QUESTION 1 In an arc welding operation, a groove weld has a cross sectional area=0.055 in2 and is 24 in long. (Round your final answers to 1 decimal place) (a) What quantity of heat (in Btu) is required to accomplish the weld, if the metal to be welded is aluminum? Hw Btu (b) How much heat must be generated at the welding source, if the heat transfer factor 90% and the melting factor= 60%7 H= Btu
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- Q1-A shielded metal arc welding operation is performed on steel at E = 30 volts and I = 225 amps. The heat transfer efficiency fi= 0.85 and melting efficiency f₂=0.75. The unit melting energy for steel Um = 10.2 J/mm3. Solve for: (a) the rate of heat generation at the weld and (b) the volume rate of metal weldedTwo 3.5 mm thick metal (Um = 9.5 J/mm?) sheets are being joined using resistance spot welding. To achieve required strength, it is desired to form a weld nugget that is 5.5 mm in diameter and 4.0 mm thick. The weld duration will be set at 0.3 sec. If the electrical resistance between the surfaces is 140 microohms, and only onethird of the electrical energy generated will be used to form the weld nugget determine the current.A continuous fillet wild is used to weld two pieces of 7.0-mm-thick austenitic stainless steel plate in an arc-welding operation. The plates are joined at a 90° angle using an inside fillet corner joint. The velocity of the welding head is 6 mm/sec. Assume the cross section of the weld bead approximates a right angle isosceles triangle (a right triangle with the two legs and their corresponding angles equal) with a leg length of 4.5 mm. The length of the weld = 230 mm. The melting factor of the setup = 0.65, the heat transfer factor = 0.90, and the Tm for austenitic stainless steel = 1670°K. Determine (a) The amount of heat (in joules) required to melt the volume of metal in (b) The heat that , (c) The rate of heat generation required at the welding source to accomplish the weld this weld (filler metal plus base metal) must be generated at the heat source
- A gas tungsten arc welding operation is performed using a current of 250 A and an arc voltage of 20 V at a welding speed of 5 mm/s. Assuming that the arc efficiency is 70%, the net heat input per unit length of the weld will be kJ/mm (round off to one decimal place).A GTAW operation is performed on low carbon steel, whose unit melting energy is 10.3 J/mm3. The welding voltage is 22 volts and the current is 135 amps. The heat transfer factor is 0.7 and the melting factor is 0.65. If filler metal wire of 3.5 mm diameter is added to the operation, the final weld bead is composed of 60% volume of filler and 40% volume base metal. If the travel speed in the operation is 5 mm/sec, determine (a) cross-sectional area of the weld bead, and (b) the feed rate (mm/sec) at which the filler wire must be supplied.The unit melting energy for a certain sheet metal is 10J/mm^3 .The thickness of each of the two sheets to be spot-welded is = mm. To achive required strength, it is desired to form a weldnugget that is =7 mm in diameter and 3.5 mm thick. The weld duration will be set at 44 sec .If the electrical resistance between the two surfaces is 144 micro-ohms and only one half the electricity generated will be used to form the weld nugget Determine the minium current level required in this operation
- The below Figure Q1 shows an aluminium alloy sheet metal requires to be spot welded. In order for the weld to achieve its required strength, it has to be 2mm thick and the weld duration will be set at 0.3 sec. If it is assumed that the electrical resistance between the surfaces is 160 micro-ohms, and that only 40% of the electrical energy generated will be used to form the weld nugget (the rest being dissipated into the work), determine: a) The heat energy generated at the source b) The minimum current level required in this operation c) Assuming the heat transfer factor is 0.9, what would the melting factor be? d) The power density of the process, and comment on the value.It is desired to determine the cost of the submerged arc welding operation in the preceding problem, including electric power cost but excluding work material costs. Power during arc-on time = 9,000 W, and cost of electricity = $0.15/kWH. The labor cost rate = $33.00/hr and the SAW equipment cost = $20.00/hr (including applicable overheads). The cost of each spool of electrode wire = $50.00. The cost of granular flux used in each cycle = $2.00. What is the welding cost of each completed tube?During a TIG welding process, the arc current and arc voltage were 50 A and 60 V, respectively, when in the welding speed was 150 mm/min. In another process, the TIG welding is carried out at a welding speed of 120 mm/min at the same arc voltage and heat input to the material so that weld quality remains the same. The welding current (in A) for this process is
- 6) In the given Fig. 2, the butt-welded joint is subjected to uniaxial tensile load of 10 kN, with throat thickness of 5 mm and length of the weld as 100 mm. So calculate the tensile stress generated for each weld plates? N.B. The butt joint efficiency is 90% Fig. 2 O 22.22 MPa O11.11 MPa 2.22 MPa O1.11 MPaAssume that two 1.5-mm thick steel sheets are being spot welded at a current of 4000 A and current-flow time is 0.3 s. Using electrodes 5 mm in diameter, estimate the amount of heat generated and the amount of heat required to melt the weld nugget. Use an effective resistance of 350 un. Take u= 9,7 Joule/mm Which one of the following are correct? O a. If the electrodes were 7 mm diameter, the amount of heat generated would decrease b. The amount of heat generated by the equipment is between 1600 to 1700 Joules c. The equipment has enough power to weld the steel sheets. d. The equipment does not have enough power to weld the steel sheets e. The amount of heat required is between 700 and 750 JoulesThe welding parameters to be used to butt weld a metal alloy are being evaluated. In order to set up the welding machine, the melting factor for the metal (f2) has to be determined. The welding machine can deliver 4000 watts of power and the heat transfer factor for the welding process (f1) is 0.9. The final weld bead consists of 8 0% filler metal and 40% parent metal. The melting temperature of the filler metal and the parent metal is the same 2540 deg F. The cross-sectional area of the weld bead is 0.5 sq inches. The rate at which filler metal is added to the weld is 1 cu inch per min. Conversion factor 1 Btu = 1055 J and 0 deg F = 460 deg R Calculate the melting factor.