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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 of oxy-acetylene welding. Describe the main components of the equipment, the welding torch operation, types of flames and their applications. State the advantages and limitations of oxy-acetylene welding.

    Core theory question on oxy-acetylene welding equipment and principles; fundamental welding process frequently asked in exams.

  2. Unit 47 Marks High Priority

    Describe the Gas Metal Arc Welding (GMAW) process (commonly called MIG/MAG). Explain the role of the consumable electrode and shielding gas. Compare the application of $\mathrm{CO_2}$ and $\mathrm{Ar}$ as shielding gases and list advantages and limitations of GMAW.

    Standard question on Gas Metal Arc Welding (GMAW) covering working principle, shielding gases and practical considerations; common in practical theory sections.

  3. Unit 47 Marks High Priority

    Explain the Tungsten Inert Gas (TIG) welding process. Discuss the differences in electrode polarity and current type (DCEN, DCEP, AC) and their effects. Mention applications where TIG welding is preferred and list its advantages and disadvantages.

    TIG is a core arc welding variant; typical long-answer question asking process differences and suitable applications.

  4. Unit 47 Marks Medium Priority

    Describe resistance welding processes with emphasis on spot welding and seam welding. Explain the role of current, force and time in resistance welding. List typical applications and common defects with their remedies.

    Covers resistance welding family and parameters — commonly asked as short/medium question in exams.

  5. Unit 45 Marks Medium Priority

    Compare gas welding and arc welding with respect to heat source temperature, equipment complexity, portability, suitability for different materials and typical applications.

    Comparative conceptual question between two broad welding categories; good for short-answer sections.

  6. Unit 47 Marks High Priority

    Explain the use of welding symbols on engineering drawings. Draw and interpret the following symbols: fillet weld (single and double), square groove, V-groove and plug weld. Describe the meaning of arrow side, other side, and supplementary symbols.

    Interpreting welding symbols is a practical exam skill frequently tested in drawing/interpretation sections.

  7. Unit 47 Marks High Priority

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

    Defects and their remedies are essential for quality control; high priority question for practical knowledge and inspection.

  8. Unit 410 Marks High Priority

    Define Heat Affected Zone (HAZ) in welding. Explain the changes that occur in the microstructure and mechanical properties across the weld, HAZ and base metal. Discuss factors that influence HAZ width and methods to control adverse effects (preheating, controlled cooling, post weld heat treatment).

    Metallurgical effects around welds (HAZ) are core engineering concepts often asked as longer marks question.

  9. Unit 45 Marks Medium Priority

    Explain the processes of brazing and soldering. State the differences between brazing, soldering and fusion welding. Describe the role of flux and typical filler materials used in brazing and soldering.

    Brazing and soldering are related joining processes; straightforward comparison and technical details often appear in exams.

  10. Unit 47 Marks Medium Priority

    Discuss the weldability of low carbon steel, stainless steel and aluminum alloys. For each material mention typical welding processes used, major welding problems encountered and methods to improve weldability (e.g., choice of filler, preheat, shielding, interpass temperature control).

    Weldability and material-specific considerations are important for design and process selection; medium priority theoretical question.

  11. Unit 410 Marks Medium Priority

    What is a Welding Procedure Specification (WPS) and Procedure Qualification Record (PQR)? Explain the information typically contained in a WPS and the purpose of PQR and WPQ (Welder Performance Qualification). Describe how WPS and PQR ensure repeatable weld quality.

    Procedural control and standards (WPS, PQR) are part of quality assurance in welding; asked as detailed descriptive question.

  12. Unit 45 Marks Low Priority

    Describe the safety precautions to be followed during welding operations. Include hazards due to fumes, radiation, electric shock, fire and hot work, and list recommended personal protective equipment (PPE) and ventilation measures.

    Safety is essential but often covered with short questions; included for completeness and practical exam preparation.

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