ARC LENGTH

1) Arc length- voltage characteristic for a welding operation is given by V = 20 + 4L. If the arc
length varies b/w 4mm to 6mm and welding current varies b/w 450 amp to 550 amp.
Assuring linear power source, calculate (a) Open Circuit Voltage (b) Short Circuit Current.
Ans. Voc = 80 V & Isc = 1000 Amp.

2) Calculate the melting ƞ in the case of arc. Welding of steel with a potential of 20 V and
current of 200A. The travel speed is 5mm/s and CSA of joint is 20mm2. Heat required to melt
steel is 10 J/mm3. Heat transfer ƞ = 85%. Ans. 29.4%

3) The arc length – voltage characteristic is given by V = 24+ 4L where L is the arc length. The
volt – Amp characteristic of a power source can be approximated by a straight line with open
circuit voltage 80 V and short circuit current 600A. Determine optimum Arc length for max.
Power. Ans. L= 4mm

4) Volt Amp. Characteristic of a power source is given by the equal I2t = -600(V-60). If the arc
characteristic is I = 20(V-16), determine the power of the stable arc. Ans. 3.5 kw

5) In an arc welding of a butt joint, the welding speed is to selected such that highest cooling
rate is achieved. Melting efficiency and heat transfer efficiency are 0.5 and 0.7 respectively.
The area of weld cross section is 5mm2. The unit energy required to melt metal is 10 J/mm3.
If the welding power is 2 KW. What is the welding speed in mm/s Ans. 14 mm/s

6) The net heat supplied in arc welding process is 120 J/mm. The melting efficiency is 45%. The
welding speed is 6 mm/s. The rate of melting is 15 J/mm3. Calculate the area of the joint that
can be obtained. Ans. 36 mm2

7) A linear power source provides open circuit voltage of 80 V and short circuit current of 1000
Amp. The arc length varies from 4mm to 7mm. The arc voltage varies from 40 V to 70 V.
What is the variation in the arc current? Ans. 500 A, 125 A

8) The Voltage – Current characteristic for a dc source for arc welding is linear with open circuit
voltage of 80 V and short circuit current of 600 Amp. The max arc power of the source will
be. Ans. 12 KW

9) In an arc welding process the voltage and current are 25 V and 300 Amp. The arc heat
transfer efficiency is 0.85 and welding speed is 8 mm/s. The net heat input in J/mm is
Ans. 797 J/mm.

10) A weld is made using MIG welding process with following parameters. Current = 200 Amp,
Voltage = 25V, Welding speed = 18 cm/min, Wire diameter = 1.2 mm, Wire feed rate =
4mm/min. Thermal efficiency of the process is 65%. Calculate (a) The heat input per unit
length of weld in KJ/cm is (b) The area of cross section of weld bead is Ans. 10.83 KJ/cm,
25.13 mm2.
11) A 900 mm long steel plate is welded by manual arc welding process using a welding current
of 150 A, arc voltage of 20 V, welding speed 300 mm/min. If the process efficiency is 0.8 and
surface resistance is 36 µΩ. The heat input will be Ans. 116.64 J

12) Two 8 mm thick steel plates are placed 5mm apart and welded by a butt joint. Welding is
carried out at 20 V and speed 5 mm/s. Heat transfer efficiency is 0.8. If heat required to melt
steel is 10 J/mm3 and melting efficiency is 0.625, the weld current (amp) will be Ans. 200A

13) Autogenous gas tungsten arc welding of a steel plate is carried out with welding current of
500 A, voltage of 20 V and welding speed of 20 mm/min. Heat transfer efficiency from the
arc to the weld pool is 90%. The heat input per unit length in KJ/mm is Ans. 27 KJ/mm

14) During a steady state gas metal arc welding with direct current electrode positive, the
welding current voltage and welding speed are 150 Amp, 30 V, 6 m/min. A metallic wire
electrode of diameter 1.2 mm is being fed at constant rate of 12 m/min. The density specific
heat and melting temperature of the wire electrode are 7000 kg/m3, 500 J/Kg. 1530 0C.
Assuming ambient temperature to be 30 0C and neglect latent heat of melting. Further
consider that 2/3 of the total electrical power is available for melting. The melting efficiency
of the wire electrode (%) is Ans. 39.58%

15) Two steel plates are to be arc welded using a linear source with open circuit voltage of 60 V
and short circuit current of 120 Amp. The arc length is 4mm and welding speed is 3 mm/s.
Heat transfer efficiency is 0.8. If the arc length – voltage characteristic is given by V = 21 + 2L.
The net heat input in J/mm Ans. 479.5 J/mm

16) Two plates of symmetrical V joint of 60⁰ angle are to be arc welded in a single pass. The arc
length power characteristic is P = 4 + 0.8l - 0.1l2 where power is in 10 kw and arc length is in
mm. Assuming that the top surface of the weld is flat energy losses are 15% density of filler
metal is 9 g/cc. Calculate the time required for welding and also speed of welding. Take plate
dimensions as 800 x 5 mm. Energy required to melt one gram of metal is 1200 J Ans.
Welding Time = 23.28 sec ; Welding Speed = 34.36 mm/sec.

17) In a MIG welding process the power source characteristics is given by Vt = 48 – 0.02 It. The
arc length voltage characteristic is given by V = 24 + 4L. Find the change in power of the
source. If the arc length changes from 3mm to 5mm. Ans. 12.8 kw

18) A cross section of weld bead as shown in figure. The profile of weld bead is taken as circular
for convenience. Bead width = 10 mm. Radius of curvatures of circular profiles are given in
the fig. Calculate the penetration height, weld bead height and % of dilution Ans.
Height of penetration = 21.01 mm; Weld bead height = 2.736 mm and % of dilution =
77.298%.

19) Two alloy steel plates as shown in figure are to be butt welded using a power source rated 5
KVa having a duty cycle of 75%. Using the given data, determine the maximum welding
speed in mm/s. Data Heat input, Q = 8tkTc[0.2 + (Vb/4α)]. K = 45 W/m⁰C , Tc = 1450⁰C .
α = 1.2 x 10-5 m2/s Ans. 10.33 mm/s