MECH 6541 : QUIZ 2 : This exam has 36 questions with a total points of 80.

These
will be prorated back to 20 marks for Quiz 2 for the final grade marking

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Please submit a hard copy of this quiz with your answers on the due date to be
announced in the class.

1. For GMAW of steels is it possible to do spray transfer with 100% CO2 gas (1)

2. For GMAW of steels is it possible to do spray transfer with 100% Helium (1)

3. For GMAW of steels is it possible to spray transfer with a mixture 90% Argon
and 10% CO2 (1)

4. For GMAW welding of Aluminium what are the two principal advantages of
using Argon Helium mixtures? (2)

5. What is the principal difficulty with welding copper. ( 2 )

a. The difficulty of welding copper is

b. What is the Shielding gas used for GMAW welding of Copper.

1
6. The following GMAW mixture is used to weld what type of a steel? 90%
Helium + 7.5% Argon + 2.5% CO2 (1)

7. 25% CO2+75% Argon mixture is a standard mixture for GMAW welding while
performing type of gas transfer (1)

8. Fumes increase with decreasing amounts of CO2 gas in a mixture of shielding gas
(1)

True
False

9. Certification of FCAW wires to the CSA W48 code requires the shielding gas to
be mentioned for the certification. Explain the following FCAW classification: (6)

E491T-9M-H8 ( Select arc FCAW wire called Encore)

E=
49 =
1=
T-9 =
M=
H8 =

10. 95% Nitrogen + 5% Hydrogen is a welding gas mixture ( 1) .

True
False

11. Why is acetylene preferred over natural gas for oxy-cutting operations? (1)

12. 75% Argon +10% Helium + 15% CO2 mix is used for which semiautomatic
process(es)? This mixture is also called Arcal 211. (1)
13. Using the shielding gas mixture Arcal 211 above, what is the extent of reduction
of welding fumes compared to 100% CO2 mix? ( look up the power point on
Fume Management) ( 1)

14. If the fume generation rate of a FCAW wire is assumed to be 1 g/min ( grams per
minute), calculate the weight of fumes produced by one welder working for one
year operation. Assume working duty cycle based on the data given in the class to
calculate your answer for semiautomatic processes. ( Power Point - Welding
Productivity Measurements) (1)

15. Precipitation hardening of alloys is based on producing precipitates.

(1)

16. Explain and show variation of the alloy strength with increasing time at a given
ageing temperature of precipitation hardening alloys (3)
 17. What is meant by sensitization of stainless steel. How can you minimize it? ( 2 +
2) = 4

Sketch
 18. Based on the composition of the following stainless steels, identify each of the
categories: duplex, austenitic, precipitation hardening, ferritic, Martensitic etc (5)

Element % % % % %
Carbon 0.03 0.15 0.03 0.09 0.03
Chromium 12 13 18 17 25
Nickel 0.0 0.0 8 7 7
Manganese 1.5 1.5 1.5 1.5 1.5
Silicon 1 1 1 1 1
Columbium
Titanium Ti = 6x%C 0.45 Cb + Ta
Copper 4
Aluminium 1
Nitrogen 0.20
Type of stainless

19. Small amounts of delta ferrite ( 5 -12%) are required to be present in a fully
austenitic weld metal to avoid hot cracking. What is the metallurgical reason for
the phenomenon?(3)

20. AC current is used for welding aluminium with GTAW processes. Using the AC
for GTAW helps break up the (1)

21. The AC frequency can be varied between Hz to Hz for

GTAW welding of aluminium. (2)
 22. When welding dissimilar welds between mild steel and austenitic stainless steel a
E308L and a E309Mo-L electrode was used. Assume mild steel chemistry of base
plate to be :0.2% C and 1% Mn and 0.25% Silicon. Assume a 20% penetration of
the weld. Using the Shaeffler's diagram below, indicate which weld will have the
greatest chances of producing sound welds. Explain your answer. ( 3
+ 3)

The weld made with SMAW stainless steel electrode type E309 will not
exhibit any cracking because the diluted weld metal will not contain any martensite.

The weld made with SMAW stainless steel electrode type Austenite will exhibit
cracking because the diluted weld metal will contain martensite

23. Cast iron can be easily welded with 55% Nickel(Ni) containing electrodes. The cast
iron will very likely not crack due to opposing forces. Expansion of the weld metal,
counter acted by Thermal Contraction of the weld metal due to the precipitation of
graphite flakes in the weld metal. ( 3)

24. For producing X-Ray quality welds in aluminium 6061T6 alloy, what are the
difficulties? In other words, what is the most common welding defect observed in
aluminium welds and what is the metallurgical reason for this? (1)
 Ans. The most common defect observe in aluminum welds is the hydrogen porosity which occurs
due to the entrapped gas in the weld puddle. Molten aluminum has a high affinity for atomic
hydrogen. On the other hand, solid aluminum can contain very little hydrogen.

The other common defect observed in aluminum welds is the hot cracking which is caused due to
the stresses induced by metal contraction as the weld pool cools.

25. The CSA W59-13 code stipulates that all welds shall be visually inspected. The
contract is awarded and the fabrication and erection of a steel building has
commenced. The owner's engineer midway through the contract demands the
contractor to perform 100% RT inspection of temporary attachment welds. (3)

a. Who pays for the RT examination?

The Purchaser

b. Who pays for the repairs to welds found defective by RT examination?

The Contractor

c. Which clause of the CSA W59-13 makes reference to this

issue? Clause 7.3.4
26. Clause of 12 of W59-13 code requires visual inspection of welds. The following
defects are not acceptable per the code: (5) ( only bullet point except for the last
item h) Write any 5 out of 8.

a. Surface cracks
b. Visible Lack of fusion between welds and base metal
c. Craters
d. If there is visible porosity in the groove welds
e. If the frequency of visible porosity in fillet welds exceed one in each 100 mm of
length and the maximum diameter exceed 2.5 mm
f. that Undercut of 0.010"
or more deep when its direction is transverse to the primary stress in the part
that is undercut. And the undercut of more than (1/32) deep when its direction

27. Clause 9 of the W59-13 code deals with weld repair of existing
structures. (1)

28. What is the definition of a Fracture Critical Member according to the S-6 code.
(1)

Ans. Members or portions of member, including attachments, in a single load path structure that are
subject to tensile stress and the failure of which can lead to collapse of the structure.

29. How are FCM materials identified to the shop floor and field supervision? (1)

The components identified as fracture-critical members and primary tension members shall be
clearly identified in the plans. Shop drawings shall identify the extent of fracture-critical and
primary tension members. Attachments longer than 100 mm in the direction of tension and welded
to the tension zone of a fracture- critical or primary tension member shall be treated as part of that
member.
For each component of a fracture-critical or primary tension member, records shall be kept to
identify the heat number of the material and its corresponding mill test certificate.
 30. Determine the charpy requirement for the weld metal according to the Table
10.14 entitled "Impact test temperatures and charpy impact energy requirements
for the weld metal" on page 515 of the Bridge code S-6 for a bridge being built in
Yukon in CSA G40.21 350WT grade of steel. The location of the bridge is in
White Horse, Yukon across the Yukon river. Please refer to figure A 3.1.2 entitled
" Minimum mean Daily temperature" to determine the design temperature. (4)

The weld metal will possess charpy impact energy values of 27 Joules @
-47 C

31. All repairs in FCM groove welds will be radiographically tested. (1)

a. True
b. False

h. False

Note: Refer to Clause 10.23.5.7 on page 517 in the Bridge Code document.

32. Advanced inspection techniques such as digital radiography and phased array can be
used now in Canada to the requirements of W59-13 code. What are the conditions before
the contractor can use these techniques on the contract? (1)

Ans. Digital Radiography: It may only be used if agreed to in writing by the engineer and the Contractor,
prior to the examination. Moreover, inspection personnel shall be qualified to CAN/CGSB-48. He should
have 9712/ISO 9712 for conventional RT and, in addition, shall have completed training program specific to
the radiation imaging system used.

Phased array Method: It may only be used if agreed to in writing by the engineer and the Contractor, prior to
the examination. Moreover, inspection personnel shall be qualified to CAN/CGSB-48. He should have
9712/ISO 9712 for conventional UT and, in addition, shall have completed a level 2 or 3 training program
specific to the ultrasonic system used.
33. You are completing the welding procedure for welding of a 2 inch thick flange to
a 2 inch web of a Tee weld of a fabricated structural I beam for a bridge. Choose
the most productive process for fabricating 20 such beams which are each 80 feet
long. Choose a prequalified joint from the CSA W59-13 code. Please draw the
chosen joint geometry along with the welding symbol. (Process (1), Joint
selection (2), welding symbol ( 1)) = (4)

Process : FCAW
Joint : T-Joint
Welding symbol : FC 1- Square Groove
Sketch
 34. Laser Hybrid process with GMAW has the following advantage compared to a
plain laser welding or GMAW welding process: ( 2)
Ans. The advantages of laser hybrid process with GMAW over plain laser welding or GMAW
welding process are as follows:
(i) Laser hybrid process has higher process stability, higher bridgeability.
(ii) Laser Hybrid welding has less porosity and cracking

(iii) Laser Hybrid welding has higher welding speeds, deeper penetration, high tensile strength
and narrower weld seams.
(iv) Good metallurgical properties

35. Give one most common application for Electron Beam welding in aerospace
industry (1)

(i) Precision aerospace gears

(ii) Compressor rotor
(iii) Turbine blade repair
36. Each of the pot shells for an aluminum smelter takes 850 lbs of weld metal.
Assume that all the welds are made in the flat and horizontal position while using
large manipulators to keep the welding down hand. There are 484 pot shells to be
completed for the contract and the first 30 have to made using the SMAW process
and the remaining will be made using the MCAW welding process. Estimate the
welding hours to weld one pot using the SMAW and the MCAW welding
process: ( 3 + 3)

a. Assume a welding amperage of 250 amps with the SMAW process E7024
b. Assume the use of a 1/16 inch diameter MCAW wire at an average feed
speed of 325 inches per minute.
c. Take the deposition rates from the appropriate graphs from the course
notes ( Power point on Welding processes and dep rates)
d. Take the welding duty cycle numbers from the data provided in the class
( Power point on Welding productivity measurements)

Welding hours for SMAW process per pot shell : in Man hours

GIVEN :

For SMAW process at 250 amps using E 7024 electrode,

Deposition rate for 100 % duty cycle = 7.5 pounds/ hour.

Average duty cycle for SMAW process = 13.3 %,

Therefore, deposition rate = 7.5 x 13.3/100

= 0.9975 lb/hr.
Therefore for depositing 850 lbs of weld metal, the time taken
= 850/.9975
= 852.130 hours.
Welding Hours for SMAW process per pot shell = 852.130 hours.
Welding hours for MCAW process per pot shell: in Man Hours

For MCAW process using 1/16 diameter wire at 325 ipm the deposition rate for 100 %

duty cycle = 14.2 lb/hr. Since the average duty cycle is 15.93 %,

The corresponding deposition rate is 14.2 x 15.93/100 = 2.26206 lb/ hr

The Time taken to deposit 850 lbs is 850/2.26206 = 375.76 hours

Welding hours for MCAW process per pot shell = 375.76 hours.
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