1.

Under optimal conditions of the process the temperatures experienced by a copper work
piece in fusion welding, brazing and soldering are such that

(A) Twelding>Tsoldering>TbrazingTwelding>Tsoldering>Tbrazing (B) Tsoldering>Twel

ding>TbrazingTsoldering>Twelding>Tbrazing(C) Tbrazing>Twelding>TsolderingTbrazi
ng>Twelding>Tsoldering (D) Twelding>Tbrazing>TsolderingTwelding>Tbrazing>Tsolde
ring

2. The part of a gating system which regulates the rate of pouring of molten metal is

(A) pouring basin (B) runner (C) choke (D) ingate

3. A cylindrical job with diameter of 200 mm and height of 100 mm is to be cast using
modulus method of riser design. Assume that the bottom surface of cylindrical riser does
not contribute as cooling surface. If the diameter of the riser is equal to its height, then
the height of the riser (in mm) is

(A) 150

(B) 200

(C) 100

(D) 125

4. The welding process which uses a blanket of fusible granular flux is

(A) tungsten inert gas welding

(B) submerged arc welding

(C) electroslag welding

(D) thermit welding

Gray cast iron blocks of size 100 mm 50 mm 10 mm with a central spherical cavity of
diameter 4 mm are sand cast. the shrinkage allowance for the pattern is 3%. The ratio of volume
of the pattern to volume of the casting is ________

The voltage-length characteristic of a direct current arc in an arc welding process is V= ( 100 +
40 l ), where l is the length of the arc in mm and V is arc voltage in volts. During a welding
operation, the arc length varies between 1 and 2 mm the welding current is in the range 200-250
A. Assuming a linear power sourse, the short circuit current is _________ A.
 Equal amounts of a liquid metal at the same temperature are poured into three moulds made of
steel, copper and aluminum. The shape of the cavity is a cylinder with 15 mm diameter. The size
of the moulds are such that the outside temperature of the moulds do not increase appreciably
beyond the atmospheric temperature during solidification. The sequence of solidification in the
mould from the fastest to slowest is

(Thermal conductivities of steel, copper and aluminum are 60.5, 401 and 237 W/m-K,
respectively. Specific heats of steel, copper and aluminum are 434, 385 and 903 J/kg-K,
respectively. Densities of steel, copper and aluminum are 7854, 8933 and 2700 kg/m 3,
respectively.)

(A) Copper - Steel - Aluminum

(B) Aluminum - Steel - Copper

(C) Copper - Aluminum - Steel

(D) Steel - Copper - Aluminum

Show Answer
Question No. 258
GATE - 2016
02
Spot welding of two steel sheets each 2 mm thick is carried out successfully by passing 4 kA of
current for 0.2 seconds through the electrodes. The resulting weld nugget formed between the
sheets is 5 mm in diameter. Assuming cylindrical shape for the nugget, the thickness of the
nugget is________mm.

Latent heat of fusion for steel 1400 kJ/kg

Effective resistance of the weld joint 200
Density of steel 8000 kg/m3

Show Answer
Question No. 260
GATE - 2016
02
In a sheet metal of 2 mm thickness a hole of 10 mm diameter needs to be punched. The yield
strength in tension of the sheet material is 100 MPa and its ultimate shear strength is 80 MPa.
The force required to punch the hole (in kN) is __________
 Show Answer
Question No. 34
GATE - 2015
01
In a linear arc welding process, the heat input per unit length is inversely proportional to

(A) welding current

(B) welding voltage

(C) welding speed

(D) duty cycle of the power source

Show Answer
Question No. 41
GATE - 2015
02
A DC welding power source has a linear voltage-current (V-I) characteristic with open circuit
voltage of 80 V and a short circuit current of 300 A. For maximum arc power , the current (in
Amperes) should be set as_______.
 Show Answer
Question No. 46
GATE - 2015
02
The solidification time of a casting is proportional to (VA)2VA2 ,Where V is the volume of the
casting and A is the total casting surface area losing heat. Two cubes of same material and size
are cast using sand casting process. The top face of one of the cubes is completely insulated. The
ratio of the solidification time for the cube with top face insulated to that of the other cube is

(A) 25362536

(B) 36253625

(C) 1

(D) 6565

Show Answer
Question No. 47
GATE - 2015
02
In a slab rolling operation, the maximum thickness reduction (hmax)(hmax) is given
by hmax=2Rhmax=2R, where R is the radius of the roll and is the coefficient of friction
 between the roll and the sheet. If = 0.1 , the maximum angle subtended by the deformation
zone at the centre of the roll (bit angle in degrees) is________.

Show Answer
Question No. 158
GATE - 2015
02
A cube and a sphere made of cast iron (each volume 1000 cm3) were cast under identical
conditions. The time taken for solidifying the cube was 4 s. The solidification time ( in s) for the
sphere is ________.

Show Answer
Question No. 159
GATE - 2015
02
In a two stage wire drawing operation, the fractional reduction (ratio of change in cross sectional
area to initial cross sectional area) in the first stage is 0.4. The fractional reduction in the second
stage is 0.3. The overall fractional reduction is

(A) 0.24

(B) 0.58

(C) 0.60


(D) 1.00

Show Answer
Question No. 160
GATE - 2015
02
The flow stress (in MPa) of a material is given by

=5000.1=5000.1,
Where is true strain. The Youngs modulus of elasticity of the material is 200 GPa. A block of
thickness 100 mm made of this material is compressed to 95 mm thickness and then the load is
removed. The final dimension of the block (in mm) is ____

Show Answer
Question No. 161
GATE - 2015
02
During a TIG welding process, the arc current and arc voltage were 50 A and 60 V, respectively,
when the welding speed was 150 mm/min. In another process, the TIG welding is carried out at a
welding speed of 120 mm/min at the same arc welding voltage and heat input to the material so
that weld quality remains the same. The welding current (in A) for this process is

(A) 40.00

(B) 44.72

 (C) 55.90

(D) 62.25

Show Answer
Question No. 217
GATE - 2015
01
In full mould (cavity-less) casting process, the pattern is made of

(A) expanded polystyrene

(B) wax

(C) epoxy

(D) plaster of Paris

Show Answer
 Question No. 231
GATE - 2015
01
Which two of the following joining processes are autogeneous?

(i) Diffusion welding

(ii) Electroslag welding
(iii
Tungsten inert gas welding
)
(iv)Friction weding

(A) (i) and (iv)

(B) (ii) and (iii)

(C) (ii) and (iv)

(D) (i) and (iii)

Show Answer
Question No. 241
GATE - 2015
02
 In a rolling operation using rolls of diameter 500 mm, if a 25 mm thick plate cannot be reduced
to less than 20 mm in one pass, the coefficient of friction between the roll and the plate
is__________

Show Answer
Question No. 242
GATE - 2015
02
Ratio of solidification time of a cylindrical casting (height=radius) to that of a cubic casting of
side two times the height of cylindrical casting is________

Show Answer
Question No. 260
GATE - 2015
02
The dimensions of a cylindrical side riser (height = diameter) for a 25 cm 15 cm 5 cm steel
casting are to be determined. For the tabulated shape factor values given below, diameter of the
riser (in cm) is ______.

Shape factor 2 4 6 8 10 12
Raiser volume/ Casting volume1.00.700.550.500.400.35

Show Answer
Question No. 32
GATE - 2014
01
The major difficulty during welding of aluminium is due to its

(A) high tendency of oxidation

 (B) high thermal conductivity

(C) low melting point

(D) low density

Show Answer
Question No. 35
GATE - 2014
01
In solid-state welding, the contamination layers between the surfaces to be welded are removed
by

(A) alcohol

(B) plastic deformation

(C) water jet



(D) sand blasting

Show Answer
Question No. 65
GATE - 2014
02
An aluminium alloy (density 2600 kg/m 3) casting is to be produced. A cylindrical hole of 100
mm diameter and 100 mm length is made in the casting using sand core (density 1600 kg/m 3).
The net buoyancy force (in newton) acting on the core is _______

Show Answer
Question No. 135
GATE - 2014
01
With respect to metal working, match Group A with Group B:

Group A Group B
P: Defect in extrusion I: alligatoring
Q: Defect in rolling II: scab
R: Product of skew rolling III: fish tail
S: Product of rolling through cluster
IV: seamless tube
mill
V: thin sheet with tight tolerance
VI: semi-finished balls of ball
bearing

(A) P-II, Q-III, R-VI, S-V

(B) P-III, Q-I, R-VI, S-V



(C) P-III, Q-I, R-IV, S-VI

(D) P-I, Q-II, R-V, S-VI

Show Answer
Question No. 163
GATE - 2014
02
A mild steel plate has to be rolled in one pass such that the final plate thickness is 2/3 rd of the
initial thickness, with the entrance speed of 10 m/min and roll diameter of 500 mm. If the plate
widens by 2% during rolling, the exit velocity (in m/min) is _______

Show Answer
Question No. 165
GATE - 2014
02
A rectangular hole of size 100 mm 50 mm is to be made on a 5 mm thick sheet of steel having
ultimate tensile strength and shear strength of 500 MPa and 300 MPa, respectively. The hole is
made by punching process. Neglecting the effect of clearance, the punching force (in kN) is

(A) 300

(B) 450


(C) 600

(D) 750

Show Answer
Question No. 232
GATE - 2014
01
Match the casting defects (Group A) with the probable causes (Group B):

Group A Group B
P: Hot tears 1: Improper fusion of two streams of liquid metal
Q: Shrinkage 2: Low permeability of the sand mould
R: Blow holes3: Volumetric contraction both in liquid and solid stage
S: Cold Shut 4: Differential cooling rate

(A) P-1, Q-3, R-2, S-4

(B) P-4, Q-3, R-2, S-1

 (C) P-3, Q-4, R-2, S-1

(D) P-1, Q-2, R-4, S-3

Show Answer
Question No. 235
GATE - 2014
01
The hot tearing in a metal casting is due to

(A) high fluidity

(B) high melt temperature

(C) wide range of solidification temperature

(D) low coefficient of thermal expansion

Show Answer
 Question No. 262
GATE - 2014
02
A cylindrical blind riser with diameter d and height h, is placed on the top of the mold cavity
of a closed type sand mold son as shown in the figure. If the riser is of a constant Volume then
the rate of solidification in the riser is the least when the ratio h:d is

(A) 1:2

(B) 2:1

(C) 1:4

(D) 4:1
 Show Answer
Question No. 265
GATE - 2014
02
For spot welding of two steel sheets (base metal) each of 3 mm thickness, welding current of
10000 A is applied for 0.2 s. The heat dissipated to the base metal is 1000 J. Assuming that the
heat required for melting 1 mm3 volume of steel is 20 J and interfacial contact resistance between
sheets is 0.0002 , the volume (in mm3) of weld nugget is __

Show Answer
Question No. 330
GATE - 2014
01
Within the Heat Affected Zone (HAZ) in a fusion welding process, the work material undergoes

(A) microstructural changes but does not melt

(B) neither melting nor microstructural changes

(C) both melting and microstructural changes after solidification

(D) melting and retains the original microstructure after solidification

Show Answer
 Question No. 363
GATE - 2014
02
A cylindrical riser of 6 cm diameter and 6 cm height has to be designed for a sand casting mould
for producing a steel rectangular plate casting of 7 cm 10 cm 2 cm dimensions having the
total solidification time of 1.36 minute. The total solidification time (in minute) of the riser is
_______

Show Answer
Question No. 365
GATE - 2014
02
A butt weld joint is developed on steel plates having yield and ultimate tensile strength of 500
MPa and 700 MPa, respectively. The thickness of the plates is 8 mm and width is 20 mm.
Improper selection of welding parameters caused an undercut of 3 mm depth along the weld. The
maximum transverse tensile load (in kN) carrying capacity of the developed weld joint is
_______

Show Answer
Question No. 11
GATE - 2013
01
Match the CORRECT pairs.

Processes Characteristics / Applications

P. Friction Welding 1. Non-consumable electrode
Q. Gas Metal Arc Welding 2. Joining of thick plates
R. Tungsten Inert Gas Welding 3. Consumable electrode wire
S. Electroslag Welding 4. Joining of cylindrical dissimilar materials

(A) P-4, Q-3, R-1, S-2

 (B) P-4, Q-2, R-3, S-1

(C) P-2, Q-3, R-4, S-1

(D) P-2, Q-4, R-1, S-3

Show Answer
Question No. 16
GATE - 2013
01
A cube shaped casting solidifies in 5 min. The solidification time in min for a cube of the same
material, which is 8 times heavier than the original casting, will be

(A) 10

(B) 20

(C) 24


(D) 40

Show Answer
Question No. 37
GATE - 2012
02
Calculate the punch size in mm, for a circular blanking operation for which details are given
below.

Size of the blank 25 mm

Thickness of the sheet 2 mm
0.06 m
Radial clearance between punch and die
m
0.05 m
Die allowance
m

(A) 24.83

(B) 24.89

(C) 25.01

 (D) 25.17

Show Answer
Question No. 39
GATE - 2012
02
In a DC arc welding operation, the voltage-arc length characteristic was obtained as Varc = 20 +
5l where the arc length l was varied between 5 mm and 7 mm. Here Varc denotes the arc voltage
in Volts. The arc current was varied from 400 A to 500 A. Assuming linear power source
characteristic, the open circuit voltage and the short circuit current for the welding operation are

(A) 45 V, 450 A

(B) 75 V, 750 A

(C) 95 V, 950 A

(D) 150 V, 1500 A

Show Answer
Question No. 7
GATE - 2011
01
The operation in which oil is permeated into the pores of a powder metallurgy product is known
as


(A) mixing

(B) sintering

(C) impregnation

(D) infiltration

Show Answer
Question No. 12
GATE - 2011
01
Green sand mould indicates that

(A) polymeric mould has been cured

 (B) mould has been totally dried

(C) mould is green in colour

(D) mould contains moisture

Show Answer
Question No. 24
GATE - 2011
01
Which one among the following welding processes uses non-consumable electrode?

(A) Gas metal arc welding

(B) Submerged arc welding

(C) Gas tungsten arc welding



(D) Flux coated arc welding

Show Answer
Question No. 36
GATE - 2011
02
The shear strength of a sheet metal is 300 MPa. The blanking force required to produce a blank
of 100 mm diameter from a 1.5 mm thick sheet is close to

(A) 45 kN

(B) 70 kN

(C) 141 kN

(D) 3500 kN

Show Answer
Question No. 47
GATE - 2011
02
 A cubic casting of 50 mm side undergoes volumetric solidification shrinkage and volumetric
solid contraction of 4% and 6% respectively. No riser is used. Assume uniform cooling in all
directions. The side of the cube after solidification and contraction is

(A) 48.32 mm

(B) 49.90 mm

(C) 49.94 mm

(D) 49.96 mm

Show Answer
Question No. 19
GATE - 2010
01
In a gating system, the ratio 1:2:4 represents

(A) sprue base area: runner area: ingate area



(B) pouring basin area: ingate area: runner area

(C) sprue base area: ingate area: casting area

(D) runner area: ingate area: casting area

Show Answer
Question No. 43
GATE - 2010
02
Two pipes of inner diameter 100mm and outer diameter 110mm each joined by flash butt
welding using 30V power supply. At the interface, 1mm of material melts from each pipe which
has a resistance of 42.4. If the unit melt energy is 64.4MJm -3, then time required for welding in
seconds is

(A) 1

(B) 5

 (C) 10

(D) 20

Show Answer
Question No. 54
GATE - 2010
02
In a shear cutting operation, a sheet of 5mm thickness is cut along a length of 200mm. The
cutting blade is 400mm long and zero-shear (S=0) is provided on the edge. The ultimate shear
strength of the sheet is 100MPa and penetration to thickness ratio is 0.2. Neglect friction.

Assuming force vs displacement curve to be rectangular, the work done (in J) is

(A) 100

(B) 200

 (C) 250

(D) 300

Show Answer
Question No. 55
GATE - 2010
02
In a shear cutting operation, a sheet of 5mm thickness is cut along a length of 200mm. The
cutting blade is 400mm long and zero-shear (S=0) is provided on the edge. The ultimate shear
strength of the sheet is 100MPa and penetration to thickness ratio is 0.2. Neglect friction.

A shear of 20mm (S=20mm) is now provided on the blade. Assuming force vs displacement
curve to be trapezoidal, the maximum force (in kN) exerted is

(A) 5

(B) 10


(C) 20

(D) 40

Show Answer
Question No. 17
GATE - 2009
01
Two streams of liquid metal which are not hot enough to fuse properly result into a casting defect
known as

(A) cold shut

(B) swell

(C) sand wash

 (D) scab

Show Answer
Question No. 50
GATE - 2009
02
Match the items in Column I and Column II.

Column I Column II
P. Metallic Chills 1. Support for the core
Q. Metallic Chaplets 2. Reservoir of the molten metal
R. Riser 3. Control cooling of critical sections
S. Exothermic Padding 4. Progressive solidification

(A) P-1,Q-3,R-2,S-4

(B) P-1,Q-4,R-2,S-3

(C) P-3,Q-4,R-2,S-1

(D) P-4,Q-1,R-2,S-3

Show Answer
Question No. 63
 GATE - 2008
02
While cooling, a cubical casting of side 40 mm undergoes 3%, 4% and 5% volume shrinkage
during the liquid state, phase transition and solid state, respectively. The volume of metal
compensated from the riser is

(A) 2%

(B) 7%

(C) 8%

(D) 9%

Show Answer
Question No. 67
GATE - 2008
02
In arc welding of a butt joint, the welding speed is to be selected such that highest cooling rate is
achieved. Melting efficiency and heat transfer efficiency are 0.5 and 0.7, respectively. The area
of the weld cross section is 5mm2 and the unit energy required to melt the metal is 10 J/mm 3. If
the welding power is 2 kW, the welding speed in mm/s is closest to

 (A) 4

(B) 14

(C) 24

(D) 34

Show Answer
Question No. 68
GATE - 2008
02
In the deep drawing of cups, blanks show a tendency to wrinkle up around the periphery (flange).
The most likely cause and remedy of the phenomenon are, respectively,

(A) Buckling due to circumferential compression; Increase blank holder pressure

(B) High blank holder pressure and high friction; Reduce blank holder pressure and apply lubricant

 (C) High temperature causing increase in circumferential length; Apply coolant to blank

(D) Buckling due to circumferential compression; decrease blank holder pressure

Show Answer
Question No. 17
GATE - 2007
01
Which one of the following is a solid state joining process?

(A) gas tungsten arc welding

(B) resistance spot welding

(C) friction welding

(D) submerged arc welding

Show Answer
 Question No. 20
GATE - 2007
01
Volume of a cube of side l and volume of a sphere of radius r are equal. Both the cube and the
sphere are solid and of same material. They are being cast. The ratio of the solidification time of
the cube to the same of the sphere is

(A) (46)3(rl)6463rl6

(B) (46)(rl)246rl2

(C) (46)2(rl)3462rl3

(D) (46)2(rl)4462rl4

Show Answer
Question No. 57
GATE - 2007
02
A direct current welding machine with a linear power source characteristic provides open circuit
voltage of 80 V and short circuit current of 800 A. During welding with the machine, the
measured arc current is 500 A corresponding to an arc length of 5.0 mm and the measured arc
current is 460 A corresponding to an arc length of 7.0 mm. The linear voltage (E) arc length (L)
characteristic of the welding arc can be given as (where E is in Volt and L is in mm)


(A) E = 20 + 2L

(B) E = 20 + 8L

(C) E = 80 + 2L

(D) E = 80 + 8L

Show Answer
Question No. 60
GATE - 2007
02
Two metallic sheets, each of 2.0 mm thickness, are welded in a lap joint configuration by
resistance spot welding at a welding current of 10 kA and welding time of 10 millisecond. A
spherical fusion zone extending up to the full thickness of each sheet is formed. The properties of
the metallic sheets are given as:

ambient temperature = 293 K

melting temperature = 1793 K density = 7000 kg/m3
latent heat of fusion = 300 kJ/kgspecific heat = 800 J/kg K
Assume : (i) contact resistance along sheet sheet interface is 500 micro-ohm and along
electrode sheet interface is zero; (ii) no conductive heat loss through the bulk sheet materials;
and (iii) the complete weld fusion zone is at the melting temperature.

The melting efficiency (in %) of the process is



(A) 50.37

(B) 60.37

(C) 70.37

(D) 80.37

Show Answer
Question No. 63
GATE - 2007
02
The thickness of a metallic sheet is reduced from an initial value of 16 mm to a final value of 10
mm in one single pass rolling with a pair of cylindrical rollers each of diameter of 400 mm. The
bite angle in degree will be

(A) 5.936


(B) 7.936

(C) 8.936

(D) 9.936

Show Answer
Question No. 64
GATE - 2007
02
Match the correct combination for following metal working processes.

Processes Associated state of stress

P. Blanking 1.Tension
Q.Stretch Forming2.Compression
R.Coining 3.Shear
S. Deep Drawing 4.Tension and Compression
5.Tension and Shear

(A) P-2, Q-1, R-3, S-4

(B) P-3, Q-4, R-1, S-5



(C) P-5, Q-4, R-3, S-1

(D) P-3, Q-1, R-2, S-4

Show Answer
Question No. 65
GATE - 2007
02
A 200 mm long down sprue has an area of cross section of 650 mm 2 where the pouring basin
meets the down sprue (i.e. at the beginning of the down sprue). A constant head of molten metal
is maintained by the pouring basin. The molten metal flow rate is 6.5 10 5 mm3/s. Considering
the end of down sprue to be open to atmosphere and an acceleration due to gravity of 10 4 mm/s2,
the area of the down sprue in mm2 at its end (avoiding aspiration effect) should be


(A) 650.0

(B) 350.0

(C) 290.7

(D) 190

Show Answer
Question No. 66
GATE - 2007
02
The force requirement in a blanking operation of low carbon steel sheet is 5.0 kN. The thickness
of the sheet is t and diameter of the blanked part is d. For the same work material, if the
diameter of the blanked part is increased to 1.5 d and thickness is reduced to 0.4 t, the new
blanking force in kN is

(A) 3.0


(B) 4.5

(C) 5.0

(D) 8.0