Welding is a process that joins materials by causing fusion through heating or pressure. There are two main types of welding processes: [1] pressure welding, which joins metals without melting them, using high pressure; and [2] fusion welding, which joins metals by melting them together with or without the use of filler material. Some common welding techniques include gas welding, arc welding processes like TIG, MIG, and SAW welding, resistance welding, and chemical/thermite welding. Each process has advantages for different applications in industries like automotive, shipbuilding, construction, and more.
Welding is a process that joins materials by causing fusion through heating or pressure. There are two main types of welding processes: [1] pressure welding, which joins metals without melting them, using high pressure; and [2] fusion welding, which joins metals by melting them together with or without the use of filler material. Some common welding techniques include gas welding, arc welding processes like TIG, MIG, and SAW welding, resistance welding, and chemical/thermite welding. Each process has advantages for different applications in industries like automotive, shipbuilding, construction, and more.
Welding is a process that joins materials by causing fusion through heating or pressure. There are two main types of welding processes: [1] pressure welding, which joins metals without melting them, using high pressure; and [2] fusion welding, which joins metals by melting them together with or without the use of filler material. Some common welding techniques include gas welding, arc welding processes like TIG, MIG, and SAW welding, resistance welding, and chemical/thermite welding. Each process has advantages for different applications in industries like automotive, shipbuilding, construction, and more.
Welding is a process that joins materials by causing fusion through heating or pressure. There are two main types of welding processes: [1] pressure welding, which joins metals without melting them, using high pressure; and [2] fusion welding, which joins metals by melting them together with or without the use of filler material. Some common welding techniques include gas welding, arc welding processes like TIG, MIG, and SAW welding, resistance welding, and chemical/thermite welding. Each process has advantages for different applications in industries like automotive, shipbuilding, construction, and more.
Download as DOCX, PDF, TXT or read online from Scribd
Download as docx, pdf, or txt
You are on page 1/ 14
WELDING PROCESS
AHAMED YAHIYA AJANTH AJAY KUMAR AJAY WELDING PROCESS _________________________________________ DEFINITION: Welding is the process of ‘joining steel components’ by fusing the two pieces of steel together. This basic definition also applies to a variety of processes such as manual metal Arc welding, Automatic submerged arc welding, TIG welding for aluminum alloy element and MIG welding for thin gauge steel sheeting, etc..
TYPES OF WELDING
1. Plastic Welding OR Pressure Welding [Ex. Resistance Welding]
2. Fusion Welding OR Non-Pressure Welding [Ex. Arc Welding, Gas Welding]
1. PRESSURE WELDING: Pressure Welding is the joining of metals by the application of heat or pressure, with or without the addition of a similar metal i.e filler metal.
1.1 Cold Pressure Welding
1.2 Cryogenic Welding
1.3 Resistance Welding
1.1. COLD PRESSURE WELDING
Joining of two metals at room temperature with the application of a large amount of pressure called cold pressure welding. The welding of parts is done by extreme high pressure or by contact in a high vacuum with no application of heat. Pressure is applied to points to be welded at temperature below the recrystallization temperature of metals to be welded. Cold pressure welding carried out at ambient temperature relies upon the use of high compressive pressure 1400 to 2800 N/mm2 for Aluminium and at least double that value for copper. It provides interfacial deformations of 60% - 80% that break the oxide layers to expose fresh and uncontaminated metals make contact. ADVANTAGES:
It is simple and inexpensive to operate once dies have been produced.
The process is fast. Parts are joined without contamination from sparks or dusts and vapour.
DISADVANTAGES High specialized with respect to joint design and materials to be welded (soft iron that has no carbon content) Welds are made in the ‘solid state’ they are difficult to inspect. With the expectations of butt welds, or welds where the contact surfaces are sheared together, the thickness of the parts is reduced.
APPLICATIONS: In the electronics industry, cold welding processes are used to seal tin plated steel crystal cans and copper packages for heat sensitive semiconductor devices.
The cold-pressure welding technique is used when welding wires of non-ferrous
metals such as aluminium, copper, or aluminium- copper alloys.
1.2. CRYOGENIC WELDING
Cryogenics is the study of the production and behaviour of materials at very low temperatures (below -150ºC, -238oF or 123K). The study of how to withstand very low temperatures. Property of material change when cooled to cryogenics temperatures. Cryogenics steel are used to store and transport liquefied- gases below the temperature of -157.5o. ADVANTAGES Eco friendly
High production rate are possible through higher material removal rate.
1.3. RESISTANCE WELDING Resistance Welding is a welding process, in which work pieces are welded due to a combination of a pressure applied to them and a localized heat generated by a high electric current flowing through the contact area of the weld.
•Heat is generated passing current through a electric resistance
DISADVANTAGES: High equipment cost The thickness of work piece is limited due to current requirement. High electric power required. Weld joints have low tensile and fatigue strength. It is less efficient for high conductive materials. APPLICATIONS (RESISTANCE WELDING) - Automotive industries (PROJECTION WELDING) -Production of nut & bolt (SEAM WELDING) - Produce leak true joint required in small tanks, boilers, etc., (FLASH WELDING) - Welding pipes & tubes.
2. FUSION WELDING PROCESS
By melting of parent material if the joint is produced called as Fusion Welding Process.
2.1. Gas Welding
2.2. Arc Welding
2.3. Chemical or Thermit Welding
2.1. GAS WELDING
By burning of gases, if the heat required for melting of plates is obtained called as Gas welding operation.
Gas Welding is further classified as follows:
1. OXY -Acetylene Gas Welding
2. Air -Acetylene Gas welding 3. OXY -Hydrogen Gas welding 4. Atomic Hydrogen Gas Welding
ADVANTAGES Portable and Most Versatile Process Better Control over the Temperature Low Cost and Maintenance
APPLICATIONS: For joining thin metals. For joining metals in automotive and aircraft industries. 2.2 ARC WELDING PROCESS: By using electric arc, if the heat required for melting of plates is obtained called as Arc Welding Operation. This electric arc can create temperatures upwards of 3500°C, which is sufficiently high to melt high strength metals like carbon steel. This method also uses shielding gas in conjunction with arc welding.
Arc Welding is further classified as follows:
DC Welding – Classified as DCSP/DCRP TIG Welding – Tungsten Inert Gas Welding MIG Welding – Metal Inert Gas Welding SAW Welding-Submerged Arc Welding
2.2.1. TIG welding
The designation TIG comes from USA and is an Abbreviation of Tungsten Inert Gas. Tungsten – also called wolfram – is a metal with a Fusion point of more than 3300°C,which means More than double the fusion point of the metals Which are usually welded. During the welding process the electrode, the arc And the weld pool are protected against the Damaging effects of the atmospheric air by an Inert shielding gas.
ADVANTAGES: CO2 is accesible to make and produce at low cost Require low welding skills. Works on dirty metal. Easy automation. Good welding quality
DISADVANTAGES: Lower efficiency High skill level. Wind should be avoided so as not to disperse the protective gas. Some of protection gases are expensive.
It is also known as Gas Metal Arc Welding. It is high- deposition rate welding process. The metal wire is fed from a spool. This is a semiautomatic welding process.
Consists of a handle with trigger control to wire feed the spool to the weld joint.
MIG basically requires:
- Electricity to produce heat
- An electrode to fill the joint
- Shielding gas to protect the weld
CHARACTERISTICS MIG/MAG welding is a versatile technique suitable for both thin sheet and thick section components. An arc is struck between the end of a wire electrode and the workpiece, melting both of them to form a weld pool. The wire serves as both heat source (via the arc at the wire tip) and filler metal for the welding joint. The wire is fed through a copper contact tube (contact tip) which conducts welding current into the wire. The weld pool is protected from the surrounding atmosphere by a shielding gas fed through a nozzle surrounding the wire. Shielding gas selection depends on the material being welded and the application. The wire is fed from a reel by a motor drive, and the welder moves the welding torch along the joint line.Consumables are generally competitively priced compared with those for other processes. The process offers high productivity, as the wire is continuously fed. Manual MIG/MAG welding is often referred as a semi-automatic process, as the wire feed rate and arc length are controlled by the power source, but the travel speed and wire position are under manual control. The process can also be mechanised when all the process parameters are not directly controlled by a welder, but might still require manual adjustment during welding. When no manual intervention is needed during welding, the process can be referred to as automatic.
ADVANTAGES High quality welds can be produced much faster.
MIG welding is versatile and can be used with a wide variety of metals and alloys.
The MIG process can be operated several ways, including semi and fully automatic.
DISADVANTAGES Higher initial setup cost
Radiation effetcs are more severe
The setting of planet variables requires a high skill level.
APPLICATIONS MIG is best suited for fabrication of sheet metal. Generally all available metals can be weld through this process & used for deep groove welding.
2.3 CHEMICAL / THERMIT WELDING PROCESS:
It is a process in which heat for coalescence is produced by superheated molten metal from the chemical reaction of thermite. Thermite is mixture of Al and Fe3O4 fine powders that produce an exothermic reaction when ignited. Also used for incendiary bombs. Filler metals obtained from liquid metal. Process used for joining, but has more in common with casting than welding.
METHODS OF THERMIT WELDING
The heat of thermit welding may be utilized in two ways-
Fusion Welding: It may hear and fuse the metal parts, thermit mixture acts as the filler metal also.
Pressure Welding: It may heat the metal parts and raise them to forging temperature, and forging force is applied to join them. Crucible: It is that part which is capable to withstand in high temperature condition. In thermite welding process, the crucible contains thermite material. The exothermic process during the welding process takes place in the crucible. The molten iron present at the bottom of the crucible and slag of aluminium oxide floats over the molten metal. The crucible contains a taping device to discharge the molten metal to the mold for the welding.
Thermite mixture: It is a pyrotechnic composition of metal oxide, aluminium powder, and fuel.
Mold: A mold is created around the section to be welded. The mold consists of runner, riser, slag basin, heating gate. The molten metal is poured into the mold for the joining of the metal.
Taping device: It is device which is used to discharged or pour molten metal form the crucible to the mold.
WORKING PRINCIPLE 1. A mold is formed over and around the section to be welded. After the mold is formed thermite material is placed in the crucible.
2. During the reaction metal oxide I.e. iron oxide educes to iron and Al gets oxidized and forms aluminium oxide. A large amount of heat is generated. This heat generated melts the iron and aluminium oxide and form molten iron and slag of aluminium oxide
3. The thermite material is ignited by the use of film sparker or magnesium ribbon. An exothermic reaction takes place in the crucible called an aluminothermic reaction.
4. The molten metal so formed is poured into the mold through taping device. As the molten metal reaches the section, it fuses with the metal pieces to be joined. After solidification, it forms a very strong weld.
ADVANTAGES In thermit welding, the weld formed has high mechanical strength and excellent corrosion resistance as compared with other forms of weld.
It is highly stable to repeated short circuit pulses and the electrical resistance remains unchanged over the lifetime of the installation.
It does not require any external power source.
It can be used at the place where power supply is not easily available.
DISADVANTAGES It is a costlier welding process in comparison with other welding processes.
It requires the supply of replaceable molds.
Lack of repeatability It cannot be used in wet conditions or bad weather when working outdoors.
APPLICATIONS The thermit welding process is mainly used for rail welding in railways. It is also used or welding copper conductors and other metals that include cast iron, stainless steel, common steels, bronze, bras and monel.
