Welding shop

What is welding? Welding is a process of joining similar metals by application of heat with or with out the application of pressure and addition of filler material. What dose the term weldability mean? Weldability can be defined as the capacity of being welded into inseparable joints having specified properties. How to increase the weldability of metal? Weldability can be increase by selecting 1. Proper shielding of atmosphere. 2. Proper use of fluxing material. 3. Proper selection of filler material. 4. Proper heat treatment of metal before and after welding. How is welding classified? Modern methods of welding can be classified as: 1. Plastic/pressure/without filler material welding. 2. Fusion/non pressure/with filler material welding. Name some of the tools and equipments used in metal arc welding? The most commonly used equipments and tools for arc welding are 1. A.C or D.C electric current source. 2. Electrode 3. Electrode holder. 4. Cables and cable connectors. 5. Earthing clamp. 6. Chipping hammer and tongs. 7. Wire brush. 8. Helmet safety goggles 9. Hand shield. 10. Apron boots, sleeves etc., Name some of the arc welded joints? Some of the welded joints are but joint, lap joint, L joint, T joint, angle joint.

Name some of the temporary fasteners and permanent fasteners? Temporary fasteners: nut and bolt, cutter joints coupling, keyed joints. Permanent fasteners: welded joints, riveted joins, and glued joints.

What is a temporary fastener? A temporary fastener is one in which the elements can be separated with out damage to the elements or to the fastener eg.. nut and bolt, coupling, key and cotter joints etc., What is a permanent fastener? A permanent fastener is one which the elements cant be separated with out a damage to the element or to the fasteners eg., welded joints riveted joints etc., Why is edge preparation required before welding? To obtain sound welds good edge preparation is essential consisting of suitable bevelling of edges and careful cleaning of the surface to be welded from dust, oil, grease, and sand particles. What is flux? Name some of the fluxes used Flux is generally added to the welding area to dissolve he metallic oxides so that surface to be welded clean metallic surface Eg ferrous materials- borax, sodium bi- carborate, silicate, Copper alloys- sodium potassium borate mixture Aluminium- alkaline fluorides, chlorides What is arc welding? When two conductors of an electric circuit are brought together separated by a small gap such that the current continues to flow through gaseous medium an electric arc is formed the heat generated by this arc will melt the parent metal and filler material to form molten pool which will bond the joint or build up the surface What distance should be maintained between the work and electrode? The distance between he electrode and work must be 2mm to 4mm. What is the arc temperature? The temperature of the arc depends upon the type of electrodes but at the centre of the arc it ranges from 40000to 70000C.

What is the arc length? The distance through the centre of the arc from the lip of electrode to the bottom of arc carter is termed as arc length. It ranges from 3 to 4 mm Name the different types of arc welding process? The different types of welding processes arc: 1. carbon arc welding 2. metal arc welding 3. inter gas arc welding

4. 5.

sub merged arc welding atomic hydrogen arc welding

How are electrodes classified for arc welding? Electrodes can be classified as: 1. consumable electrodes eg., same as the parent metal 2. Non consumable electrodes eg., Carbon, graphite, tungsten. How are consumable electrodes classified? Consumable electrodes are classified as: 1. Bare/plain electrodes. 2. Coated electrodes eg., lightly coated heavily coated.

What is the function of coating in coated electrodes in metal arc welding? Coated serves several purpose they are: 1. to the protect the molten metal surface from oxygen and nitrogen of air by providing a gas shield around the weld pool 2. to help in formation of slag over the welding pool to prevent rapid cooling of molten metal. 3. To establish the arc and maintain its stability. 4. To add alloying elements not contained in core wire. What is the output range of voltage and current on the metal arc welding? The voltage and current depends upon electrode material, material being welded, material thickness etc., 1. Voltages - 40 to 100v. 2. Current - 100 to 600amp. What is the composition of coating in heavy coated electrodes in arc welding? What is their function? The compositions of coating in electrodes are: 1. Chalk For ionising. 2. Aluminium / Ferromanganese For deoxidising. 3. Starch For gas generation. 4. Kaolin For slag formation. 5. Alloying materials. 6. Binding materials. Name the sources for AC & DC current in metal arc welding. The sources for AC & DC current are: 1. AC step down transformer. 2. DC DC generator, DC rectifier set.

How does the heat generated gets distributed in AC & DC arc welding? In AC arc welding heat is equally distributed the work and the electrode. In Dc arc welding 66% of heat is generated at positive pole and 33% of heat is generated at negative pole. Therefore in DC arc welding for thin work material; the electrode is made positive and for thick work material; work is made positive. What are the characteristics of DC arc welding? The characteristics of DC arc welding are: 1. Low no-load voltage. 2. Suitable for welding non ferrous metals. 3. Bare electrodes can be used. 4. Initial cost is very high. 5. No load requirements are high. 6. Overall efficiency is low.
What is the use of Vice in workshop? Vices are the most suitable and widely used tools for gripping different jobs in position during the various operations carried out in a fitting shop. List different types of Vices used in workshop. 1. Parallel jaw vice 2. Swivel vice 3. Machine vice 4. Hand vice 5. Leg vice 6. Pipe vice & 7. Tool makers vice. Which is the Most commonly used vice in general fitting work? Parallel Jaw vice is the most commonly used vice in fitting work. Mention the material from which the body of the vice is made Body of the vice is made from Cast Steel. What is the use of V Block? Its specific use is in holding the round bars during marking and centre drilling their end faces, which are to be held between centres on the lathe. Mention the use of surface plate in workshop. Its specific use is in testing the trueness of a finished surface, testing a try square, providing adequate bearing surface for V-block and angle plates, in scribing work. What is Try square? It is a very common tool used for scribing straight lines at right angles to a true surface or testing the trueness of mutually normal surfaces.

What are Files? These are hand tools used by a fitter for removal of extra metal from the work-piece. Mention the main parts of a Files. 1.Toothed blade 2. Pointed tang. Mention the material used for manufacture a File. Files are generally forged out of High carbon steel or Tungsten steel, followed by cutting of teeth, hardening and tempering etc. Mention the commonly used lengths of a File. Length of the files varies according to the need but the most commonly used lengths range usually from 10 to 40 cm. Name different types of Files in use. 1. Square file 2. Triangular file 3. Round file 4. Half round file 5. Flat file 6. Knife edge file According to type of teeth how do you classify files? 1. Single cut file 2. Double cut file. What is Single cut file. In single cut files the teeth are cut in parallel rows running across the faces and are normally inclined at an angle of 60 degrees with the centre line of the face. What is a Double cut file? In a double cut file there are two sets of teeth, one similar to those of a single cut file and the other running diagonally across the first set and inclined at an angle of about 10 degrees, the centre line of the face on which the teeth are cut. What is Float? Float is the term frequently used for Single cut files & they are particularly used for hard metals.

Define Welding. Welding is defined as metallurgical process of joining two similar or dissimilar metals by heating, with the use of filler metal or without the application of pressure and with or without the use of filler metal. Define Weldability. Weldability of a metal is the ease with which two similar or dissimilar metals are joined by fusion with or without the application of pressure and with or without the use of filler metal. Which is called as Base Metal? The metal to be joined or cut is termed as the base metal.

What is Bead or Weld Bead? Bead is the metal added during welding. What do you mean by weld pass? A single movement of the welding torch or electrode along the length of the joint, which results in a bead, is called as weld pass. What is Backing? It is the material support provided at the root side of a weld to aid in the control of penetration is called as Backing in welding. What do you mean by Puddle? The portion of the weld joint that is melted by the heat of welding is called Puddle. What is Toe of weld? It is the junction between the weld face and the base metal. What do you mean by Tack weld? A small weld, generally used to temporarily hold the two pieces together during actual welding, is called the tack weld. How do you classify welding process? 1. Forge or Pressure or Plastic welding 2. Fusion or Non-Pressure welding. Define Plastic welding. In Plastic welding, the workpieces are heated to plastic state and then, the workpieces are joined together by applying external pressure on them. Define Fusion welding. In this welding, the material at the joint is heated to a molten state and then allowed to solidify.

List the advantages of welding. 1.A good weld is as strong as the base metal. 2. A large number of metals/alloys can be joined by welding 3. Portable welding equipment is available 4.General welding equipment is not very costly 5. welding can be easily mechanized. List the Dis-advantanges of welding. a. Welding produces the harmful radiation, fumes and spatter b. A skilled welder is required c. Welding heat produces metallurgical changes. d. More safety devices are required e. Jigs & fixtures are required to hold the parts to be welded.

Mention Applications of welding. a. Automobile construction b. Railroad equipment, Ship building construction, Pressure vessels c. Aircraft construction, Bridges construction d. Building construction, Storage tanks e. Piping & pipe lines f. Fabrication of jigs, fixtures and machine tools g. Repair of broken and damaged parts h. House hold furniture i. Material handling equipments etc.

Mention the types of welding joints. a. Lap joint b. Butt joint c. Corner joint d. Edge joint e. T-joint List the different welding positions in use. a. Flat position b. Horizontal position c. Vertical position d. Overhead position. what is fitting? Fitting is the assembling together of parts by removing small amount of material to secure the necessary fit what are the various operations carried out in the fitters shop ? The operations commonly performed in the fitter shop are : (i)marking (2) sawing(3)chipping (4) scraping (5) filling (6) drilling (7) reaming (8) tapping (9) Dieing What is the material of the workpiece? What is its composition? Material of the work piece is Mild steel. Its composition is Iron, Carbon (0.05 0.45%), Sulphur. Silicon. Phosphorus, Manganese etc. Name the commonly used tools in fiotter shop. The commonly used tools in fitter shop are: Vice: Bench Vice, Leg vice, Machine vice, Pipe vice, Pine vice, hand vice, Any angle tool vice etc.

Hammers: Ballpeen, Crosspeen, Straight peen, Soft faced hammers etc. Chisels: flat chisel , cross cut chisel , half round chisel, diamond point chisel etc., Files: flat file, hand file, square file, piller files, pound file, triangular file , half round file, knife edged file, etc., Marking tools; surface plate, surface gauge,angle plate, scriber, scale, v block and clamp, dividers, punch , anvil, hammer, tri square etc., Measuring insturement: scale inside and out side spring calipers, vernier calipers, micrometer, depth gauge, height gauge, pitch gauge, radius gauge etc, Sawing: solid frane hack saw, adjuastable frame hack saw, power hack saw, etc., Drilling machine : bench drilling machine, radial drilling machine, column drilling machine etc., Drill bits: taper sunk drill bit mounted with sleeve , parallel shard drill bit mounted with drill chuck, helical flute / straight flute etc ., Taps: for internal threads Taper tap/ first tap, second tap, plug / bottom tap Die : for external threads Solid die adjustable split die, 2 piece rectangular die. Which type of vice is suitable for heavy hammering, chipping and cutting operation in fitter work? Leg vice in most suitable for chipping, hammering and cutting operation. What material is the face made3 of in soft faced hammers? The soft faced hammer face is made from raw hide, hard rubber, copper, brass, lead wood, plastic etc. What is cold chisel? Cold chisels are used for cutting metal at room temperature. They have sharpercutting edges than a hot chisel what is hot chisel? Hot chisels are sued for cutting metal at elevated temperatures. They do not have sharp cutting edge as in cold chisel.

What is chipping? Chipping is a process of removing thick layers of metal by use of cold chisel and hammer. Name the different methods of hand filling. Straight filing cross filing Draw filing. What is scraping? Scraping is a process in which shaving or paring off thin slices of flakes of metal to make a fine, smooth surface after machining or filing the surface. Name the different types of Scrapers. Flat scraper Triangular scraper, Half round scraper. How are Hack saw blades specified? Hack saw blades are specified by their !. Length, Width, Thickness, Pitch of teeth, Material of blade. How are Hack saw blades classified according to pitch? Coarse saw 1.8mm pitch, Medium saw 1.4mm pitch, Fine saw 1.0 mm pitch. What is sawing? Hack sawing is the quickest method of severing, shaping and slotting cold metal. What is try square? A try square is an instrument made of thick beam and a thin blade fixed at one end, at right angle to it, each other. What is the use of try square? Try square is mused when it is necessary to get another edge or surface exactly at right angles to an already trued edge or surface and also for lay outing on work piece. Name two important types of twist drills. The two important types of twist drill are: Parallel shank drill, Taper shank drill.

What is drilling? Drilling is an operation of producing circular holes in a work piece. What is the lip angle/ cutting angle in twist drill? Drill chucks are used for holding parallel shank drill bits of larger diameter ranging from 3mm to 100 mm. Name the operation for enlarging a drilled hole. The process of enlarging a drilled hole is known as boring operation.

What is reaming? Reaming is an operation performed to obtain accurate size of hole with smooth finish with very little amount of material removal.

What is tapping ? Tapping is a process of cutting internal threads in a drilled hole using tap and tap wrench. What is dieing? Dieing is a process of cutting external threads on cylindrical work piece (pipes, bars etc.) using a die and die stock. What is Least count? Least count = 1 main scale division 1vernier scale division. Measurement with vernier = Main scale +Vernier scale x Least count. Use full tips in fitting shop. 1.Hold the work parallel to ground for filing operation. 2. Do not wipe the surface of filed work piece with hand. 3. Cut work piece with hack saw perpendicular to ground 4.Lift the file in return stroke of filing operation 5. File from left to right over the entire width of the work piece with even pressure. 6.Do not blow iron filings from the surface. Use hand brush. What is the aim of fitters shop? Even with automated ways of producing components still the parts require small amount of material removal to secure the necessary fit before they could be assembled . Therefore fitter's shop teaches those operations that are needed to do perfect assembly What are the characteristics of AC arc welding? The characteristics of AC arc welding are: 1. No load requirements are low. 2. Initial cost is very low. 3. Overall efficiency is high. 4. No load voltage is high. 5. Only coated electrodes can be used. 6. Not suitable for welding non ferrous metals. Name some of the welding defects? Some of the defects in arc welding are: 1. Crack. 2. Poor fusion. 3. Slag inclusions

4.

Porosity

etc.,

Why chipping done for the welded surface after metal arc welding? The weld surface during welding process gets coated with slag to prevent welding from rapid cooling. This coating has to be chipped after the weld has cooled down with chipping hammer. How are welding defects detected? Welding defects can be detected by: 1. Visual inspection. 2. Non destructive testing. 3. Destructive testing. Name some of the non destructive testing methods used in testing welded joints. The modern inspection equipments and techniques have made non destructive testing an effective tool. They are: 1. Magnetic particle testing. 2. Radio graphic testing. 3. Eddy current testing. 4. Leak detection. 5. Dye penetrant test. 6. Ultrasonic inspection.

Name some of the destructive testing methods used in testing welded joints. Mechanical testing of weld samples are done by: 1. Tensile test. 2. Bending test. 3. Impact test. 4. Fatigue test. 5. Corrosion test etc., How are welding electrodes specified? Welding electrodes are specified by: 1. Diameter 1.6mm to 12mm. 2. Length 200 to 450mm. 3. Core wire material. 4. Coated / Non coated. 5. Coating materials.

Useful tips in welding shop. 1. Before welding prepare the edge by filing & remove grease, oil, dust etc., 2. Prepare a sheet metal template for welding L-joints, T-joint, angular joint. 3. Tac weld corners and weld with fresh electrode one end to the other end maintaining the steady arc length. 4. Use all safety precautions during welding, keep safe distance from welding, use protective hand shield with dark glasses to prevent ultra violet rays etc., Name five different types of welds. The five different types of weld are Bead weld, Fillet weld, Groove weld, Plug weld and Track weld What is the purpose of tack welding? Tack welds holds separate parts together in a assembly before welding. They are series of short welds spaced at interval. Name four fundamental welding positions. The four fundamental positions in welding are Flat, Horizontal, Vertical and Overhead. What is the purpose of the polarity switch in D.C. welding? In D.C. welding polarity switch can be changed thereby making work positive or negative depending upon were heat should be concentrated. List three important advantages of A.C. welding. The three important advantages of A.C. welding are: 1. No load requirement is low. 2. Initial cost is very low. 3. Overall efficiency is high. List some of the distortion in welding. 1. Lengthwise shrinkage (longitudinal contraction). 2. Crosswise shrinkage (transverse contraction). 3. Warping (construction of weld deposits). 4. Angular distortion. List how distortion in welding can be prevented. 1. Prevention of distortion before welding. Good design of weld joints. Selection of proper process and equipment. Pretending the parts to be welded.

2.

Spacing of parts. Using jigs and fixtures.

Distortion control during welding. - Chain intermittent fillet weld - Staggered intermitted fillet weld. 3. Correction of distortion after welding. - Shrinkage. - Shrink welding. - Add stiffening. What is the aim of having welding shop for workshop practise? Welding has two major functions as a means of fabrication and for maintenance and repair. It is difficult to find any single industry that does not use welding because of greater design flexibility, elimination of patterns, low coast of material etc. What is the use of weld gauge? It is meant for measuring the depth of weld. What is a welding clamp? It is used for gripping a job properly during the course of welding. What is spot welding? In this method, job is placed between two electrodes and a high current at low voltage is passed. It is suitable for joining two metal sheets and wires. What is seam welding? In this method of welding, job of two over laps are placed between two revolving wheel electrodes. The pressure of wheel and movement of work gives a continuous weld. What is edge preparation? The edge preparation means cutting or filling of jobs to get V or U grooves in jobs so as to obtain complete penetration of weld pool. How are electrodes coded in regards to their characteristics? Electrodes are coded by a group of eight numbers and letter. First is a letter then six numbers and last a letter. How is resistance welding classified? Resistance welding is classified as spot welding and seam welding. What is gas welding? In gas welding, the joint to be welded is heated by flame of a fuel gas and oxygen up to molten state and to allow to cool to get welded. Sometimes filler material may also be used.

Name of the fuel gases used in gas welding? Some of fuel gases used are: Acetylene, hydrogen, propane, butane etc. How many types of oxy-acetylene flames are there? Neutral, Carburizing and oxidising flames.