Great!

Let’s continue with the *viva questions explanations* for the

remaining shops from the *MP Workshop Manual 2022–23 (SKIT/RTU)*:

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## 🔥 WELDING SHOP – *Arc Welding* (Experiment 6) & *Gas Welding*

(Experiment 7)

### ✅ ARC WELDING (Electric)

1. *Define welding.*

→ Welding is a process of joining materials (usually metals) by melting

the workpieces and adding filler material.

2. *Classification of welding.*

→ Fusion (arc, gas, thermit) and Pressure welding (forge, resistance).

3. *Temporary vs permanent joining methods?*

→ Temporary: nuts, bolts, rivets. Permanent: welding, brazing, soldering.

4. *Difference: arc welding vs gas welding.*

→ Arc: uses electric arc for heat. Gas: uses flame from oxy-acetylene.

5. *Advantages/disadvantages of arc welding?*

→ Adv: Strong joint, deeper penetration. Disadv: High temp, electric

hazards.

6. *Difference: welding vs brazing vs soldering.*

→ Welding: melts base metal. Brazing: filler at \~600°C. Soldering: filler

<450°C.
7. *Fusion zone temp in arc welding?*

→ Around 3600°C (electric arc temperature).

8. *Tools in arc welding?*

→ Transformer, electrode holder, ground clamp, hammer, brush, tongs,

apron, gloves.

9. *Transformer used in arc welding?*

→ 0–400A, 3-phase, oil/air cooled.

10. *Electrode used by you?*

→ Mild steel (E6013), flux-coated rod.

11. *Size of welding electrode?*

→ 3.15 mm diameter, 350 mm length.

12. *Why electrodes are flux-coated?*

→ Flux protects weld from oxidation, stabilizes arc, improves quality.

13. *Tool for chipping welding spots?*

→ Chipping hammer.

14. *What is “ground” in welding setup?*

→ Negative terminal connected to workpiece for completing circuit.

15. *Transformer specifications?*

→ Rated by current capacity (Amps), phase, voltage.

16. *What is arc blow?*

 → Deflection of arc due to magnetic field imbalance.

17. *Distance between rod & job?*

→ 2 to 3 mm (depends on rod diameter).

18. *Safety precautions in arc welding?*

→ Wear PPE, avoid looking at arc, check grounding, no flammable

materials nearby.

19. *Filler material for MS welding?*

→ Mild steel electrode (E6013).

20. *Which metals can be arc welded?*

→ Mild Steel ✔, Cast Iron ✔, High Carbon Steel ✔, SS ✔, Copper ❌,

Aluminium ❌ (use TIG/MIG for Cu/Al).

21. *Gases in gas welding/gas cutting?*

→ Oxygen + Acetylene.

22. *Welding defects seen?*

→ Porosity, cracks, undercut, lack of fusion, slag inclusion.

23. *Types of joint made?*

→ Lap joint and Butt joint.

24. *What is weld bead?*

→ Deposited filler metal on the weld surface.

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### ✅ GAS WELDING (Oxy-Acetylene)

1. *Advantages/disadvantages of gas welding?*

→ Adv: Portable, simple setup. Disadv: Slower, limited for thick sections.

2. *Tools required?*

→ Cylinders, regulators, hoses, torch, filler rods, lighter, tongs, brush,

PPE.

3. *Color of hose pipes?*

→ Oxygen = Blue / Black, Acetylene = Red.

4. *Cylinder colors?*

→ Oxygen = Black, Acetylene = Maroon.

5. *Function of pressure regulators?*

→ Control gas pressure from cylinders to torch.

6. *Types of flames?*

→ Neutral (≈3200°C), Carburizing (excess acetylene), Oxidizing (excess

oxygen).

7. *Flame for welding steel?*

→ Neutral flame.

8. *Flame for copper alloys?*

→ Carburizing flame.

9. *Flame for decarburizing steel?*

→ Oxidizing flame.
10. *Highest temperature flame?*

→ Oxidizing flame.

11. *How to get neutral flame?*

→ Equal flow of oxygen and acetylene.

12. *How to identify oxidizing flame?*

→ Small, sharp inner cone; hissing sound.

13. *Neutral flame temperature?*

→ \~3200°C.

14. *What is filler material?*

→ Metal rod melted to fill the joint.

15. *Why borax used?*

→ Acts as flux to prevent oxidation.

16. *Torch angle during welding?*

→ 40°–50° to workpiece.

17. *Forward vs backward technique?*

→ Forward (leftward): thin metal; Backward (rightward): thick sections.

18. *Recommended gas pressure?*

→ Oxygen: 1.5–2 kg/cm², Acetylene: 0.15–0.2 kg/cm².

19. *Gas welding safety precautions?*

 → Check for leaks, PPE, correct valve sequence, good ventilation.

20. *Difference: gas welding vs brazing?*

→ Welding melts base metal, brazing uses filler without melting base.

21. *Brazing & soldering temperatures?*

→ Brazing: 600–900°C, Soldering: <450°C.

22. *Composition of tin solder?*

→ Typically 60% tin, 40% lead.

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## 🏗 FOUNDRY SHOP (Experiment 9–10)

1. *Define casting.*

→ Process of making parts by pouring molten metal into a mold cavity.

2. *What is pattern?*

→ Replica of the final object used to create the mold.

3. *Types of pattern?*

→ Single piece, split, match plate, gated.

4. *What is molding sand made of?*

→ Silica sand + clay + moisture.

5. *Properties of molding sand?*

→ Permeability, refractoriness, cohesiveness, collapsibility, strength.

6. *What is green sand?*

→ Moist molding sand used for making molds.

7. *Function of vent holes?*

→ Escape path for gases during pouring.

8. *What is riser and its purpose?*

→ Extra cavity to feed molten metal to avoid shrinkage defects.

9. *What is runner and gate?*

→ Runner: channel; Gate: opening through which metal enters the

cavity.

10. *What is flask?*

→ Box (cope & drag) to hold molding sand during casting.

11. *Tool used to cut mold cavity?*

→ Rammers, trowels, draw spike, slick, lifter.

12. *What is core?*

→ Insert used to create internal cavities in casting.

13. *Defects in casting?*

→ Blow holes, shrinkage, misrun, cold shut.

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## 🧰 SHEET METAL SHOP (Experiment 11–12)

1. *What is sheet metal?*

→ Thin metal sheets (usually <6 mm) used in fabrication.

2. *Tools used in sheet metal shop?*

→ Shears, snips, stakes, hammers, grooving tools.

3. *What is single hem joint?*

→ A folded edge to reinforce sheet and avoid sharp edge.

4. *Difference: stake vs anvil?*

→ Stake: fixed shaping tool. Anvil: large metal base for hammering.

5. *Cutting tools used?*

→ Straight snip, curved snip, shears.

6. *Folding tools?*

→ Folding bar, bending brake, wooden mallet.

7. *Material of sheet used in practice?*

→ Galvanized Iron (G.I.).

8. *Safety precautions?*

→ Use gloves, watch edges, clamp workpiece, avoid hand near blade.

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## 🌀 LATHE MACHINE SHOP (Experiment 13–14)

1. *Main parts of lathe machine?*

→ Bed, headstock, tailstock, carriage, chuck, feed rod, leadscrew.

2. *Operations performed on lathe?*

→ Turning, facing, chamfering, threading, knurling, boring, parting.

3. *What is facing?*

→ Making the end surface flat.

4. *What is turning?*

→ Removing material from the outer diameter.

5. *What is chamfering?*

→ Cutting a sloped edge at a corner.

6. *What is feed?*

→ Distance tool advances per revolution.

7. *What is depth of cut?*

→ Thickness of material removed in one pass.

8. *What is spindle speed?*

→ RPM of chuck. Selected based on material and diameter.

9. *Lathe specifications?*

→ Swing over bed, distance between centers, spindle bore, power.

10. *Materials used for job piece?*

→ Mild steel rods.

11. *Tool material used?*

→ HSS (High-Speed Steel), Carbide-tipped tools.

12. *Safety precautions?*

→ Wear safety glasses, don’t touch rotating part, remove tools before
starting, avoid loose clothing.

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Let me know if you want a printable summary or mock viva based on

these questions!