Short Notes
Classification of Welding Processes:
1) Arc Welding
a. Carbon Arc
b. Metal Arc
c. Metal Inert Gas (MIG)
d. Tungsten Inert Gas (TIG)
e. Plasma Arc
f. Submerged Arc
g. Electro-Slag
2) Gas Welding
a. Oxy-acetylene
b. Air-acetylene
c. Oxy-hydrogen
3) Resistance welding
a. Butt
b. Spot
c. Seam
d. Projection
e. Percussion
4) Thermit Welding
5) Solid State Welding
a. Friction
b. Ultrasonic
c. Diffusion
d. Explosive
6) Newer Welding
a. Electron-beam
b. Laser
7) Related Process
a. Oxy-acetylene cutting
b. Arc cutting
c. Hard facing
d. Brazing
e. Soldering
% in Electrode
C
Mn
Si
S
P
N2
O2
0.12
0.50
0.3
0.04
0.03
0.003
0.02
0.02
0.10
Trace
0.03
0.025
0.10
0.35
Weld using
Covered
Electrode
0.09
0.50
0.10
0.03
0.025
0.03
00.1
11)
The obvious move to fix this was to use coated electrodes
which provide the three main requirements of modern electrode
coating:
a. Protective Coating
b. Arc Stabilization
c. Slag
12)
The coating used was flux, and the difference in figures
between a bare wire weld and a coated electrode weld can be seen
in the table below. Big improvements were made which led to
acceptable figures.
Material Properties
YS
UTS
% Reduction in Area
Elongation
Impact Izod
Coated Weld
26
32
50
30
60
13)
It is interesting to note that a bare arc weld on a medium
carbon steel results in a material with worse properties than mild
steel.
14)
Disadvantages of flux covered electrodes:
a. Slag Deposit: very problematic in carpet welding
b. Slow Process: current cannot be dramatically increased to
make the process faster due to the flux.
c. Discontinuous Process: makes it vulnerable to defects
15)
An interesting feature of metal arc welding is that it can be
carried out in the vertical or overhead position. This means that
there are forces operating in the arc which propel the molten droplet
upwards from the end of the electrode against gravity.
16)
The coating of an electrode must provide:
a. A protective slag to prevent oxidation of the weld metal,
improve weld metal quality (by slag-metal reactions) and give
good weld bead shape
b. Gas shielding for the arc
c. Adequate mechanical properties of the weld metal
d. Easy arc striking and stability
17)
The coating can also be used to introduce alloying additions
and improve the handling characteristics.
Continuous Electrodes
1) Two problems had to be overcome:
a. The electrode had to be sufficiently flexible to prevent flaking
of the coating
b. Current had to be introduced into the core wire through the
non-conducting coating.
2) These were solved by developments in coating binders and by
winding two or more spirals of fine wire around the thicker core wire
Electro-slag Welding
Submerged Arc Process
Comparing the following three Arc welding methods, the following welding
rates can be observed:
5cm
10cm
MMA
Submerged
60 minutes
150 minutes
13 minutes
36 minutes
Electroslag
Electrode x1
5.4 minutes
10 minutes
Electroslag
Electrode x3
/ (negligible)
3 minutes
The previous methods for welding have problems if an attempt is made to use
them on non-ferrous materials such as Aluminium. You want the flux material to
be more reactive than the metal that needs to be protected. With steel and other
ferrous metals, almost everything is more reactive than them, so it is not a
problem. But for non-ferrous metals, this can be a problem, since they tend to be
more reactive than the elements in the flux. This is needed for the elements to
react with the oxygen and not for the metal to react. Thus finding a flux that is
more reactive than them is a challenge. There do exist metals such as fluorine
which are more reactive, but they are by nature very corrosive materials, which
is highly undesirable. Welded objects tend to be subjected to fatigue, so cracks
caused by corrosion by the flux is highly problematic.
1) One of the most popular arc welding techniques used for nonferrous metals.
2) Advantages of TIG:
a. No slag inclusion
b. Very flexible
c. Can weld many different metals
d. Can be used in a lot of positions and situations
e. A relatively cheap process when compared to electroslag
3) Disadvantages of TIG:
a. Half the heat is wasted as it goes into the electrode
b. It is not a continuous process
c. An expensive process from the consumable point of
view, since the gases used such as Argon and Helium.
d. Two-Three handed process
e. Requires skilled personnel to carry out
4) The arc is struck between the non-consumable tungsten electrode
and the metal to be welded, while filler metal is added by feeding a
rod into the molten pool.
5) Because of the low level of contamination this process produced
welds of very good quality
Stud Welding
Arc Welding
1) Can be automated.
2) Welds studs with another surface.
3) Used for pre-stressed concrete and when repetition is employed for
welding.