1. Describe the principles of spot welding process.

Firstly, the surfaces of metal sheets are cleaned from all contamination like dirt, grease and oil. Then,
the metal sheets are placed together using clamp. Then, two copper electrodes were placed at one side
of the metal sheet surface and another one at other surface. Next, the electric current was passed
through the two plates. Because of that, resistance occurs and heat is generated at the contact point.
The time taken for heat to dissipate is very short thus the metal gets melted and then the joint is
formed.

2. What advantages does friction stir welding have over other methods?

There are many advantages of friction stir welding over other methods. First of all, friction stir welding
have no arc or fume, porosity and spatter. Besides that, it also can operate in all positions and can weld
aluminum and copper of >75mm thickness in one pass. It also have low distortion and shrinkage even in
long welds. Other than that, resistance stir welding are energy efficient and have excellent mechanical
properties in tensile, fatigue and bend test.

3. How important is closed fit for two parts that are to be brazed? Explain

Since brazing use the principle of capillary action to distribute the molten filler metal between the
surfaces of the base metals, it is important to determine the size of clearance between the base metal
metals. It is because to allow the capillary work at optimum level. The amount of clearance between the
metals depends on the tensile strength of the brazed metal. If the gap is to narrow, it is harder for the
filler metal to distribute through the joint.

4. Refer to the simple butt and lap joint. Assuming that the area of the butt joint is 10mm x 25mmand
referring to the adhesive properties given in table, estimate minimum and maximum tensile force that
this joint can withstand. Then estimate these forces for the lap joint, assuming that its area is 15mm x
15mm.