WELDING SHOP

Introduction: -
The welding is a process of joining two similar or dissimilar metals by fusion, with or
without the application of pressure and with or without the use of filler metal. The fusion of
metal takes place by means of heat. The heat may be obtained from electric arc, electric
resistance, chemical reaction, friction or radiant energy.

Classification of welding: -
In general, various welding and allied processes are classified as follows:-
1. Gas welding: -
* Air-acetylene welding * Oxy-acetylene welding
* Oxy-hydrogen welding * Pressure gas welding
2. Arc welding: -
* Carbon Arc welding * Shielded Metal Arc welding
* Flux cored Arc welding * Submerged arc welding
* TIG (or GTAW) welding. (Gas Tungsten Arc welding)
* MIG (or GMAW) Welding (gas metal arc welding)
* Plasma Arc Welding * Electro slag welding
* Electro gas Arc welding * Stud Arc welding
3. Resistance welding: -
* Spot welding * Seam welding
* Projection welding * Resistance butt welding
* Flash butt welding * Percussion welding
* High frequency resistance welding
4. Solid state welding: -
* Cold welding * Diffusion welding
* Explosive welding * Forge welding
* Friction welding * Hot pressure welding
* Roll welding * Ultrasonic welding
5. Thermo-chemical welding processes: -
* Thermit welding * Atomic Hydrogen welding
6. Radiant Energy Welding Processes: -
* Electron Beam welding * Laser Beam welding

Welding Processes can also be divided into the following two groups.
1. Forge or pressure welding (Plastic welding):- In forge or pressure welding, the work
piece are heated to plastic state and then, the work pieces are joined together by applying
external pressure on them.
2. Fusion or Non-pressure welding: - In this welding, the material at the joint is heated to
a molten state and then allowed to solidify.

Advantages of welding: -
1. A good weld is as strong as the base metal.
2. A large number of metals/alloys can be joined by welding.
3. Repair by welding is very easy.
4. Welding can be easily mechanized.
5. Portable welding equipment is available.
6. General welding equipment is not very costly.
7. Total joining cost is less in case of welding joint.

Disadvantages of welding: -
1. Welding produces the harmful radiation, fumes and spatter.
2. A skilled welder is required.
3. Welding heat produces metallurgical changes.
4. Cost of equipment (Initial cost) is high.
5. Edge preparation is required before welding.
6. More safety devices are required.
7. Jigs and fixtures are required to hold and position the parts to be welded.

Application of welding: -
1. Automobile construction
2. Railroad equipment
3. Ships
4. Aircraft construction
5. Building construction
6. Bridges construction
7. Pressure vessels
8. Storage tanks
9. Piping and-pipe lines
10. Fabrication of jigs, fixtures and machine tools
11. Repair of broken and damaged parts
12. House hold furniture
13. Material handling equipments etc.
Types of welding Joints: -
The following are the five basic types of joints commonly used in fusion welding.
1. Lap joint: - The lap joint is obtained by overlapping the plates and then welding the
edges of the plates.

2. Butt joint: - The butt joint is obtained by welding the ends or edges of the two plates,
which are approximately in the same plane, the butt joint, may be.
a) Square butt joint b) Single V-butt joint c) Double V-butt joint
d) Single U-butt joint e) Double U-butt joint

3. Corner Joint: - The corner joint is obtained by joining the edges of two bleats whose
surfaces are at an angle of approx.90 to each other.
4. Edge Joint: - The edge joint is obtained by joining two parallel plates. It is economical
for plates having thickness less than 6 mm.
5. T-Joint: - The T-joint as shown in figure is obtained by joining two plates whose
surfaces are approximately at right angles to each other. These joints are suitable up to
3mm thickness.

Edge preparation: - In order to obtain sound welded joint edge preparation is very essential.
It consists of beveling the edges. After that cleaning of faces is done.
1. The square butt welded joins are used when thickness of the plates is from 3 to 5mm. In
this edges are kept apart 3 mm as shown in figure.
2. The single V-butt welded joints are used when the thickness of the plates is between 8 to
16 mm. The angle of bevel is about 70° to 90° as shown in figure.

3. The double V-butt welded joints are used when the thickness of the plates is more than 16
mm and where welding can be performed on both sides of the plate.
4. The single and double V-butt welded joints are used when the thickness of the plates is
more than 20 mm. Double V-butt welded joints can be performed on both sides of the
plate.
Welding Positions: - The common welding positions can be summarized as follows:
1. Flat position: - In this welding position, the work piece lies flat. The axis of the weld
remains horizontal. Welding is done from the upper side of the joint.
2. Horizontal position: - In horizontal position of welding, the relative location of the two
work pieces rest one over the other the other with their flat faces in vertical plane. After
tacking welding is performed. In case of fillet weld the two work pieces are at right
angles to each other.

3. Vertical position: - In this position of welding the axis of the weld remain vertical. The
welding commences at the bottom and proceeds upward.
4. Overhead position: - In this welding position, welding is performed from the underside of
the joint, the work piece remains over the head of the welder.

Arc welding principle: -

In arc welding, arc is generated between the positive pole of D.C. (direct current) called
anode and negative pole of D.C. called cathode. When these two poles are brought together,
and separated for a small distance (1.5 to 3 mm) such that the current continues to flow
through a path of ionized particles, called plasma, an electric arc is formed. Since the
resistance of this ionized gas column is high, so more ions will flow from anode to the
cathode. Heat is generated as the ions strike the cathode.

Arc Crater: - Because of the penetration of electric arc into the parent metal, small
depression will be formed in the parent metal around which molten metal is piled up is
known as the arc crater. Its depth depends on the thickness of the parent metal. Operator
judges arc penetration presentation by observing this crater depth. If arc is broken defect will
be occur therefore care should be taken to prevent this defect.

Arc Length: - The distance through the center of the arc from the tip of the electrode to the
bottom of the arc crater is termed as are length. It should be 2 to 4 mm. Arc length should be
proper and constant during welding to obtain good result.

Are Blow: - Arc blow is the phenomenon of wandering of arc and it occurs in D.C. welding.
When a current flows in any conductor, a magnetic field is formed around the conductor in
direction right angles to the current. Since in the case of D.C. arc welding, there is current
through the electrode. Work piece and ground clamps. Magnetic field exists around each of
these components, so they tend to bend the arc from its intended path is called Arc blow.
Magnetic field concentration is always more at the ends so a chance of arc blow is also more
at the beginning and the end of the weld. In D.C. welding, since there is fixed polarity, the
induced magnetic fields are constant in one direction but in A.C. welding polarity is not fixed
(direction of current flows goes a changing) so there is no arc blow. A chance of Arc Blow is
also more if welding is done at very high speed. Movement of arc blow causes atmospheric
gases to be pulled into the arc, resulting in porosity or other defects.
Corrective measures: -
1. The ground connections should be placed as far as possible form the joints to be welded.
2. If possible A.C. current may be used instead of D.C.
3. Arc length and current should be proper (By reducing).
4. Arc blow can also be minimized by welding towards a heavy tack welds or an already
existing weld.
5. The ground cable may be wrapped around the work piece such that the current following in
it sets up a magnetic field in a direction, which will counteract the arc blow.

Electrodes: - The electrodes are used for providing heat input in arc welding. Electrodes can
be classified on the following basis:
1. Consumable or Non-consumable
2. Bare or coated electrodes
1. (a) Consumable or Non-consumable: - When the arc is obtained with consumable
electrodes, the weld metal under the arc melts as also the tip of the electrodes. The molten
metal from the electrode and the base metal gets mixed under the arc and provides the
necessary if joint. So in this process, once the arc is initiated, the electrode is serving the
purpose of filter rod as well as heat input to the joint. Consumable electrodes are made of
various materials depending on the purpose and chemical composition of the metals so be
welded.
(b)Non-Consumable electrode: - Non-consumable electrodes are those electrodes, which
were not consumed during welding. Separate filter rod is necessary if can be used to fill
the gap along the joints. Non consumable electrodes are made of carbon, graphite or
tungsten. The carbon and graphite electrodes are used only in D.C. welding, where as
tungsten electrodes are used for both D.C. and AC welding. So in this, we can have better
control over the heat input and filter metal because the sources are separate. Non
consumable electrodes are used in carbon arc welding or tungsten is welding (TIG).
2. (a) Bare Electrode: - If the electrode is not coated with flux that electrode is called the
base electrode. In that case flux will be added separately if necessary. Bare electrodes are
used in carbon arc welding & tungsten arc welding. The striking of arc is difficult with
this type of electrode especially with AC supply.
(b) Coated Electrode: - If the electrodes are coated with flux that electrode is called the
coated electrode. The coating on the electrodes serves many purposes. The coated
electrode also called stick electrodes is available in the length 350 or 450 mm.
One of the major concerns with the coated electrodes is the moisture pick up by the
coating. This moisture, dissociates into oxygen and hydrogen with the hydrogen being
absorbed by the liquid metal and subsequently released during solidification, causing
porosity. These should be kept in a dry place.

Flux: - During welding if the metal is heated / melted in air, oxygen from the air combines
with the metal to form oxides which result in poor quality, low strength welds, in some
cases, may even make welding impossible. Sometimes the flux will be added separately.
Covering of the coated electrode is also called flux. Sometimes the purpose of flux is also
solved by inert or active gas (TIG, MIG, and MAG).

Precautions in Arc welding: -

1. All instruction supplied by the manufacturer should be strictly followed.
2. Working area and floor should be kept clean and clear. of electrode stubs, metal scrap etc.
3. Power supply source should be isolated from the main supply.
4. Before starting welding, ensure that the welding equipment is properly earthen.
5. One should not look at an electric arc with naked eye use helmet or hand shield.
6. Eye trouble may be relaxed by eye bathing with the following solution.
(a) Sodium bicarbonate 340gm. (b) Purified water 1000 ml.
7. Welder should not leave the electrode holder on the table or in contact with the metallic
surface.
8. Welder should use goggles with clear glasses while he is chipping off scale, slag etc.
9. Welding operation should be carried out in clean, dry, well-ventilated locations.
10. Welding cables should be completely insulated. The welding cable should be flexible,
dry, and free from grease and oil, free from repair up to a minimum distance of 3 m from
the electrode holder.
11. Electrode holder should be soundly connected to the welding lead. Hot electrode holder
shall not be permitted to dip in water because the retained moisture may cause an electric
shock. .
12. Arc welding Machine (Power supply)
i) Input terminals shall be completely enclosed.
ii) Greasing points needs attention regularly.
ill) At or near each welding machine; a disconnecting switch shall be provided.
iv) Periodically clear out the accumulated dust from the welding machine with suction
cleaner.
v) Check and if necessary, clean commentators periodically, using fine sand paper (dc
welding).
vi) Welding (secondary) terminals shall be separate from the power circuit and it shall be
so arranged that current carrying parts are not exposed to accidental contact.
vii) Before undertaking any maintenance work on welding machine, disconnect them
from the main supply.
13. Never weld unless qualified to do so.

Flux shielded Metal Arc Welding: - In this arc welding process, welding heat is produced
from an electric arc set up between a flux coated electrode and the work piece. The electrode
is consumable and supplies the necessary filler metal. The covering on the electrode serves
the purposes or flux.
During the welding process, the metal electrode is melted by the heat of the arc and
fused with the work piece. The temperature produced by the heat is about 2400°C to 2700°C.
The arc temperature and thus the arc heat can be increased or decreased by employing higher
or lower arc currents. A high current arc with a smaller arc length produces a very intense
heat. Both DC and AC current may be used. For current over 750 amperes, AC equipment is
preferred as it has high efficiency, negligible loss at peak load and minimum maintenance.
Striking the arc: -
Arc between the electrode and work piece generally struck either by momentarily
touching the electrode with the work piece and when the arc starts, the electrode is taken
away at a predetermined distance (Arc length).

Welding the joint: -

Once the arc has been established and the arc length adjusted, the electrode is inclined to
an angle of approx. 20 degrees with the vertical. Arc gap should be maintained constant. The
bead width can be increased by employing higher arc current, lower arc travel speeds and by
suitably weaving the electrode. Before using the fresh electrode (New) the bead should be
properly cleaned. After completing the weld, the slag is chipped off and weld bed is cleaned
with a wire brush.
Advantages: -
1. The welding equipment is simple, less costly, and portable.
2. Welding can be carried out in any position with highest weld qualities.
3. Wide varieties of electrodes arc available.
4. Total welding cost is less.

Disadvantages: -
1. The length of each electrode is limited and when new electrode is used proper cleaning is
to be done which decreases the welding speed.
2. Welding control is difficult as compared to MIG welding.
3. If the covering absorbs moisture, this moisture causes the porosity defect.
4. Because of flux coating, chances of slag entrapment are more.

Applications: -
1. It is used both as a fabrication process and for maintenance and repair jobs.
2. It is also used in ship buildings, pipe lines, Buildings and bridge construction, tanks,
boilers, Automotive and Aircraft industry.