By S K Mondal

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‘‘maa’’
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Part -2

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During a steady gas metal arc welding with direct current electrode
positive polarity, the welding current, voltage and weld speed are
150 A, 30 V and 6 m/min, respectively. A metallic wire electrode of
diameter 1.2 mm is being fed at a constant rate of 12 m/min. The
density, specific heat and melting temperature of the wire
electrode are 7000 kg/m3, 500 J/kgoC and 1530oC, respectively.
Assume the ambient temperature to be 30oC and neglect the latent
heat of melting. Further, consider that two-third of the total
electrical power is available for melting of the wire electrode. What
is the melting efficiency of the wire electrode? 6
The voltage - length characteristics of a direct current arc is
given by V = (22 + 40l) Volts,

where l is the length of the arc in cm. The power source

characteristic is approximated by a straight line with an open
circuit voltage = 80 V and short circuit current = 1000 Amp.
Determine the optimum arc length and corresponding
power.

[20 Marks]
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Two pipes of inner diameter 100 mm and outer diameter
110 mm each joined by flash butt welding using 30 V power
supply. At the interface, 1 mm of material melts from each
pipe which has a resistance of 42.4 Ω. If the unit melt
energy is 64.4 MJm-3, then calculate the time required for
welding?

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The volume of a weld nugget produced by spot welding process is 80
mm3. Welding is performed using 10000 A current. Energy required
for melting of unit volume of metal is 10 J/mm3. Assume that heat
lost to the surrounding base metal is 500 J and contact resistance is
0.0002 ohms.

Calculate :

(i) Time (in second) for which the welding current is supplied, and

(ii) Thermal efficiency of the spot welding process if other heat

losses are negligible.
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Two plates with symmetrical V joint penetration of V angle
𝟔𝟎° are to be arc welded in a single pass. The power P (kW) arc
length L (mm) characteristic is given by P = 4 + 0.8 L – o.1 L2 .
Assuming that the top surface of the weld is flat and flush with
the plate top surface, & the energy losses are 20%, the density of
filler material is 8 gm/cc and the energy required to melt 1 gm is
1400 Joules. The plate dimensions are 1000 mm length and 5 mm
thickness. What is the maximum welding speed?
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The cross-sectional area of weld bead is shown in figure.
The profile of the bead and the fusion zone are taken
circular for convenience. Bead width is 10 mm and radii of
curvature of circular profiles is given in the figure below.
Calculate :
i. Bead Height
ii. Dilution (%)

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Determine the maximum shear stress the lap joint shown in
the figure can withstand. The joint is made between two
aluminium sheets of 1.2 mm thickness with an adhesive
thickness of 0.25 mm. The overlapped length is 12 mm.
Following data is given :

Young’s Modulus of aluminium = 68 GPa

Shear Modulus of adhesive = 1.9 GPa

Contd…
Ultimate Shear stress of the adhesive = 0.6 MPa
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Two steel sheets of 1.1 mm thickness are to be spot welded.

Following data is given for the welding :

Current = 10000 Ampere

Maximum Allowable Indentation = 10 % of sheet thickness

Specific Melting Energy = 1800 J/gram

Effective resistance = 200 𝜇Ω

Density of weld nugget = 8 g/cc

Calculate the melting efficiency of the weld.

(NOTE: Radius of Nugget = 3√𝑡 mm , where t is the sheet thickness. )

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V-I Characteristics of a power source is given by the relationship,

𝐼!" = 600 50 − 𝑉
i. If the arc characteristics is given by equation, Ia = 25 ( V – 20) ,
then determine the power of stable arc.

ii. If arc length l (in mm) and arc voltage Va (in Volt) are related
by , Va = 5 ( l + 6 ) Volt, then determine the optimum arc
length corresponding to maximum power. Also, calculate the
maximum power.
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(i) The voltage-length characteristics of a dc arc is given by :
V = (20 + 4l) volts,

Where l = length of the arc in mm. During a welding operation, it is

expected that the arc length will vary between 4 mm and 6 mm. It is
desired that the welding current be limited to the range 450-550
amp. Assuming a linear power source characteristic, determine the
open circuit voltage and the short circuit current of the power
source.
Contd…
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(ii) Consider the voltage – length arc characteristics described
in the part (i). Let the power source characteristic be given by

! !
𝑉 𝐼
+2 =1
Vo Is
Where Vo is the open circuit voltage and Is is the short circuit
current. If Vo and Is remain the same as obtained in part (i),
determine the range of welding current for the arc length
variation mentioned in part (i).
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A round casting is 20 mm in diameter and 50 mm in
length. Another casting of the same metal is elliptical in
cross section, with a major to minor axis ratio of 2, and
has the same length and cross-sectional area as the
round casting. Both pieces are cast under the same
conditions. What is the difference in the solidification
times of the two castings?

[10 – Marks]
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Compare the solidification time of two optimum
side – risers of the same volume when one has a
cylindrical shape and other is square
parallelopiped.

[30 Marks]

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Calculate the time
required to fill up the
mould shown in the
figure. Assume that the
liquid metal level at X-X is
maintained constant and
time to fill the runner is
negligible.
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Calculate the size of a cylindrical riser (height and
diameter equal) necessary to feed a steel slab casting of
dimensions 30 x 30 x 6 cm3 with a side riser, casting poured
horizontally into the mould. [Use Modulus Method]

[10 - Marks]

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Calculate the size of a cylindrical riser (height and
diameter equal) necessary to feed a steel slab casting of
dimensions 25 x 25 x 5 cm3 with a side riser, casting
poured horizontally into the mould. [Use Caine’s Method]

[ For steel a = 0.10, b = 0.03 and c = 1.00]

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The dimensions of a cylindrical side riser (height = diameter) for
a 25 cm x 15 cm x 5 cm steel casting are to be determined. For the
tabulated shape factor values given below, calculate the
diameter of the riser.

Shape factor 2 4 6 8 10 12
𝑹𝒊𝒔𝒆𝒓 𝒗𝒐𝒍𝒖𝒎𝒆 1.0 0.70 0.55 0.50 0.40 0.35
𝑪𝒂𝒔𝒕𝒊𝒏𝒈 𝒗𝒐𝒍𝒖𝒎𝒆

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Determine the dimensions of an optimum cylindrical
riser attached to the side of a steel plate casting having
dimensions 25 cm × 12.5 cm × 5 cm. The volume
shrinkage of steel during solidification is 3% and the
volume of riser is 3 times the that of dictated by the
shrinkage consideration alone.
[10 marks]

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