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Assignment 2 Introduction to Welding Process

This document outlines an assignment for a course on Manufacturing Science, focusing on various welding processes. It includes multiple problems related to spot welding, arc welding, and resistance welding, requiring calculations of current, heat input, melting efficiency, and welding speed. Each problem provides specific parameters and conditions for the welding scenarios presented.

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Prasant Sahay
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27 views2 pages

Assignment 2 Introduction to Welding Process

This document outlines an assignment for a course on Manufacturing Science, focusing on various welding processes. It includes multiple problems related to spot welding, arc welding, and resistance welding, requiring calculations of current, heat input, melting efficiency, and welding speed. Each problem provides specific parameters and conditions for the welding scenarios presented.

Uploaded by

Prasant Sahay
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Assignment 2

MT 309: Introduction to Manufacturing Science (Credit 3.0)


Module 2: Introduction to Welding Process
Instructor: Dr Prosenjit Das
(5 marks)

1. Spot welding of two 2 mm thick sheets of steel (density=8000 kg/m3) is carried out
successfully by passing a certain amount of current for 0.05 second through the
electrodes. The resultant weld nugget formed is 3 mm in diameter and 1.5 mm thick. If
the latent heat of fusion of steel is 1500 kJ/kg and the effective resistance in the welding
operation in 300Ω, what is the current passing through the electrodes?

2. In an arc welding process, the voltage and current are 50 V and 250 A respectively. The
arc heat transfer efficiency is 0.80 and the welding speed is 20 mm/sec. What is the net
heat input (in J/mm)?

3. Two metallic sheets, each of 1.0 mm thickness, are welded in a lap joint configuration
by resistance spot welding at a welding current of 15 kA and welding time of
30 milliseconds. A spherical fusion zone extending up to the full thickness of each sheet
is formed. The properties of the metallic sheets are given as:

Ambient temperature = 293 K


Melting temperature = 1793 K
Density =7000 kg/m3
Latent heat of fusion=300 kJ/kg
Specific heat =800 J/kg K

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. What
will be the melting efficiency?

4. The Arc length voltage characteristic is given by the equation V = 24 + 4 l, where l is


the arc length in mm. The static volt-ampere characteristic of the power source can be
approximated by a straight with OCV = 80 V and a short circuit current of 600 A.
Determine the optimum arc length for maximum power.

5. A direct current welding machine with a linear power source characteristic provides an
open circuit voltage of 40 V and a short circuit current of 1000 A. During the welding
the machine, the measured arc current is 500 A corresponding to an arc length of 5.0
mm and the measured arc current is 460 A corresponding to an arc length of 7.0 mm.
What will be the linear voltage (E)-arc length (L) characteristic of the welding arc?
(Where E is in volt and L is in mm)
6. In arc welding of a butt joint, the welding speed is to be selected such that the highest
cooling rate is achieved. Melting efficiency and heat transfer efficiency are 0.5 and
0.7 respectively. The area of the weld cross-section is 5 mm2 and the unit energy
required to melt the metal is 10 J/mm3. If the welding power is 2 kW, what is the
welding speed in mm/s?

7. Two pipes of inner diameter 90 mm and outer diameter 100 mm each is joined by flash
welding using 30 V power supply. At the interface, 1 mm of the material melts from
each pipe which has a resistance of 44.2 Ω. If the unit melt energy is 64.4 MJ/mm-3,
then what is the time required for welding (in seconds)?
8. Resistance spot welding is performed on two plates of 1.5 mm thickness with 6 mm
diameter electrode, using 15000 A current for a time duration of 0.25 seconds.
Assuming the interface resistance to be 0.0001, what is the heat generated to form the
weld?
9. Calculate the melting efficiency in the case of arc‐welding of steel with a potential of
20 V and a current of 200 A. The travel speed is 5 mm/s and. The cross‐sectional
sectional area of the joint is 20 mm2. Heat required to melt steel may be taken as 10
J/mm3 and the heat transfer efficiency as 0.85.
10. Two steel plates each 1 mm thick are spot welded at a current of 5000 A. The current
flow time is 0.1 s. The electrodes used are 5 mm in diameter. Determine the heat
generated and its distribution in the weld zone. The effective resistance in the operation
is 200 μΩ.
11. Two steel sheets of 1.0mm thickness are resistance welded in a lap joint with a current
of 10 000 A for 0.1 second. The effective resistance of the joint can be taken as 100
micro ohms. The joint can be considered as a cylinder of 5 mm diameter and 1.5mm
height. The density of steel is 0.00786 g/mm3 and heat required for melting steel is 10
J/mm3.
12. Two 1.2 mm thick, flat copper sheets are being spot welded using a current of 6000 A
and a current flow time of t = 0.18 s. The electrodes are 5 mm in diameter. Estimate the
heat generated in the weld zone. Take effective resistance as 150 μΩ.
13. How much heat would be generated in the spot welding of two sheets of 1 mm thick
steel that required a current of 10000 A for 0.1 seconds? An effective resistance of 100
μΩ. is assumed.
14. Two steel sheets of 1.0‐mm thickness are resistance welded in a projection welding
with a current of 30000 A for 0.005 second. The effective resistance of the joint can be
taken as 100 micro ohms. The joint can be considered as a cylinder of 5 mm diameter
and 1.5 mm height. The density of steel is 0.00786 g/mm3 and heat required for melting
steel is 10 J/mm3.

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