Contents
Welding Basics
Types of Weld Joints
Welding Positions
Welding Types
Welding Processes
Welding Symbols
Welding Safety
What is Fabrication /
Welding?
Fabrication
Welding
A fabrication process that joins materials, usually metals by
causing coalescence
Coalescence means
Fusion
Welding Terms
Weldments
Weld puddle
Slag
Weld Bead
Backing
Tack Weld
Heat Affected Zone
(HAZ)
Parts of a Weld
Fillet Weld
Types of Joints
Category A:
Longitudinal welded joints within the main shell or nozzles;
any welded joint within a formed or flat head; circumferential
welded joints connecting hemispherical heads to main shells,
to transitions in diameters.
Category B:
Circumferential welded joints within the main shell, nozzles,
or transitions in diameter; circumferential welded joints
connecting formed heads other than hemispherical to main
shells, to transitions in diameter.
Category C:
Welded joints connecting flanges, tubesheets, or flat heads
to main shell, to formed heads, to transitions in diameter, to
nozzles.
Category D:
Welded joints connecting nozzles to main shells, to spheres,
to transitions in diameter, to heads.
Welding Positions
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Weld
Passes
Fill Pass
Cover Pass
Root Pass
Hot Pass
TYPES OF
WELDING
APPLICATION
CONSTRUCTION
IN-SERVICE
PROCESS
ARC
GAS
RESISTANCE
SOLID STATE
ENERGY BEAM
Welding Process
Arc Welding
Arc welding process
use electric power
supply to create &
maintain an electric arc
b/w an electrode and
the base material to
melt metals at the
welding point.
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20
Welding Procedure
Thickness
Electrode extension
Angle of bevel
Travel speed
Cleanliness
Type of joint
Polarity, Current & Voltage
Root Opening distance
Welding Position
GAS WELDING
Oxyacetylene Welding
(OAW)
Direct Current
Direct current
straight polarity
(DCSP)
Direct current
reverse polarity
(DCRP)
Alternating Current
Type of Power
Source
Generator
Transformer
Tungsten Electrode
Non consumable
Melting point = 6170F
Tungsten Alloys :
Thoria, Zirconia, Ceria,
Lanthana or a
combination of oxides.
Length = 3 to 24
inches
Diameter = .01 to .
25inches
Extension & Shape
Properties of Helium
Deeper penetration
Lower cost
Expensive
More availability
Less available
Argon - helium mixture are used when better control of argon and the deeper penetration of
helium are needed. (75% helium, 25% Argon)
Filler Metals
Selection of Filler metal depends upon chemical
composition of base metal.
To increase the tensile strength, ductility, and corrosion
resistance.
Filler metal is kept in HOT OVENS for preheating for
smooth operation.
Classification of Filler metals in AWS
Stainless steel
Carbon steels
Low alloy steel
A5.9
A5.18
A5.28
Deposition Rate
R 70
1 8
A1
6)
Electrode
(usually for
GTAW
only)
Cost of GTAW
Labor
(20% to 40%)
Overhead cost
(Major Cost)
Filler metal cost
Shielded gas cost
Electric power cost
(Minor cost)
Tungsten Electrode cost
(4%of Shielding gas cost)
Welding Torch
Advantages
Limitations
Used for metals such as: steel, aluminum and stainless steel.
Instead of using shielding gas, the arc and weld zone are
completely submerged under a blanket of granulated
flux.
Welding Symbols
Welding symbols contain information about the weld to be made
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Reference Line
Reference Line (Required element)
Always Horizontal
Arrow Line
Reference Line (Required element)
Arrow
Tail
Reference Line (Required element)
Arrow
Tail
Arrow
Tail
The tail of the welding symbol is used to indicate the welding or cutting
processes, as well as the welding specification, procedures, or the supplementary
information to be used in making the weld.
Arrow
Tail omitted when reference not used
Tail
The tail of the welding symbol is used to indicate the welding or cutting
processes, as well as the welding specification, procedures, or the supplementary
information to be used in making the weld.
1/4
1/4
Depth of penetration
Single-Bevel-Groove and
Double Fillet Weld Symbol
5/16
5/16
Single-Bevel-Groove and
Double Fillet weld Symbols
1/4
2-10
1/4
2-10
10 in
Staggered Intermittent
Fillet Weld
Weld ends than 10 inch
centers staggered each side
1/4
2-10
1/4
2-10
10 in
10 in
Back Purging
.
Minimum purge time before welding, flow rate and
venting, etc
Shielding Gas type (Argon, He or mixture of 2-Inert Gases
for shielding)
Occupational Opportunities in
Welding
Welders
Tack Welders
Welding Helper
Welding Operators
Welder Assemblers/ Welder fitters
Welding Inspection
Welding Shop Supervisor
Welding Engineers
66
REFERENCES
Questions?
Thank You