The GATE Grind

GATE Manufacturing Processes I: Joining of Materials – Previous Year Questions

11 GATE previous year questions on Joining of Materials (Manufacturing Processes I, Production and Industrial Engineering) with answers and explanations, from every paper.

  1. GATE 2021 PI Q17 (1 mark, Multiple choice) – Which defect is NOT associated with welding?
  2. GATE 2021 PI Q54 (2 marks, Numerical answer) – An arc-welding DC source has linear characteristic with open-circuit voltage 60 V and short-circuit current 600 A. Melting energy is 10 J/mm³;…
  3. GATE 2022 PI Q51 (2 marks, Numerical answer) – Steady GTAW uses 18 V and 160 A. Arc creation loses 40% of input power; workpiece convection/radiation lose 800 W. Find effective power melting the…
  4. GATE 2023 PI Q34 (1 mark, Numerical answer) – Resistance spot welding uses current 4500 A for 0.2 s. Effective interface resistance is 400 × 10⁻⁶ Ω and thermal efficiency is 50%. Find heat used to…
  5. GATE 2023 PI Q59 (2 marks, Numerical answer) – An arc weld is made at 25 V, 200 A and speed 2 mm/s. Heat used for melting is 80% of generated heat; unit melting energy is 10 J/mm³. Find volume of…
  6. GATE 2024 PI Q29 (1 mark, Multiple select) – Which ONE OR MORE statements about friction stir welding are true?
  7. GATE 2024 PI Q52 (2 marks, Numerical answer) – Mild-steel butt joints are arc welded at 85% heat-transfer efficiency, ignoring other losses. First weld: 30 V,180 A,6 mm/s. Second uses identical…
  8. GATE 2025 PI Q16 (1 mark, Multiple choice) – In which welding process is an exit hole common?
  9. GATE 2025 PI Q47 (2 marks, Numerical answer) – For DC arc welding, voltage V (V) and arc length l (cm) satisfy V = 30 + 30l. Open-circuit voltage is 80 V. Find maximum possible arc length (two…
  10. GATE 2026 PI Q12 (1 mark, Multiple choice) – Which statement about brazing filler material is FALSE?
  11. GATE 2026 PI Q13 (1 mark, Multiple choice) – A 6 kW arc-welding source joins two similar metals. Total energy loss is 50%, weld cross-sectional area is 10 mm² and specific melting energy is 15…