Welding

Welding
Parts are joined together by Fusion. Fusion is brought about by a combination of heat and pressure between parts being joined. In normal welding processes very high temperatures and little or no pressure is used.

Welding conditions
Smooth joint surfaces that match each other

Surfaces clean and free from oxides, grease and dirt. Metals to be joined have same microstructure

Welding conditions continued.

The metals should be good quality (no internal impurities)

Welding Preparation
Before starting a weld, the joint edges should be carefully prepared. Beveling large edges Cleaning (Chemical/Mechanical)

Weld Joints

Weld defects
Welding Techniques

Welding Symbols

Weld Joints - Parts of a Weld Joint

Joint root Groove face, Root face and Root edge Root opening and Bevel Bevel angle, Groove angle and Groove radius

Weld Joints - Types of Weld Joint

Butt Joint Lap Joint T Joint Corner joint Edge Joint Splice Member

Joint Root
is that portion of a joint to be welded where the members are closest to each other The joint root may be either a point, line, or an area The joint roots are shown as shaded areas in (A)-(D) and lines in (E) (F)

Groove face, Root face and Root edge

Groove face is that surface of a member included in the groove Root face (land) is that portion of the groove face within the joint root

Root edge is a root face of zero width

Root opening and Bevel

Root opening is the separation between the work pieces at the joint root Bevel (chamfer) is an angular edge preparation

Bevel angle, Groove angle and Groove Radius

Butt Joint
A joint between two members aligned approximately in the same plane

Lap Joint
A joint between two overlapping members

T Joint
A joint between two members located approximately at right angles to each other

Corner Joint
A joint between two members located at right angles to each other

Edge Joint
A joint between the edges of two or more parallel or nearly parallel members

Splice member
is the work piece that spans the joint in a spliced joint

Singlespliced butt joint

Double-spliced butt joint with joint filler

Basic components of a WELDING SYMBOL

Reference Line (Required element)

Arrow Tail

Reference Line must always be horizontal, Arrow points to the line or lines on drawing which clearly identify the proposed joint or weld area.

Weld Symbol Terminology

OTHER SIDE ARROW SIDE

Fillet Weld (Arrow Side Only) Fillet Weld (Both sides)

Work

Welding Techniques
There are many different methods of welding. The difference between them is outlined by two important features The way the metal is heated The way additional filler metal if any is fed into the weld

Types of Welding
Electric Arc Welding Friction Welding

Gas Welding
Resistance Welding

Robotic Welding

Electric Arc Welding

The heat for fusion is supplied by an electric arc

Arc is formed between electrode and work this melts and fuses the joint edges

Types of Electric Arc Welding

Manual Metal Arc (MMA) Metal Arc Gas Shielded (MAGS) MIG

Tungsten Arc Gas Shielded (TAGS) TIG

Submerged Arc Welding (SAW)

Manual Metal Arc (MMA)

Most widely used of all the arc welding processes Commonly called stick welding

Applications
repair work, structural steelwork,

Touch electrode against work withdraw electrode to establish arc. Heat of arc melts base metal, the electrodes metal core, and any metal particles in electrodes covering. Heat also melts, vaporises, or breaks down chemically non-metallic substances in covering for arc shielding. Mixing of molten base metal and filler metal from electrode produces coalescence required to effect joining.

Advantages
Used with many electrode types & sizes Used in all positions

Used on great variety of materials

Flexibility in operator control makes it the most versatile of allwelding processes Low cost of equipment

Dis-advantages
Rod becomes shorter & periodically needs replacing Slows production rate (% time welder welding)

The Electrode and Coating

Coating is a combination of chemicals

Cellulosic electrodes contain cellulose

Rutile electrodes titanium oxide (rutile)

Basic electrodes contain calcium carbonate (limestone) and calcium fluoride (fluorspar)

Function of Electrode Coating

Produce gas to shield weld pool from oxidisising effects of atmosphere

Fluxing elements help weld pool to form

Helps slag to form-removes impurities

Slag slows down cooling preventing Brittleness

Can contain alloying elements or additional filler metal

Equipment used in MMA

AC power source
Takes power directly from mains power supply. It use a transformer to supply the correct voltage to suit the welding conditions.

DC power source
Two types

DC generator
Transformer-rectifier

DC Generator An electricity generator is driven by a motor. The motor can be electric, petrol or diesel. The generator provides DC current for the arc

Transformer-rectifier A transformer with an electrical device to change AC to DC, this is known as a rectifier. It has the advantage of being able to supply both DC and AC

Basic Transformer-rectifier circuit (AC to DC)

On/Off switch Step Down Transformer Bridge Rectifier

Smothing Capacitor
High AC Voltage 230V + DC output _ Low AC Voltage 1050V

Transformer
A transformer converts AC current at one voltage to AC at a higher or lower voltage

Step Down

Step Up

Metal Arc Gas Shielded (MAGS) MIG

MIG is similar to MMA in that heat for welding is produced by forming an arc between a metal electrode and the workpiece

Applications
Sheet and Heavy plate, production welding by robots on cars

MIG is similar to MMA in that heat for welding is produced by forming an arc between a metal electrode and the workpiece; the electrode melts to form the weld bead. The main difference is that the metal electrode is a small diameter wire fed from a spool and a sheilding gas is used. As the wire is continuously fed, the process is often referred to as semi-automatic welding.

Advantages

Large gaps filled or bridged easily Welding can be done in all positions No slag removal required High welding speeds High weld quality Less distortion of work piece

Equipmnt used in MAGS

Three major elements are : Welding torch and accessories Welding control & Wire feed motor Power Source

Shielding Gas

Welding torch and accessories

GAS DIFFUSER NOZZLE

CONTACT TIP

The welding torch guides the wire and shielding gas to the weld zone. Brings welding power to the wire also Major components/parts of the torch are the contact tip, shielding gas nozzle, gas diffuser, and the wire conduit

Welding control and wire feed motor

Main

function is to pull the wire from the spool and feed it to the arc Controls wire feed speed and regulates the starting and stopping of wire feed

Welding power source

Positive (+) lead is connected to the torch Negative (-) lead is connected to the work piece

Sheilding Gas
Purpose of shielding gas is to protect the weld area from the contaminants in the atmosphere Gas can be Inert, Reactive, or Mixtures of both Argon, Helium, and Carbon Dioxide are the main three gases used in MAGS

Tungsten Arc Gas Shielded (TAGS) TIG

TIG is similar to MMA in that heat for welding is produced by forming an arc between a metal electrode and the workpiece

Applications
Used in joining magnesium and Aluminium, stainless steels for high quality welding Thin sheet material

In the TIG process the arc is formed between a pointed tungsten electrode and the work piece in an inert atmosphere of argon or helium. The small intense arc provided by the pointed electrode is ideal for high quality and precision welding. The electrode is not consumed during welding. When filler metal is required, it must be added separately to the weldpool. There are two currents one for starting the arc the other switched on using a trigger or foot pedal, this is a high frequency current to maintain the arc, this is generated by a separte unit.

Advantages
Superior quality welding

Can be used in mechanised systems

Used to weld aluminium and stainless steels

Free of spatter
Low distortion

Equipment used in TAGS Power source

TIG must be operated with a constant current power source either DC or AC

Electrodes
Electrodes for DC welding are normally pure tungsten. In AC welding, as the electrode will be operating at a much higher temperature, It should be noted that because of the large amount of heat generated at the electrode, it is difficult to maintain a pointed tip and the end of the electrode assumes a spherical or 'ball' profile.

Sheilding Gas
Shielding gas is selected according to the material being welded. Argon Argon + Hydrogen Argon/Helium Helium is generally added to increase heat input (increase welding speed or weld penetration). Hydrogen will result in cleaner looking welds and also increase heat input, however, Hydrogen may promote porosity or hydrogen cracking.

Submerged Arc Welding (SAW)

Similar to MIG welding, SAW involves formation of an arc between a continuously-fed bare wire electrode and the workpiece

Applications
SAW welding taking place in the flat position. Ideal for heavy workpieces Carbon-manganese steels,low alloy steels and stainless steels

Submerged Arc Welding (SAW)

The process uses a flux to generate protective gases and slag, and to add alloying elements to the weld pool. A shielding gas is not required. Prior to welding, a thin layer of flux powder is placed on the work piece surface. The arc moves along the joint line and as it does so, excess flux is recycled via a hopper. Remaining fused slag layers can be easily removed after welding. As the arc is completely covered by the flux layer, heat loss is extremely low. There is no visible arc light, welding is spatter-free and there is no need for fume extraction.

Equipmnt used in SAW

Wire SAW is normally operated with a single wire on either AC or DC current. Common variants are: twin wire triple wire

single wire with hot wire addition

metal powdered flux addition All contribute to improved productivity through a marked increase in weld metal deposition rates and/or travel speeds.

Flux
Fluxes used in SAW are granular fusible minerals The flux is specially formulated to be compatible with a given electrode wire type so that the combination of flux and wire yields desired mechanical properties. All fluxes react with the weld pool to produce the weld metal chemical composition and mechanical properties

Gas Welding (Oxy-acetylene)

A number of welding processes use a flame produced by burning a mixture of fuel gas and oxygen. The gas usually used is Acetylene but other gases are also used.
Separate cylinders and a hose pipe from each cylinder transports the gases to a torch. Gas and fuel mix in the torch burns @ 3100C.

During the welding heat from the flame is concentrated on the joint edges until the metal melts and starts to flow. When the molten metal from both sides melts it starts to fuse, when the metal cools down the two parts become Permanently joined
Additional Filler Metal is fed in by hand into the weld pool, at regular intervals where it becomes molten and joins with the parent metal.

The Oxy-acetylene welding Flame

Reducing or Carburizing Excess acetylene (0.9:1) (Alloy steels and aluminium alloys) Oxidizing Excess oxygen (1.5:1) (Brasses, Bronzes, copper) Neutral Equal acetylene & oxygen (low carbon steel, mild steels). Inner Cone

Max. Temp. Zone

Secondary Combustion envelope

Acetylene feather

The Oxy-acetylene welding Flame

Carburising Neutral Oxidising

The Oxy-acetylene welding Flame

The oxy-acetylene flame has two distinct zones.

The inner zone (Primary combustion Zone) is the hottest part of the flame. The welding should be performed so as the point of the inner zone should be just above the joint edges.
C2H2 + O2 2CO + H2

Primary Combustion zone

The outer zone the secondary combustion envelope performs two functions Preheats the joint edges Prevents oxidation by using some of the surrounding oxygen from weld pool for combustion and gives off carbon dioxide and water vapour CO + H2 + O2 CO2 + H2O

Secondary Combustion zone

Equipment used in O-A welding

The oxygen and acetylene hose pipes Gases used Gas pressure Regulators Flashback arrestor Welding torch/Welding nozzle Filler rods and fluxes

The oxygen and acetylene hose pipes

Reinforced rubber hoses. Acetylene hose has left hand thread couplings and colour coded red. Oxygen hose has right handed thread couplings and colour coded blue

Gases used
Oxygen extracted from air and compressed into cylinders at high pressure. Cylinder is black. Oil should never be brought into contact and should not be used on fittings Acetylene (C2H2) is a fuel gas. Cannot be compressed directly as explodes at high pressures. Cylinders are packed with porous material which is filled with acetone Acetone absorbs acetylene. Cylinder colour coded maroon

Gas Pressure Regulators

One gauge indicates the pressure of the cylinder and the other indicates the pressure in the supply pipe to the torch.

Welding torch
Oxygen and acetylene are delivered to the torch by separate hoses. Each gas is controlled by a valve on the torch. The two gases mix in the torch and after they are ignited burn at the nozzle.

Mixer

Needle valves

Flashback Arrestors
These are positioned on both the fuel gas and oxygen supply between the hose and the regulator. Their purpose is to prevent the return of a flame through the hose into the regulator.

Filler Rods and fluxes

Filler rods are used when additional filler metal is required in the weld area they come in different diameters.

Fluxes protect the weld pool from contamination by oxygen and nitrogen, they are normally in paste form placed on a heated filler rod before welding begins

Resistance welding
Resistance welding uses the application of electric current and mechanical pressure to create a weld between two pieces of metal. Weld electrodes conduct the electric current to the two pieces of metal as they are forged together. The welding cycle must first develop sufficient heat to raise a small volume of metal to the molten state. This metal then cools while under pressure until it has adequate strength to hold the parts together. The current density and pressure must be sufficient to produce a weld nugget, but not so high as to expel molten metal from the weld zone.

 Spot welding Seam Welding

Spot welding
Ideal for joining light sheet metal. The electrodes are made from copper. Pressure is applied to the electrodes and an electric current is passed through the circuit. The high resistance between the joint faces causes rapid heating and fusing of a small globule of metal from both faces.

Seam welding

The rollers allow the workpiece to move through the welder continously. A stream of electrical pulses pass through the rollers and welds the joint

Resistance Welding Benefits

High speed welding Easily automated Suitable for high rate production Economical

Resistance Welding Limitations

Initial equipment costs Lower tensile and fatigue strengths Lap joints add weight and material

Friction welding
One part is held stationary while the other part is rotated When the parts are hot enough the rotation is stopped and the parts forged together

Robotic welding
Robots are driven using actuators which control the robotic arm from an input signal. They can use hydraulic (large robots), pneumatic(small actuators with simple control movements) or electrical principles of operation. A computer sends instructions in electrical signals or pulses. An interface converts these digital pulses into analogue electricity for the motors. The robot is fitted with sensors which can send feedback on the position of the robot.

Advantages of Robotic welding

Faster production rates Efficent continous operation Safe working practice Reliable and consistent welds Full automation

Cost effective

Examples
Automated welding of motor vehicles skeletel frames and bodies.

Robotic welding Terms

Lead through programming Teaching robot movements through guiding it manually through a sequence of operations. These are recorded to memeory Machine Vision Area of vision robot has, limits which robot sensors can operate Working enevelope The area within which a robot can operate. Where the work is caried out by robotic arm Yaw left and right movment of robotic arm Roll rotation of robot about one of its axis Degrees of freedom These are the number of independent movements of the arm joints( or actuators) the robot has.