Class 4 (4th Engineer) MEKG 📅 May 2023

Exam Question

With reference to electric arc welding:

(a) Draw a labeled sectional sketch of a satisfactory butt weld. (6)

(b) Briefly define the following defects that may occur and how they may have been caused:

(i) Under cut (2)

(ii) Splatter (2)

(iii) Inclusion (2)

(iv) Blow hole (2)

(v) Incomplete root penetration (2)

Reference Answer

### (a) Satisfactory Butt Weld
A satisfactory butt weld exhibits complete fusion between the filler metal and the parent metal throughout the entire thickness of the joint. The key characteristics to be illustrated in a sectional sketch for full marks are:
* **Weld Profile:** The weld face should have a slightly convex profile, known as reinforcement, ensuring the weld is at least as thick as the parent material. Excessive reinforcement is undesirable as it can create stress concentrations at the toes of the weld.
* **Penetration:** The weld must achieve full penetration to the root of the joint, ensuring a strong, continuous connection. The root bead should be smooth and fully fused.

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