Content
• Classification of fabrication(joining) process
• Different types of welding
– Gas welding
• Principle, equipment
• Different type of flames
– Arc welding
• Manual metal arc welding/Shielded metal arc welding
• Inert gas arc welding (GTAW or TIG process, GMAW or MIG)
• Submerged arc welding
• Plasma arc welding
– Resistance welding
• Spot
• Seam
• Projection
– Some other welding processes
Fabrication Processes
Some products cannot be manufactured as a single piece.
The desired shape and size of such products can be
obtained by joining two parts of same or different
materials. These parts are manufactured individually and
are joined together to obtain the desired product.
For example, aircraft and ship bodies, welded machine
frames, furniture, computers, bridges and the transmission
or electric towers etc., are all fabricated by joining several
different parts.
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Classification of joining processes:
Temporary Joint
Permanent Joint
A temporary joint can be easily dismantled separating the
original parts without any damage to them
In case it is a permanent joint, an attempt to separate the
parts already joined will result in the damage of the parts.
In a permanent joint, the joint is made such that it has
properties similar to the base metal of the two parts. These
parts cannot be separated into their original shape, size and
surface finish
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Based on the process used for making the joint, the joining
processes can be further classified as:
Mechanical Fasteners – bolts-nuts, rivets, screws
Adhesive bonding
Welding, Brazing, Soldering
The choice of a particular joining process depends on
several factors such as application, nature of loads or
stresses, joint design, materials involved and size and shape
of the components
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WELDING
Welding is one of the most extensively used fabrication method.
The joint strength obtained in welding is being equal to or some
times more than that of the parent metal. It is not only used for
making structures, but also for repair work such as the joining
of broken castings.
Welding is a process of metallurgical joining of two pieces of
metals by the application of heat with or without the application
of pressure and addition of filler metal. The joint formed is a
permanent joint.
It is extensively used in the fabrication work in which metal
plates, steel sections, castings of ferrous metals are joined
together. It is also used for repairing broken, worn-out or
defective metal parts.
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Modern methods of welding may be classified under two
broad headings.
• Plastic or pressure welding process
• Fusion or non-pressure welding process
In plastic or pressure welding process the pieces of metal
to be joined are heated to a plastic state and then forced
together by external pressure. This procedure is used in
forge welding, resistance welding, spot welding in which
pressure is required.
In the fusion or non-pressure welding, the material at the
joint is heated to a molten state and allowed to solidify.
This includes gas welding, arc welding
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STEPS OF WELDING PROCEDURE
1. Surface Cleaning:
Surfaces of the parts to be welded need to be
thoroughly cleaned to remove dust, dirt, oil, grease etc.
2. Edge Preparation:
Preparing a contour at the edges of the pieces to be
joined. It may involve beveling or grooving. This is
done in order to get the fusion or penetration through
the entire thickness of the member.
3. Clamping:
Pieces to be welded are clamped suitably so that there
are no undesirable movements during welding.
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4. Initial Weld:
Initial tack welds are done at the opposite corners of the
joint to secure the pieces together. Any cracks at this
stage must be removed as they cause residual stresses.
5. Intermediate and Final Welding:
The weld joint is formed through various weaving
movements (weld beads). During this process, filler
metal and a suitable flux are used. After the
intermediate run of welding, final run is taken.
6. Removal of Excess Material:
Extra material on the weld surface can be removed
using tongs and chipping hammer. The weld is allowed
to cool and then cleaned.
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Classification of welding processes:
(i). Arc welding
• Carbon arc (iv).Thermit Welding
• Metal arc (v).Solid State Welding
• Metal inert gas Friction
• Tungsten inert gas Ultrasonic
• Plasma arc Diffusion
• Submerged arc Explosive
• Electro-slag (vi).Advanced Welding process
(ii). Gas Welding Electron-beam
• Oxy-acetylene Laser
• Air-acetylene (vii).Related Process
• Oxy-hydrogen Oxy-acetylene cutting
(iii). Resistance Welding Arc cutting
• Butt Hard facing
Brazing
• Spot
Soldering
• Seam
• Projection
• Percussion
GAS WELDING
Gas welding is a fusion welding process.
The flame produced by the combustion of gases is
employed to melt the metal. The molten metal is allowed
to flow together thus forming a solid continuous joint
upon cooling.
By burning pure oxygen in combination with other
gases, in special torches, a flame up to 33000C can be
attained.
In oxy-fuel gas welding (OFW) the heat is obtained
from the combustion of a fuel gas such as acetylene in
combination with oxygen.
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Oxy-acetylene Gas Welding Equipment
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Oxy-acetylene Gas Welding Equipment
1. Welding torch & tip
2. An acetylene cylinder:15.5 bar, red or maroon
3. An oxygen cylinder: 125 bar, blue or black
4. Pressure regulator: control flow/pressure of gases
5. Pressure gauge: shows cylinder pressure and gas working
or delivery pressure
6. Rubber hoses: black/green hose for oxygen & red/orange
hose for acetylene
7. Safety devices: Goggle with coloured glasses, hand gloves,
helmet, apron, sleeves, shoes etc.
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The oxy-acetylene flame is used to pre heat the parts to be
welded around the joint and also to melt the filler metal.
A jet of oxy acetylene flame issuing from the nozzle of a
burner is played on the junction of the two pieces to be
welded.
At the same time a filler rod is held in the zone of jet and its
melt is deposited on the fused junction.
A weld is obtained after the molten metal solidifies. The
coating on the filler rod acts as a flux to keep the joint clean.
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GAS WELDING FLAMES (OXY-ACETYLENE FLAMES)
Neutral Flame
1. Neutral Flame: (Gas ratio is 1)
A certain amount of oxygen is required for complete combustion of
fuel gases. When the oxygen supply varies, the flame appearance
obtained would also vary.
•In neutral flame all the acetylene present is completely burned and
thus all the available heat in the fuel gas is released.
•This is the most desirable flame to be used in oxy-acetylene
welding. Due to neutral flame no chemical change and no oxidation
in molten metal. This is desired for most welding operations. Used
for welding steel, stainless steel, cast iron, Cu etc.
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2. Carburizing or Reducing Flame: ( Gas ratio 0.95 to 1)
Excess of acetylene is present, Low temp flame. The excess un-
burnt carbon is absorbed in ferrous metals, making the weld hard and
brittle.
An intermediate flame feather exists - reddish in colour. The
length of the flame feather is an indication of the excess acetylene
present.
Carbonizing flame is used for welding high carbon steels and cast
iron, alloy steel.
Since this flame provides a strong reducing atmosphere in the welding
zone, it is useful for those materials which are readily oxidize like
oxygen free copper alloys.
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3. Oxidizing Flame: (Gas ratio 1.15 to 1.5)
Excess of oxygen is present, similar to the neutral flame
Inner white cone is some what small, giving rise to higher
tip temperatures.
Excess of oxygen causes the metal to burn/oxidize quickly.
Desirable for welding only brass because a thin layer of slag
forms over the molten metal.
Widely used for oxyacetylene cutting and not suitable for
welding since the weld metal will be oxidised.
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Advantages of Oxy-acetylene Gas Welding
1.The equipment is inexpensive, simple and is easily
portable.
2.Useful for welding light metals such as automobile
bodies and repair works.
3.A large variety of material can be welded.
4.Welds can be produced at reasonable cost.
5.Compared to electric arc welding this provides greater
flexibility with respect to heat impact and cooling rates.
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Disadvantages of Oxy-acetylene Gas Welding
1. It is much slower than electric arc welding and does not
concentrate the heat close to the weld. Thus, the heat
treated area is larger, which causes more distortion.
2. If electric arc welding is available gas welding is seldom
used for work over 3.2mm thick.
3. The process is not satisfactory for heavy sections
4. Highly skilled operators are required to produce a good
weld.
5. Equipment should be handled carefully as in certain
circumstances acetylene is explosive.
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Applications of Oxy-acetylene Gas Welding:
• For joining of thin materials.
• For joining materials in whose case excessively high
temperature or rapid heating and cooling of the job
would produce unwanted changes in the metal.
• For welding both ferrous and non-ferrous metals.
• In automotive &aircraft industries, project site works,
workshops etc.
Other Gas Welding
Oxygen-Hydrogen Welding
• The oxygen-hydrogen torch can reach temperatures much
higher than the oxy-acetylene torch.
• More expensive than oxy-acetylene welding and involves the
flammability risk with hydrogen.
Plasma Welding
• Hydrogen plasma burns even hotter than hydrogen gas,
permitting the welding of extremely high-melting-point
metals.
• Very clean procedure that results in very little slag or foreign
matter in the weld.
Gas Cutting
• Iron and steel get oxidised when it is heated to a temperature
between 800 to 10000 0C
• When a high pressure oxygen jet with a pressure of the order of
300 KPa is directed against a heated steel plate, the oxygen jet
burns the metal and blows it away causing the cut
•This process is used for cutting steel
plates of various thicknesses (up to 2 m)
mainly because the equipment required
is simple and can be carried anywhere
without handling the heavy steel plates.
•The torch tip has a provision for
preheating the plate as well as providing
the oxygen jet. Thus the tip has a
central hole for oxygen jet with
surrounding holes for preheating flames
