ASSIGNMENT-2 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

[Q1]
Comparing to riveting, welding has various advantages and disadvantages. Pick out three
advantages and three disadvantages of welding respectively.

Advantages
o Welding has more strength than riveting
o Welding process takes less time than riveting
o Welding provide maximum efficiency

Disadvantages
o The inspection of welding is more difficult than riveting
o To obtain a good welded surface needs a good welding skill
o Metal that welded will occur a changing of microstructure because heat transfer

[Q2]
Welding processes are able to be classified into the category of (a) fusion welding, (b)
pressure welding (solid state) or (c) soldering. What the following welding processes should
be classified into the category of (a), (b), or (c). Put a category mark (a), (b), or (c) for each
welding process.
No.

Type of welding processes

Category

Friction welding

(b)

Electron beam welding

(a)

Electro slag welding

(a)

Thermit (Almino-thermic) welding

(a)

CO2 gas shielded metal arc welding

(a)

Soft soldering

(c)

Submerged arc welding

(a)

Resistance spot welding

(a)

TIG welding

(a)

10

Ultrasonic welding

(b)

[Q3]
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ASSIGNMENT-2 ENMT610029 WELDING

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Welding processes may be classified according to the type of energy source used directly for
welding. Choose the welding processes from Group B that belong to the energy sources in
Group A, and put the corresponding marks in the parentheses.
[Group A]
No.

Type of energy source

Electric energy

Mechanical energy

Chemical energy

Light energy

Category
(a, b, d, e, g, h)
(j)
(c, i)
(f)

[Group B]
(a) Submerged arc welding

(b) Electro slag welding

(c) Explosion welding

(d) Plasma arc welding

(e) SMAW (Manual metal arc welding)

(f) Laser welding

(g) MAG welding

(h) Resistance welding

(i) Oxy-flame (gas) welding

(j) Friction welding

[Q4]
Welding processes may be classified according to the types of energy source utilized directly
for welding. Choose the energy source in [Word Group] that is applied in each welding
process, and put its alphabet into each ( ).
No.

Type of welding processes

Category

MAG welding

(a)

Aluminothermic welding

(c)

Electron beam welding

(d)

Oxy-fuel gas welding

(c)

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Friction stir welding

(b)

Laser welding

(d)

Manual metal arc welding (SMAW)

(a)

Explosion welding

(c)

TIG welding (GTAW)

(a)

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Electroslag welding

(a)

[Word Group]
(a) Electrical energy

(b) Mechanical energy

(c) Chemical energy

(d) Light energy

[Q5]
Regarding to the features of the following welding and cutting processes, choose the relevant
one from among the words in the word group given below and enter its alphabetic symbol
into each parentheses.
No.

Features of welding and cutting processes

Category

MAG welding

(a)

Laser welding and cutting

(d)

SAW (Submerged arc welding)

(a)

Friction welding

(b)

Gas welding

(c)

[Word Group]
(a) Electrical energy

(b) Mechanical energy

(c) Chemical energy

(d) Light energy

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ASSIGNMENT-2 ENMT610029 WELDING

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[Q6]
Regarding the classification of welding processes, choose five gas-shielded arc welding
processes and encircle their alphabets.
(a) Stud welding

(b) TIG welding

(c) Laser welding

(d) Submerged arc welding

(e) Self-shielded arc welding

(f) MAG welding

(g) Shielded metal arc welding

(h) Electro-slag welding

(i) Brazing

(j) Electro-gas arc welding

(k) Resistance spot welding

(l) MIG welding

(m) Electron beam welding

(n) Plasma arc welding

[Q7]
In case of using 100% CO2 gas as shielding, droplet size is becoming larger than that in case
of using CO2 - Argon gas mixture. Explain the reasons.
Pure carbon dioxide allows for deep penetration welds but encourages the
formation of oxides, which affects the mechanical properties of the weld. CO2
reactivity of the plasma arc, spatter unavoidable and welding thin materials
are difficult. As a result, argon and carbon dioxide is often mixed in 75% /
25% to 90% mix / 10%. Generally, the short circuit GMAW, higher content
of carbon dioxide will increase the welding heat and energy when all other
welding parameters (volts, current, electrode type and diameter) are not
changed. With rising levels of carbon dioxide over 20%, spray transfer
GMAW becomes increasingly problematic, especially with smaller diameter
electrodes. Spattering cause diameter welding be great because there will be
turbulence around welding using CO2 which causes the plasma arc spatter.

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ASSIGNMENT-2 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

[Q8]
The following sentences describe the metal transfer modes. Choose the relevant one and put
its alphabet into each parenthesis.
1. The molten metal droplet, which is detached from the tip of electrode by the arc force,
transfers along the cavity wall in the flux covering around the electrode. This metal
transfer mode can be observed in submerged arc welding. ((b) flux-wall-guided transfer)
2. The molten metal droplet is punctured by rapid expansion of the internal gases generated
in the droplet. This metal transfer mode can be observed in shielded metal arc welding.
((d) explosive transfer)
3. The molten metal droplet grows in size as large as the electrode diameter or larger to
transfer. This metal transfer mode can be observed in shielded metal arc welding with lowhydrogen type electrodes and CO2 shielded arc welding with high currents. The both
amount and size of the spatter increases in general. ((e) globular transfer)
4. The molten metal droplet whose diameter is a small as the electrode diameter or smaller
transfers in free light in the arc column. This metal transfer mode can be observed in MAG
welding with high currents and Argon rich shielding gas (Argon: 80% or larger) and
MIG welding. In general, spatter decreases, and the arc is likely to become stable. ((a)
spray transfer)
5. The molten metal droplet, which is developed on the tip of the electrode, makes a contact
to the weld pool and is transferred with the aids of the electromagnetic pinching effect and
the surface tension of the droplet. This metal transfer mode can be observed in MIG and
MAG welding with low current, low arc voltage, and short arc length. This transfer mode
is suitable for sheet metal welding and all welding position. ((c) short-circuiting transfer)
[Word Group]
(a) Spray transfer

(b) Flux-wall-guided transfer

(c) Short-circuiting transfer

(d) Explosive transfer

(e) Globular transfer

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ASSIGNMENT-2 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

[Q9]
Regarding the transfer metal modes, choose the relevant one in the word group and enter its
alphabet into each parenthesis.
No.

Type of welding processes

Transfer modes

CO2-shielded arc welding with low currents

(a)

Pulsed MAG welding with low average currents

(c)

CO2-shielded arc welding with medium currents

(b)

MAG welding with high currents and a mixed

(c)

shielding gas of 80% Ar, 20% CO2

5

MIG welding with high currents

(d)

[Word Group]
(a) Short-circuiting transfer

(b) Globular transfer

(c) Spray transfer

(d) Explosive transfer

[Q10]
The following sentences are describing electrode wire melting and metal transfer modes in
MAG welding with solid wire. Choose the relevant one and circle its alphabet.
1. Wire melting rate is given mainly by the heat from the arc and also the following due
to the current flow in the wire.
(a) Electromagnetic force
(b) Radiation heat
(c) Resistance heat
(d) Convection heat
2. When the wire melting rate (or wire feeding speed) is kept constant, welding current
may change if the following parameter is changed.
(a) Torch angle
(b) Wire extension
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ASSIGNMENT-2 ENMT610029 WELDING

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(c) Welding speed

(d) Flow rate of shielding gas
3. In MAG welding using 100% CO2 gas for shielding gas, when higher arc voltage is
applied, the arc is becoming unstable. In that case at lower welding current, usually
the following metal transfer mode is adopted at lower arc voltage.
(a) Short circuiting transfer (Dip transfer)
(b) Globular transfer
(c) Spray transfer
(d) Explosive transfer
4. In MAG welding with Argon base mixture shielding gas (Ar+CO2) spray transfer
mode may be obtained by licensing the following parameter more than a certain
critical value.
(a) Arc voltage
(b) Welding current
(c) Wire extension
(d) Flow rate of shielding gas
5. In spray transfer mode, the force which acts to detach the droplet from the wire tip
is mainly the following
(a) Plasma stream
(b) Surface tension
(c) Stiffness of the arc
(d) Electric magnet force
[Q11]
Pick out a non-consumable electrode gas-shielded arc welding process using DC power
source with constant current characteristics. And then give the kind of shielding gas, the
material of electrode and the polarity of electrode, when the process is applied on welding of
stainless steel.
Welding process

(Gas Tungsten Arc Welding = GTAW)

Shielding gas

(Argon, CO2, Helium)

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ASSIGNMENT-2 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

Material of electrode (Austenitic: E308L, E309H, E309L, E310H, E316H, E316L, depends on
the composition)
Polarity of electrode (DC+)
[Q12]
Pick out at least three advantages and three disadvantages of TIG arc welding process.

Advantages
o Filler metal is optional
o Good for non-ferrous metals
o Non-Consumable Electrode

Disadvantages
o Complicated (Requires skills)
o Time consuming (Slow method)
o Producing smoke screen

[Q13]
Give four advantages and four disadvantages of SAW, comparing with the SMAW (Manual
metal arc welding).

Advantages
o Good for thick sessions welding
o Suitable for welding carbon, low alloy and alloy steels
o Minimum of welding radiation
o High metal deposition rates

Disadvantages
o More complicated equipment
o Higher cost
o The electrode needs certain care
o Flat/horizontal position welding only

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ASSIGNMENT-2 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

[Q14]
Pick out five features of submerged arc welding process, comparing to manual metal arc
welding (shielded metal arc welding) process.

Features
o Low Cost
o Portable
o Used for maintenance, repair, and field construction
o Simple Equipment
o Because of the molten welded material barrier with flux thus the weld quality is
better

[Q15]
The sentences below, describing MAG welding, have error(s) in the parentheses. Correct
them.
1. In the case of shielding gas containing Argon mixed with 20% CO2 gas, the metal
transfer mode become spray transfer (when the welding speed is higher than a certain
critical value).

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ASSIGNMENT-2 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

2. Comparing with 100% CO2 gas shielded arc welding under the same parameters, MAG
welding with using mixed gas of 80% Argon and 20% of CO2 has (wider bead, but hardly
more spatter).
[Q16]
Pick out at least three features of TIG welding (GTAW), comparing with MMA welding
(SMAW).

Features
o Filler metal is optional
o Can be used for welding reactive metals
o Suitable for joining thin section

[Q17]
Pick out three advantages and three disadvantages of MAG welding comparing to SAW
(Submerged arc welding) respectively.

Advantages
o MIG welding is quicker than SAW welding and produce a durable product
o Can be used in any welding position (positive welding)
o It needs a few of cleaning post-weld

Disadvantages
o The welding set-up is difficult
o Because of inert gas, MIG welding cannot be used in open area because of wind
would be cause more gases
o Welding defects of porosity often happened because of the usability of protective
gas which is not good

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ASSIGNMENT-2 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

[Q18]
Pick out three advantages and three disadvantages of FCAW welding comparing to MAG
(Metal active gas) respectively.

Advantages
o Versatility
o Capable of high deposition rates
o Good for non-ferrous metals

Disadvantages
o Wrong selection of consumables may lead to lower weld toughness
o Fume extraction may be required
o Potential of lack of fusion type defects

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