solidification
y If padding is not provided, centre line shrinkage or
the mould to increase the cooling rate of castings. porosityy will result in the thinner section.
p (b) To provide efficient venting
y Riser: It is a reservoir of molten metal provided in the
(c) For aligning the mold boxes
casting so that hot metal can flow back into the mould
(d) To support the cores
cavity
i when
h there
h i a reduction
is d i in i volume
l off metall due
d
to solidification
Contd…
IES‐1996 IES 2007 GATE‐2009

Which of the following methods are used for Which one of the following is the correct
obtaining directional solidification for riser design statement? Match the items in Column I and Column II.
Column I Column II
G
Gate i provided
is id d in
i moulds ld to
1. Suitable placement of chills P. Metallic Chills 1. Support for the core
((a)) Feed the casting g at a constant rate
Q M t lli Ch l t R
Q. Metallic Chaplets 2. Reservoir of the molten metal
i f th lt t l
2. Suitable placement of chaplets (b) Give passage to gases R. Riser 3. Control cooling of critical
3. Employing
l padding
dd ( ) Compensate
(c) C f shrinkage
for hi k sections
i
((d)) Avoid cavities S. Exothermic Padding 4. Progressive solidification
S l t the
Select th correctt answer. (a) P‐1,Q‐3, R‐2, S‐4 (b) P‐1,Q‐4, R‐2, S‐3
(a) 1 and 2 (b) 1 and 3 (c) 2 and 3 (d) 1,
1 2 and 3 ((c)) P‐3, Q‐4, R‐2, S‐1
3, Q 4, , ((d)) P‐4, Q‐1, R‐2, S‐3
4, Q , , 3
For-2013 (IES, GATE & PSUs) Page 2

GATE‐1992 GATE 2011 Pattern
In a green‐sand moulding process, uniform Green sand mould indicates that
A pattern is a replica of the object to be made by the
ramming leads to (a) polymeric mould has been cured
casting process, with some modifications.
(a) Less chance of gas porosity (b) mould has been totally dried
The main modifications are
(b) Uniform flow of molten metal into the mould (c) mould is green in colour
y The addition of pattern allowances,
cavity (d) mould contains moisture
y The provision of core prints, and
(c) Greater dimensional stability of the casting
y Elimination of fine details, which cannot be obtained
(d) Less sand expansion type of casting defect by casting and hence are to be obtained by further
processing
Pattern Allowances Shrinkage allowance Liquid shrinkage and solid shrinkage

y All metals shrink when cooling except perhaps y Liquid shrinkage refers to the reduction in
1. Shrinkage or contraction allowance
g
volume when the metal changes from liquid to
bismuth. solid state at the solidus temperature. To account
2. Draft or taper allowance
y This is because of the inter‐atomic vibrations which f this,
for hi risers
i are provided
id d in
i the
h moulds.
ld
3. Machining or finish allowance
are amplified
l f d by
b an increase in temperature.
4. Distortion or camber allowance y Solid shrinkage is the reduction in volume
y The
Th shrinkage
hi k allowance
ll i always
is l to be
b added
dd d to the
h caused, when a metal loses temperature in the
caused
5. Rapping allowance solid state. The shrinkage allowance is provided to
linear dimensions.
dimensions Even in case of internal dimensions.
dimensions take
k care off this
hi reduction.
d i
Contd…
y Pattern Allowances IES‐1995 GATE‐1999

Cast Iron 10 mm/m
Which one of the following materials will require
Brass, Copper, Aluminium 15 mm/m Which of the following materials requires the
Steel 20 mm/m the largest size of riser for the same size of casting? largest shrinkage allowance, while making a
Zinc, Lead 25 mm/m pattern for casting?
(a) Aluminium
(a) Aluminium
(b) Cast iron (b) Brass
y In grey cast iron and spheroidal graphite iron, the
amount off graphitization
hi i i controls
l the
h actuall (c) Steel (c) Cast Iron
shrinkage. When graphitization is more, the (d) Plain Carbon Steel
shrinkage would be less and vice versa. (d) Copper.

IES‐1999 GATE‐2001
In solidification of metal during casting,
ISRO‐2007
Shrinkage allowance on pattern is provided to
Shrinkage allowance is made by
compensation for
f solid
l d contraction is compensate for shrinkage when
(a) Adding to external and internal dimensions
(a) The temperature of liquid metal drops from
( ) Provided
(a) P id d byb the
h oversize
i pattern (b) Subtracting from external and internal pouring to freezing temperature
dimensions
(b) Achieved
A hi d byb properly
l placed
l d risers
i (b) The
Th metalt l changes
h f
from li id to
liquid t solid
lid state
t t att
(c) Subtracting from external dimensions and freezing temperature
(c) Obtained by promoting directional adding to internal dimensions
(c) The temperature of solid phase drops from
solidification (d) Adding to external dimensions and subtracting freezing to room temperature
from internal dimensions
(d) The temperature of metal drops from pouring
((d)) Made byy p
providing
g chills
to room temperature
GATE‐2004 GATE‐2008 GATE 2011

A cubic casting of 50 mm side undergoes volumetric
Gray cast iron blocks 200 x 100 x 10 mm are to be solidification shrinkage g and volumetric solid
Whil cooling,
While li a cubical
bi l casting
ti off side
id 40 mm
cast in sand moulds. Shrinkage allowance for contraction of 4% and 6% respectively. No riser is
pattern making is 1%.1% The ratio of the volume of undergoes 3%,
3% 4% and 5% volume shrinkage used Assume uniform cooling in all directions.
used. directions The
pattern to that of the casting will be side of the cube after solidification and contraction is
during
g the liquid
q state, p
phase transition and solid
( ) 48.32
(a) 8 mm
state, respectively. The volume of metal ((b)) 49
49.90
9 mm
(a) 0.97
0 97 (b) 0.99
0 99 (c) 1.01
1 01 (d) 1.03
1 03
compensated from the riser is (c) 49.94 mm
(a) 2% (b) 7% (c) 8% (d) 9% (d) 49.96 mm
IAS‐1995 IAS‐2003 Draft

Assertion (A): A pattern is made exactly similar to Match List I (Material to be cast) with List II y To reduce the chances of the damage of the mould
the part to be cast. ((Shrinkage g Allowance in mm/m) / ) and select the
correct answer using the codes given below the lists: cavity at the
h time off pattern removal,
l the
h verticall faces
f
Reason (R): Pattern is used to make the mould
cavity for pouring in molten for casting.
casting List‐II
List List‐II
List II of the pattern are always tapered from the parting line.
line
(a) Both A and R are individually true and R is the (Material to Cast) (Shrinkage Allowance in mm/m)
(A) Grey cast iron 1
1. 7 10
7 ‐ This provision is called draft allowance.
correct explanation
l i off A
(b) Both A and R are individuallyy true but R is not the (B) Brass 2. 15
y Inner surfaces of the p
pattern require
q higher
g draft than
correct explanation of A ( ) Steell
(C) 3. 20
(c) A is true but R is false (D) Zinc 4. 24 outer surfaces.
(d) A is false but R is true Codes:A B C D A B C D
y Draft is always provided as an extra metal.
(a) 1 2 3 4 (b) 3 4 1 2
(c) 1 4 3 2 (d) 3 2 1 4
Shake Allowance Distortion Allowance
y At the time of p
pattern removal,, the p
pattern is rapped
pp y A metal when it has just solidified is very weak and
therefore is likely to be distortion prone.
all around the vertical faces to enlarge the mould
cavity slightly to facilitates its removal. y This is particularly so for weaker sections such as long
flatt portions,
fl ti V U sections
V, ti or in
i a complicated
li t d casting
ti
y It is a negative allowance and is to be applied only to which may have thin and long sections which are
those dimensions, which are parallel to the parting connected to thick sections.
plane.
l
y The foundry practice should be to make extra
material
i l provision
i i for
f reducing
d i theh distortion.
di i
DRAFT ALLOWANCE
Pattern Materials The pattern material should be IES‐1994

y Wood patterns are relatively easy to make. Wood is not
y Easily worked, shaped and joined Which of the following materials can be used for
veryy dimensionallyy stable. Commonlyy used teak,, white
pine and mahogany wood. y Light in weight making patterns?
y Metal patterns are more expensive but are more
y Strong, hard and durable 1. Aluminium 2. Wax 3. Mercury 4. Lead
dimensionally stable and more durable. Commonly used
CI Brass,
CI, Brass aluminium and white metal.
metal y Resistant to wear and abrasion
R i t t t d b i
Select the correct answer using the codes given below:
y Hard plastics, such as urethanes, and are often preferred
y Resistant to corrosion, and to chemical reactions
withh processes that
h use strong, organicallyll bonded
b d d sands
d Codes:
that tend to stick to other pattern materials. y Dimensionally stable and unaffected by variations in
y In the full‐mold process, expanded polystyrene (EPS) is ( ) 1,3 and
(a) d 4 (b) 2,3 and
d 4 (c)
( ) 1, 2 and
d 4 (d) 1, 2 and
d3
temperature and humidity.
used.
y Investment casting uses wax patterns. y Available at low cost.
GATE‐2000 Types of Pattern Types of Pattern

Single Piece Pattern Split Pattern or Two Piece Pattern
These are inexpensive and the simplest type of This is the most widelyy used type
yp of ppattern for intricate
Di
Disposable patterns are made of
bl tt d f
patterns. As the name indicates, they are made of a castings. When the contour of the casting makes its
(a) Wood single piece.
piece withdrawal from the mould difficult, or when the depth
of the casting is too high, then the pattern is split into two
(b) Rubber parts so that one part is in the drag and the other in the
Gated Pattern cope.
(c) Metal Gating and runner system are integral with the
pattern. This would eliminate the hand cutting of
(d) Polystyrene the runners and gates and help in improving the
productivity of a moulding.

Types of Pattern Types of Pattern Types of Pattern
y Cope and Drag Pattern y Loose Piece Pattern
y Match Plate Pattern
These are similar to split patterns. In addition to This type of pattern is also used when the
splitting
p g the p
pattern,, the cope
p and dragg halves of The cope and drag patterns along with the
gating
i andd the
h risering
i i are mounted d on a single
i l contour of the part is such that withdrawing the
the pattern along with the gating and riser systems pattern from the mould is not possible.
are attached separately to the metal or wooden g metal or wooden p
matching plate on either side.
plates along with the alignment pins. They are
called the cope and drag patterns.
patterns
Types of Pattern IES‐2008 Types of Pattern

y Follow
F ll Board
B d Pattern
P y Sweep Pattern
yp of p
This type pattern is adopted
p for those The pattern adopted for those castings where there It is used to sweep the complete casting by means
castings where there are some portions, which are some portions which are structurally weak and of a plane sweep. These are used for generating
are structurally weak and if not supported are likely to break by the force of ramming are large shapes,
shapes which are axi‐symmetrical
axi symmetrical or
properly are likely to break under the force of called: prismatic in nature such as bell‐shaped or
ramming.
ramming (a) Loose piece pattern cylindrical.
li d i l
(b) Follow board pattern
(c) Skelton pattern
(d) Single piece pattern
Types of Pattern g
Cooling Curve Fluidity
y Skeleton
Sk l Pattern
P The ability of a metal to flow and fill a mold is known
A skeleton of the p
pattern made of strips p of wood as fluidity.
is used for building the final pattern by packing Pouring Temperature
sand around the skeleton.
skeleton After packing the y The most important controlling factor of fluidity is the
sand, the desired form is obtained with the help pouring temperature or the amount of superheat.
of a strickle.
strickle This type
t pe of pattern is useful y Higher the pouring temperature,
temperature the higher the fluidity.
fluidity
generally for very large castings, required in y Excessive temperatures should be avoided, however. At
high pouring temperatures,
temperatures metal‐mold reactions are
smallll quantities where
h l
large expense on
accelerated and the fluidity may be so great as to permit
complete
p wooden ppattern is not jjustified. penetration.
y Penetration is a defect where the metal not only fills the
mold cavity but also fills the small voids between the sand
particles in a sand mold.
ISRO‐2011 Core
GATE 2012 (PI)
GATE 2012 (PI)
Fluidity in casting (CI) operation is greatly y Used for making cavities and hollow projections.
In sand casting, fluidity of the molten metal
increases with influenced by
y All sides of core are surrounded by the molten metal
(A) increase
i i degree
in d off superheat
h
a) Melting temperature of molten metal and are therefore subjected to much more severe
((B)) decrease in p
pouring
g rate thermal and mechanical conditions and as a result the
(C) increase in thermal conductivity of the mould b) Pouring temperature of molten metal core sand should be of higher strength than the
(D) increase
i i sand
in d grain
i size
i moulding
ldi sand.
d
c) Finish of the mould
d) Carbon content of molten metal
y Then,
Then the permeability number,
number R is obtained by
Desired characteristics of a core y Permeability:
y Gases evolving
g from the molten metal R=
VH
and generated from the mould may have to go pAT
AT
y Green Strength: A core made of green sand should through the core to escape out of the mould. Hence Where V= volume of air = 2000 cm3
be strong enough to retain the shape till it goes for cores are required to have higher permeability. H = height of the sand specimen = 5.08 cm
baking.
baking y Permeability
P bilit Number:
N b Th rate
The t off flow
fl off air
i passing
i
p = air pressure, g/cm2
y Dry Strength: It should have adequate dry strength through a standard specimen under a standard pressure is
termed
d as permeability
bili number.
b A = cross sectional area of sand specimen = 20 268 cm2
A = cross sectional area of sand specimen = 20.268 cm
so that when the core is placed in the mould, it
should be able to resist the metal p
pressure acting
g on y The standard p
permeabilityy test is to measure time T = time in minutes for the complete air to pass through
it. taken by a 2000 cu cm of air at a pressure typically of
Inserting the above standard values into the
y Refractoriness: Since in most cases,cases the core is 980 Pa (10 g/cm2), to pass through a standard sand
expression, we get
i
surrounded all around it is desirable that the core specimen confined in a specimen tube. The standard 501.28
specimen size is 50.8
50 8 mm in diameter and a length of R=
material
i l should
h ld have
h hi h refractoriness.
higher f i p.T
Contd… 50.8 mm.
y Calculate the permeability number of sand if it takes 1 min
25 s to pass 2000 cm3 of air at a pressure of5 g/cm2 through
the standard sample.
IES 2007
IES 2007
y Collapsibility: At the time of cooling, casting shrinks, and
p y g, g ,
What is permeability? Permeability is more important
unless the core has good collapsibility (ability to decrease
p = 5.0 g / cm 2 in the basic process of sand casting than porosity. Give
p g p y in size) it is likely to provide resistance against shrinkage
) y p g g
T = 1 min 25 s = 1.417 min and thus can cause hot tears.
one important reason for this feature.
501.28
501 28
R= = 70.75 [2 marks]
5 × 1.417

Core Sands Carbon Dioxide Moulding
y Friability: The ability to crumble should be a very y Sodium
S di silicate
ili (water
( glass,
l SiO2:Na
N 2O) is
i used
d as a binder.
bi d
y Used clay free silica sand. This is essentially a quick process of core or mould
important
p consideration at the time of removal.
preparation.
y Binders used are linseed oil, core oil, resins, dextrin,
y Smoothness: Surface of the core should be smooth y The mould is pprepared
p with a mixture of sodium silicate and
molasses, etc. sand and then treated with carbon dioxide for two to three
for good finish to the casting.
minutes such that a dryy compressive
p strength
g of over 1.44
y Core oils
l are mixtures off linseed,
l d soy, fish
f h and
d MPa is arrived.
y Low Gas Emission
petroleum oils and coal tar.
tar y The carbon dioxide is expected to form a weak acid,
acid which
hydrolyses the sodium silicate resulting in amorphous silica,
y The general composition of a core sand mixture could which forms the bond.
bond
be core oil ((1%)) and water ((2.55 to 6%).
) y The introduction of CO2 gas starts the reaction by forming
h d
hydrated
d sodium
d carbonate
b ( 2CO
(Na O3 + H2O).
O)
Contd…
IES‐2002 G
GATE – 2008 ( )
2008 (PI)
y The compressive strength of the bond increases with In sand casting of a hollow part of lead,
lead a cylindrical core
Assertion (A): In CO2 casting process, the mould or
standing time due to dehydration. core attains maximum strength. of diameter 120 mm and height 180 mm is placed inside
y Because of the high strength of the bond, the core need not Reason (R): The optimum gassing time of CO2
through the mould or core forms Silica Gel which the mould cavity. The densities of core material and lead
be provided with any other reinforcements. imparts sufficient strength to the mould or core. are 1600 kg/m3 and 11,300 kg/m3 respectively. The net
y It does not involve any distortions due to baking and also (a) Both A and R are individually true and R is the
correct explanation of A force (in N) that tends to lift the core during pouring of
better dimensional accuracies are achieved.
achieved ( ) Both A and R are individually true but R is not the
(b) molten metal will be
y The sand mixture does not have good shelf life and correct explanation of A
(c) A is true but R is false ( ) 19.7
(a) ( ) 64.5
(b) ( ) 193.7
(c) ( ) 257.6
(d)
therefore should be used immediately after preparation.
(d) A is false but R is true
Moulding Sand Composition Other Additives Moulding Sand Properties

y Sand: Ordinary silica Sand (SiO2), zircon, or olivine y Porosity or Permeability: Permeability or porosity of
y Cereal binder up to 2% increases the strength.
the moulding g sand is the measure of its abilityy to
sands.
d permit air to flow through it.
y Pitch if used up to 3% would improve the hot
y Clay:
Cl A
Acts as binding
bi di agents mixed
i d to the
h moulding
ldi y Strength: It is defined as the property of holding
strength.
together of sand grains. A moulding sand should have
sands amplel strength h so that
h the
h mouldld does
d not collapse
ll or
y Saw dust up to 2% may improve the collapsibility by
Kaolinite or fire clay (Al2O3 2SiO2 2H2O),
O) and get partially destroyed during conveying, turning over
slowly
l l burning,
b i and
d increase
i the
h permeability.
bili or closing.
Bentonite (Al2O3 4SiO2 H2O nH2O). y Other
Oth materials:
t i l sea coal,
l asphalt,
h lt fuel
f l oil,
il graphite,
hit y Refractoriness: It is the ability of the moulding sand
mixture to withstand the heat of melt without showing
y Water: Clay
y is activated byy water. molasses iron oxide,
molasses, oxide etc.
etc any signs
i off softening
ft i or fusion.
f i
y Plasticity: It is the measure of the moulding sand to flow Other Sands IES‐2008
around and over a pattern during ramming and to uniformly
d d d i i d if l y Facing sand: The small amount of carbonaceous
fill the flask. material sprinkled on the inner surface of the mold
y Collapsibility: This is the ability of the moulding sand to cavity
i to give
i a better
b surface
f fi i h to the
finish h castings.
i S ll amountt off carbonaceous
Small b material
t i l sprinkled
i kl d
decrease in volume to some extent under the compressive
p y Backing g sand: It is what constitutes most of the on the inner surface of mould cavity is called
forces developed by the shrinkage of metal during freezing refractory material found in the mould. This is made
and subsequent cooling.
q g up of used and burnt sand.
sand (a) Backing sand
y Adhesiveness: This is the property of sand mixture to y Green Sand: The molding sand that contains
adhere to another body (here the moulding flasks) The
adhere to another body (here, the moulding flasks). The ((b)) Facing
g sand
moisture is termed as green sand. The green sand
moulding sand should cling to the sides of the moulding
should have enough g strength
g so that the constructed ((c)) Green sand
boxes so that it does not fall out when the flasks are lifted
mould retains its shape.
and turned over. This property depends on the type and (d) Dry sand
amount of binder used in the sand mix.
t f bi d d i th d i y Dry sand: When the moisture in the moulding sand is
completely expelled, it is called dry sand.
Grain size number IES‐2002 Casting Yield

y ASTM (American Society for Testing and Materials) In the grain ‐size determination using standard The casting yield is the proportion of the actual
grain size number,
number defined as casting mass, w, to the mass of metal poured into the
n-1
charts, the relation between the given size
N 2 mould, W, expressed as a percentage.
p p g
number
b n and
d the
th average number
b off grains
i 'N'
N
y Where N is the number of grains per square inch
visible in a prepared specimen at 100X and n is the per square
p q inch at a magnification
g of 100 X is
w
ASTM grain‐size number.
(a) N = 2n Casting yield = × 100
y Low
L ASTM numbers b mean a few
f massive
i grains;
i hi h
high W
numbers refer to many small grains. (b) N = 2n‐l
(c) N = 2n + 1
(d) N = 2n + 1
G i S
Gating System G ti S t
Gating System
y Ingate: A channel through which the molten metal
y Pouring
P i basin:
b i A small
ll funnel
f l shaped
h d cavity
i at the
h
enters the mould cavity.
top of the mould into which the molten metal is
poured. y Vent:
V S ll
Small opening in the mould to facilitate escape
i i h ld f ili
of air and gases.
y Sprue: The passage through which the molten metal,
ffrom the
h pouring basin,
b reaches
h the
h mould
ld cavity. In
many cases it controls the flow of metal into the
mould.
y Runner: The channel through which the molten

metal is carried from the sprue to the gate.
For-2013 (IES, GATE & PSUs) Contd… Page 9 Contd…
Types of Gate or In‐gate IES 2011 GATE – 2010 (PI)
Top gate: Causes turbulence in the mould cavity, it is prone In light metal casting, runner should be so designed During the filling process of a given sand mould cavity by
that:
to form
f d
dross, f
favourable
bl temperature gradient
d towards
d the
h molten
lt metal
t l through
th h a horizontal
h i t l runner off circular
i l cross‐
1. It avoids aspiration
gate only for ferrous alloys.
gate, alloys section the frictional head loss of the molten metal in the
2. It
I avoids
id turbulence
b l
runner will increase with the
Bottom g
gate: No mould erosion,, used for veryy deep
p moulds,, 33. The p
path of runner is reduced in area so that
higher pouring time, Causes unfavourable temperature
unequal volume of flow through each gate (a) increase in runner diameter
takes place (b) decrease in internal surface roughness of runner
gradients.
(a) 1 and 2 only (b) 1 and 3 only
Parting Gate: most widely used gate,gate easiest and most (c) decrease in length of runner
economical in preparation. (c) 2 and 3 only (d) 1, 2 and 3
(d) increase in average velocity of molten metal
Step Gate: Usedd for
f heavy
h and
d large
l castings, size off ingates
are normally increased from top to bottom.
IES 2011
IES 2011 IES‐1998 GATE‐2002
g
Match List –I with List –II and select the correct answer using
the code given below the lists : A sand d casting
i mould
ld
assembly is shown in The primary purpose of a sprue in a casting
List –I
List I List –II
List II
the above figure. The mould is to
A. Top gate 1. Heavy and large castings elements marked A (a)Feed the casting at a rate consistent with the rate
B. Bottom gate 2. Most widely used and economical and B are respectively of solidification
C. Parting gate 3. Turbulence (a) Sprue and riser (b)A as a reservoir
(b)Act i for
f molten
l metall
(b) Ingate and riser ((c)Feed
) molten metal from the ppouring g basin to the
D St t
D. Step gate 4. Unfavourable
U f bl temperature gradient
t t di t
(c) Drag and runner gate
Codes
(d) Riser
Ri and d runner (d)Help feed the casting until all solidification takes
A B C D A B C D place
(a) 3 4 2 1 (b) 1 4 2 3
(c) 3 2 4 1 (d) 1 2 4 3
The goals for the gating system IES‐1998 IES‐2009

y To minimize turbulence to avoid trapping gasses into Which of the following are the requirements of an ideal Consider the following statements:
the mold gating system?
1 The actual entry point through which the molten
1.The actual entry point through which the molten
1. The molten metal should enter the mould cavity with as
y To get enough metal into the mold cavity before the metal enters the mould cavity is called ingate.
high a velocity as possible.
metall starts to solidify
lidif 2.Bottom gate in case of a mould creates unfavourable
2. It should facilitate complete filling of the mould cavity.
y To avoid shrinkageg temperature gradient.
p g
3. It should be able to prevent the absorption of air or gases
I h ld b bl h b i f i
y Establish the best possible temperature gradient in the from the surroundings on the molten metal while 3.Sprue in case of a mould is made tapered to avoid air
solidifying casting so that the shrinkage if occurs must flowing through it. inclusion.
inclusion
be in the gating system not in the required cast part. Select the correct answer using the codes given below:
g g Which of the above statements is/are correct?
y Incorporates a system for trapping the non‐metallic (a) 1, 2 and 3 (b) 1 and 2 (c) 2 and 3 (d) 1 and 3 (a) 1 only (b) 1 and 2 (c) 2 and 3 (d) 1 and 3
inclusions.

Types of Gating Systems Pressurized Gating System Un‐Pressurized Gating System
y The total cross sectional area decreases towards the y The total cross sectional area increases towards the
The gating systems are of two types: mold
ld cavity
it
mold cavity
y Back ppressure is maintained byy the restrictions in the
y Pressurized gating system metal flow y Restriction only at the bottom of sprue
y Flow of liquid (volume) is almost equal from all gates
y Flow of liquid (volume) is different from all gates
y Un‐pressurized gating system
p g g y y Back pressure helps in reducing the aspiration as the
sprue always runs full y Aspiration in the gating system as the system never
y Because of the restrictions the metal flows at high runs full
f ll
velocity leading to more turbulence and chances of
mold erosion.
erosion y Less turbulence.
turbulence
S
Sprue D i
Design Since the velocities are proportional to the square of
y Sprue: Sprue is the
h channel
h l through
h h which
h h the
h molten
l the potential heads, as can be derived from
the potential heads as can be derived from
metal is brought into the parting plane where it enters the Bernoulli's equation,
runners and gates to ultimately reach the mould cavity.
hc
y The molten metal when moving g from the topp of the cope
p to At = Ac
ht
the parting plane gains in velocity and some low‐pressure
area would be created around the metal in the sprue.
y Since the sand mould is permeable, atmospheric air would The exact tapering can be obtained by the equation of
be breathed into this low‐pressure
low pressure area which would then continuity Denoting the top and choke sections of The sprue by
continuity. Denoting the top and choke sections of The sprue
be carried to the mould cavity. the subscripts’t’ and 'c' respectively, we get
Where H = actual
Where H actual
y To eliminate
l this
h problem
bl off air aspiration, the
h sprue is
sprue height
tapered to gradually reduce the cross section as it moves Vc
A t Vt = A c Vc At = Ac and ht = h + H
h + H
away from the top of the cope as shown in Figure below (b). Vt
Contd… Contd…
GATE‐2007
GATE‐2001 A 200 mm long down sprue has an area of cross
section of 650 mm2 where the pouring basin meets the
The height of the down
down‐sprue
sprue is 175 mm and its
d
down sprue (i.e.
(i at the
h beginning
b i i off the h down
d sprue).)
cross‐sectional area at the base is 200 mm2. The
A constant head of molten metal is maintained by the
cross sectional area of the horizontal runner is
cross‐sectional
pouring basin. The Molten metal flow rate is 6.5 × 105
also 200 mm2. Assuming no losses, indicate the
mm3/s. Considering the end of down sprue to be open
correct choice
h i for
f the
h time
i (i seconds)
(in d ) required
i d to
to atmosphere and an acceleration due to gravity of
fill a mould cavity of volume 106 mm3. (Use g = 10
104mm/s2, the area of the down sprue in mm2 at its end
m/s2).
(avoiding aspiration effect) should be
(a)2 67 (b)8.45
(a)2.67 (b)8 45 (c)26 72
(c)26.72 (d)84 50
(d)84.50
( )
(a)650.0 ( )
(b)350.0 ( )
(c)290.7 ( )
(d)190.0
Contd…
Gating ratio IES‐2003 IES‐2005
A gating ratio of 1: 2: 4 is used to design the gating
y Gating ratio is defined as: Sprue area: Runner area:
system
y for magnesium
g alloyy casting.
g This g
gating
g ratio The gating ratio 2: 8: 1 for copper in gating system
Ingate area. refers to the cross∙ section areas of the various gating design refers to the ratio of areas of:
elements as given below:
y For high quality steel castings, a gating ratio of 1: 2: 2 or ( ) Sprue:
(a) S R
Runner: I
Ingate
1. Down sprue 2. Runner bar 3. Ingates
1: 2: 1 5 will produce castings nearly free from erosion
1: 2: 1.5 will produce castings nearly free from erosion, ((b)) Runner: Ingate:
g Sprue
p
Th correct sequence off the
The h above
b elements
l i the
in h
ratio 1: 2: 4 is (c) Runner: Sprue: Ingate
will minimize oxidation, and will produce uniform
, p
(a) 1, 2 and 3 (d) Ingate:
I R
Runner: S
Sprue
flow.
(b) 1,3 and 2
y A gating ratio of 1: 4: 4 might favour the formation of (c) 2, 3 and 1
oxidation defects. (d) 3, 1 an 2
GATE‐2010 IAS‐1999 Risers and Riser Design

Assertion (A): The rate of flow of metal through sprue
y Risers
Ri are added
dd d reservoirs
i designed
d i d to feed
f d liquid
li id
is NOT a function of the cross‐sectional areas of metal to the solidifying casting as a means of
I ti t
In a gating system, the ratio 1:2:4 represents
th ti t sprue, runner and gate. compensating for solidification shrinkage.
(a) Sprue base area: runner area: ingate area Reason (R): If respective cross
cross‐sectional
sectional areas of y To perform this function,
function the risers must solidify after
sprue, runner and gate are in the ratio of 1: 2: 2, the the casting.
(b) Pouring basin area : ingate area : runner area y
system is known as unpressurised
p gating
g g system.
y
(a) Both A and R are individually true and R is the correct y According
d to Chvorinov's
Ch ' rule,
l a goodd shape
h f a riser
for
(c) Sprue base area : ingate area : casting area explanation of A would be one that has a long freezing time (i.e., a small
(b) Both A and R are individually true but R is not the surface area per unit volume).
(d) Runner area : ingate area : casting area correct explanation of A y Live risers (also known as hot risers) receive the last
(c) A is true but R is false hot metal that enters the mold and generally do so at a
(d) A is false but R is true ti
time when
h th metal
the t l in
i the
th moldld cavity
it has
h already
l d
begun to cool and solidify.
IES‐1994 Chvorinov’s rule IES 2011

Assertion
A i (A):
(A) In
I a mould, ld a riser
i is
i designed
d i d andd placed
l d y Total solidification time (t
l ldf )n
( s) = B (V/A)
) ( The
h relationship
l h between
b totall freezing
f time t,
so that the riser will solidify after the casting has solidified. volume of the casting V and its surface area A,
where n 1.5 to 2.0
where n = 1.5 to 2.0
Reason (R): A riser is a reservoir of molten metal which according to Chvorinov’s rule is :
[Where, B = mould constant and is a function of (mould
will supply
pp y molten metal where a shrinkage g cavityy would
material, casting material, and condition of casting]
t i l ti t i l d diti f ti ] ⎛V ⎞
have occurred. (a ) t = k ⎜ ⎟
⎝ A ⎠
(a) Both A and R are individually true and R is the correct n = 2 and triser = 1.25 t
5 casting
⎛ A ⎞
explanation of A (b ) t = k ⎜ ⎟
⎛V⎞
2
⎛V⎞
2 ⎝V ⎠
(b) Both
B th A and d R are individually
i di id ll true
t b t R is
but i nott the
th or ⎜A⎟ = 1.25
1 25 ⎜ ⎟
⎛ A ⎞
2
⎝ ⎠riser ⎝ A ⎠casting (c ) t = k ⎜ ⎟
correct explanation of A ⎝V ⎠
(c) A is true but R is false ⎛V ⎞
2
For cylinder V = πD2H / 4 (d ) t = k ⎜ ⎟
( )
((d)) A is false but R is true of diameter D 2 ⎝ A ⎠
A = πDH + 2 πD Wh
Where K is
i a constant
and height H 4
IES‐1998 GATE‐2003 IES‐2006
A spherical
p drop
p of molten metal of radius 2 mm According to Chvorinov's equation, the
With a solidification f t off 0.97 x 106 s/m
lidifi ti factor / 2, the
th
was found to solidify in 10 seconds. A similar drop solidification time of a casting is proportional to:
solidification time (in seconds) for a spherical
of radius 4 mm would solidify in (a) v2
casting
g of 200 mm diameter is
(a) 14.14 seconds (b) v
(a) 539 (b) 1078 (c) 4311 (d) 3233
(b) 20 seconds (c) 1/v
(c) 28.30 seconds (d) 1/v2
(d) 40 seconds Where, v = volume of casting
GATE – 2010 (PI) GATE‐2007

Solidification time of a metallic alloy casting is
GATE ‐2011 (PI)
GATE ‐2011 (PI)
Volume of a cube of side 'l'l and volume of a sphere of In a sand casting gpprocess,, a sphere
p and a cylinder
y
(a) Directly proportional to its surface area of equal volumes are separately cast from the same
radius ‘r’ are equal.
q Both the cube and the sphere
p are solid molten metal under identical conditions. The
(b) Directly proportional to the specific heat of the height and diameter of the cylinder are equal. The
and of same material. They are being cast. The ratio of the
ratio of the solidification time of the sphere to that
castt material
t i l
solidification time of the cube to the same of the sphere is: of the cylinder is
(c) Directly proportional to the thermal diffusivity of 3 6 2 2 3 2 4
(a) 1.14
1 14
⎛ 4π ⎞ ⎛ r ⎞ 4π ⎞ ⎛ r ⎞ 4π ⎞ ⎛ r ⎞ 4π ⎞ ⎛ r ⎞
(a ) ⎜ 6 ⎟ ⎜l⎟ ( b ) ⎛⎜ ⎟⎜ ⎟ ( c ) ⎛⎜ ⎟ ⎜ ⎟ ( d ) ⎛⎜ ⎟ ⎜ ⎟ (b) 0.87
the molten metal ⎝ ⎠ ⎝ ⎠ ⎝ 6 ⎠⎝ l ⎠ ⎝ 6 ⎠ ⎝l⎠ ⎝ 6 ⎠ ⎝l⎠
( ) 1.31
(c)
((d)Inversely
) y proportional
p p to the pouring
p g ((d)) 0.76
7
temperature.
IES ‐ 2012
( )
GATE‐2009 (PI)
A solid cylinder of diameter D and height equal to D, and a solid The ratio of surface area of volume for a unit volume of
cube of side L are being sand cast by using the same material.
material riser is minimum in case off
Assuming there is no superheat in both the cases, the ratio of
solidification time of the cylinder to the solidification time of the ( ) C li d i l i
(a) Cylindrical riser
cube is
(b) S h i l i
(b) Spherical riser
(a) (L/D)2
(c) Hemispherical riser
(b) (2L/D)2
( D/L)2
( ) (2D/L)
(c) (d) Cuboids riser
(d) (D/L)2

IES 2011 C ti l
IES 2011 Conventional Modulus Method
y A round casting
g is 20 mm in diameter and 550 mm in Conventional Question ESE 2003
y It has been empirically established that if the modulus
length. Another casting of the same metal is elliptical in
Compare the solidification time of two optimum side – off the
h riser
i exceeds
d the
h modulus
d l off the
h casting
i b a
by
cross section, with a major to minor axis ratio of 2, and
factor of 1.2,
1 2 the feeding during solidification would be
has the same length and cross‐sectional area as the risers off the
h same volume
l with
h one has
h cylindrical
l d l shape
h
satisfactory.
round casting. Both pieces are cast under the same and other is parallopiped.
parallopiped [30 Marks]
MR = 1.2 Mc
conditions What is the difference in the solidification
conditions.
y Modulus = volume/Surface area
times of the two castings ? [10 – Marks]
Area of ellipse = π ab y In steel castings, it is generally preferable to choose a
Circumference = π ⎡3 ( a + b ) − ( 3a + b )( a + 3b ) ⎤⎦
⎣ riser
i with
i h a height‐to‐diameter
h i h di ratio
i off 1.
= 2π (a 2
+ b2 ) / 2 (approx.) Contd…
Caine’s Method
Conventional Question IES‐2008
Conventional Question IES‐2008 Freezing ratio = ratio of cooling characteristics of casting to
y Calculate the size of a cylindrical riser (height and diameter
the riser. A ( V)
X= Casting
πD 2
+π D 2
equal) necessary to feed a steel slab casting of dimensions ( AV ) Riser
4 30 x 30 x 6 cm with a side riser, casting poured horizontally The riser should solidify last so x > 1

into the mould.
a
According to Caine X =
X +c
[Use Modulus Method] Y−b
[[10 ‐ Marks]] V riser
Y = and a, b, c are constant.
Y d b
Vcasting
Table: Constants in Caine’s Method
Conventional Question IES‐2007
Question IES‐2007
y Calculate the size of a cylindrical
y riser (height
g and
diameter equal) necessary to feed a steel slab
casting of dimensions 25 x 25 x 5 cm with a side
riser, casting poured horizontally into the mould.
[Use Caine’s Method]
[ For
F steell a = 0.10, b = 0.03 and
d c = 1.00 ]

Chills IES‐1995 GATE‐1998,2007
y External
E l chills
hill are masses off high‐heat‐capacity,
hi h h i high‐thermal‐
hi h h l
conductivity material that are placed in the mould (adjacent to
the casting)
th ti ) to
t accelerate
l t theth cooling
li off various
i regions.
i Di ti
Directional
l solidification
lidifi ti i castings
in ti can be
b Chill are used
Chills d in
i moulds
ld to
t
Chills can effectively promote directional solidification or
i
increase the
h effective
ff i feeding
f di distance
di off a riser.
i Th can often
They f improved by using (a) Achieve directional solidification
be used to reduce the number of risers required for a casting.
(a) Chills and chaplets (b) Reduce the possibility of blowholes
y Internal chills are pieces of metal that are placed within the
mould cavity to absorb heat and promote more rapid ((b)) Chills and p
padding
g
solidification.
lidifi i Si
Since some off this
hi metall willill meltl during
d i the
h (c) Reduce freezing time
operation, it will absorb not only the heat‐capacity energy, but ((c)) Chaplets
p and p
padding
g
also
l some heat h t off fusion.
f i Si
Since th ultimately
they lti t l become
b partt off (d) Smoothen metal flow for reducing splatter.
the final casting, internal chills must be made from the same (d) Chills, chaplets and padding.
alloy
ll as that
th t being
b i cast.t
Cupola
IAS 1994 y Cupola has been the most widely used furnace for IES‐1997
melting cast iron. Assertion (A): Steel can be melted in hot blast cupola.
Chills are used in casting moulds to
y In hot blast cupola, the flue gases are used to preheat the Reason (R): In hot blast cupola,
cupola the flue gases are used to
( ) Achieve directional solidification
(a) A hi di i l lidifi i
air blast to the cupola so that the temperature in the preheat the air blast to the cupola so that the temperature in
((b)) Reduce possibility of blow holes
p y furnace is considerably higher than that in a th furnace
the f i considerably
is id bl higher
hi h th
than th t in
that i a
(c) Reduce the freezing time conventional cupola. Coke is fuel and Lime stone conventional cupola.
(d) Increase the smoothness of cast surface
I h h f f (C CO3) is
(CaCO i mostlyl used d flux.
fl (a) Both A and R are individually true and R is the correct
y Cost of meltingg low. explanation
p of A
y Main disadvantages of cupola is that it is not possible to (b) Both A and R are individually true but R is not the
produce iron below 2.8%
2 8% carbon.
carbon correct explanation of A
y Steel can be also prepared in cupola by employing (c) A is true but R is false
duplexing and triplexing operations. (d) A is
i false
f l but
b R isi true
IES ‐ 2012 El
Electric Arc Furnace
i A F
Statement
St t t (I):
(I) Cupola
C l furnace
f is
i nott employed
l d for
f Crucible Furnace
y For heavy steel castings, the open‐hearth type of
melting steel in foundry y Smaller foundries generally prefer the crucible furnace.
Statement (II): The temperatures generated within a f
furnaces with
h electric
l arc or oill fired
f d would
ld be
b generally
ll y The crucible is generally heated by electric resistance
cupola are not adequate for melting Steel or gas flame.
suitable in view of the large heat required for melting.
melting
(a) Both Statement (I) and Statement (II) are
individuallyy true and Statement ((II)) is the correct y Electric arc furnaces are more suitable for ferrous
explanation of Statement (I) Induction Furnace
(b) Both Statement (I) and Statement (II) are materials and are larger
g in capacity.
p y y The induction furnaces are used for all types of
individually true but Statement (II) is not the correct materials, the chief advantage being that the heat
explanation of Statement (I) source is isolated from the charge and the slag and flux
(c) Statement (I) is true but Statement (II) is false get the necessary heat directly from the charge instead
( ) Statement (I)
(d) ( ) is false but Statement (II)
( ) is true off the
th heat
h t source.
Ladles Casting Cleaning (fettling) GATE‐1996
Impurities in the molten metal are prevented from
y Two types of ladles used in the pouring of castings.
reaching the mould cavity by providing a
g y yp g Light impurities in the molten metal are prevented
(i) Strainer from reaching the mould cavity by providing a
(ii) Bottom well
B tt ll ( ) Strainer
(a) S i
(iii) Skim bob ((b)) Button well
(c) Skim bob
(d) All off the
h above
b
P i
Pouring time
i GATE‐2005 GATE‐2006
In a sasandd cast g ope
casting at o , tthee tota
operation, qu d head
total liquid ead iss
Time taken to fill the mould with top gate maintained constant such that it is equal to the mould
Where A = Area of mould A mould has a downsprue whose length is 20 cm height The time taken to fill the mould with a top gate
height.
AH
A.H
tA = H = Height of mould and the cross sectional area at the base of the is tA. If the same mould is filled with a bottom gate,
A g 2ghg m
Ag = Area of Gate
A f G t downsprue is 1cm2. The downsprue feeds a th the
then th time
ti t k is
taken i tB. Ignore
I th time
the ti required
i d to
t
Hm = Gate height horizontal runner leading into the mould cavity of fill the runner and frictional effects. Assume
volume
l 1000 cm3. The
Th time
i required
i d to fill the
h atmospheric pressure at the top molten metal surfaces.
mould cavity will be The relation between tA and tB is
Time taken to fill the mould with bottom gate
(a)4.05 s (b)5.05 s (c)6.05 s (d)7.25 s (A) tB = 2 t A
( )
2A ((B)) tB = 2 t A
tB = hm − hm − H tA
Ag 2g (C) tB =
2
(D) tB = 2 2 t A
GATE – 2007 (PI) Linked S‐1
( ) k d GATE – 2007 (PI) Linked S‐2
( ) k d Expression for choke area
In
I a sand d casting
ti process, a sprue off 10 mm base
b In
I a sand d casting
ti process, a sprue off 10 mm base
b m
diameter and 250 5 mm height
g leads to a runner diameter and 250 5 mm height
g leads to a runner CA = mm2
cρt 2gH
which fills a cubical mould cavity of 100 mm size which fills a cubical mould cavity of 100 mm size
Th volume
The l (i mm3/s)
fl rate (in
flow / ) is
i Th mould
The ld filling
filli time
i (i seconds)
(in d ) is
i Where m = mass of the casting, kg
0 8 x 105
(a) 0.8 1 1 x 105
(b) 1.1 (a) 2.8
28 (b) 5.78
5 78 y , g/ 3
ρ = Density of metal, kg / m
t = pouring time
(c) 1.7 x 105 (d) 2.3 x 105 (c) 7.54 (d) 8.41
c = Efficiency factor and is the function of gate
Effi i f t d i th f ti f t
system used
H = Effective head of liquid metal
= h for top gate
pg

H=h‐
hm
for bottom gate
IES 2009
IES 2009 IAS‐2011 Main
IAS‐2011 Main
2 y 2 marks
hc2
Sk t h a mould
Sketch ld for
f two
t h ll
hollow components
t to
t be
b
=h‐ for parting line gate
2h m cast On the diagram,
cast. diagram indicate runner,
runner gate,
gate riser,
riser
p sprue,
core, cope, p pouring
p g basin, sprue
p well, drag,
g
parting line.
hC
hm
[10‐Marks]
hm hm
P i li
top gate parting line gate bottom gate
Casting Defects Gas Defects Sh i k
Shrinkage Cavities
C ii
y These are caused by liquid shrinkage occurring during the
The following are the major defects, which are likely to y A condition existing in a casting caused by the solidification of the casting.
occur in sand castings:
d trapping of gas in the molten metal or by mold gases y To
T compensate for
f this,
hi proper feeding
f di off liquid
li id metall is
i
evolved during the pouring of the casting. required. For this reason risers are placed at the
y Gas defects
G d f y The defects in this category can be classified into appropriate
i places
l i the
in h mold.
ld
blowholes and p pinhole p
porosity.
y y Sprues
p mayy be too thin, too long
g or not attached in the
y Shrinkage cavities
Sh i k iti proper location, causing shrinkage cavities.
y Blowholes are spherical or elongated cavities present
y Molding material defects in the casting on the surface or inside the casting.
casting y It is recommended to use thick sprues to avoid shrinkage
cavities.
y Pinhole porosity occurs due to the dissolution of
y Pouring metal defects
hydrogen gas, which gets entrapped during heating of
y Mold shift.
Mold shift molten metal.
Cut and washes S b
Scab
g
Molding Material Defects y This defect occurs when a portion of the face of a mould
y These appear as rough spots and areas of excess metal, and lifts or breaks down and the recess thus made is filled by
y Cuts and washes,
Cuts and washes are caused byy erosion of molding g sand byy the flowing
g metal.
metal
metal.
y When the metal is poured into the cavity, gas may be
y Scab y This is caused by the molding sand not having enough di
disengaged d with
i h such
h violence
i l as to break
b k up the
h sand, d
strength and the molten metal flowing at high velocity. which is then washed away and the resulting cavity filled
y Metal penetration,
Metal penetration y The
Th former
f can beb taken
k care off by
b the
h proper choice
h i off with
i h metal.
l
molding sand and the latter can be overcome by the y The reasons can be: ‐ too fine sand, low p permeabilityy of
y Fusion, and
proper design
d off the
h gating system. sand, high moisture content of sand and uneven mould
y Swell ramming. g

Metal penetration
y When
h molten
l metall enters into the
h gaps between
b sand
d
Fusion Swe
Swell
grains, the result is a rough casting surface. y This is caused by the fusion of the sand grains with Under the influence of metallostatic forces, the mold
wall may move back causing a swell in the dimension
y This occurs because the sand is coarse or no mold wash was the molten metal, giving a brittle, glassy appearance of the casting. A proper ramming of the mold will
applied
pp on the surface of the mold. The coarser the sand correct this defect.
defect
grains more the metal penetration. on the casting surface.
y The main reason for this is that the clay or the sand Inclusions
particles
ti l are off lower
l refractoriness
f t i or that
th t the
th Particles of slag,
slag refractory materials sand or
deoxidation products are trapped in the casting during
pouring temperature is too high.
high pouring solidification.
solidification The provision of choke in the
gating system and the pouring basin at the top of the
mold can prevent this defect
Pouring Metal Defects y The mis‐run and cold shut defects are caused either by
y
GATE‐2004
The likely defects in this category are a lower fluidity of the mold or when the section
y Mis
Mis‐runs
runs and thickness of the casting is very small. Fluidity can be Mi
Misrun i a casting
is ti defect
d f t which
hi h occurs due
d tot
y Cold shuts improved by changing the composition of the metal
and by increasing the pouring temperature of the (a) Very high pouring temperature of the metal
metal.
y A mis
mis‐run
run is caused when the metal is unable to fill (b) Insufficient fluidity of the molten metal
the mold cavity completely and thus leaves unfilled
cavities.
cavities (c) Absorption of gases by the liquid metal
y A cold shut is caused when two streams while meeting (d) Improper alignment of the mould flasks
in the mold cavity, do not fuse together properly thus
forming a discontinuity in the casting.
Contd…
GATE‐2009 Mold Shift IES‐2001

Two streams of liquid metal which are not hot The mold shift defect occurs when cope and drag
S b i
Scab is a
enough to fuse properly result into a casting defect or molding boxes have not been properly aligned.
(a) Sand casting defect
known as
(b) Machining defect
(a) Cold shut
(c) Welding defect
(b) Swell
(d) Forging defect
( ) Sand
(c) d wash
h
(d) Scab
S b
IAS‐2004 GATE‐2003 IES‐1998
Match List‐I (Casting Defects) with List‐II (Explanation) and select the correct
answer using the codes given below the lists: Hardness of green sand mould increases with Assertion (A): Stiffening members, such as webs
List‐II
List List‐II
List II
( ) Increase in moisture content beyond 6 percent
(a) I i i b d 6 and ribs, used on a casting should be liberally
(Casting Defects) (Explanation)
A. Metallic projections 1. Consist of rounded or rough internal or exposed cavities
provided.
including blow holes and pin holes ((b)) Increase in permeability
p y Reason (R): They will provide additional strength
B. Cavities 2. Formed during melting, solidification and moulding.
C. Inclusions 3. Includes single folds, laps, scars adhering sand layers and (c) Decrease in permeability to a cast member.
oxide scale
D. Discontinuities 4. Include cracks, cold or hot tearing and cold shuts (d) Increase in both moisture content and
I i b h i d ( ) Both A and R are individually true and R is the
(a) B h A d R i di id ll d R i h
5.Consist of fins, flash or massive projections and rough permeability correct explanation of A
surfaces
Codes: A B C D A B C D (b) Both A and R are individually true but R is not the
(a) 1 5 3 2 (b) 1 5 2 4 correct explanation of A
p
(c) 5 1 2 4 (d) 5 1 3 2
(c) A is true but R is false
IES‐2005 IES‐1997 IES‐2009

In gating system design, which one of the If the melting ratio of a cupola is 10: 1, then the In which one of the following furnaces most of the
following is the correct sequence in which choke coke requirement for one ton melt will be non ferrous alloys are melted?
non‐ferrous alloys are melted?
area, pouring time, pouring basin and sprue sizes (a) 0.1 ton (a) Reverberatory furnace
are calculated?
l l d? (b) 10 tons (b) Induction furnace
((a)) Choke area ‐ Pouring time ‐
g Pouring basin –
g Sprue
p (c) 1 ton (c) Crucible furnace
(b) Pouring basin ‐ Sprue ‐ Choke area ‐ Pouring time (d) 11 tons (d) Pot furnace
( ) Choke area ‐
(c) Ch k Sprue
S ‐ Pouring basin ‐
P i b i Pouring time
P i i
((d)) Pouring basin ‐
g Pouring time ‐
g Choke area ‐ Sprue
p
C t Al i i C d
Cast Aluminium Code
IAS‐2001 IAS‐2004 y Four digit identification system
ou d g t de t cat o syste
Which of the following pattern‐materials are used Which one of the following gating systems is best y First digit indicates alloy group
in Precision Casting? suited to obtain directional solidification? 1 – Aluminium, 99% or more
l
1. Plaster of Paris (a) Top grating 2 – copper
2
2. Plastics (b) Part‐line grating 3 – Silicon, with copper and/or magnesium
3 Anodized Aluminium Alloy
3. (c) Bottom grating 4 – silicon
4. Frozen Mercury (d) Stepped grating 5 – magnesium
5
Select the correct answer using the codes given below: 6 – not used
(a) 1 and 2 (b) 2 and 4 (c)3 and 4 (d) 1 and 3 7 – zinc
8 – tin
8
9 – other elements
Cast Aluminium Code Contd.. IES 2011
y Second
S d two digits
di i identify
id if the
h aluminium
l i i alloy
ll or In the designation of Aluminium casting A514.0
indicate the aluminium purity. indicates :
y The last digit is separating from the other three by a (a) Aluminium purity
Sp i l C ti g
Special Casting
decimal point and indicates the product form; that is, is (b) Aluminium
Al i i content
castings or ingots
((c)) Percentage
g of alloyy element
y A modification
df off the
h originall alloy
ll is indicated
d d by
b a
(d) Magnesium Content
serial letter before the numerical designation.
y Alloy A514.0 indicates an aluminium alloy casting with
magnesium as the principal alloy.
alloy One modification to Ans.
s (d)
the original alloy has made, as indicated by the letter A.
By S K Mondal
Shell Mouldingg
y Can produce complex parts.
y The
e sa
sand
d iss mixed
ed w
with
t a tthermosetting
e osett g resin
es iss
allowed to come in contact with a heated metal pattern y A good surface finish and good size tolerance
(2000C).
C)
reduce the need for machining.
y A skin (shell) of about 3.5 mm of sand and plastic
mixture adhere to the pattern. y Materials can be cast: CI, Al and Cu alloys.
y Then the shell is removed from the pattern.
y The cope and drag shells are kept in a flask with
necessary backup
b k material
t i l andd the
th molten
lt metal
t l is
i
poured into the mold.
Shell moulding process
Advantages
Molding Sand in Shell Molding
Molding Sand in Shell Molding y Hot coating: 5 oC– 180oC p
g the mixture is heated to 150 prior
y Dimensional accuracy.
y The molding sand is a mixture of fine grained quartz sand to loading the sand. In the course of sand mixing, the
and powdered bakelite. soluble phenol formaldehyde resin is added. The mixer is y Smoother surface finish. (Due to finer size grain used)
allowed
ll 8 – 90o C.
d to cooll up to 80 C Hot
H coting
i gives
i b
better y Very thin sections can be cast.
y Cold coating and Hot coating methods are used for
properties to the mixtures than cold method.
method
coating
i the
h sand
d grains
i with
i h bakelite.
b k li y Very small amount of sand is needed.
y Cold coating: quartz sand is poured into the mixer and
then the solution of p
powdered bakelite in acetone and
ethyl aldehyde are added. (mixture is 92% quartz sand,
5% bakelite, 3% ethylaldehyde )
For-2013 (IES, GATE & PSUs) Contd… Page 20
Limitations IES 2010
y Expensive pattern
Applications Consider the following advantages of shell
C id th f ll i d t f h ll
mould casting: g
y Small size casting only. y Cylinders
C li d and
d cylinder
li d heads
h d for
f air‐
i cooled
l d IC
1. Close dimensional tolerance.
y Highly
Hi hl complicated
li d shapes
h cannot be
b obtained.
b i d engines
2. Good surface finish.
y Automobile transmission parts. 3 Low cost
3. Low cost.
y More
M sophisticated
hi ti t d equipment
i t is
i needed
d d for
f handling
h dli
the shell moldings.
moldings y Piston rings
g 4
4. Easier.
Which of these are correct?
(a) 1, 2 and 3 only (b) 2, 3 and 4 only
( ) d l (d) 1, 2, 3 and 4
(c) 1, 2 and 4 only (d) d
IES‐1996 IES‐2005 IES‐2006

Consider the following ingredients used in In shell moulding, how can the shell thickness Shell moulding can be used for:
moulding: be accurately maintained? ( ) Producing milling cutters
(a) P d i illi
1. Dry silica sand (a) By controlling the time during which the pattern ((b)) Making gold ornaments
gg
2.Clay i i
is in contact with mould
i h ld
(c) Producing heavy and thick walled casting
3 Phenol formaldehyde
3.Phenol ( ) y
(b) By controlling the time during which the pattern
g g p
(d) Producing thin casting
P d i hi i
is heated
4.Sodium silicate
(c) By maintaining the temperature of the pattern in
Those used for shell mould casting include
the range of 175oC – 380oC
(a) 1,
1 2 and 4 (b) 2,
2 3 and 4
(d) By the type of binder used
(c) 1and 3 (d) 1, 2, 3 and 4
IES 2007 IAS‐2007 IAS‐1999

Match List I (Moulding Process) with List II (Binding
The mould in shell moulding process is made up Agent) and select the correct answer using the codes
Which of the following are employed in shell
given below
b l the
h lists:
l
moulding? of which of the following? List I List II
1. Resin
R i binder
bi d 2. Metal
M l pattern 3. Heating
H i coils il A. Green sand 1. Silicate
(a) Gypsum + setting agents
Select the correct answer using
g the code g given B. Core sand 2. Organic
below: (b) Green sand + clay C. Shell moulding 3. Clay
D. CO2 p process 4. Plaster of Paris
(c) Sodium silicate + dried sand 5. Plastic
(c) 2 and 3 only (d) 1, 2 and 3 Codes:A B C D A B C D
(d) Dried silica + phenolic resin (a) 3 2 5 1 (b) 3 2 4 1
((c)) 2 3 5 4 ((d)) 2 3 4 5

Investment Casting Ceramic Shell Investment Casting
Investment casting process or lost wax process
p
Basic steps: y In ceramic shell investment casting
g a ceramic shell is
1. Produce expendable wax, plastic, or polystyrene patterns.
built around a tree assembly by repeatedly dipping a
2 Assemble these patterns onto a gating system
2.
3. Investing or covering the pattern assembly with refractory pattern into a slurry (refractory material such as
slurry
zircon with binder).
4. Melting the pattern assembly to remove the pattern material
5. Firing
ii the
h mould ld to remove theh last
l traces off the
h pattern y After each dipping and stuccoing is completed, the
material
6. Pouring molten metal assembly is allowed to thoroughly dry before the next
7. Knockout, cutoff and finishing.
g coating is applied.
Fig. Investment flask‐casting procedure
Advantages
IES 2009
IES 2009
y Tight dimensional tolerances
y 2 marks
y Excellent surface finish (1.2 to 3.0 μm )
y Machining can be reduced or completely

eliminated
li i t d
y High melting point alloy can be cast,
cast almost any
metal can be cast
y Almost unlimited intricacy
Limitations Applications IES 2011

The proper sequence of investment casting steps is :
y Costly
C tl patterns
tt and
d moulds
ld y Aerospace
A and
d rocket
k t components.
t (a) Slurry coating – pattern melt out
out‐Shakeout
Shakeout – Stucco
coating
y Labour costs can be high y Vanes and blades for gas turbines.
turbines (b) Stucco
S coating
i – Slurry
Sl coating
i – Shakeout
Sh k – Pattern
P
melt out
y Limited size y Surgical instruments
(c) Slurry coating – Stucco coating – Pattern melt out –
Shakeout
(d) Stucco coating – Shakeout – Slurry coating – Pattern
melt
l out

GATE‐2006 GATE‐2011 (PI)
ISRO‐2010
An expendable pattern is used in Whi h off the
Which th following
f ll i casting
ti processes uses Investment casting is used for
(a) Slush casting
expendable pattern and expendable mould? ((a)) Shapes
p which are made byy difficultyy using
g complex
p
(b) Squeeze casting
patterns in sand casting
(c) Centrifugal casting (a) Shell mould casting
(d) Investment casting (b) Mass production
((b)) Investment casting
g
(c) Shapes which are very complex and intricate and
((c)) Pressure die casting
g can'tt be cast by any other method
can
(d) Centrifugal casting ((d)) There is nothing
g like investment casting
g
IES‐1992 JWM 2010 IES 2010

Consider the following materials : Assertion (A): The investment casting is used for
The most preferred process for casting gas turbine precision parts such as turbine plates, sewing
1. Wax
blades is: machines
hi etc.
2. Wood
(a) Die moulding Reason ((R): ) The investment castings g have a g good
3 Plastic
3. Plastic
(b) Shell moulding surface finish and are exact reproductions of the
Which of these materials can be used as pattern in master pattern.
pattern
(c) Investment moulding
investment casting process ?
(d) Sand casting (a) Both A and R are individually true and R is the
(a) 1 2 and 3
(a) 1, 2 and 3 (b) 1 and 2 only correct explanation of A
(c) 2 and 3 only (d) 1 and 3 only (b) Both A and R are individually true but R is NOT the
correct explanation of A
( ) A is
(c) i true
t b t R is
but i false
f l
IES 2007
IES 2007 IES‐2006 IAS‐1996
Consider the following statements in respect of
investment castings: Which of the following materials are used for Light and intricate parts with close dimensional
1. The
Th pattern
tt or patterns
tt i /
is/are nott joined
j i d to
t a stalk
t lk or making patterns in investment casting method? tolerances of the order of ± 0.0050 005 mm are
sprue also of wax to form a tree of patterns. 1. Wax 2. Rubber 3. Wood 4. Plastic produced by
2.The prepared moulds are placed in an oven and heated Select the correct answer using the codes given below: (a) Investment casting
gently to dry off the invest and melt out the bulk of wax. (b) Die casting
(a) Only 1 and 3 (b) Only 2 and 3
3.The moulds are usually poured by placing the moulds in
(c) Only 1, 2 and 4 (d) Only 2, 3 and 4 (c) Centrifugal casting
a vacuum chamber. Which of the statements given above
are correct? (d) Shell mould casting
(c)2 and 3 only (d) 1, 2 and 3

Permanent Mould Casting Advantages Disadvantages
y The p
process in which we use a die to make the y Good su
surface
ace finish
s aand
dddimensional
e s o a accu
accuracy
acy y High
g initial mold cost
castings is called permanent mold casting or gravity y Metal mold gives rapid cooling and fine‐grain y Shape, size, and complexity are limited
die casting, since the metal enters the mold under structure
t t y Mold life is very limited with high‐melting‐point
gravity. metals such as steel.
y Multiple‐use
p molds.
y Some
S ti
time i die‐casting
in di ti we inject
i j t the
th molten
lt metalt l y Low melting point metals can be cast
with a high pressure. When we apply pressure in ‐ Aluminum
injecting the metal it is called pressure die casting ‐ Zi
Zinc
p
process. ‐ Magnesium alloys
y Grey cast iron is used for mould material. ‐ Brass
‐ Cast iron
Applications Die Casting
y Molten metal is injected
j into closed metal dies under
Die casting machines can be
y Pistons/cylinders/rods
Pi t / li d / d
pressures ranging from 100 to 150 MPa.
y Gears
y Pressure is maintained during solidification y Hot chamber
y Kitchenware
y After which the dies separate and the casting is ejected y Cold chamber
along with its attached sprues and runners.
y Cores must be simple and retractable and take the

f
form off moving
i metall segments
Hot chamber machines are
Hot chamber machines are Cold chamber machines
y Good for low temperature (approx. 400
400°C)
C) y Casts high melting point metals ( > 600
Casts high melting point metals ( > 600°C)
C)
y Faster than cold chamber machines
y High pressures used
g p
y Cycle times must be short to minimize metal
contamination y Metal is heated in a separate crucible
y Metal starts in a heated cylinder y Metal is ladled into a cold chamber
y A piston
i f
forces metall into
i the
h die
di y The metal is rapidly forced into the mold before it
y The ppiston retracts,, and draws metal in
cools
l
y Metal: Lead, Tin, Zinc
y Copper, Brass and Aluminium can cast.
For-2013 (IES, GATE & PSUs) Hot Chamber

Page 24
Ad t
Advantages
y Extremely smooth surfaces (1 µm)
E l h f ( ) Limitations
y Excellent dimensional accuracy
E ll t di i l y High initial die cost
y Rapid production rate y Limited to high
Limited to high‐fluidity nonferrous metals
fluidity nonferrous metals
y Better mechanical properties compared to sand y Part size is limited
casting
g y Porosity may be a problem
y Some scrap in sprues, runners, and flash, but this can
y Intricate parts possible
p p
be directly recycled
y Minimum finishing operations
g p
y Thin sections possible
IES 2011 IES‐2009
¾Applications
A li i Consider d theh following
f ll advantages
d off die
d casting over
Which of the following are the most suitable
y Carburettors sand casting :
materials for die casting?
y Automotive parts 1. Rapidity of the process
(a) Zinc and its alloys
2 Smooth surface
2.
y Bathroom
B h fi
fixtures (b) Copper and its alloys
3. Strong dense metal structure
y Toys
y (c) Aluminium and its alloys
Whi h off these
Which h advantages
d are correct ?
((a)) 1,, 2 and 3 (d) Lead and its alloys
¾Common metals
l (b) 1 and 2 only
y Alloys of aluminum, zinc, magnesium, and lead (c) 2 and 3 only
y Also possible with alloys of copper and tin (d) 1 and 3 only
JWM 2010 IES‐2005 IES‐2006

Assertion (A) : In die casting method, method small
thickness can be filled with liquid metal. Which one of the following processes produces a In which of the following are metal moulds used?
casting when pressure forces the molten metal ( ) Greensand
(a) G d mould
ld
Reason (R) : The air in die cavity trapped inside the
into the mould cavity? ((b)) Dryy sand mould
castingg causes pproblems.
(a) Shell moulding (b) Investment casting (c) Die casting process
(a) Both A and R are individually true and R is the
t l ti f A (c) Die casting (d) Continuous casting (d) Loam
L moulding
ldi
(b) Both A and R are individually true but R is not
y the

IES‐1995 IES‐1995 IAS‐2007
Assertion (A): An aluminium alloy with 11 % silicon is Match List I with List II and select the correct answer taking the help
of codes given below the lists: Consider the following statements:
used for making g engine
g pistons by
p y die casting g List I List II
technique. 1. Zinc die castings have low strength.
Zi di i h l h
(Products) (Process of manufacture)
Reason (R): Aluminium has low density and addition A. Automobile piston in aluminium
p alloyy 1. Pressure die‐casting
g gp , y
2. In the die casting process, very thin sections or
B. Engine crankshaft in spheroidal
of silicon improves its fluidity and therefore its
graphite iron 2. Gravity die‐casting
complex shapes can be obtained easily.
y
castability. C
C. Carburettor housing in aluminium alloy 3. Sand casting
3 Sand casting Which of the statements given above is/are correct?
(a) Both A and R are individually true and R is the correct D. Cast titanium blades 4. Precision investment
explanation of A casting (a) 1 only
5. Shell moulding
h ll ld
(b) Both A and R are individually true but R is not the Code: A B C D A B C D (b) 2 only
correct explanation of A (a) 2 3 1 5 (b) 3 2 1 5 (c) Both 1 and 2
(c) 2 1 3 4 (d) 4 1 2 3
(d) Neither 1 nor 2
IAS‐1996 IES 2011 GATE‐2007

Assertion (A): Die casting yields a product of good Consider the following statements :
accuracy and finish. 1 Hot chamber machine is used for casting zinc,
1. zinc tin and Which of the following engineering materials is
Reason (R): Low melting alloys used in die other low melting alloys. the most suitable candidate for hot chamber die
casting.
casting 2. Cold
C ld chamber
h b machine hi i used
is d for
f die
di casting
i off casting?
(a) Both A and R are individually true and R is the ferrous alloys (a) Low carbon steel
correct explanation
l i off A (b) Titanium
3. Rapid cooling rate in die casting produces high
(b) Both A and R are individuallyy true but R is not the strength and quality in many alloys.
alloys
correct explanation of A (c) Copper
Which of these statements are correct? (d) Tin
(d) A is false but R is true (a) 1, 2 and 3 (b) 1 and 2 only
(c) 2 and 3 only (d) 1 and 3 only
IES‐1995 C
Centrifugal Casting
if l C i
Assertion (A): Aluminium alloys are cast in hot
GATE ‐2009 (PI)
GATE ‐2009 (PI) y Process: Molten metal is introduced into a rotating sand,
sand
chamber die casting g machine. metal, or g
graphite
p mould, and held against
g the mould
Hot chamber die casting process is NOT suited for
Reason (R): Aluminium alloys require high melting wall by centrifugal force until it is solidified
when compared to zinc alloys. (a) Lead and its alloy
(a) Both A and R are individually true and R is the correct y A mold is set up and rotated along a vertical (rpm is
explanation of A ((b)) Zinc and its alloyy
reasonable), or horizontal (200‐1000 rpm is reasonable)
(b) Both A and R are individually true but R is not the (c) Tin and its alloy
correct explanation of A axis.
axis
(c) A is true but R is false (d) Aluminum and its alloy
y The mold is coated with a refractory coating.
(d) A is false but R is true y During
g cooling
g lower densityy impurities
p will tend to rise
towards the center of rotation.
Properties Advantages
y The mechanical properties of centrifugally cast jobs are y Fine grained structure at the outer surface of the
better compared to other processes, because the inclusions casting free of gas and shrinkage cavities and
such as slag and oxides get segregated towards the centre porosity
and can be easilyy removed byy machining. g Also, the
pressure acting on the metal throughout the solidification y Formation
F i off hollow
h ll i
interiors
i i cylinders
in li d without
ih
causes the pporosityy to be eliminated g
giving
g rise to dense cores
metal. y Can produce a wide range of cylindrical parts,
y No cores are required for making concentric holes in the including ones of large size.
size
case of true centrifugal casting. y Good dimensional accuracy, soundness, and
cleanliness
l li
Fig True centrifugal casting
Fig. True centrifugal casting y There is no need for g gates and runners,, which
increases the casting yield, reaching almost 100 %.
Limitations Common metals GATE‐2002

y More segregation of alloy component during pouring under y Iron
the forces of rotation y steel In centrifugal casting, the impurities are
y stainless steel (a) Uniformly distributed
y Contamination of internal surface of castings with non
non‐
y alloys of aluminium, copper, and nickel
ll f l i i d i k l (b) Forced towards the outer surface
metallic inclusions
(c) Trapped near the mean radius of the casting
y Inaccurate internal diameter (d) Collected at the centre of the casting
y Shape is limited.
y Spinning equipment can be expensive
y Poor machinability
GATE‐1993 IES‐2008
Centrifugally cast products have
GATE ‐2008 (PI)
GATE ‐2008 (PI) Which
h h off the
h following
f ll casting processes does
d not
In hollow cylindrical
y parts,, made byy centrifugal
p g casting,
g, /do not require central core for producing pipe?
( ) Large
(a) L grain
i structure with
i h high
hi h porosity
i 1. Sand casting process
((b)) Fine g
grain structure with high
g densityy the density of the part is
2 Die casting process
2.
(c) Fine grain structure with low density (a) maximum at the outer region 3. Centrifugal casting process
(d) Segregation
S i off slug
l towards d the
h outer skin
ki off the
h S l
Select the
h correct answer using
i the
h code
d given
i b l
below:
casting (b) maximum at the inner region ((a)) 1 and 2
(c) maximum at the mid‐point between outer and inner (b) 2 only
(c) 2 and 3
surfaces
(d) 3 only
(d) uniform throughout
IES‐2009 IES 2007 IES‐1998
Which one of the following casting processes is Which one of the following is the correct Poor machinability of centrifugally cast iron pipe
statement? is due to
best suited to make bigger size hollow In a centrifugal casting method (a) Chilling
symmetrical pipes? (a) No core is used (b) Segregation
(b) Core may be made of any metal (c) Dense structure
(a) Die casting
(c) Core is made of sand (d) High mould rotation speed
(b) Investment casting (d) Core is made of ferrous metal
( ) Shell
(c) h ll moulding
ld
(d) Centrifugal
C if l casting
i
IES‐2009 IES 2007 IES‐2000

Which of the following are the most likely Match List I with List II and select the correct answer using the code given
below the Lists:
Match List I (Process) with List II (Products/materials)
List I List II and select the correct answer using the codes given
characteristics in centrifugal casting? (Casting Process) (Principle) b l
below the Lists:
h
(a) Fine grain size and high porosity A. Die casting 1.The metal solidifies in a rotating mould List I List II
B
B. Investment casting 2 The pattern cluster is repeatedly dipped
2.The pattern cluster is repeatedly dipped
(b) Coarse grain size and high porosity into a ceramic slurry and dusted with A. Die casting 1. Phenol formaldehyde
refractory
C
C. Shell moulding 3 Molten metal is forced by pressure into
3. Molten metal is forced by pressure into
B. Shell molding 2. C.I. pipes
(c) Fine grain size and high density a metallic mould C. CO2 molding 3. Non‐ferrous alloys
D. Centrifugal casting 4. After cooling, the invest is removed
(d) Coarse grain size and high density from the Casting by pressure jetting or
g yp j g D. Centrifugal casting
g g 4. Sodium silicate
vibratory cleaning
Code: A B C D A B C D
Codes:A B C D A B C D
((a)) 2 1 3 4 ((b)) 3 4 2 1 ((a)
) 1 33 4
4 2 ((b)
) 33 1 4
4 2
(c) 2 4 3 1 (c) 3 1 2 4 (c) 3 1 2 4 (d) 1 3 2 4
IAS‐2004 Semi‐centrifugal Casting
Match List‐I (Name of the Process) with List‐II (Advantage) and select the correct y Centrifugal force assists the flow of metal from a
answer using the codes given below the lists:
List‐I List‐II central reservoir to the extremities of a rotating
(Name of the Process) (Advantage)
A. Sand Casting 1. Large cylindrical parts with good quality
B. Ceramic mold casting 2.Excellent dimensional accuracy and surface
symmetrical mold, which may be either expendable or
finish
C. Die casting 3. Intricate shapes and close tolerance parts multiple‐use
li l
D. Centrifugal casting 4. Almost any metal is cast and there if no limit to
size, shape and weight
h d h y Rotational
R t ti l speeds
d are lower
l th for
than f true
t centrifugal
t if l
5. Good dimensional accuracy, finish and low
p
porosityy
casting
(a) 2 3 5 1 (b) 4 1 2 3
y Cores can be used to increase the complexity of the
(c) 2 1 5 3 (d) 4 3 2 1
For-2013 (IES, GATE & PSUs) product. Page 28 Fig. Semi‐centrifugal casting
IAS‐2003 Centrifuging
Assertion (A): Semi‐centrifugal casting process is y Uses centrifuging action to force the metal from a central
similar to true centrifugal g casting g except
p that the
central core is used in it to form inner surface. pouring reservoir into separate mold cavities that are
Reason (R): In semisemi‐centrifugal
centrifugal casting process the offset
ff t from
f th axis
the i off rotation.
t ti
axis of spin is always vertical
(a) Both A and R are individually true and R is the correct y Low speed
explanation of A
(b) Both A and R are individually true but R is not the y May
y used to assist in the p
pouring
g of investment casting
g
correct explanation of A trees.
Fig. Method of casting by the centrifuging process
IES‐2000 Dry Sand Molding Slush Casting

Match List I (Type of casting) with List II (Working principles)
and select the correct answer using the codes given below the y To reduce gas forming materials air dried mould used. y Slush casting is a variation of the permanent mold process
Lists: in which the metal is permitted to remain in the mold only
List I List II Types: until a shell of the desired thickness has formed.
A. Die casting 1. Molten metal is forced into the die
under pressure y The mold is then inverted and the remaining liquid is
B. Centrifugal casting 2. Axis of rotation does not coincide with 1.Skin drying and poured out.
axis of mould
C. Centrifuging 3. Metal solidifies when mould is rotating 2.Complete mold drying y When the mold halves are separated, the resulting casting
D. Continuous casting 4. Continuously pouring molten metal iss a hollow
o o sshape
ape with
t good susurface
ace deta
detail but va
variable
ab e wall
a
into mould thickness.
Codes: A B C D A B C D
( ) 1
(a) 3 2 4 (b)
(b) 4 3 2 1 y Frequently used to cast low‐melting‐temperature
low melting temperature metals
(c) 1 2 3 4 (d) 4 2 3 1 into ornamental objects such as candlesticks, lamp bases,
and statuary.
statuary
IAS‐2004 IES 2011 IES ‐ 2012

The method of casting for producing ornamental pieces The
Th process off making
ki hollow
h ll castings
i off non‐circular
i l
Which of the following are produced by slush
are: shape and desired thickness by permanent mould
casting?
(a) Slush and gravity casting without the use of cores is known as
(a) Hollow castings with thick walls
(b) Pressed
P d andd slush
l h casting
i (a) Die casting (b) Slush casting
(b) Hollow castings with thin walls
((c)) Gravityy and semi ppermanent mould casting
g (c) Pressed casting (d) Centrifugal casting
(c) Thin castings
(d) Thick castings (d) Semi permanent mould and pressed casting

Squeeze Casting IAS‐2002 Single Crystal Casting
Match List I (Casting Process) with List II The process is effectively:
Th i ff i l
Process:
(Applications) and select the correct answer using the 1. Prepare a mold so that one end is a heated oven, and
p ,
1. Molten
M l metall is
i pouredd into
i an open face
f di
die. codes given below the Lists:
d b l h
the other end chilled. The part should be oriented so
2. A p
punch is advanced into the die,, and to the metal. List I List II
that the cooling happens over the longest distance.
that the cooling happens over the longest distance
(Casting Process) (Applications)
3.Pressure (less than forging) is applied to the punch 2. Cast metal into the mold
A. Centrifugal casting 1. Carburetor
and die while the part solidifies.
solidifies B. Squeeze casting 2. Pipes 3. Solidification will begin at the chill plate. These
4.The punch is retracted, and the part is knocked out C. Die Castingg 33. Wheels for de d tes
dendrites will grow towards the heated end of the
g o to a ds t e eated e d o t e
with an ejector pin. automobiles
part as long dendritic crystals. The part is slowly
4. Gear housings
y Overcomes problems with feeding the die, die and pulled out of the oven past the chill plate
pulled out of the oven, past the chill plate.
Codes: A B C A B C
produces near net, highly detailed parts. 4. Remove the solidified part.
(a) 2 3 1 (b) 4 1 3
(c) 2 1 3 (d) 4 3 1
IES 2009
Plaster Casting
y Process: A slurry of plaster, water, and various additives is
y Creep and thermal shock resistance properties. additives is pouted over a pattern and allowed to set. The
pattern is removed and the mould is baked to remove
excess water. After p
pouring
g and solidification, the mould is
broken and the casting is removed.
y Advantage: High dimensional accuracy and smooth
surface finish, thin sections and intricate detail can
produce.
produce
y Limitations: Lower‐temperature nonferrous metals only:
2 marks
y Common metals: Primarily aluminium and copper
Pit Moulding IES‐1996 Loam Moulding

y This method is used for very large castings and is done on Which of the following pairs are correctly matched?
the foundry floor.
floor 1. Pit moulding
Pi ldi ..................For large jobs.
F l j b y Moulding
M ldi l
loam i generally
is ll artificially
ifi i ll composed
d off
2. Investment moulding g ... Lost wax process.
p common brick‐clay,
brick clay and sharp sand.
sand
3. Plaster moulding ……… Mould prepared in
gypsum.
gypsum y Loam means mud.
mud
(a) 1, 2 and 3 (b) 1 and 2 y Loam Moulding is restricted to forms which cannot be
(c) 1 and 3 (d) 2 and 3
cast conveniently in any other process.
y It is costly.

IES‐1997 GATE‐1998 GATE‐1992
Which one of the following pairs is not correctly List I List II Match the following moulding/casting processes with
matched? ((A)) SaSand casting
d cas g ()
(1) Symmetrical and
Sy e ca a d p
the product:
circular shapes only Moulding/Casting processes Product
(a) Aluminium alloy piston …………Pressure die casting ((B)) Plaster mould casting
g ((2)) Parts have hardened (A) Slush casting (P) Turbine blade
(b) Jewellery……………………….. Lost wax process skins and soft interior
(C) Shell mould casting (3) Minimum post‐ (B) Shell moulding (Q) Machine tool bed
(c) Large pipes ……………………..Centrifugal
Centrifugal casting casting processing
i i (C) Dry sand moulding
D d ldi (R) C li d bl k
(R) Cylinder block
(d) Large bells ………………………Loam moulding (D) Investment casting (4) Parts have a tendency (D) Centrifugal casting (S) Hollow castings
tto warp
lk l
like lamp shades
h d
(5) Parts have soft skin (T) Rain water pipe
and hard interior
(U) Cast iron shoe
(6) Suitable only for non‐
ferrous metals brake
GATE‐1996 IES‐2003 IES‐1993

List I List II Match List I (Products) with List II (Casting Process) and select Match the items of List I (Equipment) with the items
the correct answer using the codes given below the Lists:
( )
of List II (Process) and select the correct answer using g
(A) Rivets for aircraft body
Ri f i f b d 1. F i
Forging Li I
List I Li II
List II
the given codes.
(Products) (Casting Process)
((B)) Carburettor body
y 2. Cold headingg A
A. Hollow statues 1
1. Centrifugal Casting List I (Equipment) List II (Process)
(C) Crankshafts 3. Aluminium‐based B. Dentures 2. Investment Casting P ‐ Hot Chamber Machine 1. Cleaning
C. Aluminium alloy pistons
yp 33. Slush Casting
g
alloy Q Muller
Q ‐ 2
2. Core making
D. Rocker arms 4. Shell Moulding
(D) Nails 4. Pressure die casting 5. Gravity Die Casting R ‐ Dielectric Baker 3. Die casting
5. Investment casting Codes: A B C D A B C D S ‐ Sand Blaster
d l 4. Annealing
l
(a) 3 2 4 5 (b) 1 3 4 5 5. Sand mixing
( ) 1
(c) 2 3 4 (d) 3 2 5 4
(a) P‐2, Q‐1, R‐4, S‐5 (b) P‐4, Q‐2, R‐3, S‐5
(c) PP‐4, Q‐5, R‐1, S‐2
4, Q 5, R 1, S 2 (d) P P‐3, Q‐5, R‐2, S‐1
3, Q 5, R 2, S 1
IAS‐2004 GATE – 2007 (PI)

( )
Match List‐I (Name of the Casting Process) with List‐II (Process Definition) and select
Match the lists
the correct answer using the codes given below the lists:
List I
List‐I List II
List‐II Group 1
Group‐1 Group 2
Group‐2
(Name of the Casting Process) (Process Definition)
A. Die casting 1.This process involves use of a mould made of P. Sand Casting 1. Turbine blades
Dried silica sand and phenolic resin mixture
B. Electroslag casting 2. In this process, molten metal is forced by Q. Centrifugal Casting 2. IC Engine Pistons
Pressure into a metal mould
C. Centrifugal casting 3. This process employs a consumable electrode R I
R. Investment Casting
C i 3. Large bells
L b ll
D. Precision casting 4. This process involves rotating a mould while the
metal solidifies
l ldf S Die Casting
S. Die Casting 4 Pulleys
4. Pulleys
5. This process produces very smooth, highly
Accurate castings from both ferrous and non
g
ferrous alloys
(a) P – 4,
4 Q – 1,
1 R – 3,
3 S–2 (b) P – 2,
2 Q – 4,
4 R – 3,
3 S‐1
Codes:A
(a) 5
B
4
C
1
D
2 (b)
A
2
B
3
C
4
D
5
(c) P – 3, Q – 4, R – 1, S – 2 (d) P – 3, Q – 2, R – 1, S ‐ 4 By S K Mondal
y
(c) 5 3 4 2 (d) 2 4 1 5
Welding Definition Requirement for a high quality welding l ifi i f ldi
Classification of welding processes
¾ Oxy
y fuel g g ((OFW))
gas welding
y Welding is a process by which two materials, usually ¾ Arc welding (Aw)
1. A source of satisfactory heat and/or pressure,
metals, are permanently joined together by
metals ¾ Resistance welding
coalescence, which is induced by a combination of 2. A means of protecting or cleaning the metal, and ¾ Solid state welding (friction welding, ultrasonic welding,
temperature, pressure, and
d metallurgical
ll i l conditions.
di i forge welding etc.)
etc )
3. Caution to avoid, or compensate for, harmful
y The pparticular combination of these variables can y Unique
q p process
range from high temperature with no pressure to high metallurgical effects. ¾ Thermit welding
pressure with no increase in temperature.
temperature ¾ Laser beam welding
y Welding (positive process) ¾ Electroslag welding
¾ Flash welding
y Machining (negative process)
¾ Induction welding
y Forming,
F i casting
i (zero
( process)) ¾ Electron beam welding
IES ‐ 2012 Weldability / Fabrication Processes Case of Aluminium

The
Th advantage
d o the
h welding
ldi process isi y The weldability of a material will depend on the y The oxide coating on aluminum alloys causes some
((a)) It relieves the jjoint from residual stresses specific welding or joining process being considered.
considered difficultyy in relation to its weldability.
y
(b) It helps in checking of distortion of work piece y For resistance welding of consistent quality, it is y It also has high thermal conductivity and a very short
( ) Large
(c) L number
b off metals l and
d alloys,
ll b h similar
both i il and/or
d/ usually
ll necessary to remove the h oxideid immediately
i di l temperature range between liquidus and solidus and when
before welding. liquid its viscosity is very low.
dissimilar can be joined.
y Al i i
Aluminium i poor absorber
is b b off laser
l li h
light.
(d) Heat produced during the welding does not produce y Fabrication weldability test is used to determine
mechanical properties required for satisfactory y During g fusion welding, g the aluminum would oxidize so
metallurgical changes.
changes
readily that special fluxes or protective inert‐gas
performance of welded joint.
atmospheres
p must be employed.
p y
y The
Th correct sequence off the h given
i materials
i l ini
y Friction welding and TIG welding is good for aluminium.
ascending order of their weldability is
y For aluminium AC current plus high frequency is must.
must
Aluminum < copper < cast iron < MS Contd…
Case of Cast Iron Case of Stainless Steel Case of Stainless Steel

y Cast iron is more difficult to weld because of its high y Stainless steel is a difficult metal to weld because it y The ferritic stainless steels are generally less weldable
carbon content and brittleness (p
(poor ductility)
y) contains both nickel and chromium. q
than the austenitic stainless steel and require both
y Massive carbon deposits have a tendency to form in y The best method for welding stainless steel is TIG preheating and postweld heat treatments.
the areas adjacent to the weld,
weld and high
high‐carbon
carbon welding.
welding y Welds of ferritic stainless steel can be by
martensite tends to form in the heat‐affected zones. y The electric arc is also preferred for welding stainless (i) autogenously (i.e. without the addition of filler
These microstructures are very brittle and may crack steels A heavily coated welding rod,
steels. rod which produce a metal)
spontaneously while welding is in progress or later shielded arc, is employed. (ii) with an austenitic stainless steel
when load is applied to the workpiece.
workpiece y You
Y must do d a better
b j b off pre‐cleaning.
job l i (iii) using
i a high
hi h nickel
i k l filler
fill alloy.
ll
y Cast iron can be joined by the oxyacetylene brazing (iv) Type 405 filler (low 11% Cr, low carbon and small
y Usingg a low arc current setting g with faster travel
process and shielded metal‐arc
metal arc welding (stick) speeds is important when welding stainless steel, 0.2%% Al)
l)
process. because some stainless steels are subject j to carbide y Welding
g p
process: TIG, MIG, Shielded‐metal arc
y Some cases preheating
h and/or
d post heating
h is required.
d precipitation. welding and Plasma arc welding
Contd…..
IES 2010 IES‐2006 IES 2011
Assertion (A): It is generally difficult to weld During plasma arc welding of aluminium, improved
Aluminum parts by normal arc welding process. Assertion (A): Aluminium has poor weldability.
removal of the surface oxide from the base metal is
Reason (R): Hard and brittle Aluminum‐oxide film R
Reason (R): Aluminium
(R) Al i i h hi h h
has high thermal
l
obtained with typical polarity of :
is formed at the welded joints.
j conductivity and high affinity to oxygen.
(a) DC Straight
(a) Both A and R are individually true and R is the (a) Both A and R are individually true and R is the
correct explanation of A (b) DC reverse
correctt explanation
l ti off A
(b) Both A and R are individually true but R is not the (c) AC potential
(b) Both A and R are individuallyy true but R is NOT the
l i f A (d) Reverse polarity of phase of AC potential
(c) A is true but R is false ((c)) A is true but R is false
(d) A is false but R is true (d) A is false but R is true
IES 2011 IES‐2006 IES‐1999

Consider the following statements.
d h f ll
Fabrication weldability test is used to determine The correct sequence of the given materials in
Cast iron is difficult to weld, because of
,
(a) Mechanical properties required for satisfactory ascending order of their weldability
di d f th i ld bilit is i
1. Low ductility
p
performance of welded joint
j ((a)) MS, copper, cast iron, aluminium
, pp , ,
2. Poor fusion
P f i
(b) Susceptibility of welded joint for cracking (b) Cast iron, MS, aluminium copper
3
3. Tendency to crack on cooling
y g
( ) Suitability for joint design
(c) S i bili f j i d i ( ) Copper, cast iron, MS, aluminium
(c) C i MS l i i
Which of these statements are correct ?
(a) 1 2 and 3
(a) 1, 2 and 3 ((d)) Appropriate machining process
pp p gp ((d)) Aluminium, copper, cast iron, MS
, pp , ,
(b) 1 and 2 only
(c) 2 and 3 only
(d) 1 and 3 only
IES 2010 IES 2010 IES ‐ 2012

Weldability
W ld bilit off ferritic
f iti stainless
t i l steel
t l used
d in
i Consider the following statements regarding Which of the following factors improve weld ability of
Whi h f h f ll i f i ld bili f
automotive exhaust systemy is improved
p byy welded joints: steel?
selecting stainless steel electrode having low 1. It is a permanent type of joint. 1. Low carbon content
content of 2 It is reliable and economical for pressure vessel
2. 2 High carbon content
2. High carbon content
construction. 3. Good affinity content
((a)) Carbon ((b)) Nitrogen
g
3. It is free
f f
from f b
fabricationall residual
d l stresses. 4. Poor affinity to oxygen
(c) Chromium (d) Carbon and Nitrogen
4. Such joints are suitable for static loading only. ( ) d
(a) 1 and 3 (b) d
(b) 2 and 3
5. Welding is a versatile and flexible metal joining process. (c) 1 and 4 (d) 2 and 4
Which of the above statements are correct?
(a) 1, 2 and 3 only (b) 2, 3 and 4 only
(c) 1, 2, 3, 4 and 5 (d) 1, 2 and 5 only
Gas Flame Processes: y Combustion of oxygen and acetylene (C2H2) in a
Welding, Cutting and Straightening
W ldi C i dS i h i welding torch produces a temp. in a two stage reaction.
ldi t h d t i t t ti
y Oxy‐fuel gas Welding (OFW): Heat source is the y In the first stage
g
flame produced by the combustion of a fuel gas and C2 H2 + O2 → 2CO + H2 + Heat
oxygen. This reaction occurs near the tip of the torch.
Thi i h i f h h
y In the second stage combustion of the CO and H
g 2 and
y OFW has largely been replaced by other processes but occurs just beyond the first combustion zone.
it is still popular because of its portability and the low 2CO + O2 → 2CO2 + Heat
1
capital investment.
2 2 → H2O + Heat
H2 + O
Oxygen for secondary reactions is obtained from the
y Acetylene is the principal fuel gas employed. atmosphere.
atmosphere
Three types of flames can be obtained by varying y Excess fuel, on the other hand, produces a carburizing
y A higher ratio, such as 1.5 : 1, produces an oxidizing
the
th oxygen/acetylene
/ t l (or
( oxygen/fuel
/f l gas)) ratio.
ti flame.
flame Carburizing flame can carburize metal also.
also
flame, hotter than the neutral flame (about 3300oC)
y If the ratio is about 1 : 1 to 1.15
5 : 1,, all reactions are but similar in appearance.
pp y The excess fuel decomposes to carbon and hydrogen,
carried to completion and a neutral flame is produced. andd the
h flame
fl temperature isi not as great (about
( b
y Used when welding copper and copper alloys but
3000oC).
y Most welding is done with a neutral flame. flame It is harmful when welding steel because the excess oxygen
chemically neutral and neither oxidizes or carburizes reacts with the carbon, decarburizing the region y Flames of this type are used in welding Monel (a
the
h metall being
b i welded.
ld d aroundd the
h weld.
ld nickel‐copper
nickel copper alloy),
alloy) high
high‐carbon
carbon steels,
steels and some
alloy steels, and for applying some types of hard‐facing
material.
material
Oxy‐acetylene gas welding Oxidising flame
Oxy‐acetylene gas welding neutral flame Oxy‐acetylene gas welding Carburizing flame
IES 2009 Conventional
Metal Flame Explain the three types of oxy‐acetylene flames.
MS N Indicate with the help of sketches the various
High carbon steel R
Grey cast iron
Alloy steel
Aluminium
N, slightly oxidizing
N
Slightly carburizing
zones, respective
applications of each type
temperature
t pe of flame.
flame
ranges and
Diagram
Di g
Brass Slightly oxidizing
C
Copper, B
Bronze N slightly
N, li h l oxidizing
idi i [ 20 Marks]
[ 20 –
Nickel alloys Slightly carburizing
L d
Lead N

d d i i i
Uses, Advantages, and Limitations Oxy acetylene welding equipment
y Exposer
p of the heated and molten metal to the various
y OFW is
i fusion
f i welding.
ldi
gases in the flame and atmosphere makes it difficult to y Oxygen is stored in a cylinder at a pressure ranging
y No p
pressure is involved. from 13.8
13 8 MPa to 18.2
18 2 MPa .
y Filler metal can be added in the form of a wire or rod. prevent contamination.
y Due to high explosiveness of free acetylene it is stored
y Fluxes
Fl may be
b used
d to clean
l the
h surfaces
f and
d remove y Heat source is not concentrated, a large area of the in a cylinder with 80‐85% porous calcium silicate and
contaminating oxide. The gaseous shield produced by then filled with acetone which absorb upto
p 4 420 times
vaporizing flux can prevent oxidation during welding, metal is heated and distortion is likely to occur. by its volume at a pressure 1.75 MPa .
aand
d tthee sslag
ag p
produced
oduced by so
solidifying
d y g fluxu ca
can p
protect
otect y At the time of acetylene release if acetone comes with
y Flame
Fl welding
ldi isi still
ill quite
i common in
i field
fi ld work,
k in
i
the weld pool. Flux can be added as a powder, the acetylene the flame would give a purple colour.
welding rod can be dipped in a flux paste,
paste or the rods maintenance and repairs,
repairs and in fabricating small
y Another option is acetylene generator.
can be pre‐coated.
quantities
qua t t es o
of spec
specialized
a ed p products.
oducts.
CaC2 + 2 H 2O → C2 H 2 + Ca (OH ) 2
Contd…
IES 2010 GATE‐1994
Pressure Gas Welding
Pressure Gas Welding The
Th ratioti between
b t Oxygen
O andd Acetylene
A t l
y Pressure g
gas welding
g ((PGW)) or Oxyacetylene
y y gases for neutral flame in g
g gas welding
g is Thee ratioat o o
of acetylene
acety e e to o oxygen
yge iss
Pressure Welding is a process used to make butt (a) 2 : 1 (b) 1 : 2 approximately………. for a neutral flames used in
jjoints between the ends of objects
j such as ppipe
p gas welding.
welding
and‐railroad rail. (c) 1 : 1 (d) 4 : 1
(a) 1 : 1
y The ends are heated with a gas flame to a
temperature below the melting point, and the soft (b) 1 : 2
metal is then forced together under considerable (c) 1 : 3
pressure. (d) 1.5 : 1
y This
Thi process, therefore,
th f i actually
is t ll a 'form
'f off solid‐
lid
state welding.
GATE‐2003 IES 2010 GATE‐2002

Assertion (A): Oxidizing flame is used in gas
In Oxyacetylene gas welding, temperature at the welding to join medium carbon steels having high The temperature of a carburising flame in gas
inner cone of the flame is around melting
l i point.i welding is that of a neutral or an oxidising flame.
flame
(a) 3500°C Reason ((R): ) In g gas welding,
g, oxidizingg flame (a) Lower than
(b) 3200°C produces the maximum temperature compared to (b) Higher than
(c) 2900
2900°C
C neutral and reducing flame.flame (c) Equal to
(d) 2550°C (a) Both A and R are individually true and R is the (d) Unrelated to
(b) Both A and R are individually true but R is NOT the
( ) A is
(c) i true
t b t R is
but i false
f l
IES‐2009 IES‐1998 IAS 1994
By which one of the following methods gray cast In oxy‐acetylene gas welding, for complete In gas welding of mild steel using an oxy‐
i
iron i usually
is ll welded?
ld d? combustion,
b ti th volume
the l off oxygen required
i d per acetylene
t l fl
flame. th total
the t t l amountt off acetylene
t l
((a)) TIG weldingg ((b)) MIG welding
g unit of acetylene is consumed was 10 litre. The oxygen consumption
(c) Gas welding (d) Arc welding (a) 1 from the cylinder is
(b) 1.5
15 (a) 5 litre
(c) 2 (b) 10 litre
(d) 2.5 (c) 15litre
(d) 20 litre
IAS‐1995 IES ‐ 2012 Oxygen Torch Cutting (Gas Cutting)

Statement
St t t (I):
(I) In
I gas welding
ldi the
th metal
t l to
t beb joined
j i d gets
t
Assertion (A): If neutral flame is used in oxy‐ oxidized or carburized y Iron and steel oxidize (burn) when heated to a
acetylene
y welding,g, both oxygen
yg and acetylene
y temperature between 8000C to 10000C. C
cylinders of same capacity will be emptied at the same Statement (II): The neutral flame affects no chemical
time. change on the molten metal. y High‐pressure oxygen jet (300 KPa) is directed against
Reason (R): Neutral flame uses equal amounts of (a) Both Statement (I) and Statement (II) are a heated steel plate, the oxygen jet burns the metal and
oxygen and acetylene. blows it awayy causingg the cut ((kerf).
)
individuallyy true and Statement ((II)) is the correct
( ) Both A and R are individually true and R is the correct
(a) B h A d R i di id ll d R i h explanation of Statement (I)
explanation of A y For cutting metallic plates shears are used. These are
(b) Both A and R are individually true but R is not
B th A d R i di id ll t b t R i t the th (b) Both Statement (I) and Statement (II) are useful for straight‐line
straight line cuts and also for cuts up to 40
correct explanation of A individually true but Statement (II) is not the correct mm thickness.
(c) A is true but R is false explanation of Statement (I)
(d) A is false but R is true (c) Statement (I) is true but Statement (II) is false
( ) Statement (I)
( ) is true
Contd…
y For thicker plates with specified contour, shearing y Larger size orifice produces kerf width wider and larger
y For
o co p ete o
complete dat o 0.
oxidation 87 m3 o
0.287 yge / g o
oxygen/kg o iss
of iron
cannot be used and oxy‐fuel gas cutting (OFC) is oxygen consumed. d
required
useful. y At kindlingg temperature
p (about 870oC), iron form iron
oxide. y Due
D t unoxidized
to idi d metalt l blown
bl away theth actual
t l
y Gas‐cutting is similar to gas welding except torch tip. requirement is much less.
y Reaction:
3Fe + 2O2 → Fe3O4 +6.67 MJ/kg of iron
y Torch tip held vertically or slightly inclined in the
direction of travel.
The
h other
h reactions:
y Torch position is about 1.5 to 3 mm vertical from plate.
2Fe + O2 → 2FeO + 33.18 MJ/kg
J g of iron
4Fe + 3O2 → 2Fe2O3 + 4.9 MJ/kg of iron
y All exothermic reactions preheat the steel.
steel
Fig‐ differences in torch tips for gas welding and gas cutting
Contd…
y The drag lines shows the characteristics of the movement y If torch moved too rapidly, the bottom does not get y Gas cutting
g is more useful with thick p
plates.
off the
h oxygen stream. sufficient
ffi i t heat
h t and
d produces
d large
l drag
d so very rough
h
and irregular‐shaped‐cut edges.
y For
F thin
thi sheets
h t (less
(l th 3 mm thick)
than thi k) tip
ti size
i should
h ld
y If torch moved slowly a large amount of slag is
be small. If small tips are not available then the tip is
generated and produces irregular cut.
cut
inclined at an angle of 15 to 20 degrees.
Fi positioning of cutting torch in oxy‐
Fig‐ iti i f tti t h i f l tti
fuel gas cutting
y Drag is the amount by which the lower edge of the drag
line trails from the top edge.
edge
y Good cut means negligible drag.
Fig. Recommended torch position for cutting thin steel
Contd… Contd…
Application Difficulties
IAS‐2011 Main
IAS‐2011 Main y Metal temperature goes beyond lower critical
y Useful only for materials which readily get oxidized
D
Draw a self
lf explanatory
l t sketch
k t h off oxy‐acetylene
t l gas temperature and structural transformations occur.
occur
and the oxides have lower melting points than the
cutting torch.
torch Briefly explain how cutting is
metals. y Final microstructure depends on cooling rate.
effected.
y Widely used for ferrous materials.
[20‐Marks] y Steels with less than 0.3 % carbon cause no problem.
y Cannot be used for aluminum, bronze, stainless steel
and
d like
lik metals
t l since
i th resist
they i t oxidation.
id ti
Contd…
y For high
g carbon steel material around the cut should IES‐1992 IES 2007
be preheated (about 250 to 300oC) and may post heat The edge of a steel plate cut by oxygen cutting will Consider the following statements in respect of oxy‐
acetylene welding:
y g
gett hardened
h d d when
h theth carbon
b content t t is
i
also necessary. 1. The joint is not heated to a state of fusion.
((a)) Less than 0.1 p
percent 2. No pressure is used.
y Cutting CI is difficult, since its melting temp. is lower (b) Less than 0.3 percent 3. Oxygen is stored in steel cylinder at a pressure of 14
MPa.
than iron oxide. ( ) More
(c) M than
h 0.3 percent 4. When there is an excess of acetylene used, there is a
((d)) Anywhere
y between 0.1 to 1.0 p
percent decided change in the appearance
g pp
y If chromium
h i and
d nickel
i k l etc are present in
i ferrous
f of flame.
alloys oxidation and cutting is difficult.
difficult Which of the statements given above are correct?
g
(a) 1, 2 and 3 (b) 2, 3 and 4
((c)) 1, 3 and 4
,3 4 ((d)) 1, 2 and 4
, 4

IES‐2001 IES‐1992 IES‐2005
Oxyacetylene reducing flame is used while Thick steel plate cut with oxygen normally shows Consider the following statements:
carrying out the welding on
i t th ldi signs
i off cracking.
ki Thi tendency
This t d f cracking
for ki can 1. I ldi th t h h ld b h ld t
In gas welding, the torch should be held at an angle of
l f
be minimised by 30° to 45° from the horizontal plane.
((a)) Mild steel ((b)) High carbon steel
g
2. In gas welding, the Size of the torch depends upon the
I ldi h Si f h h d d h
(c) Grey cast iron (d) Alloy steels (a) Slow speed cutting
thickness of metal to be formed.
(b) Cutting in two or more stages 3. Drag in gas cutting is the time difference between
h d ff b
(c) Preheating the plate heating of the plate and starting the oxygen gas for
cutting.
tti
(d) Using oxy‐acetylene flame
Which of the statements given above are correct?
(a) 1, 2 and 3 (b) 1 and 2
(c) 2 and 3 (d) 1 and 3
Powder Cutting Plasma Cutting
l
y Cast iron,
iron stainless steel,
steel and others high alloy steels are GATE‐2009 (PI)
GATE‐2009 (PI) y Uses ionized gas jet (plasma) to cut materials resistant to
difficult to cut by oxy‐fuel cutting and we can use powder oxy‐fuel cutting,
cutting.
i Whi h off the
Which th following
f ll i powders
d should
h ld be
b fed
f d for
f y Highh velocity
l electrons
l generated d by
b the
h arc impact gas
y By
y injecting
j g a finelyy divided 200‐mesh iron p
powder into molecules, and ionize them.
effective oxy
oxy‐fuel
fuel cutting of stainless steel?
the flame, a lower melting point eutectic oxide is formed y The ionized gas is forced through nozzle (upto 500 m/s), and
at the cutting interface,
interface where additional iron‐oxygen (a) Steel the jjet heats the metal,, and blasts the molten metal away.
y
reaction is generated and cutting proceeds in a similar y More economical, more versatile and much faster (5 to 8
((b)) Aluminum times) than oxyfuel cutting,
cutting produces narrow kerfs and
way off oxy‐fuel
f l cutting.
tti
smooth surfaces.
y The heat and the fluxing g action of the burningg iron ((c)) Copper
pp
powder enable the cutting oxygen stream to oxidize the y HAZ is i 1/3
/ to ¼ thh than
h oxyfuel
f l cutting.
i
base metal continuously, just as in cutting carbon steel. (d) Ceramic y Maximum plate thickness = 200 mm
l i ldi
Electric Arc Welding Principle of Arc
y An arc is generated between cathode and anode when
they are touched to establish the flow of current and
Electric Arc Welding
l i ldi then separated by a small distance.
y 65% to 75% heat is generated at the anode.
y If DC is used and the work is positive (the anode of the

Fig Basic circuit for arc welding
Fig. Basic circuit for arc welding circuit),
i it) theth condition
diti isi known
k as straight
t i ht polarity
l it
(SPDC).
(SPDC)
y Manual arc welding is done with shielded (covered)
y Work is negative
g and electrode is p
positive is reverse ISRO‐2011 electrodes
polarity (RPDC). y Bare
Bare‐metal
metal wire used in automatic or semiautomatic
I ldi
In arc welding, penetration is minimum for
t ti i i i f
y SPDC conditions are preferred. machines.
( ) DCSP
(a) DCSP y Non
N consumable
bl electrodes
l t d (
(e.g t
tungsten)
t ) isi nott
y DC arc‐welding maintain a stable arc and preferred for consumed by the arc and a separate metal wire is used
(b) DCRP as filler.
difficult tasks such as overhead welding.
y There are three modes of metal transfer (globular,
(globular
y For a stable arc, the gap should be maintained. ( ) AC
(c) AC
spray and short‐circuit).
(d) DCEN
(d)
Contd…
Three modes of metal transfer during arc welding Major Forces take part in Metal Transfer JWM 2010

(i) gravity force Assertion (A) : Bead is the metal added during
single pass of welding.
(ii) Surface tension
Reason (R) : Bead material is same as base metal.
(iii) electromagnetic interaction (a) Both A and R are individually true and R is the
correct explanation
p of A
( )
(iv) hydrodynamic action of plasma
(b) Both A and R are individually true but R is NOT the
GATE‐1993 Arc welding equipments
In d.c. welding, the straight polarity (electrode 1. Droopers: Constant current welding machines
negative) results in ¾ Good
G d for
f manuall welding
ldi
(a) Lower penetration 2. Constant voltage
g machines
(b) Lower deposition rate ¾ Good for automatic welding Fig. Machine with different settings
(c) Less heating of work piece
(d) Smaller weld pool
For-2013 (IES, GATE & PSUs) Page 39 Contd… Fig. Characteristic curve of a constant voltage arc‐welding machine

IES 2010
Formula y Requires a large current (150 to 1000 A),
A) voltage is InI arc welding,
ldi the
th arc length
l th should
h ld be
b equall to
t
between 30 and 40 V, actual voltage across the arc ((a)) 44.55 times the rod diameter
(b) 3 times the rod diameter
varying from 12 to 30 V.
( ) 1.5 times
(c) i the
h rodd diameter
di
y To initiate a weld, the operator strike the electrode and ((d)) Rod diameter
start arc.
V I
+ =1
OCV SCC
IES‐2005 IES‐2001 IES‐2001

Consider the following statements:
1. In arc welding, 65% to 75% heat is generated at the In manual arc welding, the equipment should
g q p In arc welding, d.c. reverse polarity is used to bear
anode.
d greater advantage in
t d t i
have drooping characteristics in order to maintain ((a)) Overhead welding g
2. Duty cycle in case of arc welding is the cycle of
y y g y
complete welding of work piece from the (a) Voltage constant when arc length changes (b) Flat welding of lap joints
beginning.
beginning ( ) Edge welding
(c) Ed ldi
3. Arc blow is more common with DC welding. (b) Current constant when arc length changes
((d)) Flat welding of butt joints
g j
Which of the statements given above are (c) Temperature in the are constant
correct?
(d) Weld pool red‐hot
((a)) 1, 2 and 3
, 3 ((b)) 1 and 2
(c) 2 and 3 (d) 1 and 3
IES‐1998 IAS‐1999 IAS‐1998

The voltage‐current characteristics of a dc Open‐circuit voltage of 60 V and current of 160A Assuming a straight line V‐I characteristics for a
generator
t f
for arc welding
ldi i a straight
is t i ht line
li were the
th welding
ldi conditions
diti f arc welding
for ldi off a d ldi
dc welding generator, short circuit current as 400A
t h t i it t A
between an open‐circuit voltage of 80 V and short‐ certain class of steel strip of thickness 10 mm. For and open circuit voltage as 400 which one of the
circuit current of 300 A. The generator settings for arc welding of 5mm thick strip of the same steel, following is the correct voltage and current setting
maximum arc p power will be the welding g voltage
g and current would be for maximum arc power?
p
(a) 0 V and 150 A (b) 40 V and 300 A (a) 60 V and 80 A (a) 400 A and 100 V (b) 200 A and 200 V
( ) 40 V and
(c) d 150 A (d) 808 V and
d 300 A (b) 120 V and d 160
6 A ( ) 400 A and 50 V
(c) A d V (d) 200 A and 50 V
A d V
((c)) 60 V and 4
40 A
(d) 120 V and 40 A

GATE ‐2012 Same Q in GATE ‐2012 (PI) GATE – 2007 (PI)
( ) GATE‐1992
In a DC arc welding operation, the voltage‐arc
The
Th DC power source for f arc welding
ldi has
h the
th
A low carbon steel plate is to be welded by the manual
length characteristic was obtained as Varc = 20 + 5L characteristic 33V + I = 240,
4 where V = Voltage
g and metal arc welding process using a linear V ‐ I
where the arc length L was varied between 5 mm I = Current in amp. For maximum arc power at characteristic DC Power source. The following data are
and 7 mm.
mm Here Varc denotes the arc voltage in Volts.
Volts the electrode,
electrode voltage should be set at available
il bl :
The arc current was varied from 400 A to 500 A. ((a)) 20 V ((b)) 4
40 V ((c)) 60 V ((d)) 80 V OCV of Power source = 62 V
A
Assumingi li
linear power source characteristic,
h i i the h
Short circuit current = 130 A
open circuit voltage and the short circuit current for
the welding operation are A length,
Arc l h L = 4 mm
(a) 45 V,
V 450 A (b) 75 V,
V 750 A p
Traverse speed of weldingg = 155 cm/s
/
(c) 95 V, 950 A (d) 150 V, 1500 A Efficiency of heat input = 85%
V l
Voltage i given
is i as V = 20 + 1.5 L
Calculate the heat input into the workprice
Duty Cycle
y The percentage of time in a 5 min period that a
IFS‐2011
welding machine can be used at its rated output What is the maximum output current that can be
without overloading. 2 drawn at 100% duty cycle from a welding power source
⎛ I⎞
Required duty cycle Ta = ⎜
Required duty cycle, ⎟ T rated at 600A at 60% duty cycle.
cycle
y Time is spent in setting up, metal chipping, cleaning ⎝ Ia ⎠ [3‐Marks]
and inspection.
p
y For manual welding a 60% duty cycle is suggested and Where ,T = rated duty cycle
for automatic welding 100% duty cycle.
cycle I = rated current at the rated duty cycle
Io = Maximum current at the rated duty cycle
Contd…
Electrode Consumable Electrodes Consumable electrodes are three kinds:

1. Non‐consumable Electrodes ¾Provides filler materials. (a) Bare
2. Consumable Electrodes
C bl El d ¾Same composition.
composition (b) Fluxed
Fl d or lightly
li htl coated
t d
¾This requires that the electrode be moved toward or ((c)) Coated or extruded / shielded
away from the work to maintain the arc and y For automatic welding, bare electrode is in the form of
Non‐consumable Electrodes
satisfactoryy welding
g conditions.
¾Made of carbon, Graphite or Tungsten.
M d f b G hi T continuous wire (coil).
(coil)
¾Carbon and Graphite are used for D.C.
p
¾ Electrode is not consumed, the arc length remains
constant arc is stable and easy to maintain
constant, arc is stable and easy to maintain.

Electrode coating characteristic GATE‐1994 Electrode coatings
1. Provide a protective atmosphere. The electrodes used in arc welding are coated. l. Slag Forming Ingredients. asbestos, mica, silica,
2. Stabilize
S bili theh arc. This coating is not expected to fluorspar titanium dioxide,
fluorspar, dioxide Iron oxide,
oxide magnesium
33. Provide a p
protective slag
g coating
g to accumulate (a) Provide protective atmosphere to weld carbonate, Calcium carbonate and aluminium oxide.
impurities, prevent oxidation, and slow the cooling of (b) Stabilize the are
the weld metal.
metal (c) Add alloying elements 2. Arc Stabilizing Ingredients. or ionizing agents:
4. Reduce spatter. (d) Prevents electrode from contamination potassium silicate, TiO2 + ZrO2 (Rutile), Mica,
5. Add alloying elements. Calcium oxide,
oxide sodium oxide,
oxide magnesium oxide,
oxide
feldspar (KAI Si3 O8)
6
6. Affect arc penetration
7. Influence the shape of the weld bead.
8. Add additional filler metal.
Contd…
3. Deoxidizing Ingredients. Cellulose, Calcium y The slag is then easily chipped.

carbonate, dolo‐
b d l mite, starch, dextrin, wood flour,
i h d i d fl
graphite, aluminium, ferromanganese.
y Coatings are designed to melt more slowly than the
4. Binding Materials
g Sodium silicate, potassium silicate, filler wire.
asbestos.
5. Alloying Constituents to Improve Strength of Weld
6. TiO2 and potassium compounds increase the melting
rate of the base metal for better penetration.
rate of the base metal for better penetration
7. Iron powder provides higher deposition rate.
I d id hi h d ii
Contd… Contd…
Binders IES 2007 IES‐1997

y AC arc welding used potassium silicate binders. The coating material of an arc welding electrode Assertion (A): The electrodes of ac arc welding are
coated with sodium silicate,, whereas electrodes used
contains
t i which hi h off the
th following?
f ll i ? for dc arc welding are coated with potassium silicate
y DC arc welding used sodium silicate binders.
1. Deoxidising g agent
g binders.
y Potassium has a lower ionization potential as compared Reason (R): Potassium has a lower ionization
2. Arc stabilizing agent potential than sodium.
with
h sodium.
d 3. Slag
Sl forming
f i agent ( ) Both
(a) B h A and d R are individually
i di id ll true and
d R is
i the
h correct
explanation of A
Select the correct answer using g the code g
given below:
(b) Both
i di id ll true
t b t R is
but i nott the
th
(a) 1, 2 and 3 (b) 1 and 2 only correct explanation of A
( ) 2 and
(c) d 3 only
l (d) 1 andd 3 only
l (c) A is true but R is false

IES‐2002 Welding Flux
Low Hydrogen Electrode
Low Hydrogen Electrode
Match List I with List II and select the correct answer: Available in three forms
List I (Ingredients) List II (Welding y The basic coatings contain large amount of
functions)
y Granular calcium carbonate (limestone) and calcium
A Silica
A. Sili 1. A stabilizer
Arc t bili y Electrode wire coating fluoride (fluorspar) and produce low hydrogen.
hydrogen
B. Potassium oxalate 2. De‐oxidizer y Electrode core y But it can absorb moisture therefore coated low
C. Ferro silicon 3. Fluxing agent hydrogen electrodes are backed before use to a
D. Cellulose 4.
4 Gas forming material
g temperature
p of 200oC to 33000C and stored in an
Codes:A B C D A B C D oven at 110 C to 150oC
o
(a) 3 4 2 1 (b) 2 1 3 4 y Other types of electrode release large amount of

(c) 3 1 2 4 (d) 2 4 3 1 hydrogen, which can dissolve in the weld metal
andd lead
l d to embrittlement
bi l or cracking.
ki
W ldi P iti
Welding Positions ldi
Welding Current
IFS‐2011 y Welding current depends upon: the thickness of the
What is meant by low hydrogen electrode ?
What is meant by low ‐hydrogen electrode ? welded metal, type of joint, welding speed, position of
welded metal type of joint welding speed position of
[2‐marks] the weld, the thickness and type of the coating on the
electrode and its working length.
l d d i ki l h
Fig. The position of electrode for horizontal welding y Welding current, I = k. d, amperes; d is dia. (mm)
g , , p ; ( )
Fig. Positioning of electrode for welding in vertically upward position
Welding Voltage Arc Length g arc results in

A long
y The arc voltage depends only upon the arc length y For good welds, a short arc length is necessary, y Large heat loss into atmosphere.
because: y Unstable
U t bl arc.
V = k1 + k2l Volts 1. Heat is concentrated. y Weld p
pool is not p
protected.
2. More stable y Weld has low strength, less ductility, poor fusion and
Where l is the arc length in mm and k
Wh l i h l h i d k1 and k
d k2 are 3 More protective atmosphere.
3. atmosphere excessive spatter.
spatter
constants,
k1 = 10 to 12; and k2 = 2 to 3
The minimum Arc voltage is given by
Vmin = (20 + 0.04 l) Volt
Arc length should be equal to the diameter of the electrode size GATE‐2002, Conventional
The arc length‐voltage characteristic of a DC arc is given
by the equation: V = 24 + 4L, where V is voltage in volts
and
d L is
i arc length
l h in
i mm. The
Th static
i volt‐ampere
l
characteristic of the power source is approximated by a
Bead width should be equal to three diameter of the electrode size
q straight
g line with a no load voltage
g of 80 V and a short
circuit current of 600A. Determine the optimum arc
length for maximum power.
Fig. Arc Power Vs Arc Length
GATE‐2010 (PI) GATE‐2008 GATE‐2006

During
D i a steady
t d gas metal t l arc welding
ldi with
ith direct
di t
current electrode positive polarity, the welding current, In arc welding of a butt joint, the welding speed is In an arc welding process, the voltage and current
voltage
lt andd weld
ld speed d are 150 A,
A 30 V and d 6 m/min,
/ i to be selected such that highest cooling rate is are 25 V and 300 A respectively.
respectively The arc heat
respectively. A metallic wire electrode of diameter 1.2 achieved. Melting efficiency and heat transfer transfer efficiency is 0.85 and welding speed is 8
mm is i being
b i f d att a constant
fed t t ratet off 12 m/min.
/ i The Th efficiency
ffi i are 0.5 and
d 0.7, respectively.
i l TheTh area off mm/sec./ Th net heat
The h i
input (i J/mm)
(in J/ ) is
i
density, specific heat and melting temperature of the the weld cross section is 5 mm2 and the unit ((a)) 64 4
wire
i electrode
l t d are 7000 kg/m k / 3, 500 J/kg
J/k oC and d 1530oC,
C energy required to melt the metal is 10 J/mm3. If
respectively. Assume the ambient temperature to be 30oC (b) 797
the welding gp
power is 2 kW,, the welding g speed
p in
andd neglect
l the
h latent
l h
heat off melting.
li F h consider
Further, id ( ) 1103
(c)
mm/s is closest to
that two‐third of the total electrical power is available for ((d)) 797
79700
melting
l i off the
h wirei electrode.
l d TheTh melting
l i efficiency
ffi i (i
(in (a) 4 (b) 14 (c) 24 (d) 34
percentage) of the wire electrode is
(a) 39.58 (b) 45.25 (c) 49.38 (d) 54.98
Example Arc blow in DC arc welding
GATE‐2009 (PI)
GATE‐2009 (PI)
Calculate the melting efficiency in the case of
A t
Autogenous gas tungsten
t t arc welding
ldi off a steel
t l arc‐welding
ldi off steel
t l with
ith a potential
t ti l off 20 V andd
plate is carried out with welding current of 500 A,
A a current of 200 A. The travel speed
p is 5 mm/s/
and .the cross‐sectional area of the joint is 20
g of 20 V, and weld speed
voltage p of 20 mm/sec.
mm2. Heat required to melt steel may be taken
Consider the heat transfer efficiency from the arc as 10 J/mm3 and the heat transfer efficiency as
to the weld pool as 90%. The heat input per unit 0.85.
length (in KJ/mm) is
(a) 0.25 (b) 0.35 (c) 0.45 (d) 0.55

Effect of arc blow The effects of arc blow can be minimized with D.C.
y Arc
A blow
bl occurs during
d i the
th welding
ldi off magnetic
ti welding
ldi byb
materials with DC. y Low heat penetration.
y Shortening
g the arc.
y The effect of arc blow is maximum when welding y Excessive
E i weld
ld spatter.
y Reduce current
corners where magnetic field concentration is y Pinch effect in welding
g is the result of electromagnetic
g
maximum. y Reducing
R d i weld ld speed.
d
forces
y The effect is p
particularlyy noticeable when welding
g with y Balance magnetic
g field byy p
placing
g one g
ground lead at
y Weld spatter occurs due to
bare electrodes or when using currents below or above each end of the work piece.
¾High welding current
y Again the problem of arc blow gets magnified when y Wrapping the electrode cable a few turns around the
welding highly magnetic materials such as Ni alloys, ¾Too small an electrode arc
work piece.
because of the strong magnetic fields set up by these
metals.
y Cause:
C U b l
Unbalanced d magneticti forces.
f
Contd… Contd…
IES‐2001 IES‐2001 ISRO‐2006

Arc blow is more common in Pinch effect in welding is the result of Too high welding current in arc welding would result in
(a) A.C. welding (a) Expansion of gases in the arc (a) Excessive spatter,
spatter under cutting along edges,
edges irregular
deposits, wasted electrodes
(b) D.C. welding with straight polarity (b) Electromagnetic forces
(b) Excessive piling up of weld metal, poor penetration,
(c) D.C. welding with bare electrodes (c) Electric force
wasted electrodes
(d) A.C. welding with bare electrodes (d) Surface tension of the molten metal
(c) Too small bead, weak weld and wasted electrodes
(d) Excessive
E i piling
ili up off weldld metal,l overlapping
l i
without penetration of edges, wasted electrodes
Gas shields y Helium, most expensive, has a better thermal Carbon Arc welding

y An inert gas is blown into the weld zone to drive away conductivity, is useful for thicker sheets, copper and y Arc is produced between a carbon electrode and the
other atmospheric gases. aluminium welding, higher deposition rate. work.
y Gases are argon, helium, nitrogen, carbon dioxide and y The arc in carbon dioxide shielding gas is unstable, y Shielding is not used.
a mixture of the above gases. l t expensive,
least i deoxidizers
d idi needed.
d d
y No pressure
y Argon ionizes easily requiring smaller arc voltages.It is y It is
i a heavy
h gas and
d therefore
th f covers the
th weld
ld zone
y With or without filler metal
good
d for
f welding
ldi thin
thi sheets.
h t very well.
well
y May be used in "twin arc method", that is, between
two carbon
b (graphite)
( hi ) electrodes.
l d
IES 2010 Tungsten Inert Gas welding (TIG) y Very clean welds.
Assertion (A): Straight polarity is always
y Arc is established between a non‐consumable y All metals and alloys can be welded. (Al, Mg also)
recommended for Carbon‐electrode welding.
tungsten electrode and the workpiece.
workpiece
Reason (R): Carbon arc is stable in straight polarity. y Straight polarity is used.
y Tungsten is alloyed with thorium or zirconium for
better current‐carrying and electron‐emission y Weld voltage 20 to 40 V and weld current 125 A for
characteristics.
(b) Bothh A and d R are individually
d d ll true but
b R is NOT the
h RPDC to 1000 A for SPDC.
SPDC
y Arc length is constant, arc is stable and easy to
correct explanation
p of A
maintain.
maintain y Shielded Gas: Argon
y With or without filler.
(d) A is
i false
f l but
b t R is
i true
t y Torch is water or air cooled.
cooled
Contd…
GATE 2011 IES 2010
Which one among the following welding processes In an inert gas welding process,
process the commonly used
used non – consumable electrode? gas is
(a) Gas metal arc welding (a) Hydrogen
(b) S b
(b) Submerged arc welding
d ldi (b) Oxygen
( )
(c) Gas tungsten arc welding
g g (c) Helium or Argon
(d) Flux coated arc welding (d) Krypton
Fig. TIG
GATE‐2002 IES‐1994
ISRO‐2009 Which of the following arc welding processes does Which one of the following welding processes
Following gases are used in tungsten inert not use consumable electrodes? uses non‐ consumable electrodes?
bl l t d ?
gas welding (a) GMAW ((a)) TIG weldingg
(a) CO2 and H2 (b) GTAW (b) MIG welding
(b) Argon
A and
d neon (c) Submerged Arc Welding ( ) Manual arc welding
(c) M l ldi
(c) Argon and helium (d) None of these ((d)) Submerged arc welding.
g g
(d) Helium and neon

IES‐2000 Gas Metal Arc Welding (GMAW) or MIG
Which one of the following statements is correct? y A consumable electrode in a gas shield.
y Fast and economical.
(a) No flux is used in gas welding of mild steel y Arc
A isi between
b workpiece
k i and
d an automatically
i ll fed
f d
bare‐wire electrode. y A reverse‐polarity dc arc is generally used because
(b) Borax is the commonly used flux coating on off its
i deep
d penetration,
i spray transfer,
f andd ability
bili
welding electrodes y Argon, helium, and mixtures of the two can be used.
to produce smooth welds with good profile.
( ) Laser beam welding employs a vacuum chamber
(c) L b ldi l h b y Any metal can be welded but are used primarily with
and thus avoids use of a shielding method the non‐ferrous metals.
(d) AC can be used for GTAW process y When welding steel, some O2 or CO2 is usually added
to improve
p the arc stabilityy and reduce weld spatter.
p
Contd…
IES 2007 IES‐1997
In MIG welding, the metal is transferred into the Consider the following statements:
f
form of which one of the following?
f hi h f th f ll i ? MIG ldi
MIG welding process uses

((a)) A fine spray of metal
p y 1. Consumable electrode 2. non‐consumable electrode
(b) Molten drops 3. D.C. power supply 4. A.C. power supply
( ) Weld pool
(c) W ld l Of these statements
((d)) Molecules (a) 2 and 4 are correct
(b) 2 and 3 are correct
(c) 1 and 4 are correct
(d) 1 and 3 are correct
Fig. MIG
IES 2010 IES ‐ 2012 Submerged Arc welding (SAW)

Assertion (A): Inert gas and bare electrode instead Statement (I): DC with reverse polarity is used in MIG
St t t (I) DC ith l it i d i MIG
of flux coated electrode is used in the case of welding y A thick layer of granular flux is deposited just ahead of
automatic TIG and MIG welding processes.
i TIG d MIG ldi Statement (II):Use of DC with reverse polarity enables
a bare wire consumable electrode, and an arc is
( ) p p y
Reason (R): Better protection is provided by a cloud deeper penetration and a clean Surface
of inert gas than the cover created by the flux. (a) Both Statement (I) and Statement (II) are maintained beneath the blanket of flux with only a few
individuallyy true and Statement ((II)) is the correct
( ) Both
(a) B th A and d R are individually
i di id ll true
t and
d R is
i the
th small
ll flames
fl b i visible.
being i ibl
explanation of Statement (I)
(b) Both Statement (I) and Statement (II) are y A portion
ti off the
th flux
fl melts.
lt Molten
M lt fl
flux and
d flux
fl
(b) Both A and R are individually true but R is NOT the individually true but Statement (II) is not the correct
correct explanation of A explanation of Statement (I) provides thermal insulation,
insulation slows cooling rate and
(c) A is true but R is false (c) Statement (I) is true but Statement (II) is false produce soft,, ductile welds.
p
(d) A is false but R is true ( ) Statement (I)
( ) is true
Characteristic of submerged arc welding
y Most suitable for flat butt or fillet welds in low y High speeds,
carbon steel (< 0.3% carbon).
y High deposition rates,
y The process is not recommended for high‐carbon
y Deep penetration,
steels,
t l t l
tool steels,
t l aluminum,
l i magnesium,
i
y High cleanliness (due to the flux action).
titanium, lead, or zinc.
zinc
Advantages Limitations IES 2011

The welding process in which bare wire is used as
y Wire electrodes are inexpensive. y Extensive flux handling, electrode,, g
granular flux is used and the p process is
y No weld spatter. y Contamination of the flux by moisture.
characterized by its high speed welding, is known as:
(a) Shielded arc welding
y Nearly 100% deposition efficiency. y Large‐grain‐size structures. (b) Plasma arc welding
y Lesser electrode consumption. y Welding is restricted to the horizontal position. (c) Submerged arc welding
(d) Gas metal arc welding
y Chemical control is important
IES‐2006 IES‐2005 IES‐2008

In which of the following welding processes, flux Which of the following are the major Assertion (A): Submerged arc welding is not
characteristics of submerged arc welding? recommended for high g carbon steels,, tool steels,,
i
is used in the form of granules?
d i th f f l ? aluminium, magnesium etc.
((a)) AC arc weldingg 1. High welding speeds. Reason ((R): ) This is because of unavailability y of
2. High deposition rates. suitable fluxes, reactivity at high temperatures and
(b) Submerged arc welding low sublimation temperatures.
3. Low penetration.
o pe et at o .
( ) Argon arc welding
(c) A ldi ( ) Both
(a) B h A and d R are true and
d R is
i the
h correct explanation
l i
4. Low cleanliness. of A
((d)) DC arc welding
g
S l t th
Select the correct answer using the code given below:
t i th d i b l (b) Both
B th A and d R are true
t b t R is
but i NOT theth correctt
(a) 2 and 3 (b) 1, 2 and 3 explanation of A
(c) 3 and 4 (d) 1 and 2 (d) A is false but R is true

GATE‐1999 Atomic Hydrogen welding (AHW)
y Temperature of about 3700oC.
C
For butt ‐welding 40 mm thick steel plates, when y An a.c. arc is formed between two tungsten electrodes
the expected quantity of such jobs is 5000 per along which streams of hydrogen are fed to the y Hydrogen acts as shielding also.
also
month over a period of 10 year, choose the best welding zone. The molecules of hydrogen are
suitable
i bl welding
ldi process out off the
h following
f ll i dissociated by the high heat of the arc in the gap y Used for very thin sheets or small diameter wires.
wires
between the electrodes. The formation of atomic
available alternatives. hydrogen proceeds with the absorption of heat: y Lower thermal efficiency than Arc welding.
welding
(a) Submerged arc welding H2 = 2H ‐ 421.2 k J / mol
(b) Oxy‐acetylene
Oxy acetylene welding y Ceramics may be arc welded.
y This
Thi atomic i hydrogen
h d recombines
bi to form
f molecular
l l
(c) Electron beam welding hydrogen outside the arc, particularly on the relatively y AC used.
(d) MIG welding cold
ld surface
f off the
h work k being
b i welded,
ld d releasing
l i the
h
heat gained previously:
2H = H2 + 421.2 k J / mol.
Contd…
IES‐2005 Resistance Welding
Principle
In atomic hydrogen welding, hydrogen acts as
y Both heat and pressure are used.
used
(a) A heating agent Resistance Welding
R i t W ldi y Heat is generated by the electrical resistance of the
(b) One of the gases to generate the flame
workk pieces
i andd the
h interface
i f b
between them.
h
(c) An effective shielding gas protecting the weld
y Pressure is supplied
pp externallyy and is varied
(d) A lubricant to increase the flow characteristics of throughout the weld cycle.
weld metal
y Due to pressure,
pressure a lower temperature needed than
oxy‐fuel or arc welding.
By S K Mondal Contd…
y Overall resistance very low.

y They are not officially classified as solid state welding
solid‐state
byy the American Welding
g Society.
y y Very high‐current (up to 100,000 A)
y Very rapid and economical. y Very low‐voltage (0.5 to 10 V) is used.
y Extremely well suited to automated manufacturing.
y No filler metal, no flux, no shielding gases.
Fig. The desired temperature Fig. Typical current and

di t ib ti
distribution across th
the pressure cycle for resistance
electrodes and the work welding. The cycle includes
pieces in lap
p p resistance forging and post heating
welding. operations.
FIG. The fundamental resistance‐welding circuit
Advantages
IES 2007
IES 2007
1. Very rapid.
Wh t is
What i the
th principle
i i l off resistance
i t welding?
ldi ?
2. Fully automation possible.
Indicate where the resistance is maximum in spot
welding
g operation.
p 3. Conserve material; no filler metal, shielding gases, or
flux is required.
[ 2 marks]
4. Skilled operators are not required.
5.Dissimilar metals can be easily joined.
Fig. The arrangement of the electrodes and the work in spot 6. High reliability and High reproducibility.
welding, showing design for replaceable electrode tips.
Limitations Application Different types

1. High initial cost. y The resistance welding processes are among the 1. Resistance spot welding
2. Limitations to the type of joints (mostly lap joints).

most common technique for high volume 2. Resistance seam welding
joining.
joining
3. Skilled maintenance personne1 are required: 3. Projection welding
4. special surface treatment needed. 4. Upset welding
5. Flash welding
6. Percussion welding
Resistance spot welding Heat input and Efficiency Calculations ect c Res

Electric sta ce We
Resistance d g
Welding
y The process description given so far is called resistance
spot welding (RSW) or simply spot welding.
welding Joule’s
l ’ law
l applicable
l bl
y This is essentially done to join two sheet‐metal jobs in 2
Q = I Rt, Joules
a lap joint, forming a small nugget at the interface of
the two plates.
p

IES‐2003 IES‐2001 GATE‐2007
Two
T metallic lli sheets,
h eachh off 2.0 mm thickness,
hi k are welded
ld d in
i a lap
l joint
j i
configuration by resistance spot welding at a welding current of 10 kA
In resistance welding, heat is generated due to the The maximum heat in resistance welding is at the and welding time of 10 millisecond. A spherical fusion zone extending
resistance between
i t b t (a) Tip of the positive electrode up tot the
th full
f ll thickness
thi k off each
metallic sheets are given as:
h sheet
h t isi formed.
f d The
Th properties
ti off the
th
((a)) Electrode and workpiece
p (b) Tip of the negative electrode ambient temperature = 293 K
melting temperature = 1793 K
(b) Asperities between touching plates (c) Top surface of the plate at the time of electric latent heat of fusion = 300 kJ/kg
density = 7000 kg/m3
( ) Two dissimilar metals being in contact
(c) T di i il l b i i contact with the electrode
i h h l d specific heat = 800 J/kg K
((d)) Inter atomic forces ((d)) Interface between the two plates being Joined
p gJ Assume:
(i) Contact resistance along sheet‐sheet interface is 500 micro‐ohm and
along electrode‐sheet interface is zero;
(ii) No conductive heat loss through the bulk sheet materials; and
(iii) The complete weld fusion zone is at the melting temperature.
The melting efficiency (in %) of the process is
( ) 50.37 (b)
(a) 6
60.37 ( )
(c) 70.37 (d) 8
80.37
GATE‐2009 (PI) Linked S‐1 GATE‐2009 (PI) Linked S‐2 GATE‐2005

Resistance
R i spot welding
ldi off two steell sheets
h is
i carried
i d out in
i Resistance
R i spot welding
ldi off two steell sheets
h is
i carried
i d out in
i
lap joint configuration by using a welding current of 3 kA and lap joint configuration by using a welding current of 3 kA and Spot welding of two 1 mm thick sheets of steel
a weldld time off 0.2 S. A molten
l weld
ld nugget off volume
l 20 mm3 a weldld time off 0.2 S. A molten
l weld
ld nugget off volume
l 20 mm3 (density = 8000 kg/m3) is carried out successfully
is obtained. The effective contact resistance is 200 µΩ is obtained. The effective contact resistance is 200 µΩ by passing a certain amount of current for 0.1
(micro‐ohms). The material properties of steel are given as: (micro‐ohms). The material properties of steel are given as: secondd through
h h the
h electrodes.
l d TheTh resultant
l weld
ld
(i) latent heat of melting: 1400 kJ/kg, (ii) density: 8000 (i) latent heat of melting: 1400 kJ/kg, (ii) density: 8000 nugget formed is 5 mm in diameter and 1.5 mm
kg/m3, (iii) melting temperature: 1520oC, (iv) specific heat: kg/m3, (iii) melting temperature: 1520oC, (iv) specific heat: thick. If the latent heat of fusion of steel is 1400
0.55 kJ/kggoC. The ambient temperature
p is 20oC. 0.55 kJ/kggoC. The ambient temperature
p is 20oC. kJ/kg
J/ g and the effective resistance in the welding g
Heat (in Joules) used for producing weld nugget will be Heat (in Joules) dissipated to the base metal will be operation in 200 , the current passing through the
(assuming 100% heat transfer efficiency) (neglecting all other heat losses) electrodes is approximately
(a) 324 (b) 334 (c) 344 (d) 354 (a) 10 (b) 16 (c) 22 (d) 32 (a) 1480A (b) 3300 A
(c) 4060 A (d) 9400 A
GATE‐2001 GATE‐2004 GATE‐1992

Resistance spot welding is performed on two Two 1 mm thick steel sheets are to be spot welded For resistance spot welding of 1.5 mm thick steel
plates of 1.5
1 5 mm thickness with 6 mm diameter at a current of 5000 A. A Assuming effective sheets the current required is of the order of
sheets,
electrode, using 15000 A current for a time resistance to be 200 micro‐ohms and current flow (a) 10 A
d
duration
i off 0.25 seconds.
d Assuming
A i the
h interface
i f time
i off 0.2 second,
d heat
h generated
d during
d i the
h (b) 100 A
resistance to be 0.0001 , the heat generated to process will be
form the weld is (c) 1000 A
(a) 0.2 Joule (b) 1 Joule
(a) 5625 W
W‐sec
sec (b) 8437 W
W‐sec
sec (d) 10,000 A
(c) 5 Joule (d) 1000 Joules
(c) 22500 W‐sec (d) 33750 W‐sec

GATE‐2010 IAS‐2003 IES 2007 Conventionall
Two steel sheets of thickness one mm are welded
Two pipes of inner diameter 100 mm and outer Assertion (A): Spot welding is adopted to weld two by resistance projection welding technique. A
diameter 110 mm each joined by flash butt overlapped
pp metal p pieces between two electrode
points. currentt off 30,000 A for
f 0∙005 second d is
i made
d tot
welding using 30 V power supply. At the interface, Reason ((R):) In this p process when current is switched flow. The effective resistance of joint can be taken
1 mm off material
i l melts
l from
f eachh pipe
i which
hi h has
h on, the lapped pieces of metal are heated in a as 100 micro ohms.
h The
h joint can be
b considered
d d as
a resistance of 42.4 Ω. If the unit melt energy is restricted area. a cylinder
y of diameter 5 mm and height g 1∙55 mm.
64.4 MJm‐3, then time required for welding in ( ) Both
(a) B h A and d R are individually
i di id ll true and
d R is
i the
h correct The density of steel is 0∙00786 gm/mm3. The heat
explanation of A
seconds is needed for welding steel is 10 J/mm3. Calculate the
(b) Both
i di id ll true
t b t R is
but i nott the
th
(a) 1 (b) 5 (c) 10 (d) 20 correct explanation of A efficiency of welding. [20]
GATE – 2008 (PI) Resistance seam welding y Welding current is a bit higher than spot welding, to
Aluminum strips of 2 mm thickness are joined together compensatet short
h t circuit
i it off the
th adjacent
dj t weld.
ld
y Weld is made between overlapping sheets of metal. y In other p
process a continuous seam is p produced byy
by resistance spot welding process by applying an
The seam is a series of overlapping spot welds. passing a continuous current through the rotating
electric current of 6000 A for 0.15 sec. The heat required
electrodes with a speed of 1.5
1 5 m/min for thin sheet.
sheet
for melting aluminum is 2.9 J/mm3. The diameter and y The basic equipment is the same as for spot welding.
the thickness of weld nugget are found to be 5 mm and
except that the electrodes are now in the form of
2.5 mm, respectively. Assuming the electrical resistance
rotating
t ti disks.
di k
to be 75 µΩ (micro – ohms), the percentage of total
energy utilized in forming the weld nugget is y Timed
Ti d pulses
l off currentt pass to
t form
f th overlapping
the l i
((a)) 28 ((b)) 35 ((c)) 655 ((d)) 772 welds.
welds
Contd… Contd…
Projection welding
GATE –
GATE – 2012 (PI)
2012 (PI) y Limitations of spot welding.
In resistance seam welding, the electrode is in the 1. Electrode
El d condition
di i must be b maintained
i i d
form of a continually, and only one spot weld at a time.
( ) cylinder
(a) li d 2. For additional strength multiple welds needed.
((b)) flat p
plate y Projection welding (RPW) overcomes above
(c) coil of wire limitations.
(d) circular
i l discdi
Fig. Resistance seam welding
y Dimples are embossed on work pieces at the weld
y Projections
j are p
press‐formed in anyy shape.
p
Upset welding
locations and then placed between large‐arealarge area
electrodes, and pressure and current applied like spot y Multiple
p welds at a time. y Made butt joint compared to lap joint.
welding.
ldi
y Current flows throughg the dimples
p and heats them y No indentation mark on the surface. y Pieces are held tightly and current is applied.
and pressure causes the dimples to flatten and form a y Due to pressure joints get slightly upset and hence its
y Bolts and nuts can be attached to other metal parts.
weld.
weld
name.
Fig. Principle of y Useful for joining rods or similar pieces.

p j
projection welding,
g
(a) prior to application of
current and pressure
(b) and after formation of
welds
Contd… Contd…
y This is the process used for making electric resistance‐ Flash Welding

welded
ld d (ERW) pipesi starting
i from
f a metall plate
l off suitable
i bl
thickness. y It is similar to upset welding except the arc rather than
y The plate is first formed into the shape of the pipe with the resistance heating.
helpp of the three roll set as shown in Fig.
g above. The ends
of the plate would then be forming the butt joint. y One pieces is clamped with cam controlled movable
y The two rotating copper disc electrodes are made to
contact the two ends of the plate through which the platen and other with is fixed platen.
current is passed.
passed The ends get heated and then forge‐ forge
welded under the pressure of the rolls.
y The
Th ends d off the
h pieces
i to be
b upset welded
ld d must beb perfectly
f l
parallel. Any high spots if present on the ends would get
melted first before the two ends are completely joined.
Contd… Contd…
y Two pieces are brought together and the power supply is Percussion Welding
switched on.
on Momentarily the two pieces are separated
to create the arc to melt the ends of the two pieces. y Similar to flash welding except arc power by a rapid
Th
Then again
i theh pieces
i are brought
b h together
h and d the
h
discharge of stored electrical energy.
power switched off while the two ends are fused under
force. Most of the metal melted would flash out y The arc duration is only 1 to 10 ms, heat is intense and
through
g the jjoint and forms like a fin around the jjoint. highly concentrated.
concentrated
y Faster than upset welding.
y Small weld metal is produced,
produced little or no upsetting,
upsetting and
low HAZ.
y Application: Butt welding of bar or tube where heat

damage is a major concern.
Thermit Welding y Temp.
p 2750°C p p g
produced in 30 seconds, superheating
y Heating and coalescence is by superheated molten the molten iron which provide both heat and filler
g
Other Welding metal obtained from a chemical reaction between a
metal oxide and a metallic reducing agent.
metal.
y Runners and risers are provided like casting.

Technique y Used mixture one part aluminum and three parts iron y Copper, brass, and bronze can be welded using a
oxide
id and
d ignited
i it d by
b a magnesium
i f
fuse. (
(1150°C).
°C) diff
different starting
i mixture.
i
8Al F 3O4 → 9Fe + 4Al
8Al+ 3Fe F Al2O3 + heat
h t y Used
U d to joint
j i thick
hi k sections,
i i remote locations.
in l i
Contd…
IES‐2000 Electro Slag Welding y A 65‐mm deep

p layer
y of molten slag,
g pprotect and
Consider the following processes: y Very effective for welding thick sections. cleanse the molten metal.
1. Gas welding
G ldi
2. Thermit welding y Heat is derived from the passage of electrical current y Water‐cooled copper molding plates confined the
3. Arc welding through a liquid slag and temp. 1760°C liquid and moved upward.
4 Resistance welding
4.
y Multiple electrodes are used to provide an adequate
The correct sequence of these processes in increasing
order of their welding temperatures is
d f th i ldi t t i supply
l off filler.
fill
(a) 1, 3, 4, 2 (b) 1, 2, 3, 4
(c) 4, 3, 1, 2 (d) 4, 1, 3, 2
Contd… Contd…
y Applications: Shipbuilding, machine manufacture, IAS‐2003

heavy pressure vessels, and the joining of large Which one of the following is not an electric
castings and forgings. resistance method of welding?
i t th d f ldi ?
((a)) Electro slag welding
g g
y Slow cooling produces a coarse grain structure. (b) Percussion welding
y Large HAZ. ( ) Seam welding
(c) S ldi
((d)) Flash welding
g

IAS‐2000 Electron Beam Welding
Consider the following welding processes: y A beam of electrons is magnetically focused on the
1. TIG welding 2. Submerged arc welding
work piece in a vacuum chamber.
3. Electro
Electro‐slag welding 4.
slag welding 4. Thermit welding
Which of these welding processes are used for welding y Heat of fusion is produced by electrons decelerate.
thick pieces of metals?
hi k i f l ?
y Allows precise beam control and deep weld
((a)) 1, 2 and 3
, 3 ((b)) 1, 2 and 4
, 4
penetration.
(c) 1,3 and 4 (d) 2, 3 and 4
y No shield
h ld gas (vacuum
( chamber
h b used)
d)
IES‐2004 IES‐2002 IES‐1993

Assertion (A): In electron beam welding process, In which one of the following welding techniques Electron beam welding can be carried out in
vacuum is an essential process parameter iis vacuum environment required?
i t i d? (a) Open air
Reason (R): Vacuum provides a highly efficient ((a)) Ultrasonic welding
g
shield
hi ld on weld ld zone (b) A shielding gas environment
(b) Laser beam welding (c) A pressurized inert gas chamber
correct explanation of A ( ) Plasma arc welding
(c) Pl ldi (d) Vacuum
(b) Both A and R are individually true but R is not the ((d)) Electron beam weldingg
IAS‐2004 Laser Beam Welding y Very

y thin HAZ and little thermal distortion.
Which one of the following welding processes y Used a focused laser beam provides power intensities y Filler metal and inert gas shield may or may not used.
consists of smaller Heat Affected Zone (HAZ)?
i t f ll H t Aff t d Z (HAZ)?
in excess of 10kW/cm2 y Deep penetration.
((a)) Arc welding
g ((b)) Electron beam welding
g
(c) MIG welding (d) Thermit welding y The high‐intensity beam produces a very thin column y No vacuum needed.
of vaporized metal with a surrounding liquid pool.
y No direct contact needed.
y Depth‐to‐width ratio greater than 4: 1.
For-2013 (IES, GATE & PSUs) Page 55 Contd… Contd…

y Heat input
p is veryy low, often in the range
g 0.1 to 10 J. IES 2007 IES‐2006
Consider the following statements in respect of the Which one of the following welding processes
y Adopted by the electronics industry.
laser beam welding: consists of minimum heat affected zone (HAZ)?
i t f i i h t ff t d (HAZ)?
y Possible to weld wires without removing the 1. It can be used for welding any metal or their
combinations because of very high temperature of the ((a)) Shielded Metal Arc Welding (SMA W)
g( )
polyurethane insulation. focal points. (b) Laser Beam Welding (LBW)
2 Heat affected zone is very large because of quick
2. ( ) Ultrasonic Welding (USW)
(c) Ul i W ldi (USW)
heating.
((d)) Metal Inert Gas Welding (MIG)
g( )
3. High vacuum is required to carry the process.
Hi h i i d t th
Which of the statements given above is/are correct?
((c)) 1 onlyy ((d)) 1, 2 and 33
Contd…
GATE‐2012 (PI) IAS‐2007 IAS‐1999

Which of the following welding processes results in Consider the following welding processes: Match List I (Shielding method) with List II (Welding
process)) and select the correct answer using
p g the codes
th smallest
the ll t heat
h t affected
ff t d zone?? 1. Arc welding 2. MIG welding given below the lists:
((a)) Shielded metal arc welding
g List I List II
3. Laser beam welding 4. Submerged arc
A. Fluxl coating 1. Gas metall arc welding
ld
(b) Gas welding welding B. Flux granules 2. Submerged arc welding
( ) Laser
(c) L b
beam welding
ldi S l
Select the
h correct sequence in i increasing
i i order
d off Heat
H C CO2
C. 3. Shi ld d metall arc welding
Shielded ldi
affected zone (HAZ) using the code D. Vacuum 4. Laser beam welding
((d)) Thermit weldingg
5. El t
Electron b
beam welding
ldi
given below: Codes:A B C D A B C D
(a) 1 ‐ 2 ‐ 3 – 4 (b) 1 ‐ 4 ‐ 2 – 3 (a) 1 2 5 3 (b) 1 4 2 5
(c) 3 5 1 4 (d) 3 2 1 5
(c) 3 ‐ 2 ‐ 4 – 1 (d) 4 ‐ 3 ‐ 2 – 1
Forge Welding Friction Welding y Machine is similar to a centre lathe.
y Blacksmith do this. y Heat is obtained by the friction between the ends of y Power requirements 25 kVA to 175 kVA.
y The
Th axial
i l pressure depends
d d on the
th strength
t th and
d
y Borax is used as a flux. the two parts to be joined. hardness of the metals being joined.
y One part is rotated at a high speed and other part is y Pressure 40 MPa for low‐carbon steels to as high as 450
y The ends to be joined were then overlapped on the
MPa for alloy steels.
anvil and hammered to the degree necessary to axially aligned and pressed tightly against it.
produce an acceptable weld. y Friction raises the temperature of both the ends. Then
y Quality
l d
depends
d on the
h skill
k ll off the
h worker
k and
d not rotation
t ti i stopped
is t d abruptly
b tl and
d the
th pressure is
i
used by industry.
industry increased to join.
join
y Very efficient.
efficient
GATE‐2007
y Wide variety of metals or combinations of metals can Which one of the following is a solid state joining
be joined
b d suchh as aluminium
l to steel.
l process?
y Grain size is refined (a) Gas tungsten arc welding
y Strength is same as base metal. (b) Resistance spot welding
y Only round bars or tubes of the same size, or (c) Friction welding
connecting g bars or tubes to flat surfaces can jjoin. (d) submerged arc welding
y One of the components must be ductile.
y Friction
F i ti welding
ldi is i a solid
lid state
t t welding.
ldi
Fig‐ friction welding process
Contd…
GATE ‐2010 (PI) Ultrasonic Welding (USW)
Two steel bars, each of diameter 10 mm, are coaxially
IFS‐2011 • USW is a solid‐state welding.
friction welded, end to end, at an axial pressure of 200 Di
Discuss with figure the various steps required for
ith fi th i t i d f • High‐frequency
Hi h f ( to 200, KHz)
(10 KH ) is
i applied.
li d
friction welding mentioning at least two methods
friction welding, mentioning at least two methods • Surfaces are held together
g under light
g normal
MP and
MPa d at a rotational
i l speed
d off 4000 rpm. The
Th pressure.
coefficient of friction between the mating faces of the of control.
• Temp.
Temp do not exceed one‐half
one half of the melting point.
point
rotating
g bars is 0.50.
5 The torque
q is assumed to act at the [5‐marks] • The ultrasonic transducer is same as ultrasonic
machining.
3/4th radius of the rotating bar. The power (in KW)
consumed at the interface for welding is
(a) 12.33 (b) 16.44 (c) 18.50 (d) 24.66

Contd…
• Restricted to the lap joint Explosion Welding

• Weld
W ld thin
hi materials‐sheet,
i l h foil,
f il and
d wire‐‐or
i the
h Applications
attaching thin sheets to heavier structural members. y Done at room temperature in air, water or vacuum.
y Joining the dissimilar metals in bimetallics
• Maximum thickness 2.5 mm for aluminum and 1.0
y Making microcircuit electrical contacts.
g
y Surface contaminants tend to be blown off the surface.
mm for harder metals.
metals
• Number of metals and dissimilar metal combinations y Welding refractory or reactive metals y Typical impact pressures are millions of psi.
andd non metalsl can beb joined
j i d such h as aluminum
l i to
y Bonding ultrathin metal. y Well suited to metals that is prone to brittle joints
ceramics or glass.
• Equipment is simple and reliable. when heat welded, such as,
• Less surface preparation and less energy is needed.
needed y Aluminum on steel
y Titanium
Ti i on steell
y Typically the detonation velocity should not exceed High velocity explosives, 4572‐7620 m/s.
120%
% off the
th sonic
i velocity
l it ini the
th metal.
t l y TNT
Important factors are, y RDX
y PETN
y Critical
C i i l velocity
l i
y Composition B
y Critical angle
g y Composition C4
y The cladding plate can be supported with tack welded y Datasheet
supports at the edges,
edges or the metal inserts.
inserts y Primacord
Medium velocity explosives, 1524‐4572 m/s
y Ammonium nitrate
y Ammonium perchlorate
y Amatol
y Nitroguonidine
y Dynamites
y diluted PETN
Contd… Contd… Contd…
Advantages,
Advantages Disadvantages,
Disadvantages Typical applications:
y Can bond many dissimilar, normally unweldable y The metals must have high enough impact resistance,
and
d ductility
d l (at( least
l 5%)
%) y Very large plates can be cladded.
Very large plates can be cladded
metals
y The lack of heating preserves metal treatment y The cladding plate cannot be too large. y Joins dissimilar metals.
Joins dissimilar metals
y The process is compact, portable, and easy to contain y Noise and blast can require worker protection, vacuum
chambers,
h b b i d in
buried i sand/water.
d/ t (titanium to steel, Al to steel, Al to Cu etc )
(titanium to steel, Al to steel, Al to Cu etc.)
y Inexpensive
y No need for surface preparation y Join tube to tube sheets of large heat exchangers.
Contd… Contd… Contd…
IES 2011 S‐1 Contd…
Match List –I with List –II and select the correct answer
GATE‐1992 using the code given below the lists:
In an explosive welding process, the……….. List‐I List –II
(maximum/minimum) velocity of impact is fixed A. Laser beam
A L b 1. Can be applied for welding or refractory metals
C b li d f ldi f l
by the velocity of sound in the……………… welding like niobium, tantalum, molybdenum and tungsten.
(fl /
(flyer/target) plate material
) l i l B. Electron 2. A sound and clean welded joint is created due to
((a)) Maximum; target
; g beam welding rubbing of two parts against each other with
adequate speed and pressure producing intense heat
d d d d h
(b) Minimum; target raising temperature above melting point.
( ) Maximum; flyer
(c) M i fl C. Ultrasonic 3. Clean heat source created much away from job, a
((d)) Minimum; flyer
; y welding narrow spot is heated, work chamber operates in a
high vacuum.
D. Friction 4. Clean heat source very quick heating, very small
4 yq g y
welding focal spot, no vacuum chamber is required.
IES 2011 From S‐1 IES‐2009 IAS‐2002
Codes : Match List‐I with List‐II and select the correct answer using the code given Match List I, (Welding) with List II (Application) and select the correct
below the Lists: answer using the codes given below the Lists:
A B C D A B C D List I
List‐I List II
List‐II Li I
List I Li II
List II
(Welding Process) (Application) (Welding) (Application)
(a) 4 3 1 2 (b) 2 3 1 4 A. Laser welding 1. Uniting large‐area sheets
A. Explosive 1. Joining thick sheets
B. Friction welding
i i ldi 2. Repairing large parts
i i l
(c) 4 1 3 4 (d) 2 1 3 4 C. Ultrasonic welding 3. Welding a rod to a flat surface B. Ultrasonic 2. Manufacture of heat exchanges
D. Explosive welding
g 4. Fabrication of nuclear reactor C. Thermit 3. Joining thin sheets or wires of
components similar/dissimilar metals
5. Welding very thin materials D. Projection 4. Joining hydraulic piston rods for
Code: agricultural machinery
(a) A B C D (b) A B C D 5. Joining rails, pipes and thick steel
5 4 3 2 1 4 2 5 sections
(c) A B C D (d) A B C D (a) 2 5 1 3 (b) 4 5 1 3
1 3 4 2 5 3 4 1 (c) 2 3 5 1 (d) 4 3 5 1
Autogeneous Welding Micro Plasma Arc Weld (PAW)

IFS ‐
IFS ‐ 2009
y Autogeneous welding or fusion of the parent y Similar to GTAW except the plasma caused by the arc
T plates
Two l t off aluminium
l i i and
d stainless
t i l steel
t l are to
t material
t i l in
i an inert
i t gas shield
hi ld without
ith t the
th use
is constricted by a water‐cooled orifice
be welded back to back to create a single plate of of filler metals.
y Capable of high welding speeds where size permits
thickness equal
q to the sum of the thicknesses of
the two plates. Suggest the suitable process and y Argon is used as the shielding gas.
explain it in brief.
[ 10 – marks]
Diffusion Welding GATE – 2008 (PI) IAS‐2001

y It is
i a solid
lid state
t t welding
ldi process which
hi h produces
d
coalescence of the faying surfaces by the application of Which pair among the following solid state welding Match List I (Welding processes) with List II (Features) and
select the correct answer using the codes given below the Lists:
pressure and d elevated
l t d temperatures
t t ( b t 50 to
(about t 80%
8 % processes uses heat from an external source?
of absolute melting point of the parent materials) for a List I List II
ti
time ranging
i from
f a couplel off minutes
i t tot a few
f hours.
h A
A. Ultrasonic welding 1
1. Gas heated to ionized condition
P – Diffusion welding; Q‐ Friction welding for conduction of electric current
y Produces high quality bonds with good strength with B. Electron beam welding 2. High frequency and high
little or no distortion. R – Ultrasonic
l welding
ld S – Forge welding
ld intensity vibrations
b
C. Plasma arc welding 3. Concentrated stream of high‐
y Ca
Can jojoin ve
veryy d
dissimilar
ss a materials.
ate a s. energy electrons
( ) P and
(a) dR (b) R and
dS 4. Exothermal chemical reaction
y A solid filler metal may or may not be inserted.
Codes:A B C A B C
y Materials
M t i l welded ld d forf aircraft
i ft and
d rocket
k t industry:
i d t ( ) Q and
(c) dS (d) P and
dS (a) 1 2 4 (b) 4 3 1
Boron, Titanium, Aluminium, Ceramic, Composite, (c) 2 1 4 (d) 2 3 1
G hit Magnesium
Graphite, M i etc.
t
JWM 2010
Match List‐I with List‐II and select the correct answer IES 2011 C
IES 2011 Conventional
ti l
g g
using the code given below the lists :
List I List II Discuss the process capabilities and applications of Gas
A Atomic
A. Atomic 11. Two pieces are brought together and
Two pieces are brought together and M t l Arc
Metal A Welding,
W ldi G tungsten
Gas t t A Welding,
Arc W ldi and
d
hydrogen welding power supply is switched on
B. Plasma‐arc 2. Nugget is formed at the interface of
Diffusion Bonding processes.
processes Brazing and Soldering
welding two plates [15 Marks]
C. Spot welding 3. Gas is ionized
D. Flash welding 4. Inert gas shielded arc welding
Code:A
d B C D A B C D
(a) 4 3 2 1 (b) 1 3 2 4
(c) 4 2 3 1 (d) 1 2 3 4
Brazing and Soldering B i h l di i
Brazing process has several distinct
y Brazing is the joining of metals through the use of heat
advantages:
and a filler metal whose melting temperature is above 1 All metals can be joined.
1. joined
450°C; but
b below
b l the
h melting
l point off the
h metalsl being
b
joined.
C
Comparisoni with
ith welding
ldi and d the
th brazing
b i process 2. Suited for dissimilar metals.
1. The composition of the brazing alloy is significantly
different from that of the base metal.
metal 3. Qu
Quick
c aand
d eco
economical.
o ca .
2. The strength of the brazing alloy is substantially lower
than that of the base metal.
metal 4. Less defects.
4
3. The melting point of the brazing alloy is lower than that
of the base metal,
metal so the base metal is not melted.
melted
4. Capillary action or capillary attraction draws the
molten filler metal into the jjoint,, even against
g the flow of
gravity.
Contd…
y Corrosion prone y Extremely clean surface needed.

Brazing metals are typically alloys such as, y Fluxes used are combinations of borax, boric acid,
y Brazing brass (60% Cu, 40%Zn)
B i b (6 % C %Z )
chlorides, fluorides, tetra‐borates and other wetting
y Manganese bronze
g
y Nickel silver agents.
y Copper silicon
C ili
y Silver alloys (with/without phosphorous)
y ( / p p )
y Copper phosphorous

yA p p
popular p
composition is 75% borax and 25% boric GATE‐2005
acid. The strength of a brazed joint
( ) Decreases with increase in gap between the two
(a) D i h i i b h
y Sodium cyanide is used in brazing tungsten to copper. joining surfaces
y Base materials not melted. (b) Increases with increase in gap between the two
joining surfaces
(c) Decreases up to certain gap between the two
j i i f
joining surfaces beyond which it increases
b d hi h i i
((d)) Increases up to certain gap between the two
p g p
joining surfaces beyond which it decreases
IES‐2006 ISRO‐2010 Braze Welding

Which is not correct statement about the function of
Which one of the following is not a fusion welding flux in brazing y Capillary action is not required.
process?? (a) To avoid thermal distortion and cracking
((a)) Gas welding g y Edge preparation needed.
(b) To dissolve surface oxide coatings which have formed
(b) Arc welding prior to brazing y Can join cast iron.
( ) Brazing
(c) B i ( ) To prevent oxides
(c) d from
f f
forming d
during the
h brazing
b
((d)) Resistance welding
g operation
p on both the base metal and the brazing g
material
(d) To facilitate the wetting process by reducing the
viscosity of the melt
Contd…
y Done with an oxyacetylene torch. Soldering Effective soldering generally involves six important
steps:
y By definition, soldering is a brazing type of operation
(1) Design of an acceptable solder joint,
where the filler metal has a melting temperature (2) Selection of the correct solder for the job,
below 450°C. (3) Selection of the proper type of flux,
(4) Cleaning the surfaces to be joined,
y Strength of the filler metal is low.
(5) Application of flux, solder, and sufficient heat to
y Soldering is used for a neat leak‐proof joint or a low allow
ll the
h molten
l solder
ld to fill theh joint
j i by b capillary
ill
action and solidify, and
resistance
i t electrical
l t i l joint.
j i t
(6) Removal of the flux residue, if necessary.
y Not suitable for high‐temp.
high temp application.
application
Fig. Braze Welding
ld l
Solder Metals Solder Flux
y Silver solders uses for higher‐temperature
higher temperature service,
service
y Ammonium chloride or rosin for soldering tin
y Most solders are alloys of lead and tin. Electrical and Electronic purpose.
y Hydrochloric acid and zinc chloride for soldering
y Three commonly used alloys contain 60, 50, and 40%
galvanized
l i d iron
i
tin and all melt below 240°C.
y Some
S fl
fluxes are corrosive
i and
d should
h ld be
b removed
d after
ft
use
Contd…
IES‐1994 IAS‐1996
Difficulties with Grey Cast Iron
Difficulties with Grey Cast Iron Match List ‐ I with List ‐ II and select the correct Match List I with List II and select the correct answer using
answer using the codes given below the Lists:
g g the codes given below the lists
g
S ld i and
Soldering d brazing
b i are difficult
diffi lt off grey castt Iron
I d
due List –I List‐II
List ‐ I (Filler) List ‐ II (Joining process)
to surface contamination with graphite having a very low A. Cu, Zn, Ag alloy 1. Braze welding. (Filler rod material) (Joining process)
B. Cu, Sn, alloy 2. Brazing A. Mild steel 1. MIG welding
surface energy.
gy B. Bronze 2. Soldering
C Pb, Sb, alloy
C. Pb Sb alloy 3
3. Soldering
C. Brass 3. Brazing
D.Iron oxide and aluminium powder 4. TIG welding of
aluminium D. Lead and tin alloy 4. Thermit welding
5. B
Braze welding
ldi
Codes:A B C D A B C D Codes:A B C D A B C D
(a) 2 1 3 ‐ (b) 1 2 4 ‐ (a) 1 5 3 2 (b) 4 3 2 5
(c) 2 1 3 4 (d) 2 ‐ 3 4 (c) 4 3 5 2 (d) 1 3 5 4
Welding design and defect IES‐2004 IES‐2003, ISRO‐2011

Welding Problem Causes Match List I (Welding problems) with List II (Causes) and select Match List I(Welding Defects) with List II (Causes) and
Cracking of weld metal High joint rigidity the correct answer using the codes given below the Lists: select the correct answer using the codes given below the
g g
List I List II Lists:
Cracking of base metal Excessive stresses
A. Cracking of weld metal 1. Excessive stresses List‐I List II
Spatter Arc blow B
B. C ki f b t l
Cracking of base metal 2. Hi h j i t i idit
High joint rigidity ( ldi
(Welding Defects)
f ) (
(Causes) )
Distortion Poor joint selection C. Porosity 3. Failure to remove slag A. Spatter 1. Damp electrodes
Slag inclusion Improper cleaning in multi
multi- p p
from previous deposit
B
B. Di
Distortion
i 2. A bl
Arc blow
pass welding D. Inclusions 4. Oxidation
C. Slag inclusion 3. Improper cleaning in
5. Excessive H2, O2, N2, in
Porosity Excessive H2, O2, N2, in the the welding atmosphere
h ldi h multi‐pass welding
welding atmosphere or Damp Codes:A B C D A B C D D. Porosity 4. Poor joint selection
electrodes (a) 2 1 5 3 (b) 3 4 2 1 Codes:A B C D A B C D
Lamellar Tearing inclusions such as Mn Fe and S (c) 2 4 5 3 (d) 3 1 4 2 (a) 4 2 3 1 (b) 4 2 1 3
in the base metal and/or (c) 2 4 1 3 (d) 2 4 3 1
residual stress
Cracks HAZ Cracking
HAZ Cracking
Cracks may be developed due to poor ductility of base
y Cracks may be of micro or macro size and may appear in y Cracking in heat affected zone may be caused by:
metal, high sulphur and carbon contents, high arc travel
the weld metal or base metal or base metal and weld
speeds
p i.e. fast cooling
g rates, too concave or convex weld (i) Hydrogen in welding atmosphere
metal
t l boundary.
b d
bead and high hydrogen contents in the weld metal.
y Different categories
g of cracks are longitudinal
g cracks, (ii) hot cracking
transverse cracks or radiating/star cracks and cracks in
the weld crater. (iii) low ductility
y Cracks occur when localized stresses exceed the ultimate
(iv) high residual stresses
t il strength
tensile t th off material.
t i l
y These stresses are developed p due to shrinkage
g duringg ( )
(v) brittle phase in the microstructure
p
solidification of weld metal.
Fig Various Types of Cracks in Welds
Fig. Various Types of Cracks in Welds
Hydrogen Induced Cracking

Hydrogen Induced Cracking Residual stress
y Due to the presence of moisture, grease, rust etc.,
ue to t e p ese ce o o stu e, g ease, ust etc.,
hydrogen may enter the weld pool and get dissolved in y The residual stresses result from the restrained expansion
and contraction that occur during localized heating and
the weld metal
the weld metal.
cooling in the region of weld deposit.
y During cooling hydrogen diffuses to the HAZ.
y The magnitude of residual stresses depends on the weldment
y Cracking may develop due to residual stresses assisted by design, support and clamping of the components being
hydrogen coalesence. welded their materials,
welded, materials welding process used,
used part
y The factors that determine the probability of hydrogen dimensions, welding sequence, post weld treatment, size of
i d d b ittl
induced embrittlement and cracking of weld are:
t d ki f ld the deposited weld beads,
beads etc.
etc
( ) y g
(a) Hydrogen content y Residual stresses should not have a harmful effect on the
strength
h performance
f off weldments,
ld reduces
d f i
fatigue
(b) fracture toughness of weld and HAZ strength, May cause distortion. This residual stress may
( )
(c) stress to which the joint is exposed as a result of
hi h h j i i d l f result
l in theh cracking
k off a brittle
b l materiall andd is not
the weld thermal cycle. important as far as a ductile material.
Solid Inclusion
Solid Inclusion
Porosity y Solid inclusions may be in the form of slag or any other
y Porosity
P i results
l when
h the
h gases are entrapped
d in
i the
h nonmetallic material entrapped in the weld metal as
solidifying weld metal. these mayy not able to float on the surface of the
y These gases are generated from the flux or coating solidifying weld metal.
constituents of the electrode or shielding gases used y During arc welding flux either in the form of granules or
during welding or from absorbed moisture in the coating after melting, reacts with the molten weld metal
coating.
coating removing
i oxides
id and d other
h impurities
i i i in
i the
h form
f off slag
l
y Porosity can also be controlled if excessively high and it floats on the surface of weld metal due to its low
welding currents, faster welding speeds and long arc density.
lengths are avoided flux and coated electrodes are y Slag inclusion can be prevented if proper groove is
properly baked. selected, all the slag from the previously deposited bead
Fig. Different Forms of Porosities is removed,
removed too high or too low welding currents and
For-2013 (IES, GATE & PSUs) Page 63 long arcs are avoided.
Lack of Fusion
Lack of Fusion Incomplete Penetration
y Lack
ac o us o iss tthee failure
of fusion a u e to fuse
use toget e eeither
together t e tthee
y Incomplete
I l penetration
i means that
h the
h weld
ld depth
d h isi not
base metal and weld metal or subsequent beads in
upto the desired level or root faces have not reached to
multipass welding because of failure to raise the
melting point in a groove joint.
temperature of base metal or previously deposited weld
l
layer t melting
to lti point
i t during
d i welding.
ldi y If either low currents or larger arc lengths or large root
face or small root gap or too narrow groove angles are
y Lack of fusion can be avoided by y pproperly
p y cleaning
g of
used then it results into poor penetration.
penetration
surfaces to be welded, selecting proper current, proper
welding technique and correct size of electrode.
Fig Slag Inclusion in Weldments
Fig. Slag Inclusion in Weldments
Imperfect Shape, Distortions
p p ,
y Imperfect shape means the variation from the desired shape and IES 2011 Conventionall
size of the weld bead.
y Enumerate four defects caused due to residual stresses in
E f d f d d id l i
y During undercutting a notch is formed either on one side of the
weld bead or both sides in which stresses tend to concentrate and welded joints.
it can result in the early failure of the joint. Main reasons for [2 Marks]
undercutting are the excessive welding currents, long arc lengths
andd fast
f travell speeds.
d
y Underfilling may be due to low currents, fast travel speeds and Ans.
smallll size
i off electrodes.
l d Overlap
O l may occur due d to lowl currents,
longer arc lengths and slower welding speeds. 1. Distortion
y E
Excessive
i reinforcement
i f t is
i formed
f d if high
hi h currents,
t low
l voltages,
lt
slow travel speeds and large size electrodes are used. Excessive 2. Cracking in the base metal
root penetration and sag occur if excessive high currents and slow
travel speeds are used for relatively thinner members. 3. Lamellar Tearing
y Distortion is caused because of shrinkage occurring due to large
heat input during welding. 4. Reduction of fatigue strength
IES‐2004 GATE‐2003
Consider the following statements: Match the following
Work material Type of joining
yp j g
The magnitude of residual stresses in welding
P. Aluminium 1. Submerged Arc Welding
depends upon
Q. Die Steel 2. Soldering
1. Design of weldment
D i f ld t R. Copper Wire 3. Thermit Welding
2. Support and clamping of components S. Titanium sheet 4. Atomic Hydrogen Welding
3. welding process used 5. Gas Tungsten Arc Welding
4. Amount of metal melted / deposited
4 p 6. Laser Beam Welding
7. Brazing
Which of the statements given above are correct?
(a) P ‐ 2 Q ‐ 5 R ‐ 1 S ‐ 3
(a) 1, 2 and 4
1 2 and 4 (b) 1 2 and 3
(b) 1, 2 and 3 (b) P ‐ 6 Q ‐ 3 R ‐ 4 S ‐ 4
(c) 1 and 3 (d) 2 and 3 (c) P ‐ 4 Q‐ 1 R ‐ 6 S ‐ 2
(d) P ‐ 5
(d) Q ‐ 4 R ‐ 2 S ‐ 6

IES‐2004 IES‐1992 JWM 2010
Assertion (A) : Spatter is one of the welding defects.
defects
Consider the following statements: Weld spatter occurs due to any of the following Reason (R) : In submerged arc welding process,
Th i f h h ff
The size of the heat affected zone (HAZ) will increase with
d (HAZ) ill i ih exceptt there is no spatter of molten metal.
1. Increased starting temperature
g p ((a)) High welding current
g g (a) Both A and R are individually true and R is the
2. Increased welding speed (b) Too small an electrode correct explanation of A
3 Increased thermal conductivity of the base metal
3. ( ) Arc
(c) A (b) Bothh A and d R are individually
d d ll true but
b R is not the
h
4. Increase in base metal thickness ((d)) Wrong polarity
gp y correct explanation
p of A
Which of the statements given above are correct? (c) A is true but R is false
(a) 1, 2 and 3 (b) 1 and 3 (d) A is
i false
f l but
b t R is
i true
t
(c) 1 and 4 (d) 2 and 3
IES‐1998 IES‐2004 IAS‐2003

An arc welded joint is shown in the above figure. Assertion (A): A sound welded joint should not only Tool material not suited to resistance welding is
Th
The part labelled
t l b ll d 'B' in the figure is known as
'B' i th fi i k be strong enough but should also exhibits a good
amount of ductility
((a)) Weld preparation
p p Reason (R): Welding process is used for fabricating ( ) Aluminium oxide
(a) ( )
(b) Stellite
(b) Penetration mild steel components only (c) High speed steel (d) Masonite
( ) Reinforcement
(c) R i f (a) Both A and R are individually true and R is the correct
explanation of A
((d)) Slag
g
(b) Both
i di id ll true
t b t R is
but i nott the
th
( ) A is
(c) i true
t b t R is
but i false
f l
GATE‐1996 IES 2011 GATE‐2001

Preheating before welding is done to Cold‐cracking in steel weldments depends on Two plates of the same metal having equal
( ) Make the steel softer
(a) M k h l f 1 Carbon equivalent
1. Carbon equivalent thickness are to be butt welded with electric arc.
arc
((b)) Bum away oil, grease, etc, from the plate surface
y ,g , , p 2. Heat input When the plate thickness changes, welding is
3. Effective thickness achieved
hi d by
b
(c) Prevent cold cracks
3 Hydrogen content in weld pool
3. Hydrogen content in weld pool ((a)) Adjusting
j g the current
(d) Prevent plate distortion
P l di i
(a) 1, 2 and 3 only (b) Adjusting the duration of current
(b) 1, 2 and 4 only ( ) Changing
(c) Ch i theh electrode
l d size
i
(c) 2 3 and 4 only
(c) 2, 3 and 4 only ((d)) Changing
g g the electrode coating
g
(d) 1, 2, 3 and 4

IES ‐ 2012 IES ‐ 2012 IES ‐ 2012
Brittle
B i l welds
ld are mainly
i l obtained
b i d due
d to Which of the following are associated with Heat Affected
Whi h f h f ll i i d i h H Aff d Statement
St t t (I):
(I) Hydrogen
H d induced
i d d cracking
ki occurs in i the
th heat
h t
Zone? effected zone adjacent to fusion zone and classified as solid
((a)) Wrong g electrode,, faultyy p
preheatingg and metal state cracking
hardened by air 1. Cold cracking Statement (II):Hydrogen from burning of flux coating
(b) Faulty welds,
welds faulty sequence and rigid joints 2 Notch toughness
2. Notch toughness penetrates martensitic micro cracks preventing healing as
(c) Wrong speed, current improperly adjusted and faulty 3. Hydrogen embrittlement well as enlarging them.
preparation ( ) Both
(a) B th Statement
St t t (I) and
d Statement
St t t (II) are individually
i di id ll
4. Stress corrosion cracking true and Statement (II) is the correct explanation of
(d) Uneven heat,
heat improper sequence and deposited ( ) d l
(a) 1, 2 and 3 only Statement (I)
metal shrinks (b) 1, 3 and 4 only
y (b) Both Statement (I) and Statement (II) are individually
t
true b t Statement
but St t t (II) is
i nott the
th correctt explanation
l ti off
(c) 2, 3 and 4 only Statement (I)
(d) d
(d) 1, 2, 3 and 4 ( ) Statement
(c) S (I) is
i true but
b Statement
S (II) is
i false
f l
(d) Statement (I) is false but Statement (II) is true

9-Casting & Welding Theory & Questions Altogethre 2013 PDF

Caricato da

Informazioni sul documento

Descrizione originale:

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

9-Casting & Welding Theory & Questions Altogethre 2013 PDF

Caricato da

Copyright:

Formati disponibili

Sand casting

y The molten metal is p p

Metal Casting mouldability and cohesive strength, and are then

Sequential steps in making a sand casting y The mold is opened, the pattern board is drawn

y Drag: Lower moulding flask.

y Cope: Upper moulding flask.

IES‐1996 IES 2007 GATE‐2009

For-2013 (IES, GATE & PSUs) Page 2

Pattern Allowances Shrinkage allowance Liquid shrinkage and solid shrinkage

y Pattern Allowances IES‐1995 GATE‐1999

For-2013 (IES, GATE & PSUs) Page 3

GATE‐2004 GATE‐2008 GATE 2011

IAS‐1995 IAS‐2003 Draft

Pattern Materials The pattern material should be IES‐1994

GATE‐2000 Types of Pattern Types of Pattern

For-2013 (IES, GATE & PSUs) Page 5

Types of Pattern IES‐2008 Types of Pattern

For-2013 (IES, GATE & PSUs) Page 7

Moulding Sand Composition Other Additives Moulding Sand Properties

Grain size number IES‐2002 Casting Yield

y Runner: The channel through which the molten

The goals for the gating system IES‐1998 IES‐2009

For-2013 (IES, GATE & PSUs) Page 10

GATE‐2010 IAS‐1999 Risers and Riser Design

IES‐1994 Chvorinov’s rule IES 2011

(c) 28.30 seconds (d) 1/v2

(d) 40 seconds Where, v = volume of casting

GATE – 2010 (PI) GATE‐2007

For-2013 (IES, GATE & PSUs) Page 13

4 30 x 30 x 6 cm with a side riser, casting poured horizontally The riser should solidify last so x > 1

[Use Caine’s Method]

For-2013 (IES, GATE & PSUs) Page 14

For-2013 (IES, GATE & PSUs) Page 16 Contd…

For-2013 (IES, GATE & PSUs) Page 17

GATE‐2009 Mold Shift IES‐2001

IES‐2005 IES‐1997 IES‐2009

IES‐1996 IES‐2005 IES‐2006

IES 2007 IAS‐2007 IAS‐1999

For-2013 (IES, GATE & PSUs) Page 21

y Machining can be reduced or completely

Limitations Applications IES 2011

For-2013 (IES, GATE & PSUs) Page 22

IES‐1992 JWM 2010 IES 2010

For-2013 (IES, GATE & PSUs) Page 23

y Cores must be simple and retractable and take the

For-2013 (IES, GATE & PSUs) Hot Chamber

JWM 2010 IES‐2005 IES‐2006

For-2013 (IES, GATE & PSUs) Page 25

IAS‐1996 IES 2011 GATE‐2007

Limitations Common metals GATE‐2002

y Spinning equipment can be expensive

IES‐2009 IES 2007 IES‐2000

IES‐2000 Dry Sand Molding Slush Casting

IAS‐2004 IES 2011 IES ‐ 2012

For-2013 (IES, GATE & PSUs) Page 29

Pit Moulding IES‐1996 Loam Moulding

For-2013 (IES, GATE & PSUs) Page 30

GATE‐1996 IES‐2003 IES‐1993

IAS‐2004 GATE – 2007 (PI)

IES ‐ 2012 Weldability / Fabrication Processes Case of Aluminium

Case of Cast Iron Case of Stainless Steel Case of Stainless Steel

IES 2011 IES‐2006 IES‐1999