Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133128741
Author: Serope Kalpakjian, Steven Schmid
Publisher: Prentice Hall
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Textbook Question
Chapter 30, Problem 52SDP
Arc blow is a phenomenon where the magnetic field induced by the welding current, passing through the electrode and workpiece in shielded metal arc welding, interacts with the arc and causes severe weld splatter. Identify the variables that you think are important in arc blow. When arc blow is a problem, would you recommend minimizing it by using AC or DC power?
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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?
Btu
(b) How much heat must be generated at the welding source, if the heat transfer factor = 90% and the melting factor = 60%?
H=
Btu
2.8 Advantages of Submerged Arc Welding
Cost per unit length of joint is relatively low
The arc is under a blanket of flux, which virtually eliminates arc flash, spatter,
and fume.
• Extremely high deposition rates and welding speeds are possible.
• Sound welds are readily made (with good process design and control).
High current densities increase weld penetration and decrease the need for
edge preparation.
High speed welding of thin sheet steels at over 2.5 m/min is possible.
Can be easily Automated
Minimum welder training is required (relatively unskilled welders can be
employed).
• Low hydrogen weld deposits can be produced.
• The flux acts as a scavenger and deoxidizer to remove contaminants such as
oxygen, nitrogen, and sulphur from the molten weld pool. This helps to
produce sound welds with excellent mechanical properties.
26
2.9 Limitations of Submerged Arc Welding
Initial cost of wire feeder, power supply, controls, and flux-handling
equipment is high.
Limited to ferrous…
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?
Chapter 30 Solutions
Manufacturing Engineering & Technology
Ch. 30 - Describe fusion as it relates to welding...Ch. 30 - Explain the features of neutralizing, reducing,...Ch. 30 - What is stick welding?Ch. 30 - Explain the basic principles of arc-welding...Ch. 30 - Why is shielded metal-arc welding a commonly...Ch. 30 - What keeps the weld bead on a steel surface...Ch. 30 - Describe the functions and characteristics of...Ch. 30 - What are the similarities and differences between...Ch. 30 - What properties are useful for a shielding gas?Ch. 30 - What are the advantages to thermit welding?
Ch. 30 - Explain where the energy is obtained in...Ch. 30 - Explain how cutting takes place when an...Ch. 30 - What is the purpose of flux? Why is it not needed...Ch. 30 - What is meant by weld quality? Discuss the...Ch. 30 - How is weldability defined?Ch. 30 - Why are welding electrodes generally coated?Ch. 30 - Describe the common types of discontinuities...Ch. 30 - Prob. 18RQCh. 30 - Explain why hydrogen welding can be used to...Ch. 30 - Prob. 20RQCh. 30 - Prob. 21QLPCh. 30 - It has been noted that heat transfer in gas-metal...Ch. 30 - Explain why some joints may have to be...Ch. 30 - Describe the role of filler metals in welding.Ch. 30 - List the processes that can be performed with...Ch. 30 - What is the effect of the thermal conductivity of...Ch. 30 - Describe the differences between oxyfuel-gas...Ch. 30 - Could you use oxyfuel-gas cutting for a stack of...Ch. 30 - What are the advantages of electron-beam and...Ch. 30 - Describe the methods by which discontinuities...Ch. 30 - Explain the significance of the stiffness of the...Ch. 30 - Prob. 32QLPCh. 30 - Which of the processes described in this chapter...Ch. 30 - Prob. 34QLPCh. 30 - Prob. 35QLPCh. 30 - Comment on the factors involved in electrode...Ch. 30 - Prob. 38QLPCh. 30 - Prob. 39QLPCh. 30 - Prob. 40QLPCh. 30 - Prob. 41QLPCh. 30 - What is weld spatter? What are its sources? How...Ch. 30 - Describe your observations concerning Fig. 30.20.Ch. 30 - Prob. 44QLPCh. 30 - Plot the hardness in Fig. 30.20d as a function of...Ch. 30 - A welding operation will take place on carbon...Ch. 30 - In Fig. 30.26b, assume that most of the top...Ch. 30 - A welding operation takes place on an...Ch. 30 - An arc welding operation is taking place on carbon...Ch. 30 - Comment on workpiece size and shape limitations...Ch. 30 - Arc blow is a phenomenon where the magnetic...Ch. 30 - Review the types of welded joints shown in Fig....Ch. 30 - Comment on the design guidelines given in...Ch. 30 - Prob. 55SDPCh. 30 - Prob. 56SDPCh. 30 - Make a list of welding processes that are suitable...Ch. 30 - Prob. 58SDPCh. 30 - Prob. 59SDPCh. 30 - Review the poor and good joint designs shown...Ch. 30 - In building large ships, there is a need to weld...Ch. 30 - Prob. 62SDPCh. 30 - Comment on whether there are common factors...Ch. 30 - Prob. 64SDPCh. 30 - Lattice booms for cranes are constructed from...Ch. 30 - A common practice in repairing expensive broken...
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