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Welding Processes Questions and Answers

1.

The welding process commonly used for fabricating tailor-welded blanks of dissimilar thickness for automotive applications is

Exam Year(s)

GATE ME - 2025,

Answer: B

The process is laser welding.

Tailor-welded blanks join sheets of different thickness or grade into one blank before stamping. Laser welding gives a narrow, deep weld with a small heat-affected zone and little distortion, at high speed, so the blank can still be formed.

Gas welding is too slow and puts in too much heat, and arc welding gives a wider bead and more distortion in thin sheet. Friction welding suits round bars and tubes rather than long sheet seams.

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2.

Which shielding gas is commonly used in Tungston Inert Gas (TIG) welding ?

Exam Year(s)

RSMSSB JE - 2025, RSMSSB - 2025,

Answer: B

The usual shielding gas in TIG welding is argon.

In tungsten inert gas welding the arc burns between a non-consumable tungsten electrode and the work, and an inert gas shields the electrode, arc and weld pool from the air. Argon is the standard choice: it is inert, heavier than air so it blankets the weld well, and gives a stable arc. Helium, or argon-helium mixtures, are used for thicker or highly conductive metals.

Oxygen would oxidise both the tungsten electrode and the weld. Carbon dioxide is an active gas used in MAG (CO2) welding with a consumable wire, not with tungsten, and hydrogen is not an inert shielding gas.

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3.

What ranges of voltage require in butt welding ?

Exam Year(s)

RSMSSB JE - 2025, RSMSSB - 2025,

Answer: B

The keyed range is 2 to 8 volts.

Butt welding here is resistance butt welding, in which the two pieces are pressed end to end and a very large current is passed through the joint. The heat comes from the contact resistance (I2R), so the welding transformer delivers thousands of amperes at only a few volts, typically under 10 V.

The higher ranges, 15 to 22 V and 22 to 30 V, are typical arc voltages in arc welding, where an arc must be maintained across a gap. They are far more than resistance welding needs.

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