ASSIGNMENT / TEST – SLOVED

:-METAL JOINING PROCESSES-:

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1. Which one of the following methods of welding is a “welding with pressure”

method?

(a) Resistance welding (b) Arc welding (c) Gas welding (d) Thermit (fusion) welding

2. Which one of the following methods of welding is a “Fusion Welding “method?

(a)Forge welding (b) Stud Welding (c) Arc welding (d) Resistance welding

3. Which one of the following is a temporary joint?

(a)Welded joint (b) Riveted joint (c) Soldered joint (d) Press fit joint

4. A round metal bar screwed at both ends or fully screwed is called

(a) Cotter (b) collar (c) Stud (d) Circlip

5. It is a small headless screw having a slot cut for a screwdriver or a socket for a
hexagon key and used to secure a sliding component in a determined position.
What is it?

(a)Set screw (b) Grub screw (c) Phillips screw (d) Button screw

6. It is a screw is used to prevent relative motion between two rotating parts, such
as the movement of pulley on a shaft. It is called

(a) Grub screw (b) Pan screw (c) Set screw (d) Phillips screw

7. The end opposite to the head of a rivet is called

(a) Tail (b) Shank (c) Backup (d) Rear

8. The clearance is taken into consideration while riveting because by pressing
application the diameter of the rivet is somewhat increased. If diameter of rivet is
12 to 24mm, the clearance is

(a) 0.5mm (b)1.5mm (c) 2.5mm (d)3.5mm

9. The most commonly used type of rivet head is

(a)Snap Head (b) countersunk head (c) conical head (d) Flat Head

10. When the surface of the plate, in which the rivet is to be inserted, is required
to be free from projecting head of the rivet, the type of rivet head used is

(a)Snap head (b) Flat head (c) conical head (d) countersunk head

OCCUPATIONAL SAFETY AND HEALTH

1. If a worker has suffered from electric shock, he should be

(a) Given an alcoholic drink

(b) Given a cold drink

(c) Made a walk

(d) Kept warm and covered

2. Which of the following is not an insulator?

(a) Gold (b) Glass

(c) Mica (d) Wood

3. Which of the following is not a conductor?

(a) Copper (b) Aluminum

(c) Mica (d) Gold

4. During oveheadarc arc welding it is more convenient to use

(a) Welding goggles (b) helmet

(c) Hand screen (d) sun glasses

5. The safety device used to protect eyes while grinding is

(a) Hand screen (b) helmet

(c) Chipping goggles (d) chipping screen

6. There are three pre-requisites for any fire or explosion to take place. Which one
of the following is not included in the three pre-requisites?

(a) Fuel (b) Oxygen

(c) Nitrogen (d) Ignition

7. Which type of fire extinguisher is used in a welding shop?

(a) Foam type extinguisher

(b) Dry powder extinguisher

(c) CO2 extinguisher

(d) Halon extinguisher

8. The type of radiation which penetrates the interior of the eyes and can cause
burns on the retina is

(a) Infrared (b) Ultraviolet

(c) Visible light (d) none of the above

ARC WELDING
1. Which of the following substance is not an insulator?

(A) Ceramic (b) Rubber (c) Plastic (d) Copper

2. The stub end of an electrode should normally be not more than

(a)5% of the electrode (b) 10% of the electrode (c)15% of the electrode (d)20% of
the electrode

3. The distance between the tip of the electrode and the parent metal where the
arc strikes is called

(a)Arc gap (b) Arc length (c) Arc distance (d) Arc width

4. The arc utilized in electric arc welding is a

(a)High voltage, high current discharge (b) low voltage, low current discharge

(c) Low voltage, high current discharge (d) High voltage, low current discharge

5. As the arc length increase, the operating voltage will

(a) Increase (b) decrease (c) Remain the same (d) May increase or Decrease

6. An Arc cannot be maintained with a voltage lower than

(a) 14 volts (b) 24 volts (c) 34 volts (d) 44 volts

7. In arc welding the source of heat is

(a) Current (b) arc voltage (c) electricity (d) Weld transformer

8. Which one of the following is not true out air-cooled transformer?

(a) Light weight (b) less expensive (c) Uses more electricity (d) uses less electricity

9. The term used to indicate amount of current flow in a circuit is called

(a) Volt (b) Ampere (c) Ohm (d) Farad

10. When the current flowing through a given resistance increase, the voltage will

(a)Increase (b) Decrease (c) Remain the same (d) Increase initially and then
decrease

11. Which one of the following is the type of transformer used in arc welding?

(a)Step down (b) Step up (C) One- to-one (d) Capable of increasing supply voltage

12. Earth clamp is used in arc welding to

(a)Hold the electrode firmly during welding (b) Connect the earthing cable to
electrode

(c) Connect the earthing cable to workpiece (d) Conduct the current from earthing
cable to electrode

13. The deposited filler metal on and in the work surface when the wire or
electrode is melted and fused into the steel is called

(a) Base metal (b) bead (c) Run-off (d) Toe

14. A line from the welding machine that carries the current is called

(a) Path (b) stream (c) lead (d) Axis

15. A weld made to hold parts of a weldment in proper alignment unit the final
welds are made is called

(a) Tag weld (b) Toe weld (c) Tie weld (d) Tack weld

16. A device designed for checking the shape and size of weld id called

(a) Weld dial (b) Weld gauge (c) Weld indicator (d) Weld Template

17. A device in a welding machine for converting alternating current to direct

current is called

(a) Rectifier (b) Converter (c) Amplifier (d) Corrector

18. In arc welding, the metal particles expelled during welding and which do not
form a part of the weld are called

(a) Splinter (b) Spade (c) Spam (d) Spatter

ARC WELDING EQUIPMENT

1. An electrode -holder is a device use to grip and manipulate the electrode

during welding. What is it made of?

(a) Mil steel (b) Copper / Copper alloy (c) Plastic (d) Brass

2. An Earth Clamp is used to connect the earth cable firmly to the job or welding
table. What is it made of?

(a) Mil steel (b) Copper / Copper alloy (c) Plastic (d) Brass

3. A welding transformer may be

(a) Air-cooled or water cooled (b) water cooled or oil cooled (c) air cooled or oil
cooled (d) air cooled, water cooled or oil cooled

4. Which one among the following does not relate to advantages of using welding
transformer?

(a) Less initial cost (b) Less maintenance cost (c) Freedom for arc blow (d) Suitable
for welding of non-ferrous metal

5. The welding machine, which is used to convert AC welding supply to DC

welding supply is

(a) Motor generator set (b) Engine generator set (c) rectifier set (d) welding
transformer
6. In DC welding heat distribution is possible between electrode and the base
metal due to the change of polarity. The distribution of heat is

(a) Positive 2/3 and Negative 1/3 (b) Positive 1/3 and Negative 2/3 (c) Positive 3/4
and Negative1/4 (d) Positive 1/4 and Negative ¾

7. In DC welding, straghit polarity is recommended for

(a) Welding with light coated electrode (b) Welding with heavy coated electrode
(c) welding with supper heavy coated electrode (d) Sheet metal welding

8. The Voltage drop across an arc depends upon

(a) Arc length and atmosphere in which it is operating (b)Arc length and base
metal (c) Base metal and atmosphere in which arc is operating (d) Base metal, arc
length and atmosphere in which it is operating

9. Some welding machine are provided with a special device, which gives extra
current for a few seconds at the start of the arc in order to give deeper
penetration at the beginning of the weld. This device is called

(a) Arc stricker (b) Arc helper (c) Arc booster (d) Arc developer

10. Welding transformer are equipped with condensers so as to improve

(a) Power factor (b) Energy factor (c) Voltage factor (d) Current factor

11. The size of a welding machine is determined by

(a) Input amperage (b) Output amperage (c) Open circuit voltage (d) Closed circuit
voltage

12. As compared to an air cooled welding machine, an oil cooled welding machine
has

(a) Higher duty cycle (b) Low duty cycle (c) same duty cycle (d) Nearly same duty
cycle
13. To get DC for welding, it is necessary to have either

(a) Transformer or motor generator set (b) Rectifier or transformer set (c)
Rectifier or motor generator set (d) Capacitor or Reactor set

14. Welding is used in welding to supply

(a) Less welding current (b) Less welding voltage (c) More welding Voltage and
more welding current (d) Less welding voltage and more welding current

15. If the main electric supply is not available, arc welding can be done with

(a) Motor generator set (b) Transformer set (c) Engine generator set (d) Rectifier
set

16. In straight polarity

(a) Electrode is connected to positive side (b) The current change its direction a
number of times per second (C) The base metal is connected to positive side (d)
1/3rd amount of heat is generated in the base metal

17. The indication of wrong polarity in DC welding will result in

(a) The electrode will become red hot (b) Excess spatter and poor penetration (c)
The electrode will freeze with the job (d) It will produce edge plates melted off

18. Which is the correct method to remove the chips from the file?

(a) Blow away the chips (b) Brush the chips away (c) Flush the chips with water (d)
Flush the chips with coolant

19. Which one of the following firm joint caliper is used to make straight line mark
on base plate parallel to a plate edge as shown in fig.

(a) Divider (b) Inside caliper (c) Outside caliper (d) Odd leg caliper
ARC WELDING PROCEDURE

1. In general, fillet welds should be ……… the thickness of the metal plate.

(a) 1/3 (b) ½ (c) 2/3 (d) ¾

2. A depression formed at the end of the weld is called

(a) Pinhole (b) Blowhole (c) Crater (d) Crack

3. A small weld deposited on the root side of a butt or corner joint (after
completion off the weld joint) is called

(a) Sealing run (b) Backing run (c) Root run (d) Fusion run

4. Small metal particles which are thrown out of the arc during welding alone with
the weld are called

(a) Porosity (b) spatter (c) Overlap (d) Undercut

5. It is suitable to weld medium carbon steel with

(a) AC only (b) AC or DC (c) DCEN (d) DCEP

6. It is suitable to weld low carbon steel with

(a) AC only (b) AC or DC (c) DCEN (d) DCEP

7. It is suitable to weld high carbon steel with

(a) AC only (b) AC or DC (c) DCEN (d) DCEP

8. It is a joint between members lying in the same plane? What is this joint called?

(a) Butt joint (b) lap joint (c) Tee joint (d) Edge joint
9. It is the metal on the face of the weld, which is higher than the surrounding
metal. It is called

(a) Weld bead (b) Throat thickness (c) Reinforcement (d) Leg length

10. The position in which it is easiest to weld is

(a) Flat (b) Vertical (c) Horizontal (d) Overhead

11. Heat –effected zone is that portion of the metal which

(a) Melts and becomes plastic (b) Neither melts nor becomes plastic (c) melts but
does not becomes plastic (d) does not melt but becomes plastic

12. The semi-circular deposit on the weld bead is called

(a) Reinforcement (b) Crater (c) Sealing run (d) Undercut

13. The most likely reason for porosity to be caused is due to

(a) Incorrect electrode manipulation (b) Too less current (c) Too high current (d)
Damp electrodes

14. The weld position of a weld bead is define by two parameters namely

(a) Weld slope and weld angle (b) Weld angle and weld rotation (c)Weld slope and
rotation (d) Weld slope and weld cut

15. Arc blow is caused by

(a) Magnetic disturbance (b) Electrical Disturbance (c) Electronic Disturbance (d)
Radio disturbance

16. Arc blow especially noticeable when welding with

(a) Bare electrode (b) Coated electrode (c) Heavily coated electrodes (d) Low
hydrogen electrode
17. A material place at the root of weld to contain or support the molten metal is
called

(a) Sealing (b) Backing (c) Weaving (d) Facing

18. The little hole produced at the leading edge of0 the crater right under the tip
of electrode is called

(a) Blow hole (b) key hole (c) pin hole (d) root gap

19. The easy position to weld is

(a) Flat (b) vertical (c) horizontal-vertical (d) overhead

20. The depth of fusion form the surface of the weld metal is known as

(a) Fusion zone (d) heat-affected (c) penetration (d) leg length

21. The angle of electrode in welding lap joint in flat position is

(a) 80 angle to the fine of welding and 45 to each surface

(b) 60 between the weld face (c) same as butt joint

(d) Perpendicular to the plate surface

22in lap fillet joint the overlap may be left

(a) Same as thickness of plate to be weld

(b) Half the thickness of plate to be joined

(c) 2 to 3 times of plate thickness

(d) Half the width of the plate

23. The effect of arc blow will be totally absent in

(a) D C Straight polarity (b) DC reverse polarity (c) AC welding (d) Welding with
long arc
24. The root opening in square butt welding is given

(a) To keep the job in alignment (b) to control the distortion (c) To obtain
penetration (d) To maintain correct dimension

25. Lake of the penetration is due to

(a) High current (b) Low current (c) Short arc length (d) too slow welding speed

26. The edge of the plate melted off is very common mostly in

(a) Lap and corner joints (b) only in arc welding (c) Too much root gap (d) Too high
current

27. A hair line separation in root or middle or surface of the weld metal or base
metal is mainly due to

(a) Slow cooling (b) Larger dia. Electrode (c) Long arc length (d) Lack of preheating
and post heating

28. Which one of the following is the easiest position in welding?

(a) Vertical (b) Overhead (c) Horizontal –vertical (d) Flat or down hand
ELECTRODES
1. There are two methods by which flux coating is applied on the electrode core
wire. These are

(a) Dipping and sucking (b) sucking and blowing (c) Dipping and extrusion (d)
blowing and extrusion

2. The electrode size refers to

(a) Diameter of its core wire (b) Diameter (overall) of electrode (c) Thickness of
flux coating (d) Length of electrode

3. Contact electrode have in their coatings at large amount of

(a) Carbon (b) manganese (c) Silicon (d) iron

4. The last bit of electrode which is discarded is called

(a) Dead end (b) Stub end (c) Red end (d) Waste end

5. Which one of the following statement is true?

(a) Heavy coated electrode are easy to use in vertical and overhead position

(b) Flux coating is good conductor of electricity

(c ) Slag produced by burning of flux should freeze quickly

(d) It is easier to strike an arc with bare electrodes than coated electrode

6. Which gas from the atmosphere must be prevented from entering the weld
pool?

(a) Oxygen and nitrogen (b) Oxygen and carbon dioxide (c) Oxygen and argon (d)
Nitrogen and argon
7. One of the functions of electrode coating is

(a) To increase welding current (b) To stabilize the arc (c) To prevent rusting (d) To
control arc temperature

8. Flux coating on electrode serves many functions. Which of the following is

normally not the function of the coating?

(a) To protect weld metal (b) To provide the required filler metal (c) To stabilize
the arc (d) To reduce spatter

9. Heavy coated electrode is normally suitable for

(a) Welding in flat position (b) Deep groove joint in vertical position (c) AC welding
(d) Thick plates in any position

10. This type of electrode will pick up moisture easily

(a) Acidic coated electrode (b) Rutile coated electrode (c) Basic coated electrode
(d) Titanium coated electrode

11. Always cellulosic materials will be used in this type of electrode flux coating.
These electrodes are

(a) Low hydrogen Electrode (b) Gouging electrode (c) Deep penetration electrode
(d) Stainless steel electrode

12. This type of electrode deposit a large amount of weld metal per unit time

(a) Low Hydrogen electrode (b) Iron powder electrode (c) Deep penetration
electrode (d) Heavy coated S.S electrode

13. The electrode are manufactured in two standard length namely

(a) 350 mm and 250 mm (b) 350 mm and 450 mm (c) 400 mm and 500 mm (d) 18”
and 10”

14. The electrode that are not coated area called

(a) Bare electrode (b) Raw electrode (c) Base electrode (d) Nude electrode
15. A.W.S code of electrode start with the letter E followed by 4-digit number.
What do the first 2 digit represent?

(a) Polarity (b) Welding position (c) Type of flux coating (d) Tensile strength of
weld metal

16. A.W.S code of electrode start with the letter E followed by 4-digit number.
What do the first 4 digit represent?

(a) Polarity (b) Welding position (c) Type of flux coating (d) Tensile strength of
weld metal

17. What is the size of electrode suitable for welding 2.5 mm thick mild steel
sheet?

(a) Ø 1.6mm (b) Ø2.50 mm (c) Ø3.15mm (d) Ø 4.00mm

18. In coding of electrode, the digit 4 indicate

(a) All position except vertical down (b) Flat butt weld, flat fillet and
horizontal/vertical fillet weld (c) Flat butt weld and Flat fillet weld (d) Vertical
down, flat butt, flat fillet and horizontal and vertical fillet weld

19. In coding of electrode radiographic quality electrode is indicated by the letter

(a) A (b) X (c) Y (d) Z

OXY- ACETYLENE WELDING

1. In neutral oxy-acetylene flame oxygen and acetylene are mixed in the

proportion of

(a) 1: 1 (b) 1:2 (c) 1:3 (d) 1:4

2. Which one of following gas flame combination has the lowest temperature?

(a) Oxy-acetylene (b) Oxy-hydrogen (c) Oxy-coal gas (d) Oxy-liquid petroleum gas

3. Which one of the following is not a cause of backfire in oxy-acetylene blow

pipe?

(a) The gas pressure setting is high (b) The nozzle is overheated (c) The nozzle
orifice is blocked (d) There in leakage near the nozzle

4. For complete combustion one volume of acetylene require

(a) 1.5 volume of oxygen (b) 2.5 volume of oxygen (c) 3.5 volume of oxygen (d) 4.5
volume of oxygen

5. Calcium carbide is a chemical compound consisting of

(a) 63 % calcium and 37 % carbon (b) 37% calcium and 63% carbon

(c) 33% calcium and 67% carbon (d) 67% calcium and 33% carbon

6. What is not true about calcium carbide? It

(a) is brittle (b) absorbs moisture from atmosphere (C) Produces acetylene when
brought in contact with water (d) is soluble in kerosene oil

7. Acetylene is the product of chemical reaction between calcium carbide and

(a) Air (b) water (c) kerosene oil (d) lubricating oil
8. Which one of the following is not true about water to carbide acetylene
generator?

(a) It consume less water (b) pressure of gas is low (c) Any grade of calcium
carbide can be used (d) It has higher gas generator

9. A simple test to test whether acetylene is pure is to hold a filter paper soaked
in 10% silver nitrate solution against the stream of acetylene. If the gas Is impure
the filter paper changes into

(a) Black colour (b) blue colour (c) brown colour (d) red colour

10. The gas cylinder containing which one of the following gases will have left
hand valve threads?

(a) Oxygen (b) Nitrogen (c) Carbon dioxide (d) Acetylene

11. The maximum percentage of gas in air is that of

(a) Oxygen (b) Nitrogen (c) Carbon dioxide (d) Argon

12. Which material when bought in contact with water produces acetylene?

(a) Calcium chloride (b) calcium carbonate (c) Calcium carbide (d) Calcium oxide

13. For every kg of calcium carbide used, the amount of acetylene produced is
about

(a) 200 liters (b) 300 liters (c) 400 liters 500 liters

14. What two gases are formed when acetylene is completely burnt in oxygen?

(a) Carbon dioxide and carbon monoxide (b) Carbon dioxide and water vapour

(c) carbon dioxide and water vapour (d) Carbon dioxide and nitrogen dioxide

15. Which one of the following gases is a supporter of combustion?

(a) Oxygen (b) Acetylene (c) Nitrogen (d) Carbon dioxide

16. Acetylene is a chemical compound of

(a) Carbon and oxygen (b) Carbon and nitrogen (c) Carbon and hydrogen (d)
Carbon and calcium

17. At normal temperature and pressure, acetone can absorb how many times
own volume of acetylene?

(a) 5 times (b) 15 times (c) 25 times (d) 35 times

18. Which one of the following combinations of gases can produce a flame?

(a) Oxygen – acetylene (b) Oxygen –carbon dioxides (c) Oxygen – Nitrogen (d)
Oxygen – argon

19. Acetylene can be dissolved in

(a) Water (b) Acetone (c) Calcium hydroxide (d) kerosene

20. For removing the water vapour from the acetylene gas the material used is

(a) Filter wool (b) Steel wool (c) Pumic stone (d) Paper filters

21. Oil and grease can ignite violently when in contact with pressurized

(a) Carbon dioxide (b) Propane (c) oxygen (d) Hydrogen

22. When calcium carbide reacts with water, which gas is produced?

(a) Hydrogen (b) Propane (c) LPG (d) Acetylene

OXY-ACETYLENE WELDING EQUIPMENT

1. The correct colours for oxygen and acetylene hoses are

(a) Red for oxygen and blue for acetylene (b) Black for oxygen and red for
acetylene (c) Black for oxygen and maroon for acetylene (d) red for oxygen and
maroon for acetylene

2. A steel plates of 1.2 mm thickness is to be oxy-acetylene welded. The nozzle

size used to be

(a) 1 (b) 2 (c) 3 (d) 5

3. For gas welding and cutting, oxygen is store in cylinders under a maximum
pressure of

(a) 50 kg/cm2 (b) 100 kg/cm2 (c) 150 kg/cm2 (d) 200 kg/cm2

4. Tip of the welding blowpipe are made of

(a) Copper (b) Brass (c) Mild steel (d) Bronze

5. An oxy-acetylene cutting blowpipe of size 1.6mm is suitable for cutting plte

thickness of

(a) 3-6mm (b) 6-19mm (c) 19 -100mm (d) 100-150mm

6. Which one of the following is a good practice in care and maintenance of

regulators?

(a) Use oil in regulator connection (b) Fix the oxygen and acetylene regulators
close together (c) Wind the hose on the regulator (d) Use shop water to check
leakage in the regulator connection
7. In manifold system, what material the dissolved acetylene and oxygen pipes
are made of

(a) Copper pipe for DA and steel pipe for oxygen (b) Steel pipe for DA and copper
pipe for oxygen (c) Brass pipe for DA and steel pipe for oxygen (d) Steel pipe for
DA and brass pipe for oxygen

8. In oxy-acetylene welding, which one of the following does not require the use
of a flux?

(a) Aluminum (b) magnesium (c) Copper (d) Steel

9. The cylinder containing which one of the following gases is not painted red?

(a) Oxygen (b) Hydrogen (c) Coal gas (d) Liquid petroleum gas

10. DA stands for

(a) Diluted acetylene (b) Dissolved acetylene (c) Dye acetylene (d) Delayed
acetylene

11. The hourly rate of withdrawal of acetylene from the cylinder should not be
more than

(a) one half of the cylinder (b) one third of the cylinder (c) one fourth of the
cylinder (d) one fifth of the cylinder

12. In an acetylene cylinder, the acetylene is dissolved in

(a) Water (b) Carbon dioxide (c) Acetone (d) Mercury

13. Normally acetylene should be discharged from a cylinder at a rate which will
empty it in not less than

(a) 2 hours (b) 3 hours (c) 4 hours (d) 5 hours

14. On high pressure oxygen connections, oil or grease should not e used for the
following reason

(a) Spanner may slip (b) Explosion may be caused (c) Connection may e loose (d)
Connections may foul

15. Acetone is used for dissolving

(a) Oxygen (b) Hydrogen (c) Acetylene (d) Propane

16. The function of filler rod in gas welding is

(a) To increase the strength of the joint (b) to obtain proper size of weld and to
add additional elements (c) to increase the fluidity (d) to obtain good penetration

17. If oil, paint or grease and rust are not removed from the joining surface, the
weld will be

(a) Ductile (b) out of shape (c) weak and brittle (d) with less fluidity

18. The size and type of filler rod for gas welding 3 mm MS sheet is

(a) Ø 3mm MS rod (b) Ø 3mm copper coated mild steel rod (c) Ø 4 mm
manganese steel (d) CCMS rod of Ø 5mm

19. Glycerin is added to water filled in hydraulic back pressure valve in order to

(a) Prevent overheating (b) Freezing (c) cooling (d) remove salt content

20. When a hose protector is fitted and the valves are open, the gas flow

(a) From blow pipe to cylinder (b) from blow pipe to cylinder (c) both ways (d) will
not flow at all

21. Tip orifice should be cleaned with

(a) Soft copper wire (b) Steel wire (c) A small drill (d) tip cleaner

22. The main function of injector in L.P blow pipe is

(a) High pressure oxygen draws acetylene and increase the velocity (b)Decrease
the velocity of oxygen equal to acetylene velocity (c) to check the flow of oxygen
(d) Increase the velocity of oxygen

23. The nozzles are generally made of copper because

(a) Copper does not get rusted (b) Copper is cheaper (c) due to its fine threads it is
possible to get tight fitting (d) Copper has high melting point

24. The blow pipe fitted with injector will prevent

(a) Flash back (b) Reverse flow of acetylene gas (c) Flow of high pressure oxygen
(d) Defects

25. The choice of flux in gas welding depends upon

(a) Type of material to be jointed (b) Thickness of material (c) Welding position (d)
Type of fuel gas

26. The diameter of filler rod to e used in gas welding depends upon

(a) Type of material (b) Type of flame (c) thickness of plate to e welded (d) Ferrous
or non-ferrous

27. Flux reside in gas welding is requires to be removed

(a) To avoid oxidation (b) to get good appearance (c) To prevent corrosion (d) to
provide safety to the welder

28. The nozzle are generally made of copper because

(a) It will not get rusted (b) It is cheap (c) its melting point is high (d) It is possible
to make airtight fitting due to its fine threads

29. If more than one gas cylinder is connected in a system it is called

(a) Multiple system (b) manifold System (c) Series System (d) Grope system
30. in a low pressure blow pipe to avoid the danger of high pressure oxygen
entering into the acetylene pipeline

(a) A safety valve is used (b) A hose protector is used (c) A hydraulic back pressure
valve is used (d) an injector is used

31. Gas cylinder is painted with different colures for identification. Oxygen is
supplied in cylinders, which are painted

(a) Red (b) Blue (c) Black (d) Maroon

OXY-ACETYLENE WELDING PROCEDURES

1. Which one of the following statements is not true about leftward welding
technique?

(a) Welding is started at the right hand edge of the job and proceeds towards the
left.

(b) The blow pipe is held at an angle of 60deg.-70deg. With the welding line.

(c) The filler rod is held at an angle of 30 deg.- 40 deg.with the welding line.

(d) The welding rod follows the welding blowpipe.

2. Leftward welding technique is used for mild steel plate up to thickness of

(a) 1.5 mm (b) 3.0 mm (c) 5.0 mm (d) 10.0 mm

3. It is recommended to use rightward welding technique if the mild steel plate to

be welded are of thickness more than

(a) 1.5 mm (b) 3.0 mm (c) 5.0 mm (d) 10.0 mm

4. Which one of the following statement is true?

(a) A blowpipe which is used for gas welding can also be us for gas cutting

(b) In a high pressure acetylene cylinder acetylene exists in a free state

(c) In gas welding of mild steel a carburizing flame is used

(d) Gas cutting is a chemical process

5. Fluxes used for gas welding are available in various forms. Which one of the
following is not a form of flux?

(a) Coil (b) Powder (c) Paste (d) Liquid

6. To avoid lack of fusion in gas welding

(a) Weld with increased filler rod angle (b) Weld with increased gap between
flame cone and base plate (c) Weld with decreased filler rod angle (d) Weld with
uniform speed

BRAZING AND SOLDERING

1. Brazing is a process, in which a non-ferrous filler metal having a melting point

(a) Above 427deg.c but lower than that of base metal is used

(b) Below 427deg.c but lower than that of base metal is used

(c) Above 427deg.c and above that of base metal is used

(d) Below 427deg. C but above that of base metal is used

2. In resistance brazing, the electrodes used are made of

(a) Copper (b) Brass (c) Carbon (d) Aluminium

3. In resistance welding, the source of power supply is

(a) Step-up transformer (b) Step-down Transformer (c) One-two-one transformer

(d) No transformer

4. Spelter is a brazing alloy consisting normally of

(a) 50 % copper and 50% zinc (b) 50% copper and 50% lead (c) 50% lead and
50%zinc (d) 50% copper and 50% tin

5. In this method of brazing the melting point of filler metal ranges from 620deg.
C to 800 deg. C and it is used in instrument making. The method is

(a) Sliver brazing (b) Induction brazing (c) Dip brazing (d) Torch brazing

6. In the process of soldering, you have noticed solder not sticking to sufficiently
heated copper soldering it when rubbed over solder bar. What steps do you take
to overcome the problem?

(a) Pre-heat the solder (b) Clean the it thoroughly (c) change the soldering bit
shape (d) Rub the bit over solder for longer period
RESISTANCE WELDING

1. Which one of the following is a resistance welding method?

(a) Spot welding (b) Thermit welding (c) Forge welding (d) Explosive welding

2. If H is the amount of heat produces in joules I is the amount of current passing

in amps, R is the resistance of medium of ohms, T is the time in second during
which the current flows, then the relationship for converting electrical energy to
heat energy is

(a) H = I2RT (b) H=IR2T (c) H=IRT2 (d) IRT

3. In resistance welding, if the current is doubled the heating effect becomes

(a) Double (b) Four times (C) Eight time (d) Sixteen times

4. It is pressure welding process in which the heat is obtained from the resistnce
offered to the flow of current

(a) Spot welding (b) Atomic hydrogen welding (c) High pressure oxy-acetylene
welding (d) TIG welding

WELDING OF STAINLESS STEEL

1. The flame used for oxy-acetylene welding of stainless steel is neutral or

(a) Slightly carburizing (b) Slightly oxidizing (c) Heavily carburizing (d) Heavily
oxidizing

2. What percentage of chromium and nickel are usually present in stainless steel?

(a) 15% chromium, 5% Nickel (b) 16% chromium, 6% Nickel (c) 17% chromium,
7% Nickel (d) 18% chromium, 8% Nickel
3. In welding of stainless steel, what is the effect of clamping copper chill plates
adjacent to the weld?

(a) It reduces overheating of stainless steel sheet

(b) It reduces bucking of stainless steel sheet

(c) It reduces polish of stainless steel sheet

(d) It reduces rust of stainless steel sheet

4. Columbium added electrode are used for welding stainless steel because it
prevents

(a) Distortion (b) Excess penetration (c) Spatter (d) Weld decay

5. Porosity in stainless steel weld is due to

(a) Oversize electrode (b) Small diameter electrode (c) Damp electrode (d)
Unstabilised stainless steel electrode

WELDING OF CAST IRON

1. What type of flame is used for gas welding of cast iron?

(a) Neutral flame (b) oxidizing flame (c) carburizing flame (d) Flame with excess of
oxygen

2. What type flame is used in braze welding of cast iron?

(a) Neutral flame (b) slightly oxidizing flame (c) carburizing flame (d) slightly
carburizing Flame
3. The suitable flux for welding of cast iron is

(a) Sodium borate (b) Chlorides and fluorides of potassium (c) lithium chloride (d)
Magnesium chloride

4. When welding a mild steel plate with a cast iron plate which method you will
use to avoid the problem of cracking of the weld job?

(a) Use monel and nickel electrode with a preheat of the cast iron plate to
200deg.c and use a buttering run on cast iron plate

(b) Use a heavy coated cellulosic coated electrode and preheat the cast iron plate
locally to 200deg.c at the joint area only

(c) Use a rutile coated mild steel electrode and short stringer beads

(d) Use a low hydrogen electrode without preheating

WELDING OF COPPER

1. The electrode used for fusion welding of copper must be

(a) Oxidized (b) Highly oxidized (c) De – oxidized (d) Re – oxidized

2. A deoxidized copper is that to which about 0.05% to 0.15% of an element is

added. What is that element?

(a) Silicon (b) Sulphur (c) Phosphorous (d) Manganese

3. The type of flame used for oxy- acetylene welding of copper is

(a) Carburizing (b) Oxidizing (c) Neutral (d) Reducing

4. For oxy- acetylene welding of copper, a completely deoxidized copper welding

rod is used. It should be preferable have the melting point which is
(a) Substantially higher than that of base metal

(b) Slightly higher than that of base metal

(c) Substantially lower than that of base metal

(d) Slightly higher than that of base metal

5. Which one of the following metals / alloys has the highest melting point?

(a) Aluminum (b) Bronze (c) Brass (d) Copper

6. The suitable filer rod for bronze welding of copper is

(a) Brass filler rod (b) Copper filler rod (c) Manganese bronze filler rod (d) Silicon
bronze filler rod

7. Why is divergence allowance necessary in copper butt joint?

(a) It control distortion (b) It control penetration (c) Copper has high thermal
conductivity (d) Copper has high electrical conductivity

8. The filler rod suitable for fusion welding of copper is

(a) Copper silver alloy rod (b) Silicon bronze rod (c) Manganese bronze rod (d)
Silicon bronze rod

9. It is necessary to preheat copper before welding because

(a) Of its high thermal conductivity (B) it helps to control shrinkage (c) It makes
welding easy (d) It prevent oxidation
WELDING OF ALUMUNIUM

1. Electrode use for arc welding of Aluminum contain 95% Aluminum and

(a) 5% silicon (b) 5% Manganese (c) 5% Sulphur (d) 5% Phosphorous

2. For arc welding of aluminum plates 6 – 12 mm thickness edges preparation

with 90deg. V is used. A back up plate is also used which is made of

(a) Brass (b) copper (c) mild steel (d) aluminum

3. For oxy – acetylene welding of aluminum the flame use In

(a) Neutral flame (b) Neutral flame with a little haze of excess of oxygen (c)
Oxidizing flame (d) Neutral flame with a little haze of excess of acetylene

WELDING BRASS

1. Bronze is an alloy compose mainly of copper

(a) Tin and lead (b) Tin and zinc (c) Lead and zinc (d) Zinc and silicon

2. What type of welding source is preferred for welding of non- ferrous metals?

(a) Welding transformer (b) Welding rectifier (c) Motor-generator set (d)
Capacitor set

3. When comparing copper with brass, which one of the following is true about
copper?

(a) It is more ductile (b) It has higher tensile strength (c) It has higher resistance to
corrosion (d) It is more difficult to weld
DISTORTION AND ITS CONTROL

1. The process of hammering the weld metal immediately after it is deposited is

called

(a) Tinning (b) Penning (c) Pressing (d) Dressing

2. Which one of the following methods of welding is not a method used to control
distortion?

(a) Back-step welding (b) Skip welding (c) Intermittent welding (d) Right-hand
welding

3. A device intended to keep the parts to be welded in alignment is called

(a) Welding jig (b) Welding fixture (c) Welding positioner (d) Welding manipulator

4. If the distortion due to welding causes shrinkage to take place along the weld
what is this distortion called as?

(a) Angular (b) Longitudinal (c) Transverse (d) Circumferential

5. A device intended to keep the parts to be welded in alignment and also to

position the work as may be required is called

(a) Welding jig (b) Welding fixture (c) Welding positioner (d) Welding manipulator

6. The type of distortion shown the fig is

(a) Angular (b) Longitudinal (c) Transverse (d) Radial

7. If the plates to be welded are clamped how will it affect warping of plates?

(a) It is increase warping (b) It is decrease warping (c) It will have no effect on
warping (d) It will have very little effect on warping
8. If the number of passes to make a welded joint is increase how will it affect
distortion?

(a) It is increase distortion (b) It is decrease distortion(c) It will have no effect on

distortion (d) It will have very little effect on distortion

9. Intermittent welding method is use to

(a) Minimize the amount of weld metal (b) Reduce the residual stress in the joint

(c) Get uniform distortion of heat over the welded joint (d) Have the plates
expended to a lesser degree with each bead

OXY – ACETYLENE CUTTING

1. The function of the central hole in the tip of the cutting blow pipe is

(a) Supply oxygen for preheating (b) Supply acetylene for preheating (c) Supply
oxygen for cutting (d) Supply acetylene for cutting

2. Cast iron contains two elements which make it difficult to cut it by gas cutting.
What are these elements?

(a) Sulphur and phosphorous (b) Silicon and graphite (c) Graphite and phosphorus
(d) Silicon and sulphur

3. Which fuel gas is used for cutting deep underwater?

(a) Acetylene (b) Hydrogen (c) LPG (d) Methane

4. For successful flame cutting, one of the conditions is that the oxide of the metal
must melt at a point

(a) At lest 100deg.C higher than that of the metal (b) Higher than that of the
metal (c) Same as that of the metal (d) Lower than that of the metal
5. Powder cutting is a special method of flame cutting cast iron and non- ferrous
metal. The powder introduced in the flame is

(a) Iron powder (b) Aluminum powder (c) Copper powder (d) Carbon powder

6. The correct flame for preheating before cutting is

(a) Oxidizing flame (b) Neutral flame (c) Carburizing flame (d) Slightly carburizing
flame

7. While gas cutting the nozzle should

(a) Almost touch the work (b) Be 10mm away from work (c) Be 2mm away from
work (d) Be 5mm away from work

8. If the blow pipe is moved to and fro frequently while cutting the kerf will

(a) Be more (b) Of correct size (c) Be less (d) Not be effected

9. In gas cutting if too little cutting oxygen is supplied

(a) The metal will be cooled down (b) The kerf will be narrow (c) The kerf will be
wide (d) The metal will fail to cut completely

10. The minimum acetylene gas pressure required in high pressure gas cutting
blowpipe is

(a) 1.5 kgf/cm2 (b) 0.15 kgf/cm2 (c) 0.15 kgf/cm2 (d) 0.015 kgf/cm2

11. The top edge is melted round and the cut face is not smooth in gas cutting.
This is due to

(a) Extremely slow cutting speed (b) Insufficient acetylene pressure (c) The tip
being held too high (d) Too much cutting oxygen pressure

12. In a gas cut plate the cut shows grooves and has deep drag line. This is due to

(a) Tip too close to the cut surface (b) Too much travel speed (c) Less oxygen
pressure (d) Smaller size cutting nozzle
13. In a gas plate the cut is high quality although there is some surface roughness
caused by vertical drag line. This is due to

(a) Less preheating flame (b) Impure cutting oxygen (c) Too slow cutting speed (d)
Smaller size cutting nozzle

14. The size of the cutting nozzle used in oxy acetylene cutting process depends
mainly on

(a) Thickness of metal to be cut (b) Purity of oxygen (c) Duration of cut (d) Type of
cutting blow pipe

PIPE WELDING

1. What type of arc welding machine is used for welding of pipes in all positions
where welds of high radiography standards are required?

(a) Welding transformer (b) Motor generator set (c) Rectifier set (d) Capacitor set

2. Small diameter pipe end cutting may be done by

(a) Arc cutting (b) Plasma cutting (c) Oxy-fuel gas cutting (d) Pipe cutter

3. Which technique is used to make welded joints in all positions and various sizes
of thin walled pipes?

(a) Rightward welding (b) Leftward welding (c)all position Rightward welding (d)
Any technique

4. While tack butt welding a wire is inserted between the edges of plate. Why is it
done so?

(a) To control distortion (b) to get proper penetration (c) To maintain uniform
root gap (d) To avoid burn through
5. The selection of nozzle for pipe welding depended upon

(a) Wall thickness (b) Welding technique (c) Diameter of pipe (d) Welding position

6. If the thickness of pipe wall is less than 4mm the edge preparation may be

(a) Square (b) Single V (c) Single bevel (d) Edge joint

7. The pipe welding position shown in Fig. is

(a) 1G (B) 2G (c) 5G (d) 6G

WELDABILITY

1. Which one of the following elements has the highest influence on the
metallurgical weld ability of steel?

(a) Carbon (b) Manganese (c) Chromium (d) Silicon

2. The presence of which one of the following has the harmful effect of leading to
cracking?

(a) Oxygen (b) Nitrogen (c) Hydrogen (d) Argon

3. The presence of oxygen can reduce

(a) Strength (b) Ductility (c) Malleability (d) Toughness

4. Which of the following elements is added to steel used at very low temperature

(a) Manganese (b) Chromium (c) Nickel (d) Molybdenum

5. Which of the following elements is added to steel to increase its resistance to

corrosion in environments like seawater?

(a) Aluminum (b) Copper (c) Titanium (d) Vanadium

6. Which one of the elements may be used to deoxidize steel?

(a) Calcium (b) Magnesium (c) Phosphorous (d) Sulphur

7. What should be carbon equivalent of steel so that it may be welded with out
preheat?

(a) Less than 0.20 (b) Less than 0.40 (c) Less than 0.60 (d) Less than 0.80

8. There is certain maximum limit of carbon equivalent of steel beyond which it is

difficult to weld even with preheat. What is that limit?

(a) 0.30 (b) 0.50 (c) 0.70 (d) 0.9

END OF SEMISTER – 1
GAS METAL ARC WELDING

1. Which one of the following is most commonly use power supply for GMAW?

(a) AC (b) DCEP (c) DCEN (d) any one of the above

2. Some commercially available electrode contain denitriding metal such as

titanium and zirconium . What propose does it serve?