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In the previous problem, suppose an industrial robot cell were installed to replace the welder. The
\r\ncell consists of the robot (using GMAW instead of SMAW or FCAW), two welding fixtures, and
\r\nthe fitter who loads and unloads the parts. With two fixtures, fitter and robot work simultaneously,
\r\nthe robot welding at one fixture while the fitter unloads and loads at the other. At the end of each
\r\nwork cycle, they switch places. The electrode wire spool must be changed every five workparts,
\r\nwhich task requires 5.0 minutes and is accomplished by the fitter. Determine (a) arc time and (b)
\r\nproduction rate for this work cell.
A SMAW operation is accomplished in a work cell using a fitter and a welder. The fitter takes 5.5
\r\nmin to place the unwelded components into the welding fixture at the beginning of the work cycle,
\r\nand 2.5 min to unload the completed weldment at the end of the cycle. The total length of the
\r\nseveral weld seams to be made is 2000 mm, and the travel speed used by the welder averages 400
\r\nmm/min. Every 750 mm of weld length, the welding stick must be changed, which takes 0.8 min.
\r\nWhile the fitter is working, the welder is idle (resting); and while the welder is working, the fitter is
\r\nidle. (a) Determine the average arc time in this welding cycle. (b) How much improvement in arc
\r\ntime would result if the welder used FCAW (manually operated), given that the spool of flux-cored
\r\nweld wire must be changed every five weldments, and it takes the welder 5.0 min to accomplish the
\r\nchange? (c) What are the production rates for these two cases (weldments completed per hour)?
\r\n
There are 23 correct answers in the following multiple choice questions (some questions have multiple
\r\nanswers that are correct). To attain a perfect score on the quiz, all correct answers must be given. Each
\r\ncorrect answer is worth 1 point. Each omitted answer or wrong answer reduces the score by 1 point, and
\r\neach additional answer beyond the correct number of answers reduces the score by 1 point. Percentage
\r\non the quiz is based on the total number of correct answers
\r\n30.1 The feature that distinguishes fusion welding from solid-state welding is that melting of the faying
\r\nsurfaces occurs during fusion welding but not in solid-state welding: (a) true or (b) false?
\r\n30.2 Which of the following processes are classified as fusion welding (three correct answers): (a)
\r\nelectrogas welding, (b) electron-beam welding, (c) explosion welding, (d) forge welding, (e) laserbeam
\r\nwelding, and (f) ultrasonic welding?
\r\n30.3 Which of the following processes are classified as fusion welding (two correct answers): (a)
\r\ndiffusion welding, (b) friction welding, (c) pressure gas welding, (d) resistance welding, and (e) roll
\r\nwelding?
\r\n30.4 Which of the following processes are classified as solid-state welding (three correct answers): (a)
\r\ndiffusion welding, (b) friction stir welding, (c) resistance spot welding, (d) roll welding, (e) thermit
\r\nwelding, and (f) upset welding?
\r\n30.5 An electric arc is a discharge of current across a gap in an electrical circuit. The arc is sustained in
\r\narc welding processes by the transfer of molten metal across the gap between the electrode and the
\r\nwork: (a) true or (b) false?
\r\n30.6 Which one of the following arc welding processes uses a nonconsumable electrode: (a) FCAW, (b)
\r\nGMAW, (c) GTAW, or (d) SMAW?
\r\n30.7 MIG welding is a term sometimes applied when referring to which one of the following processes:
\r\n(a) FCAW, (b) GMAW, (c) GTAW, or (d) SMAW?
\r\n30.8 \"Stick\" welding is a term sometimes applied when referring to which one of the following
\r\nprocesses: (a) FCAW, (b) GMAW, (c) GTAW, or (d) SMAW?
\r\n30.9 Which one of the following AW processes uses an electrode consisting of continuous consumable
\r\ntubing containing flux and other ingredients in its core: (a) FCAW, (b) GMAW, (c) GTAW, or (d)
\r\nSMAW?
\r\n30.10 Which one of the following arc-welding processes produces the highest temperatures: (a) CAW, (b)
\r\nPAW, (c) SAW, or (a) TIG welding?
\r\n30.11 Resistance-welding processes make use of the heat generated by electrical resistance to achieve
\r\nfusion of the two parts to be joined; no pressure is used in these processes, and no filler metal is
\r\nadded: (a) true or (b) false?
\r\n30.12 Metals that are easiest to weld in resistance welding are ones that have low resistivities since low
\r\nresistivity assists in the flow of electrical current: (a) true or (b) false?
\r\n30.13 Oxyacetylene welding is the most widely used oxyfuel welding process because acetylene mixed
\r\nwith an equal volume of oxygen burns hotter than any other commercially available fuel: (a) true or
\r\n(b) false?
\r\n30.14 The term \"laser\" stands for \"light actuated system for effective reflection\": (a) true or (b) false?
\r\n30.15 Which of the following solid-state welding processes applies heat from an external source (two best
\r\nanswers): (a) diffusion welding, (b) forge welding, (c) friction welding, and (d) ultrasonic welding?
\r\n30.16 The term weldability takes into account not only the ease with which a welding operation can be
\r\nperformed, but also the quality of the resulting weld: (a) true or (b) false?
\r\n30.17 Copper is a relatively easy metal to weld because its thermal conductivity is high: (a) true or (b)
\r\nfalse?
According to the video, what are four possible functions of the electrodes in resistance
\r\nspot welding?
What are some of the design guidelines for weldments that are fabricated by arc welding?
\r\n
What are the factors that affect weldability
What are the three basic categories of inspection and testing techniques used for weldments? Name
\r\nsome typical inspections and/or tests in each category.
What are some of the important welding defects?
\r\n
Distortion (warping) is a serious problem in fusion welding, particularly arc welding. What are
\r\nsome of the techniques that can be taken to reduce the incidence and extent of distortion?
\r\n
What is a sonotrode in ultrasonic welding?
\r\n
What is friction stir welding (FSW), and how is it different from friction welding?
\r\n
There are two basic types of friction welding (FRW). Describe and distinguish the two types.
There are several modern-day variations of forge welding, the original welding process. Name
\r\nthem.
Laser-beam welding and electron-beam welding are often compared because they both produce
\r\nvery high power densities. LBW has certain advantages over EBW. What are they?
Electron-beam welding has a significant disadvantage in high-production applications. What is that
\r\ndisadvantage?
Define pressure gas welding.
\r\n
Why is the oxyacetylene welding process favored over the other oxyfuel welding processes?
\r\n
Describe cross-wire welding.
\r\n
What is resistance-projection welding?
\r\n
Describe the sequence of steps in the cycle of a resistance spot-welding operation.
\r\n
What are the desirable properties of a metal that would provide good weldability for resistance
\r\nwelding?
Define resistance welding.
Why are the temperatures much higher in plasma arc welding than in other AW processes?
\r\n
Describe submerged arc welding (SAW).
Why is the shielded metal arc-welding (SMAW) process difficult to automate?
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