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

Question 1

Friction welding is process.

A)costly
B)cost saving
C)time consuming
D)highly material selective

Answer 1

cost saving

Question 2

Friction welding produces quality joints, with a 100% weld.

A)lap joint
B)tee-joint
C)butt joint
D)edge joint

Answer 2

butt joint

Question 3

Which of the following is not true about friction welding?

A)dissimilar metals cannot be joined
B)this technique is relatively faster as compared to the other techniques
C)this technique is suitable for any parts of shape or size
D)sheared surfaces can also be joined by the process

Answer 3

dissimilar metals cannot be joined

Question 4

Which of the following holds true for friction welding?

A)hazardous fumes are generated during the process
B)argon is used as a shielding gas
C)it is a power consuming process
D)there are no solidification defects in the welded parts

Question 5

In inertia friction welding energy of welding machine is used.

A)electrical
B)potential
C)rotational
D)frictional

Question 6

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

Question 7

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

Question 8

Which of the following defects occur due to flux employed and electrode coating?

A)inclusion of slag
B)inadequate penetration
C)incomplete fusion
D)porosity

Question 9

Which of the following defects occur when the deposited metal is not focused on the root of weld?

A)inclusion of slag
B)inadequate penetration
C)incomplete fusion
D)porosity

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?

A)inclusion of slag
B)inadequate penetration
C)incomplete fusion
D)porosity

Question 11

Which of the following defects occur due to filler material having a different rate of contraction compared to parent metal?

A)undercut
B)spatter
C)cracking in weld metal
D)cold cracking

Question 12

Which of the following defects occur due to scattering of metal around the vicinity of weld?

A)undercut
B)spatter
C)cracking in weld metal
D)cold cracking

Question 13

Which of the following defects occur due to incorrect welding techniques?

A)undercut
B)hot cracking
C)cracking in weld metal
D)cold cracking

Question 14

Which of the following defects occur at a lower temperature?

A)undercut
B)hot cracking
C)cracking in weld metal
D)cold cracking

Question 15

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

Question 16

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

Question 17

Isothermal forging is also known as cold forging operation.

Question 18

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

Question 19

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

Question 20

Which of following is necessary in order to have a good set of rolls?

A)short horizontal distances
B)small lead-in flanges
C)a smooth flow of material
D)less number of forming passes

Question 21

Which of the following is true in case of "too quick" forming (too few passes)?

A)it makes the tooling and the process uneconomical
B)it makes process easier
C)it distorts the product
D)eliminate the need of a skilled operator

Question 22

What is "leg length" or "leg height"?

A)the maximum vertical dimension of the profile
B)total length of the product
C)excess length of the product
D)maximum width of the section

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?

A)0.04%
B)0.16%
C)0.63%
D)0.50%

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).

Question 25

What is camber in roll forming?

A)deviation of the strip edge from a straight line in horizontal plane
B)deviation of the strip edge from a straight line in vertical plane
C)difference in theoretical and actual elongation of the strip
D)waviness of the strip