Your boss requests a recommendation on which process to use to weld the high strength structural steel rail tank cars hull section. You have this additional information: P-GMAW HYPERFILLⓇ Productivity gains are important, and the volume of the product is sufficient on the rail tank cars to justify capital investment. With confidence, you respond: Use Productivity is substantially lower. However, you have welders already qualified to do manual p-GMAW welding. Labor is 80% of total cost process because (Give process and short explanation for why you want to use that process)

Your boss requests a recommendation on which process to use to weld the high strength structural steel rail tank cars hull section. You have this additional information: P-GMAW HYPERFILLⓇ Productivity gains are important, and the volume of the product is sufficient on the rail tank cars to justify capital investment. With confidence, you respond: Use Productivity is substantially lower. However, you have welders already qualified to do manual p-GMAW welding. Labor is 80% of total cost process because (Give process and short explanation for why you want to use that process)

Welding: Principles and Applications (MindTap Course List)

8th Edition

ISBN:9781305494695

Author:Larry Jeffus

Publisher:Larry Jeffus

Chapter10: Gas Metal Arc Welding Equipment, Setup, And Operation

Section: Chapter Questions

Problem 4R: In short-circuiting transfer, what type of current alloys the liquid metal at the electrode tip to...

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It has been reported that gas–tungsten arc welds of aluminum made in the overhead position (assumed lap weld joint) tend to have a significantly higher porosity level than those made in the flat position: Explain why Sketch the general view of the overhead position Indicate where the (most probable) location of the porosity
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.
Two 1.2 mm thick sheets of steel are joined by double-sided spot welding using a current of 6000A and current flow time of t = 0.15 sec. The electrodes are 3 mm in diameter and the weld spot thickness is approximately one third of the total thickness of the metal sheets. Assuming that the effective resistance in this operation is 200 micro resistance, estimate the heat generated and its distribution in the weld zone. (Take density of steel = 8600 Kg/m3 and its latent heat capacity, L =1400 J/g)
A welding operation on an aluminum alloy makes a groove weld. The cross-sectional area of the weld is 30.0 mm2. The welding velocity is 4.0 mm/sec. The heat transfer factor is 0.92 and the melting factor is 0.48. The melting temperature of the aluminum alloy is 650°C. Determine the rate of heat generation required at the welding source to accomplish this weld.
Assume 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 Joules
Calculate the heat input of welded Truss if the welding current is 215 amperages, its arc voltage is 21 volts, and 15cm/min. of welding travel speed usage.
During arc welding, the heat input per unit length reduces, with increase of
2. A flexible, round, plain-opening pipe removes welding fumes. The pipe is 8 in. in diameter and is positioned so the pipe face is 8 in. from the welding operation. Assume the capture velocity produced is 200 ft/min at the point of welding. (a) What is the flow rate in the pipe? (b) Estimate the velocity at the face of the pipe.
Calculate the heat input during the arc welding process, if the voltage is 33 volts, current is 115 amperes, the length of the weld is 88mm and the time to complete the weld 34 secs.
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.
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
What is staircase effect? A welding operation on an aluminum alloy makes a groove weld.The cross-sectional area of the weld is 30.0 mm2. The welding velocity is 4.0 mm/sec. Theheat transfer factor is [0.92+{AAA/(20+YY)}] and the melting factor is [0.48+{AAA/(20+YY)}], where AAA are the last three digits and YY are the first two digits of yourstudent ID. The melting temperature of the aluminum alloy is 667°C. Determine the rate ofheat generation required at the welding source.