Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133128741
Author: Serope Kalpakjian, Steven Schmid
Publisher: Prentice Hall
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Chapter 32, Problem 45SDP
To determine
Obtain a soldering iron and attempt to solder two wires together. First, try to apply the solder at the same time as you first put the soldering iron tip to the wires. Second, preheat the wires before applying the solder. Repeat the same procedure for a cool surface and a heated surface. Record your results and explain your findings.
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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
A resistance spot-welding operation is
performed on two pieces of 1.5 mm thick
sheet steel using 12000 amps current for a
duration of 0.20 second. The electrodes are
6 mm in diameter at the contacting surfaces.
Resistance is assumed to be 0.0001 ohms
and the resulting weld nugget is 6 mm in
diameter and 2.5 mm thick. The unit melting
energy for the metal is 12 Jmm³. What portion
of heat generated was used to form the weld?
An RSW operation is used to join two pieces of sheet steel having a unit melting energy of 8369.85 J/cm3. The sheet steel has a thickness of 0.3125 cm. The weld duration will be set at 0.25 sec with a current of 11,000 amp. Based on the electrode diameter, the weld nugget will have a diameter of 0.75 cm. Experience has shown that 40% of the supplied heat melts the nugget and the rest is dissipated by the metal. If the electrical resistance between the surfaces is 130 micro-ohms, what is the thickness of the weld nugget assuming it has a uniform thickness?
Chapter 32 Solutions
Manufacturing Engineering & Technology
Ch. 32 - What is the difference between brazing and...Ch. 32 - Are fluxes necessary in brazing? If so, why?Ch. 32 - Why is surface preparation important in...Ch. 32 - What materials are typically used in solder?Ch. 32 - Soldering is generally applied to thinner...Ch. 32 - Explain the reasons why a variety of mechanical...Ch. 32 - List three brazing and three soldering techniques.Ch. 32 - Describe the similarities and differences between...Ch. 32 - What precautions should be taken in the...Ch. 32 - What difficulties are involved in joining...
Ch. 32 - Prob. 11RQCh. 32 - What are the principles of (a) wave soldering...Ch. 32 - What is a peel test? Why is it useful?Ch. 32 - What is a combination joint?Ch. 32 - Prob. 15RQCh. 32 - Prob. 16QLPCh. 32 - Prob. 17QLPCh. 32 - Comment on your observations concerning the...Ch. 32 - Give examples of combination joints other than...Ch. 32 - Discuss the need for fixtures for holding...Ch. 32 - Explain why adhesively bonded joints tend to be...Ch. 32 - It is common practice to tin-plate electrical...Ch. 32 - Give three applications where adhesive-bonding is...Ch. 32 - Prob. 24QLPCh. 32 - If you are designing a joint that must be strong...Ch. 32 - Prob. 26QLPCh. 32 - Rate lap, butt, and scarf joints in terms of...Ch. 32 - Prob. 28QLPCh. 32 - Prob. 29QTPCh. 32 - Prob. 30QTPCh. 32 - Prob. 31QTPCh. 32 - Figure 32.4 shows qualitatively the tensile and...Ch. 32 - When manufacturing the fuselage of a commuter...Ch. 32 - Prob. 34SDPCh. 32 - Name several products that have been assembled...Ch. 32 - Suggest methods of attaching a round bar (made of...Ch. 32 - Prob. 38SDPCh. 32 - Prob. 39SDPCh. 32 - Prob. 40SDPCh. 32 - Prob. 41SDPCh. 32 - Describe part shapes that cannot be joined by...Ch. 32 - Prob. 43SDPCh. 32 - Prob. 44SDPCh. 32 - Prob. 45SDPCh. 32 - Prob. 46SDPCh. 32 - Review Fig. 32.9a and explain the shortcoming...
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- How do most manufacturers classify or group hard-facing or wear-resistant electrodes?arrow_forwardA 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.arrow_forwardA 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 sourcearrow_forward
- Two 1.2 mm thick flat copper sheets are being spot welded using a current of 6000 A and a current flow time of 0.18 s. The electrodes are 5 mm in diameter. Estimate the heat generated in the weld zone. Take effective resistance as 150 µΩ. Also calculate temperature rise assuming that the heat generated is confined to the volume of material directly between the two electrodes and temperature is uniformly distributed.arrow_forwardQUESTION 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= Btuarrow_forwardA gas metal arc welding test is performed to determine the value of melting factor f₂ for a certain metal and operation. The welding voltage = 25 volts, current = 125 amps, and heat transfer factor is assumed to be = 0.90, a typical value for GMAW. The rate at which the filler metal is added to the weld is 0.50 in³ per minute, and measurements indicate that the final weld bead consists of 57% filler metal and 43% base metal. The unit melting energy for the metal is known to be 75 Btu/in³. (a) Find the melting factor. (b) What is the travel speed if the cross-sectional area of the weld bead = 0.05 in²?arrow_forward
- A welding operation is time-studied during which an operator was pace-rated as 120%. The operator took, on an average, 8 minutes for producing the weld-joint. If a total of 10% allowances are allowed for this operation. What is the expected standard production rate of the weld-joint in units per 8 hour day?arrow_forwardTwo 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.arrow_forwardGive information about the reasons why the weld is preferred over other fastening methods.arrow_forward
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