Question 1

Friction welding is process.&#10;A)costly&#10;B)cost saving&#10;C)time consuming&#10;D)highly material selective

Accepted Answer

Friction welding is considered a cost-saving process because it can join materials quickly and efficiently without the need for filler materials, fluxes, or gases, leading to lower overall production costs.

Question 2

Friction welding produces quality joints, with a 100% weld.&#10;A)lap joint&#10;B)tee-joint&#10;C)butt joint&#10;D)edge joint

Accepted Answer

Friction welding is most commonly used to create butt joints, where the ends of two pieces are joined together by the heat generated through friction. This process is effective in producing strong, high-quality welds that can be considered 100% welded due to the material continuity across the joint.

Question 3

Which of the following is not true about friction welding?&#10;A)dissimilar metals cannot be joined&#10;B)this technique is relatively faster as compared to the other techniques&#10;C)this technique is suitable for any parts of shape or size&#10;D)sheared surfaces can also be joined by the process

Accepted Answer

Friction welding can join dissimilar metals, which makes choice A incorrect. This process is known for its ability to join a wide range of materials, including those that are difficult to weld by conventional methods.

Question 4

Which of the following holds true for friction welding?&#10;A)hazardous fumes are generated during the process&#10;B)argon is used as a shielding gas&#10;C)it is a power consuming process&#10;D)there are no solidification defects in the welded parts

Accepted Answer

Friction welding generates heat through mechanical friction between workpieces in relative motion to one another, followed by the application of force, facilitating a solid-state weld. This process does not involve melting the materials or using fillers that could introduce defects such as porosity or cracks typically associated with solidification in conventional welding methods. Hence, it results in joints free from solidification defects.

Question 5

In inertia friction welding energy of welding machine is used.&#10;A)electrical&#10;B)potential&#10;C)rotational&#10;D)frictional

Accepted Answer

In inertia friction welding, the energy used is primarily rotational energy, which is converted into heat through friction to join materials.

Question 6

Weld strength in inertia friction welding is more than direct drive friction welding.

Accepted Answer

Inertia friction welding typically results in higher weld strength due to the controlled application of stored kinetic energy, allowing for better heat distribution and material bonding compared to direct drive friction welding.

Question 7

In direct drive friction welding, lower weld forces are generated.

Accepted Answer

In direct drive friction welding, the weld force is generated by the direct application of force to the rotating workpiece. This results in lower weld forces compared to indirect drive friction welding, where the weld force is generated by a separate mechanism.

Question 8

Which of the following defects occur due to flux employed and electrode coating?&#10;A)inclusion of slag&#10;B)inadequate penetration&#10;C)incomplete fusion&#10;D)porosity

Accepted Answer

Inclusion of slag is a defect that occurs due to the flux employed and electrode coating, as slag is a byproduct of the welding process that can become trapped in the weld if not properly removed.

Question 9

Which of the following defects occur when the deposited metal is not focused on the root of weld?&#10;A)inclusion of slag&#10;B)inadequate penetration&#10;C)incomplete fusion&#10;D)porosity

Accepted Answer

Inadequate penetration occurs when the deposited metal does not reach the root of the weld, leading to a lack of fusion at the joint's base.

Question 10

Which of the following defects occur due to the entrapment of gas bubbles by the freezing dendrites during the cooling of molten pad?&#10;A)inclusion of slag&#10;B)inadequate penetration&#10;C)incomplete fusion&#10;D)porosity

Accepted Answer

Porosity in castings or welds occurs due to the entrapment of gas bubbles by the freezing dendrites during the cooling of the molten pad. This results in small cavities or pores within the material, which can weaken the structure and affect its integrity.

Question 11

Which of the following defects occur due to filler material having a different rate of contraction compared to parent metal?&#10;A)undercut&#10;B)spatter&#10;C)cracking in weld metal&#10;D)cold cracking

Accepted Answer

The answer of Which of the following defects occur due...

Question 12

Which of the following defects occur due to scattering of metal around the vicinity of weld?&#10;A)undercut&#10;B)spatter&#10;C)cracking in weld metal&#10;D)cold cracking

Accepted Answer

The answer of Which of the following defects occur due...

Question 13

Which of the following defects occur due to incorrect welding techniques?&#10;A)undercut&#10;B)hot cracking&#10;C)cracking in weld metal&#10;D)cold cracking

Accepted Answer

The answer of Which of the following defects occur due...

Question 14

Which of the following defects occur at a lower temperature?&#10;A)undercut&#10;B)hot cracking&#10;C)cracking in weld metal&#10;D)cold cracking

Accepted Answer

The answer of Which of the following defects occur at...

Question 15

Precision forging is a type of forging operation in which the metal stocks and dies are controlled very tightly.

Accepted Answer

The answer of Precision forging is a type of forging...

Question 16

In open die forging process, homogenous deformation of billet has occurred with uniform increase in its diameter.

Accepted Answer

The answer of In open die forging process, homogenous deformation...

Question 17

Isothermal forging is also known as cold forging operation.

Accepted Answer

The answer of Isothermal forging is also known as cold...

Question 18

The metal forging operation can be performed manually or by automation.

Accepted Answer

The answer of The metal forging operation can be performed...

Question 19

During roll forming, a flat strip is passed number of times through the rollers.

Accepted Answer

The answer of During roll forming, a flat strip is...

Question 20

Which of following is necessary in order to have a good set of rolls?&#10;A)short horizontal distances&#10;B)small lead-in flanges&#10;C)a smooth flow of material&#10;D)less number of forming passes

Accepted Answer

The answer of Which of following is necessary in order...

Question 21

Which of the following is true in case of &#34;too quick&#34; forming (too few passes)?&#10;A)it makes the tooling and the process uneconomical&#10;B)it makes process easier&#10;C)it distorts the product&#10;D)eliminate the need of a skilled operator

Accepted Answer

The answer of Which of the following is true in...

Question 22

What is &#34;leg length&#34; or &#34;leg height&#34;?&#10;A)the maximum vertical dimension of the profile&#10;B)total length of the product&#10;C)excess length of the product&#10;D)maximum width of the section

Accepted Answer

The answer of What is &#34;leg length&#34; or &#34;leg height&#34;?&#10;A)the...

Question 23

What will be the elongation if a 1in high section is formed in four passes in a mill having a horizontal distance (between passes) of 14in?&#10;A)0.04%&#10;B)0.16%&#10;C)0.63%&#10;D)0.50%

Accepted Answer

The answer of What will be the elongation if a...

Question 24

During roll forming, the strain (elongation) of the outside edge fiber of the strip must remain below the uniform engineering strain (elastic limit).

Accepted Answer

The answer of During roll forming, the strain (elongation) of...

Question 25

What is camber in roll forming?&#10;A)deviation of the strip edge from a straight line in horizontal plane&#10;B)deviation of the strip edge from a straight line in vertical plane&#10;C)difference in theoretical and actual elongation of the strip&#10;D)waviness of the strip

Accepted Answer

The answer of What is camber in roll forming?&#10;A)deviation of...

Deck 6: Friction Welding, Defects, and Metal Forging Operations