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Welding and Joining - Question

Welding and Joining - Question

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43 views

Welding and Joining - Question

Welding and Joining - Question

Uploaded by

Yih Lin Chen
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOC, PDF, TXT or read online on Scribd
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MA2004 Tutorial

Tutorial 5 Welding and Joining

For Week 10 (which is the week starting on 20 Oct 2014)

1. An experimental power source for spot welding is designed to deliver current


(I) as a ramp function of time (t): I = 10 5t for I in A and t is s. At the end of the
power-on time, the current is stopped abruptly. The sheet metal being spot
welded is low-carbon steel whose unit melting energy = 10 J/mm 3. The
resistance R = 85 . The desired weld nugget size is diameter = 4 mm and
thickness = 2 mm (assume a disc-shaped nugget). It is assumed that one-
quarter of the energy generated from the power source will be used to form
the weld nugget. Determine the power-on time the current which must be
applied in order to perform this spot welding operation.
Ans: t = 0.153 s

2. A GTAW (gas tungsten arc welding) operation is performed on stainless steel,


whose unit melting energy Um = 9.3 J/mm3. The conditions are: voltage E = 25
V, current I = 125 A, and heat transfer efficiency (f1) = 0.6. Filler metal wire of
3.0 mm in diameter is added to the operation at 10.0 mm/s, and the final weld
bead is composed of 50% filler and 50% base metal.
(a) Determine the welding volume rate.
(b) Determine the value of melting efficiency (f2).
(c) If the cross-sectional area of the weld bead is 30.6 mm2, determine the
travel speed.
(d) If the final weld bead is composed of 60% filler and 40% base metal,
determine the feed rate (in mm/s) at which the filler wire must be
supplied.
Ans: (a) 141.3 mm3/s; (b) 0.7; (c) 4.62 mm/s; (d) 12.0 mm/s

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MA2004 Tutorial

3. An electron beam welding operation is to be accomplished to butt weld two


sheet metal parts that are 3.0 mm thick. The unit melting energy = 5.0 J/mm 3.
The weld joint is to be 0.35 mm wide, so that the cross-section of the fused
metal is 0.35 mm by 3.0 mm. If accelerating voltage = 25 kV, beam current =
30 mA, heat transfer efficiency f l = 0.85, and melting efficiency f 2 = 0.75,
determine the travel speed at which this weld can be made along the seam.
Ans: 91 mm/s

4. A surface weld is to be applied to a rectangular low-carbon steel plate that is


200 mm  350 mm. The metal to be applied is a harder (alloy) grade of steel
with the same melting point. A thickness of 2.0mm will be added to the plate,
but with penetration into the base metal, the total thickness melted during
welding = 6.0 mm on average. The surface will be applied by making a series
of parallel, overlapped welding beads running lengthwise on the plate. The
operation will be carried out automatically with the beads laid down in one
long, continuous operation at a travel speed v = 7.0 mm/s, using welding
passes separated by 5 mm. Ignore the minor complications of the turnarounds
at the ends of the plate. Assuming the heat transfer efficiency = 0.8 and the
melting efficiency = 0.6, determine:
(a) The rate of heat that must be generated at the welding source; and
(b) The time necessary to complete the surfacing operation.
Ans: (a) HR= 4515 J/s; (b) 33.3 min

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