WELDING

Weldingisaprocessofjoiningmetalsbyapplication
of heat with or without application ofpressure and

withorwithouttheadditionoffillermaterial.
The result is a continuity of homogeneous material
ofthe composition and characteristics of two parts
whicharebeingjoinedtogether
Advantagesofwelding

Weldingprovidesapermanentjoint.
Weldedjointcanbestrongerthantheparent
materialsifaproperfillermetalisused
Itistheeconomicalwaytojoincomponentsinterms
ofmaterial
Disadvantagesofwelding

Labourcostsaremoresincemanualweldingisdone
mostly.
Dangeroustousebecauseofpresenceofhighheat
andpressure.
Disassemblyisnotpossibleasweldingproduces
strongjoints.
Someoftheweldingdefectscannotbeidentified
whichwillreducethestrength.
 weldability
Thetermweldabilityhasbeendefinedasthecapacity
of being welded into inseparable jointshaving
specified properties such as definite weld strength,
properstructure.
 Typesofwelding
Plastic Welding or Pressure Welding

The piece of metal to be joined are heated to a plastic

state and forced together by external pressure eg.

Resistancewelding

Fusion Welding or Non-Pressure Welding

The material at the joint is heated to a molten state and

allowedtosolidify.eg-Gaswelding,thermitwelding
ClassificationofArcWelding
1. Arc welding
Carbonarc
Metalarc
Metalinertgas
Tungsteninertgas
Plasmaarc
Submergedarc
Electro-slag
 Gas Welding
Oxy-acetylene
Air-acetylene
Oxy-hydrogen
 Resistance Welding
Buttwelding
Spotwelding
Seamwelding
Projectionwelding
Percussionwelding
ThermitWelding

SolidStateWelding
Friction
Ultrasonic
Diffusion
Explosive
 Arc welding
Inarcweldingheatisliberatedatthearcterminalsand
thisheatisusedtomeltthemetalstobeweldedatthe
pointofcontact
Themetalwillflowtogetherandformanintegral
mass,thusdifferentpartsmaybejoined
Afillermetalisalsoaddedtothesurfaceofthemetal
 Arc welding
Itisaprocessofjoiningtwometalpiecesbymelting
theedgesbyanelectricarc.

Theelectricarcisproducedbetweentwoconductors.

Theelectrodeisoneconductorandtheworkpieceis
anotherconductor.

Theelectrodeandtheworkpiecearebroughtnearer
withsmallairgap.(3mmapp.)
 Arc welding

When current is passed an electric arc is produced

betweentheelectrodeandtheworkpiece.
Theworkpieceandtheelectrodearemeltedbythearc.
Bothmoltenpieceofmetalbecomeone.Temperatureof
arcisabout4000c
Electrodes used in arc welding are coated with a flux.
This flux produces a gaseous shield around the molten
metal.
 Arc welding
It prevents the reaction of the molten metal with

oxygenandnitrogenintheatmosphere.

The flux removes the impurities from the molten

metal andform a slag.This slag getsdeposited over

theweldmetal.

Thisprotectstheweldseamfromrapidcooling.
 Arc welding
Equipments:

Aweldinggenerator(D.C.)orTransformer(A.C.)

Twocables-oneforworkandoneforelectrode

Electrodeholder

Electrode

Protectiveshield

Gloves

Wirebrush

Chippinghammer

Goggles
Arc welding
 Arc welding
Advantages Limitations
Mostefficientwaytojoin Manuallyapplied,
metals thereforehighlaborcost.

Lowest-costjoiningmethod Needhighenergy

Affordslighterweightthrough causingdanger

betterutilizationofmaterials Notconvenientfor

Joinsallcommercialmetals disassembly.

Providesdesignflexibility Defectsarehardtodetect
atjoints.
 Carbonarcwelding
Incarbonarcwelding,theintenseofheatofanelectric
arcbetweenacarbonelectrodeandworkpiecemetalis
usedforwelding.

DCpowersupplyisused.

Thecarbonelectrodeisconnectedtonegativeterminal
and work piece is connected to positive terminal,
because positive terminal is hotter (4000c) than the
negativeterminal(3000c)whenanarcisproduced.
 Carbonarcwelding
Socarbonfromtheelectrodewillnotfuseandmixup
withthemetalweld.

Ifcarbonmixeswiththeweld,theweldwillbecome
weakandbrittle.

Toprotectthemoltenmetalfromtheatmospherethe
weldingisdonewithalongarc.

Inthiscase,acarbonmonoxidegasisproduced,which
surroundsthemoltenmetalandprotectsit.
 Carbonarcweldingisusedtoweldbothferrousand
nonferrousmetals.Sheetsofsteel,copperalloys,
brassandaluminumcanbeweldedinthismethod.
 Shielded metal arc welding (SMAW )
Shielded Metal Arc Welding, also known as manual
metalarcwelding,stickwelding,orelectricarcwelding

Welding is performed with the heat of an electric arc

that is maintained between the end of a coated metal
electrodeandtheworkpiece

Theheatproducedbythe arc melts thebasemetal,the

electroderod,andthecoating
Shielded metal arc welding
 Shielded metal arc welding
Asthemoltenmetaldropletsaretransferredacrossthe
arcandintothemoltenweldpuddle,theyareshielded
from the atmosphere by the gases produced from the
decompositionofthefluxcoating.

Theslagcoversthemoltenpoolwhereitprotectsthe
weld metal from the atmosphere during solidification.
SMAWcanbeperformedbothonACandDCsource
 Submerged arc welding (SAW)
SAW is an arc welding process in which heat is
generated by an arc which is produced between
consumableelectrodeandtheworkpiece.

The arc and the weld zone are completely covered

underablanketofgranular,fusiblefluxwhichmelts
and provides protection to the weld pool from the
atmosphericgases.
Submerged arc welding (SAW)
Ahopperandafeedingmechanismareusedtoprovide
aflowoffluxoverthejointbeingwelded
Themoltenfluxsurroundsthearcthusprotectingarc
fromtheatmosphericgases.
Themoltenfluxreactswiththemoltenmetalforming
slagandimprovesitspropertiesandlaterfloatsonthe
molten/solidifyingmetaltoprotectitfromatmospheric
gascontaminationandretardscoolingrate
Submerged arc welding (SAW)

Since the arc is fully covered by the flux, it is not

visible and the weld is run without the spatter and
spark

SAWcanbeperformedbothonACandDCsource
Submerged arc welding (SAW)
Submerged arc welding (SAW)
Submerged arc welding (SAW)
 Submerged arc welding (SAW)
Advantages

JointscanbepreparedwithashallowVgrooveresultinglesser

electrodeconsumption

Weld spatter is eliminated and nearly 100% deposition is

effectivelyachieved

Highweldingspeedispossible

Wireelectrodesareinexpensive

Entire welding takes place beneath a bath of molten flux ,

withoutspark,smokeorfire
 Submerged arc welding (SAW)
Limitations

Itcantbeusedforplateslessthan5mmthick

Itcantweldcastironbecauseofhighheatinput

Slag cannot be removed continuously after it has

meltedinordertoavoidentrapmentbetweenpasses

Flux subjected to contamination and adsorption of

moisture
 TIG Welding

Tungsten Inert Gas (TIG) or Gas TungstenArc (GTA)

welding is the arc welding process in which arc is
generated between non consumable tungsten electrode
andworkpiece.

The tungsten electrode and the weld pool are shielded

byaninertgasnormallyargonandhelium.
The tungsten arc process is being employed widely
forthewhichrequirecontrolledheatinput.precision
joiningofcriticalcomponents
The small intense heat source provided by the
tungstenarcisideallysuitedtothecontrolledmelting
ofthematerial.
TIG Welding
TIG Welding
 TIG Welding
Since the electrode is not consumed during the
process, welding without filler material can be done
without the need for continual compromise between
theheatinputfromthearcandthemeltingofthefiller
metal.
Thefillermetal,whenrequired,canbeaddeddirectly
totheweldpoolfromaseparatewirefeedsystemor
manually
 TIG Welding
In TIG torch the electrode is extended beyond the
shieldinggasnozzle.
The arc is ignited by high voltage, high frequency
(HF) pulses, or by touching the electrode to the work
pieceandwithdrawingtoinitiatethearc
 Advantages

Weldcompositionisclosetothatoftheparent
metal
Highqualityweldstructure

Slagremovalisnotrequired(noslag)

Thermaldistortionsofworkpiecesareminimal
duetoconcentrationofheatinsmallzone
 Disadvantages

Lowweldingrate

Relativelyexpensive
Requireshighlevelofoperatorsskill
 MIG(GMAW)
The"Metal"inGasMetalArcWeldingreferstothewire
thatisusedtostartthearc.Itisshieldedbyinertgasand
thefeedingwirealsoactsasthefillerrod.

In MIG welding process an arc is formed between the

wireelectrodeandtheworkpiece.

During the MIG welding process, the electrode melts

withthearcandbecomesdepositedasfillermaterial.
 MIG(GMAW)
The shielding gas that is used to prevents
atmospheric contamination and protects the weld
duringsolidification

The shielding gas also assists with stabilizing the

arc which provides a smooth transfer of metal from
theweldwiretothemoltenweldpool.
MIG(GMAW)
 MIG(GMAW)
Usesaconsumablewireelectrode

Providesauniformweldbead.

Producesaslag-freeweldbead.

Usesashieldinggas,usuallyargon,argon-1to5%
oxygen, argon - 3 to 25% CO2and a combination
argon/heliumgas.
 MIG(GMAW)
Allowsweldinginallpositions.

Isconsideredasemi-automaticweldingprocess.

RequireslessoperatorskillthanTIGwelding.

Allowslongweldstobemadewithoutstartsorstops.

Needslittlecleanup.
 Advantages

Continuous weld may be produced (no

interruptions);
Highlevelofoperatorsskillisnotrequired

Slagremovalisnotrequired(noslag)
 Disadvantages
Expensiveandnon-portableequipmentisrequired
Outdoorapplicationarelimitedbecauseofeffectof
wind,dispersingtheshieldinggas.
 ResistanceWelding
Theresistanceofmetaltothelocalizedflowof
currentproducesheat

Processvariables
Current
Time
Force
 ResistanceWelding
Resistanceweldingprocessesareafastandreliable
meansofjoiningthinsheetsofmetaltogether.

Theweldiscreatedbyfirstapplyingpressureonthe
twopartstobejoined.

Oncethecorrectamountofpressureisapplied,current
ispassedbetweenthetwo(ormore)overlappedsheets.
 Resistive heating results in melting and the
formationofaweldnuggetoraweldseam.
On termination of the welding current, the weld
cools rapidly under the influence of the chilled
electrodes.
Thiscausesthenuggettoresolidify,joiningthetwo
sheetsofmetal.

AdvantagesofResistanceWelding
Highweldingrates

Lowfumes

Costeffectiveness

Easyautomation

Nofillermaterialsarerequired

Lowdistortions.
DisadvantagesofResistanceWelding

Highequipmentcost

Lowstrengthofdiscontinuouswelds

Thicknessofweldedsheetsislimited-upto6mm
 PopularmethodsofResistanceWeldingare

SpotWelding

FlashWelding

ResistanceButtWelding

SeamWelding
 SpotWelding(RSW)
Spot WeldingisaResistanceWelding(RW)process,
in which two or more overlapped metal sheets are
joinedbyspotwelds.
Themethodusespointedcopperelectrodesproviding
passageofelectriccurrent.
The electrodes also transmit pressure required for
formationofstrongweld.
 Diameteroftheweldspotisintherange3-12mm

Spot welding is widely used in automotive industry

forjoiningvehiclebodypart
 SeamWelding

Seam Weldingis aResistance Welding process of

continuous joining of overlapping sheets by passing
thembetweentworotatingelectrodewheels.

Heat generated by the electric current flowing

throughthecontactareaandpressureprovidedbythe
wheelsaresufficienttoproducealeak-tightweld.
Seam Welding is high speed and clean process,
whichisusedwhencontinuoustightweldisrequired
(fueltanks,drums,domesticradiators).
 FlashWelding(FW)

Flash Welding

isaResistanceWelding(RW)process,inwhichendsof

rods(tubes,sheets)areheatedandfusedbyanarcstruck

between them and thenforged (brought into a contact

under a pressure) producing a weld.

The welded parts are held in electrode clamps, one of

whichisstationaryandthesecondismovable.
 FlashWeldingmethodpermitsfast(about1min.)joining

oflargeandcomplexparts.Weldedpartare

oftenannealedforimprovementofToughness.

Steels,Aluminiumalloys,Copperalloys,Magnesium

alloys,CopperalloysandNickelalloysmaybewelded

byFlashWelding.

Thickpipes,endsofbandsaws,frames,aircraftlanding

gearsareproducedbyFlashWelding.
 Buttwelding

In butt welding two pieces of metal of same cross-

sectionaregrippedtogetherandpressedwhileheatis
generated in contact surface by electric resistance
whencurrentispassed.

As the pressure keeps on acting continuously, the

joint is upset slightly which can be rounded up by
machining.
 Buttwelding
Inordertohavegoodweld,firstthepressuremustbe
less and increase steadily to a value sufficient of
effectiveweld

This process is best suited for rods, pipes and other

partsofuniformcross-sections

Buttweldingcanbesubdividedintotwogroups

Upsetbuttwelding

Flashbuttwelding
Buttwelding
 Upsetbuttwelding

Inthisweldingthepartstobeweldedareclamped
edgetoedgeinclampsofthemachineandbrought
togetherwithsolidcontactwhilecurrentflows

Thepressureappliedwillupsetthejoint

Isusedfornon-ferrousmetals
Upsetbuttwelding
 Flashbuttwelding
Inflashbuttweldingthepartsarebroughttogetherin
verylightcontact.

Ahighvoltagestartsaflashingaction.

Thepartskeepmovingagainsteachothertillforging
temperatureisreached.

Thensufficientpressureisappliedtoeffecttheweld.

Thepressuresqueezesoutanyunwantedslag,oxides
andoverheatedmetalfromthejointfaces.
 Basic Steps in Flash Welding

(a)
Electrodes (c)

Position and (b)

Clamp the Parts (d)
Flash

Upset and Terminate Current

Apply Flashing Voltage
and Start Platen Motion
[Reference: Welding Handbook, Volume 2, p.583, AWS]
 Flashbuttwelding
Usuallylargeareasareweldedbyflashwelding

Thisprocessrequireslesscurrent

Mostofthenon-ferrousmetalsexceptcontaining
highpercentageoflead,zincandcopperarewelded
bythismethod

Usedforweldingbars,tubesetc
 Percussionwelding
Thisweldingdependsonthearceffectforheating
andnotresistance

Oneofthetwopiecestobeweldedisheldina
stationeryholderandtheotherinaclamp
mountedinaslideandbackedupbyheavyspring
pressure

Forweldingthemovableclampisreleased
 Percussionwelding
Whenpiecesareclosetoeachotherasudden
dischargeofelectricenergytakesplacecausingan
intensearcingoverthesurfaceandheatingthem

Aspiececomeincontactwitheachotherunderheavy
pressurethearcisextinguishedduetothepercussion
blowofthetwopartsandtheforcebetweenthem
effectstheweld
 Percussionwelding
Theactionoftheprocessissorapidthatthereislittle
heatingeffectthematerialadjacenttotheweld

Itisusedforweldingtipsoftools
 Gaswelding
Equipmentsusedforgaswelding

GasCylinders

Regulators

PressureGauges

Hoses

Weldingtorch

Nonreturnvalve(FlashbackArrestors)
 GasPressureRegulators
One gauge indicates the pressure of the cylinder and
theotherindicatesthepressureinthesupplypipetothe
torch.
 Weldingtorch
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
ignitedburnatthenozzle.

Mixer Needlevalves
 FlashbackArrestors

These are positioned on both the fuel gas and oxygen

supplybetweenthehoseandtheregulator.

Theirpurposeistopreventthereturnofaflamethrough
thehoseintotheregulator.
 FillerRodsandfluxes
Filler rods are used when additional filler metal is
requiredintheweldareatheycomeindifferentdiameters.

Fluxes protect the weld pool from contamination by

oxygen and nitrogen, they are normally in paste form
placedonaheatedfillerrodbeforeweldingbegins
 Gaswelding

Stepsinoxyacetylenewelding

Prepare the edges to be joined ,and establish and

maintain their proper position by use of clamps and
fixtures
Opentheacetylenevalveandignitethegasatthetip
ofthetorch
Open the oxygen valve and adjust the flame for a
particularoperation
 Gaswelding
Hold the torch at about 45 from the plane of the
workpiece,withtheinnerflameneartheworkpiece
andfillerrodatabout30-40

Touch the filler rod to the joint and control its

movementalongthejointlengthbyobservingtherate
ofmeltingandfillingofthejoint
Gaswelding
Gaswelding
 TheOxy-acetyleneweldingFlame

Reducing or Carburizing InnerCone

Excessacetylene(0.9:1)
(Alloysteelsand
aluminiumalloys) Max.Temp.
Zone
Oxidizing
Excessoxygen(1.5:1)
(Brasses,Bronzes,copper)
SecondaryCombustion
envelope
Neutral
Equalacetylene&oxygen
(lowcarbonsteel,mild
steels). Acetylene
feather
 TheOxy-acetyleneweldingFlame

Carburising Neutral Oxidising

 TheOxy-acetyleneweldingFlame
Theoxy-acetyleneflamehastwodistinctzones.

Theinnerzone(PrimarycombustionZone)isthehottest
partoftheflame.Theweldingshouldbeperformedsoas
thepointoftheinnerzoneshouldbejustabovethejoint
edges.
C2H2+O22CO+H2

PrimaryCombustionzone
The outer zone the secondary combustion
envelopeperformstwofunctions

Preheatsthejointedges

Preventsoxidationbyusingsomeofthesurrounding
oxygenfromweldpoolforcombustionandgivesoff
carbondioxideandwatervapour

CO+H2+O2CO2+H2O

SecondaryCombustionzone
Fusion zone
The area of base metal and filler metal that has
been completely melted

Weld interface
A thin area of base metal that was melted or
partially melted but did not mix with the filler
metal

Heat affected zone

The surrounding area of base metal that did not
melt, but was heated enough to affect its grain
structure