WELDING

Workshop Assignment #2

WELDING
Welding is defined as a process where two or more pieces of metal or thermoplastics are fastened together by use of heat and pressure. The process of applying heat softens the material and enables it to affix together as one in a joint area when an adequate amount of pressure is applied.

Welding Techniques
Welding processes can be classified into different types depending on the combination of pressure and temperature used for joining the materials. The different types of welding processes are: Gas Welding: Gas welding is also known as Oxy-fuel welding and is the oldest form of welding processes. Over the years, its importance has deteriorated; nevertheless, it is still widely used for repairing hollow items like pipes and tubes. It is also used widely in the jewelry industry and for welding materials that are unable to withstand higher temperatures.

Arc Welding: Arc welding is a popular form of welding due the low cost of the process. The process begins with a device that gives off an electric current. This device can differ greatly from process to process yet it always enables electric current to move through materials that without the device, would be considered non-conductive. It is called arc welding because an electrical current is created between the welding device and the materials to be welded which at times gives an arch like appearance. Electro-slag welding: Electroslag is a generally fast welding process used to join large materials such as thick steel plates. These plates or materials are usually arranged in a vertical position, as the Electroslag weld is designed to weld at this angle without causing distortion to the welder.

Resistance Welding: Resistance welding is a term that refers to a group of welding processes in which the resistance of the metal pieces towards each other caused by the flow of electric charge, produces the heat for joining the metals. In this type external pressure has to be applied. However, there is no need for any filler or external heat. It is the most environment friendly of all methods as it causes least pollution. However, it is an expensive method.

Solid State Welding: It refers to a group of welding processes, in which the fusion of the metals take place at temperatures which are below their melting points. The base

metals do not undergo significant melting and retain their original properties. Radiant Energy Welding: This type involves the application of an energy beam on the base metal. It involves the use of electron beam and laser beam for welding. This is one of the most modern techniques of welding, and is fast and accurate. Thermo Chemical Welding: Thermo chemical welding refers to a group of welding processes in which the base metals to be united are fused by using heat generated from the chemical reactions (Exothermic reactions). Friction Welding: We often associate welding with sparks flying all across the place. On the contrary, not all forms of welding emit sparks. Friction welding is one type of welding which does not release any sort of sparks, fumes, intense light and sprays into the air during the welding process.

Applications of Welding
Welding finds its applications in automobile industry, and in the construction of buildings, bridges and ships, submarines, pressure vessels, offshore structures, storage tanks, oil, gas and water pipelines, girders, press frames, and water turbines. In making extensions to the hospital buildings, where construction noise is required to be minimum, the value of welding is significant. Rapid progress in exploring the space has been made possible by new methods of welding and the knowledge of welding metallurgy. The aircraft industry cannot meet the enormous demands for airplanes, fighter and guided planes, space crafts, rockets and missiles without welding. The process is used in critical applications like the fabrication of fission chambers of nuclear power plants. A large contribution, the welding has made to the society, is the manufacture of household products like refrigerators, kitchen cabinets, dishwashers and other similar items.

The use of welders:

Welders are the backbone for manufacturing industry because these are the devices that used to weld the metals. Metals is what concerned about the industries and the raw metals are not useful unless they are molded and welded well. So in that aspect the welders and welding equipment play a vital role. Also, remember that with the help of

single welding supply it is not possible to weld all types of metals. For each metal different welder needed. To weld steel and other non ferrous metals, tig welder is useful similarly for other types of metals other welding machines are used.

Types of welding products used in industries

Due to the advancement in technology, different welding products have been introduced and each types has their own merits. Tig welder particularly welds steel, aluminum, magnesium and copper. Mig welder is used for aluminum and steel and it allows for lower welding time compared to other processes. Stick welding is used to weld aluminum, steel, iron, nickel and copper. For all spot repairs in industries multiprocess units can be very useful. So welding industry is in peak now and it was a time where no one knows about the welding process, but today everyone came to understand and it got spread widely. So use the appropriate welding supplies and employ the correct welding technology.

Importance of Welding Techniques in Industrial Production

Manufacturing industries always need the help of welding in all their products, particularly aircraft industries and automobile industries need the help of great welders and without proper welding machines; they fail to meet their demands. So the industries need some good welders and the machines they choose should be good in all aspects. Without welding, it is very sure we cant get some of the electronic devices, bio medical applications, automobiles and battery pack applications. That much importance the welding machines have in manufacturing industries. Let us see some of the significant machines that are widely used in the manufacturing industries. arc welding is the second most welding process that have been in the existence after forge welding and this welding process creates an electric arc between the electrode and the base material by using the welding power supply.