FORMING AND JOINING PROCESSES VIVA QUESTIONS AND ANSWERS

FORMING AND JOINING PROCESSES VIVA QUESTIONS AND ANSWERS

What is a forming process?

A forming process is a manufacturing process that involves the deformation of a material into a desired shape using various mechanical or thermal processes.

What are the different types of forming processes?

Some common types of forming processes include rolling, forging, extrusion, drawing, bending, and stamping.

What is a joining process?

A joining process is a manufacturing process that involves the joining of two or more components to create a single product or structure.

What are the different types of joining processes?

Some common types of joining processes include welding, brazing, soldering, adhesive bonding, and mechanical joining.

What is the difference between welding and brazing?

Welding involves melting and joining two pieces of metal to form a strong bond, while brazing involves heating a filler metal to a temperature below the melting point of the base metals and using it to join the pieces together.

What is the difference between soldering and welding?

Soldering involves melting a filler metal and using it to join two pieces of metal together, while welding involves melting the base metal itself to form the bond.

What is adhesive bonding?

Adhesive bonding is a process that involves the use of an adhesive to join two materials together.

What are the advantages of adhesive bonding over other joining processes?

Adhesive bonding offers several advantages over other joining processes, including the ability to join dissimilar materials, lower processing temperatures, and the ability to distribute loads evenly across the bonded area.

What is mechanical joining?

Mechanical joining involves joining two or more components together through the use of mechanical fasteners such as screws, bolts, or rivets.

What are the advantages and disadvantages of mechanical joining?

The advantages of mechanical joining include the ease of assembly and disassembly, the ability to join a wide variety of materials, and the strength of the joint. The disadvantages include the potential for stress concentration at the joint and the possibility of corrosion between the two metals.

What is a common application of rolling in forming processes?

Rolling is commonly used to form sheets, plates, and bars of metal into various shapes and sizes. It is also used to improve the surface finish of the material and to increase its strength and hardness.

What is forging and what are its advantages?

Forging is a forming process that involves the use of a hammer or press to deform a metal into a desired shape. The advantages of forging include increased strength and toughness of the material, improved dimensional accuracy, and the ability to form complex shapes.

What is extrusion and what are its advantages?

Extrusion is a forming process that involves forcing a material through a die to create a specific cross-sectional shape. The advantages of extrusion include the ability to produce long lengths of material with a consistent cross-sectional shape, improved strength and toughness of the material, and the ability to produce complex shapes with tight tolerances.

What is stamping and what are its advantages?

Stamping is a forming process that involves the use of a punch and die to cut, bend, or form a material into a desired shape. The advantages of stamping include the ability to produce high volumes of parts quickly and efficiently, the ability to produce complex shapes with tight tolerances, and the ability to work with a wide variety of materials.

What is the difference between hot and cold forming processes?

Hot forming processes involve working with a material at a high temperature, while cold forming processes involve working with a material at or near room temperature. Hot forming processes are typically used for materials that are difficult to work with at room temperature, while cold forming processes are used for materials that are more ductile and easier to deform.

What is the difference between drawing and extrusion?

Drawing is a forming process that involves pulling a material through a die to reduce its diameter or increase its length, while extrusion involves pushing a material through a die to form a specific cross-sectional shape. Drawing is typically used for wire and tube production, while extrusion is used for producing a wide range of shapes, such as rods, tubes, and profiles.

What is the difference between bending and forming?

Bending is a process that involves deforming a material to create a specific angle or shape, while forming involves deforming a material to create a desired shape or profile. Bending is typically used for creating simple bends in materials, such as sheet metal, while forming is used for creating more complex shapes, such as automobile body panels.

What is the difference between brazing and soldering?

Brazing involves heating the base metal to a temperature above the melting point of the filler metal, while soldering involves heating the filler metal to a temperature below the melting point of the base metal. Brazing produces a stronger joint than soldering and is typically used for high-stress applications, while soldering is used for low-stress applications where a strong joint is not required.

What is spot welding?

Spot welding is a welding process that involves passing a high electrical current through two pieces of metal to create a spot weld. It is commonly used in the automotive industry for joining sheet metal panels and in the construction of metal furniture.

What are some common materials used in adhesive bonding?

Some common materials used in adhesive bonding include epoxy, polyurethane, cyanoacrylate, and acrylic adhesives. The type of adhesive used depends on the materials being joined and the requirements of the application.

What is friction welding?

Friction welding is a solid-state welding process that involves rubbing two materials together at a high speed to create heat, which softens the material and allows the two pieces to be joined together. It is commonly used for joining dissimilar materials and is particularly useful for welding materials that are difficult to join using traditional welding techniques.

What is diffusion bonding?

Diffusion bonding is a process that involves heating two materials to a high temperature and pressing them together to create a solid-state bond. The high temperature causes the atoms in the materials to diffuse across the interface, creating a strong bond. It is commonly used for joining materials that cannot be welded using traditional welding techniques.

What is laser welding?

Laser welding is a welding process that uses a high-energy laser beam to melt and join two pieces of material together. It is commonly used in the automotive and aerospace industries for welding high-strength materials, such as titanium and aluminum alloys.

What is ultrasonic welding?

Ultrasonic welding is a welding process that uses high-frequency vibrations to create friction and heat between two materials, causing them to soften and fuse together. It is commonly used for joining plastic components in the automotive and medical device industries.

What is the difference between lap joint and butt joint?

A lap joint is a joint where two pieces of material overlap each other, while a butt joint is a joint where two pieces of material are joined end-to-end. Lap joints are weaker than butt joints, but they are easier to produce and are often used in low-stress applications. Butt joints are stronger than lap joints and are used in high-stress applications where a strong joint is required.

What is the difference between a weld and a braze joint?

A weld joint is a joint where two pieces of metal are melted and fused together, while a braze joint is a joint where a filler metal is melted and used to join two pieces of metal together. Welding produces a stronger joint than brazing, but brazing is often preferred for joining dissimilar metals or for creating a joint with minimal distortion.

What is the difference between a rivet and a bolt joint?

A rivet joint is a joint where a cylindrical pin is inserted through holes in two or more pieces of material and the ends are peened over to create a permanent joint. A bolt joint is a joint where a bolt is inserted through holes in two or more pieces of material and held in place with a nut. Rivet joints are stronger and more permanent than bolt joints, but they are more difficult to remove and replace.

What is the difference between a solder joint and a braze joint?

A solder joint is a joint where a low-temperature filler metal is melted and used to join two pieces of metal together, while a braze joint is a joint where a high-temperature filler metal is melted and used to join two pieces of metal together. Soldering is used for low-stress applications where a strong joint is not required, while brazing is used for high-stress applications where a strong joint is necessary.

What is the difference between a threaded fastener and a non-threaded fastener?

A threaded fastener, such as a bolt or screw, has threads that engage with corresponding threads in a tapped hole or nut to hold two or more pieces of material together. A non-threaded fastener, such as a pin or clip, does not have threads and is typically held in place by friction or pressure. Threaded fasteners are stronger and more secure than non-threaded fasteners, but they require a threaded hole or nut to be used.

What is the difference between a weld symbol and a surface finish symbol?

A weld symbol is a symbol used on a drawing to indicate the type of weld and the location of the weld joint. A surface finish symbol is a symbol used on a drawing to indicate the desired surface finish of a part. Weld symbols are used to convey information about the welding process, while surface finish symbols are used to convey information about the desired appearance and function of the finished part.

What is the difference between fusion welding and solid-state welding?

Fusion welding is a welding process that involves melting and fusing two or more pieces of material together to create a joint, while solid-state welding is a welding process that involves joining two or more pieces of material together without melting them. Solid-state welding is often preferred for materials that are difficult to weld using traditional fusion welding techniques, such as materials with high melting points or materials that are prone to distortion when exposed to high temperatures.

What is the difference between gas welding and gas cutting?

Gas welding is a welding process that uses a flame produced by burning a mixture of gases to melt and fuse two or more pieces of material together, while gas cutting is a process that uses a flame produced by burning a mixture of gases to heat and cut through a piece of material. Gas welding is used to join two or more pieces of material together, while gas cutting is used to cut through material to create a desired shape or size.

What is the difference between a groove weld and a fillet weld?

A groove weld is a type of weld joint where two pieces of material are joined together along a prepared groove, while a fillet weld is a type of weld joint where two pieces of material are joined together at a right angle, forming a triangular shape. Groove welds are used in high-stress applications where a strong, full-penetration weld is required, while fillet welds are used in low-stress applications where a less strong, partial-penetration weld is acceptable.

What is the difference between a lap weld and a plug weld?

A lap weld is a type of weld joint where two pieces of material overlap each other and are welded together along the overlapping section, while a plug weld is a type of weld joint where a hole is drilled through one piece of material and the second piece of material is welded to the first through the hole. Lap welds are often used for joining two plates together, while plug welds are often used for attaching a bracket or other component to a flat surface.

What is the difference between a resistance spot weld and a resistance seam weld?

A resistance spot weld is a type of weld joint where two or more pieces of material are joined together by passing a high electrical current through the materials and applying pressure to create a weld at the contact points, while a resistance seam weld is a type of weld joint where two or more pieces of material are joined together by passing a high electrical current through the materials as they are fed through a rolling electrode. Resistance spot welds are used for joining materials that are too thick for other welding techniques, while resistance seam welds are used for joining materials that are too long for other welding techniques.

What is the difference between a spot weld and a tack weld?

A spot weld is a type of weld where two or more pieces of material are welded together at a specific location, while a tack weld is a type of weld where two or more pieces of material are temporarily held in place with a small weld before being fully welded together. Spot welds are often used in high-stress applications where a strong, permanent weld is required, while tack welds are used to hold components in place before final welding or assembly.

What is the difference between a fusion bond and a diffusion bond?

A fusion bond is a type of bond where two or more pieces of material are joined together by melting them and allowing them to solidify together, while a diffusion bond is a type of bond where two or more pieces of material are joined together by applying heat and pressure to cause the atoms in the material to intermingle and form a strong bond. Fusion bonds are often used for joining materials of the same type, while diffusion bonds are often used for joining dissimilar materials.

What is the difference between a groove weld and a plug weld?

A groove weld is a type of weld joint where two pieces of material are joined together along a prepared groove, while a plug weld is a type of weld joint where a hole is drilled through one piece of material and the second piece of material is welded to the first through the hole. Groove welds are used in high-stress applications where a strong, full-penetration weld is required, while plug welds are often used for attaching a bracket or other component to a flat surface.

What is the difference between a lap joint and a scarf joint?

A lap joint is a joint where one piece of material is overlapped by another piece and welded or fastened along the overlapping section, while a scarf joint is a joint where two pieces of material are tapered at the end and joined together with glue or adhesive. Lap joints are often used for joining materials of different thicknesses, while scarf joints are often used for joining materials of the same thickness.

What is the difference between MIG welding and TIG welding?

MIG welding uses a consumable wire electrode that melts and fuses with the base material to create a weld, while TIG welding uses a non-consumable tungsten electrode and filler material to create a weld. MIG welding is faster and easier to use than TIG welding, but produces a less precise and less attractive weld. TIG welding produces a more precise and attractive weld, but is more difficult and time-consuming than MIG welding.

What is the difference between a backing strip and a back gouging?

A backing strip is a piece of material placed behind a joint to support the weld, while back gouging is the process of removing material from the backside of a weld to improve weld penetration and fusion. Backing strips are often used in welding thicker materials to ensure full penetration, while back gouging is used to remove defects and ensure a strong weld.

What is the difference between a submerged arc weld and a gas metal arc weld?

A submerged arc weld is a type of welding that uses a continuously fed electrode and a granular flux to create a weld, while a gas metal arc weld uses a continuously fed electrode and a shielding gas to create a weld. Submerged arc welding produces a strong and efficient weld, but is limited to flat or horizontal welding positions. Gas metal arc welding is versatile and can be used in various positions, but produces a weaker weld than submerged arc welding.

What is the difference between a spot weld and a seam weld?

A spot weld is a type of weld where two or more pieces of material are welded together at a specific location, while a seam weld is a type of weld where two or more pieces of material are joined together by welding along the entire length of the joint. Spot welds are often used for joining materials that are too thick for other welding techniques, while seam welds are used for joining materials that require a continuous, leak-proof seal.

What is the difference between brazing and soldering?

Brazing is a joining process that uses a filler metal with a melting point higher than 450°C, whereas soldering uses a filler metal with a melting point below 450°C. Brazing requires higher temperatures to melt the filler metal and join the parts, and it provides a stronger bond compared to soldering. Soldering, on the other hand, requires lower temperatures and is often used for electronic components, plumbing, and jewelry making.

What is the difference between an electric arc and a plasma arc?

An electric arc is a type of discharge that occurs between two electrodes when a high voltage is applied, while a plasma arc is an electric arc that is constricted by a gas.

FORMING AND JOINING PROCESSES VIVA QUESTIONS AND ANSWERS



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