1.

What are the advantages,disadvantages and

applications of welding joints over other joints?
Advantages and applications

FCAW may be an "all-position" process with the right filler metals (the
consumable electrode)
No shielding gas needed with some wires making it suitable for outdoor
welding and/or windy conditions
A high-deposition rate process (speed at which the filler metal is applied) in
the 1G/1F/2F
Some "high-speed" (e.g., automotive) applications
As compared to SMAW and GTAW, there is less skill required for operators.
Less precleaning of metal required
Metallurgical benefits from the flux such as the weld metal being protected
initially from external factors until the slag is chipped away

Used on the following alloys:

Mild and low alloy steels

Stainless steels
Some high nickel alloys
Some wearfacing/surfacing alloys
Porosity chances very low

Disadvantages
Of course, all of the usual issues that occur in welding can occur in FCAW such as
incomplete fusion between base metals, slag inclusion (non-metallic inclusions), and
cracks in the welds. But there are a few concerns that come up with FCAW that are
worth taking special note of:

Melted Contact Tip happens when the contact tip actually contacts the base
metal, thereby fusing the two and melting the hole on the end
Irregular wire feed typically a mechanical problem
Porosity the gases (specifically those from the flux-core) dont escape the
welded area before the metal hardens, leaving holes in the welded metal
More costly filler material/wire as compared to GMAW
The equipment is less mobile and more costly as compared to SMAW or
GTAW.
The amount of smoke generated can far exceed that of SMAW, GMAW, or
GTAW.
Changing filler metals requires changing an entire spool. This can be slow and
difficult as compared to changing filler metal for SMAW or GTAW.
Creates more fumes than stick welding

Explain the various types of joints commonly used in .2

.welding
Types

Butt joint geometries

There are many types of butt welds, but all fall within one of these categories: single
welded butt joints, double welded butt joint, and open or closed butt joints. A single
welded butt joint is the name for a joint that has only been welded from one side. A
double welded butt joint is created when the weld has been welded from both sides.
With double welding, the depths of each weld can vary slightly. A closed weld is a
type of joint in which the two pieces that will be joined are touching during the
welding process. An open weld is the joint type where the two pieces have a small gap
in between them during the welding process.

Square butt joints

The square-groove is a butt welding joint with the two pieces being flat and parallel to
each other. This joint is simple to prepare, economical to use, and provides
satisfactory strength, but is limited by joint thickness. The closed square butt weld is a
type of square-groove joint with no spacing in between the pieces. This joint type is
common with gas and arc welding.
For thicker joints, the edge of each member of the joint must be prepared to a
particular geometry to provide accessibility for welding and to ensure the desired
weld soundness and strength. The opening or gap at the root of the joint and the
included angle of the groove should be selected to require the least weld metal
necessary to give needed access and meet strength requirements.

V-joints
Single-V butt welds are similar to a bevel joint, but instead of only one side having
the beveled edge, both sides of the weld joint are beveled. In thick metals, and when
welding can be performed from both sides of the work piece, a double-V joint is used.
When welding thicker metals, a double-V joint requires less filler material because
there are two narrower V-joints compared to a wider single-V joint. Also the double-V
joint helps compensate for warping forces. With a single-V joint, stress tends to warp
the piece in one direction when the V-joint is filled, but with a double-V-joint, there
are welds on both sides of the material, having opposing stresses, straightening the
material.

J-joints
Single-J butt welds are when one piece of the weld is in the shape of a J that easily
accepts filler material and the other piece is square. A J-groove is formed either with
special cutting machinery or by grinding the joint edge into the form of a J. Although
a J-groove is more difficult and costly to prepare than a V-groove, a single J-groove
on metal between a half an inch and three quarters of an inch thick provides a stronger
weld that requires less filler material. Double-J butt welds have one piece that has a J
shape from both directions and the other piece is square.

U-joints
Single-U butt welds are welds that have both edges of the weld surface shaped like a
J, but once they come together, they form a U. Double-U joints have a U formation on
both the top and bottom of the prepared joint. U-joints are the most expensive edge to
prepare and weld. They are usually used on thick base metals where a V-groove would
be at such an extreme angle, that it would cost too much to fill.

Others
Thin sheet metals are often flanged to produce edge-flange or corner-flange welds.
These welds are typically made without the addition of filler metal because the flange
melts and provides all the filler needed. Pipes and tubing can be made from rolling
and welding together strips, sheets, or plates of material.[4]
Flare-groove joints are used for welding metals that, because of their shape, form a
convenient groove for welding, such as a pipe against a flat surface.
The Tee Butt Weld is formed when two bars or sheets are joined perpendicular to each
other in the form of a T shape. This weld is made from the resistance butt welding
process.
Selection of the right weld joint depends on the thickness and process used. The
square welds are the most economical for pieces thinner than 3/8, because they dont
require the edge to be prepared.[5] Double-groove welds are the most economical for
thicker pieces because they require less weld material and time. The use of fusion
welding is common for closed single-bevel, closed single J, open single J, and closed

double J butt joints. The use of gas and arc welding is ideal for double-bevel, closed
double-bevel, open double-bevel, single-bevel, and open single-bevel butt welds.
Below are listed ideal joint thicknesses for the various types of butt welding joints.
When the thickness of a butt weld is defined it is measured at the thinner part and
does not compensate for the weld reinforcement.
Workpiece thickness limits per joint type[citation needed]
Joint type
Thickness
Square joint
Up to 14 in (6.35 mm)
3
Single-bevel joint
1638 in (4.769.53 mm)
Double-bevel joint Over 38 in (9.53 mm)
Single-V joint
Up to 34 in (19.05 mm)
Double-V joint
Over 34 in (19.05 mm)
1
Single-J joint
234 in (12.7019.05 mm)
Double-J joint
Over 34 in (19.05 mm)
Single-U joint
Up to 34 in (19.05 mm)
Double-U joint
Over 34 in (19.05 mm)
Flange (edge of
Sheet metals less than 12 gauge (0.1046 in or 2.657 mm)[clarification
needed]
corner)
Flare groove
All thickness

Give the complete procedure of gas welding.3

Oxyacetylene gas welding is commonly used to permanently join mild steel. A
mixture of oxygen and acetylene, burns as an intense / focussed flame, at
approximately 3,500 degrees centigrade. When the flame comes in contact with steel,
it melts the surface forming a molten pool, allowing welding to take place.
Oxyacetylene can also be used for brazing, bronze welding, forging / shaping metal
.and cutting
.This type of welding is suitable for the prefabrication of steel sheet, tubes and plates
PREPARING THE CYLINDERS FOR WELDIng
Slowly open the main valve of the acetylene tank and adjust the acetylene pressure
.regulator to 5PSI (pounds to square inch)
Open the needle valve on the torch and adjust the pressure on the acetylene regulators
.to show 5PSI. Close the needle valve
.Go through the same procedure for the oxygen cylinder

Define electric arc welding.Discuss with the help of .4

neat sketch,the principle

Arc welding is a type of welding that uses a welding power supply
to create an electric arc between an electrode and the base material to melt the metals
at the welding point. They can use either direct (DC) or alternating (AC) current, and
consumable or non-consumable electrodes. The welding region is usually protected by
some type of shielding gas, vapor, or slag. Arc welding processes may be manual,
semi-automatic, or fully automated. First developed in the late part of the 19th
century, arc welding became commercially important in shipbuilding during the
Second World War. Today it remains an important process for the fabrication of steel
.structures and vehicles

explain carbon arc welding with neat sketch.5

Carbon arc welding (CAW) is a process which produces coalescence of metals by
heating them with an arc between a nonconsumable carbon (graphite) electrode and
the work-piece. It was the first arc-welding process ever developed but is not used for
many applications today, having been replaced by twin-carbon-arc welding and other
variations. The purpose of arc welding is to form a bond between separate metals. In
carbon-arc welding a carbon electrode is used to produce an electric arc between the
electrode and the materials being bonded. This arc produces extreme temperatures in
excess of 3,000C. At this temperature the separate metals form a bond and become
welded together

?Explain various hand tools used in sheet metal work.6

. Alligator shear
Bench shear
A bench shear, also known as a lever shear, is a bench mounted shear with a
compound mechanism to increase the mechanical advantage. It is usually used for
cutting rough shapes out of medium sized pieces of sheet metal, but cannot do
delicate work.[1][2] For the small shear, it mostly designed for a wide field of
applications. Light weight and easy efficient operation, yet very sturdy in
construction. The cutting blades fitted are carefully and accurately ground to give
easy, clean quick cuts, and free of burrs. These special features help the operators save
a great deal of their energy. But some shearing machines can cut sheet bar and flat bar
up to 10mm. It is electrically welded together to make it a sturdy stable unit capable
to withstand highest stresses due to heavy duty usage. The footplates are reinforced
with bracing angles so that they give firm stability to the shear. The machine is
provided with section knives with sliding blades which can be adjusted by hand to

make 90 cuts on angels and T-sections of different sizes as well as with openings for
.cutting round and square bars

Name the metals commonly used in sheet metal work .7

Sheet metal is metal formed by an industrial process into thin, flat pieces. It is one of
the fundamental forms used in metalworking and it can be cut and bent into a variety
of shapes. Countless everyday objects are constructed with sheet metal. Thicknesses
can vary significantly; extremely thin thicknesses are considered foil or leaf, and
pieces thicker than 6 mm (0.25 in) are considered plate.
Sheet metal is available in flat pieces or coiled strips. The coils are formed by running
a continuous sheet of metal through a roll slitter.
The thickness of sheet metal is commonly specified by a traditional, non-linear
measure known as its gauge. The larger the gauge number, the thinner the metal.
Commonly used steel sheet metal ranges from 30 gauge to about 7 gauge. Gauge
differs between ferrous (iron based) metals and nonferrous metals such as aluminum
or copper; copper thickness, for example is measured in ounces (and represents the
thickness of 1 ounce of copper rolled out to an area of 1 square foot).
There are many different metals that can be made into sheet metal, such as aluminum,
brass, copper, steel, tin, nickel and titanium. For decorative uses, important sheet
metals include silver, gold, and platinum (platinum sheet metal is also utilized as a
catalyst.)
Sheet metal is used for car bodies, airplane wings, medical tables, roofs for buildings
(architecture) and many other applications. Sheet metal of iron and other materials
with high magnetic permeability, also known as laminated steel cores, has
applications in transformers and electric machines. Historically, an important use of
sheet metal was in plate armor worn by cavalry, and sheet metal continues to have
many decorative uses, including in horse tack. Sheet metal workers are also known as
"tin bashers" (or "tin knockers"), a name derived from the hammering of panel seams
when installing tin roofs.[citation needed]
In 2011, the sheet metal industry was worth almost $20.5 billion in the United States.
[1]
There were 4,000 firms employing 106,000 sheet metal workers.

Discuss the different sheering operations performed on .8

?aheet metal
Shearing, also known as die cutting,[1] is a process which cuts stock without the
formation of chips or the use of burning or melting. Strictly speaking, if the cutting
blades are straight the process is called shearing; if the cutting blades are curved then

they are shearing-type operations.[2] The most commonly sheared materials are in the
form of sheet metal or plates, however rods can also be sheared. Shearing-type
operations include: blanking, piercing, roll slitting, and trimming. It is used in
metalworking and also with paper and plastics.A punch (or moving blade) is used to
push the workpiece against the die (or fixed blade), which is fixed. Usually the
clearance between the two is 5 to 40% of the thickness of the material, but dependent
on the material. Clearance is defined as the separation between the blades, measured
at the point where the cutting action takes place and perpendicular to the direction of
blade movement. It affects the finish of the cut (burr) and the machine's power
consumption
discuss the various types of hammers used in sheet metal work.9
A mallet is a kind of hammer, often made of rubber or sometimes wood, that is
smaller than a maul or beetle and usually with a relatively large head.
Tool mallets come in different types, the most common of which are:

Rubber mallets are used when a softer blow is called for than that delivered
by a metal hammer. They are typically used to form sheet metal, since they
don't leave marks and are softer, as well as for forcing tight-fitting parts
together, for shifting plasterboard into place, in upholstery, and a variety of
other general purposes, including some toys. It is a tool of preference for wood
workers using chisels, with plastic, metal or wooden handles - as they give a
softened strike with a positive drive. It is the most commonly used mallet.
Wooden mallet, usually used in carpentry to knock wooden pieces together,
or to drive dowels or chisels. A wooden mallet will not deform the striking end
of a metal tool, as most metal hammers would, and it also reduces the force
required to drive the cutting edge of a chisel. Hardwood mallets are also used
to knock in cricket wickets.
Copper, Brass and leaden mallets are typically used on machinery to apply
force to parts with a reduced risk of damaging them and to avoid sparks. As
these metals are softer than steel, the mallet is deformed rather than any steel
object it is hitting.
Meat mallets tenderise or flatten meat. Made from wood or metal, they are
typically two-sided, one flat with slight bumps, and the other with more
pronounced protrusions.[1] Their use has lessened with the invention of cube
steak machines and other electric tenderisers.[citation needed]

Less common mallets include:

Rawhide mallets, which may employ rawhide covering a steel head, or

simply consist of rolled-up rawhide, are used for leatherwork, jewellery, and
assembling electric motors and delicate machinery.
Plastic mallets, made of nylon, polycarbonate, or polystyrene are used
especially in leatherwork and jewellery.
Split head mallets, which have removable faces which can be changed to an
appropriate material for the job.

Beetle mallet, or a large mallet with a circular wood or plastic head, with
rounded ends about 18 inches to 15 inched in diameter, with a handle about 3
feet (0.91 m) long. It is used by paviours for putting paving stones into
position when bedding. Beetles are also used in jobs such as timber framing to
shift the bases of large wooden posts, fit joints, and drive in pegs.[2]
Dead blow mallets, which have an internal cavity filled with steel or lead
shot. This addition evens out the time-impulse curve of the impact, enabling a
more powerful blow to be delivered without risk of marring the target.

Mallets of various types are some of the oldest forms of tools, and have been found in
stone age gravesites.

10.name various tools,machine and equipments used in

sheet metal shop
Metal fabrication is the building of metal structures by cutting, bending, and
assembling processes:

Cutting is done by sawing, shearing, or chiseling (all with manual and

powered variants); torching with hand-held torches (such as oxy-fuel torches
or plasma torches); and via numerical control (CNC) cutters (using a laser,
mill bits, torch, or water jet).
Bending is done by hammering (manual or powered) or via press brakes and
similar tools. Modern metal fabricators utilize press brakes to either coin or
air-bend metal sheet into form. CNC-controlled backgauges utilize hard stops
to position cut parts in order to place bend lines in the correct position. Offline programing software now makes programing the CNC-controlled press
brakes seamless and very efficient.
Assembling (joining of the pieces) is done by welding, binding with adhesives,
riveting, threaded fasteners, or even yet more bending in the form of a crimped
seam. Structural steel and sheet metal are the usual starting materials for
fabrication, along with the welding wire, flux, and fasteners that will join the
cut pieces. As with other manufacturing processes, both human labor and
automation are commonly used. The product resulting from fabrication may
be called a fabrication. Shops that specialize in this type of metal work are
called fab shops. The end products of other common types of metalworking,
such as machining, metal stamping, forging, and casting, may be similar in
shape and function, but those processes are not classified as fabrication.

Fabrication comprises or overlaps with various metalworking specialties: