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BT-106 · Manufacturing Practices/Important Questions

Manufacturing Practices (BT-106) - Important Questions

  1. Unit 47 Marks High Priority

    Explain the principle, equipment, advantages and limitations of Gas Tungsten Arc Welding (GTAW/TIG). Mention typical applications and the role of shielding gas.

    Core definitional and principle question on welding processes; fundamental topic in Unit 4 and frequently examined.

  2. Unit 410 Marks High Priority

    Compare Shielded Metal Arc Welding (SMAW or MMAW), Gas Metal Arc Welding (GMAW/MIG), and Gas Tungsten Arc Welding (GTAW/TIG) under the following headings: principle, electrode/filler, shielding, advantages, disadvantages and typical applications.

    Comparison and conceptual understanding of major arc welding processes; commonly asked as a long answer or comparative table.

  3. Unit 47 Marks Medium Priority

    Define welding heat input and calculate the heat input $Q$ in kJ/mm for an arc welding run given voltage $V$, current $I$, travel speed $S$ (in mm/min) and process efficiency $\eta$. Use the standard relation and show the formula. $$Q = \left(\frac{V \times I \times 60}{S \times 1000}\right) \times \eta$$ Explain the effect of heat input on the weld microstructure and HAZ.

    Calculation-based question using the standard welding heat input formula; tests numerical competency and units handling.

  4. Unit 410 Marks High Priority

    Describe the principle, working, advantages, disadvantages and typical applications of Resistance Spot Welding. Include the role of current, pressure and time in nugget formation.

    Fundamental process description and application — frequently appears as diagram + explanation in exams.

  5. Unit 410 Marks High Priority

    Explain the metallurgical changes that occur in the Heat Affected Zone (HAZ) during welding. Discuss the factors that influence the HAZ width and how HAZ properties affect the performance of welded joints.

    Common theoretical question addressing welding metallurgy, crucial for understanding weld quality and defects.

  6. Unit 47 Marks High Priority

    List and explain common welding defects such as porosity, slag inclusion, lack of fusion, incomplete penetration, undercut and cracks. For each defect give probable causes and remedies.

    Core question covering welding defects — commonly asked in practical and theory papers.

  7. Unit 45 Marks Medium Priority

    Differentiate between brazing and soldering with respect to temperature ranges, filler materials, joint strength, and typical applications. Give two examples of each process.

    Brazing and soldering distinctions are standard short-answer or comparison questions.

  8. Unit 47 Marks Medium Priority

    Explain the elements of a welding symbol as per standard practice. Interpret the following symbol and describe the weld required: a single bevel groove weld on the arrow side with root gap of 3 mm and weld length 50 mm (describe in words).

    Welding symbols are a routine topic; students are expected to read and interpret symbols.

  9. Unit 410 Marks High Priority

    Describe Non-Destructive Testing (NDT) methods used for inspection of welds: Radiographic Testing (RT), Ultrasonic Testing (UT), Dye Penetrant Testing (PT) and Magnetic Particle Testing (MT). For each method mention principle, applications, advantages and limitations.

    NDT methods in welding are universally important — frequently appears as short/long answer topics.

  10. Unit 47 Marks Medium Priority

    Explain the working principle, advantages, limitations and typical industrial applications of Laser Beam Welding (LBW) and Electron Beam Welding (EBW). Compare energy density and penetration characteristics of the two processes.

    Advanced processes question — laser and electron beam welding are modern topics often asked for their advantages and application scope.

  11. Unit 47 Marks Medium Priority

    Discuss the weldability issues and recommended welding practices for aluminum alloys and stainless steels. Include considerations of thermal conductivity, oxide layer, filler selection and post-weld treatments.

    Material-specific welding challenges and procedures are important for engineering practice and exam questions.

  12. Unit 47 Marks Medium Priority

    A welding procedure specification (WPS) must control parameters for a repeatable weld. List the essential parameters that must be included in a WPS for arc welding and explain why each parameter is important.

    Practical procedure and parameter selection question; suitable for medium-length answers.

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