WELDING
WELDING
Welding is a materials joining process which produces
coalescence of materials by heating them to suitable
temperatures with or without the application of
pressure or by the application of pressure alone, and
with or without the use of filler material.
Welding is used for making permanent joints.
It is used in the manufacture of automobile
bodies, aircraft frames, railway wagons,
machine frames, structural works, tanks,
furniture, boilers, general repair work and
ship building.
Welding
Welding is a process of joining similar metals by
application of heat with or without application of
pressure and addition of filler material.
Wealdability:
It is define as the capacity of being welded into
inseparable joints having specified properties such
as definite wild strength proper structure etc.
Welding may be classified under headings:
(1)Plastic welding, (2) Fusion welding
• In the plastic or pressure welding, the pieces to be
joined are heated to the plastic state and then forced
together by external pressure
Eg resistance welding
• In fusion welding material at joint is heated to
molten state and allowed to solidify
Eg arc welding, gas welding etc
re heated to a plastic state and then
forced together by external pressure.
Solid state welding
It merges all the welding processes in which there is no fusion of the
workpieces .
For example, in the solid welding process named resistance seam welding,
the welding join is produced in the wheel electrodes region by applied a
current and a pressure without fusion of the base metal.
The resistance seam welding
(source: Modern Welding (p73))
Fusion welding
This process involves the partial melting of the two members welded in the
join region. The thermal energy required for this fusion is usually supplied
by chemical or electrical means.
Base metal melt + filler melt
Electric arc welding
• A group of fusion welding processes that use an
electric arc to produce the heat required for
melting the metal.
• Advantages
– Inexpensive power source
– Relatively inexpensive equipment
– Welders use standard domestic current.
– Portable equipment is available
– Process is fast and reliable
• Electric arc is about 9,000 oF
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Introduction-cont.
• All fusion welding process have three
requirements.
– Heat
– Shielding
– Filler metal
• The method used to meet these three
requirements is the primary difference
between arc welding processes.
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Arc Welding Equipments
Arc welding
Equipments:
• A welding generator (D.C.) or Transformer (A.C.)
• Two cables- one for work and one for electrode
• Electrode holder
• Electrode
• Protective shield
• Gloves
• Wire brush
• Chipping hammer
• Goggles
Metal arc welding
Arc welding
Advantages Limitations
– Most efficient way to • Manually applied,
join metals therefore high labor
– Lowest-cost joining cost.
method • Need high energy
– Affords lighter weight causing danger
through better
utilization of materials
• Not convenient for
– Joins all commercial disassembly.
metals • Defects are hard to
– Provides design detect at joints.
flexibility
Comparison of A.C. and D.C. arc welding
Alternating Current (from Transformer)
More efficiency
Power consumption less
Cost of equipment is less
Higher voltage – hence not safe
Not suitable for welding non ferrous metals
Not preferred for welding thin sections
Any terminal can be connected to the work or electrode
Comparison of A.C. and D.C. arc welding
Direct Current (from Generator)
Less efficiency
Power consumption more
Cost of equipment is more
Low voltage – safer operation
suitable for both ferrous non ferrous metals
preferred for welding thin sections
Positive terminal connected to the work
Negative terminal connected to the electrode
Joints, Welds & Positions
Electric arc welding uses the same five
(5) types of joints and five (5) types of
welds and five (5) positions.
Five (5) joints:
Corner
Butt
Lap
Edge
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Five types of welds
1. Surface
2. Groove
3. Fillet
4. Plug
5. Slot
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1. Surface Welds
• Surface welds are welds where a material has been applied
to the surface of another material.
• Two common applications are for
hard surfacing
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2. Groove Welds
Groove welds are
used to fuse the sides
or ends of two pieces
of metal.
The primary use of groove
welds is to complete butt
joints.
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3. Fillet Welds
Fillet welds have a triangular cross section and are used to fuse two
faces of metal that are at a 90 degree angle to each other.
Lap Joint
Outside Corner T Joint
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4. Plug Welds
Plug welds are used to attach
two surfaces together when
a complete joint is not
required and the design does
not allow for any weld bead
outside the dimensions of
the metal.
The holes can be made with a drill bit or punch.
The weld is completed by establishing the arc on the
bottom plate and then continuing to weld until the hole is
full.
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5. Slot Welds
Slot welds are identical to plug welds except for the shape of the
holes. For slot welds, slots are machined or stamped in the
upper plate.
They are complete the same as plug welds.
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Arc Welding Positions
Flat
Horizontal
Vertical Up Vertical Down
Overhead
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Weld Defects
• A weld defect is any physical characteristic in the completed
weld that reduces the strength and/or affects the appearance
of the weld.
• The mark of a good welder is the ability to identify weld
defects and adjust the welding parameters to eliminate them.
• Defects that are not visible must be detect by using
destructive or nondestructive testing.
• If the defects in a weld exceed the specifications, the weld
must be removed and redone.
• Welds are removed by grinding, gouging and cutting.
• Eliminating a weld defect is time consuming and expensive --
you must be able to complete the weld correctly the first
time.
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Common Defects and Causes
Description Cause(s)
The depth of the Excessive heat
weld is less than Excessive speed.
specifications.
The weld metal is not Incorrect angle
completely fused to Incorrect
base metal or passes are manipulation
not completely fused.
Insufficient heat
Weld material flows Slow speed
over, but is not fused
with the base metal.
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Common Defects and Causes--cont.
Description Cause(s)
Weld bead does not Low heat
extend to the desired Long arc
depth. Incorrect joint design
Small indentions in Excessive gas in the
the surface of the weld zone.
weld
Moisture
Rust
Small voids Dirt
throughout the weld Accelerated cooling
material.
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Common Defects and Causes--cont.
Description Cause(s)
Usually visible cracks Accelerated cooling
on the surface or Constrained joint
through the weld Small weld volume
Cracks in the transition Induced hydrogen
zone between the weld Incompatible electrode
and base metal or wire
Accelerated cooling
Misshapen Inconstant speed
and/or uneven Incorrect manipulation
ripples Incorrect welder settings
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Gas welding
• Done by burning or combustible gas with air or oxygen in a
concentrated flame of high temperature.
• Flame is used to heat and melt the parent metal and filler rod of a
joint.
• The edges to be joined by gas flame and allowing the molten metal
to flow together thus forming a solid continuous joint upon cooling.
• Suitable for joining metal sheets and plated having thickness of 2 to
50 mm.
• For material thicker than 15 mm additional meal called filler metal is
added.
• Flux is used to obtain satisfactory bond and to remove impurities and
oxides.
• Hottest region is about 32000 C.
• High pressure system
Oxygen and acetylene are taken for use from high
pressure cylinders
• Low pressure system
Oxygen is taken from high pressure
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cylinder and the
acetylene is produced by the action of calcium carbide
and water.
CaC2 + 2H2 O = Ca(OH)2 + C2H2
C2H2 + O2 =2CO+ H2
2CO +H2 +3O=2CO2 + H2 O
Welding equipment:
Welding equipment:
• Welding torch: mixing of oxygen and acetylene.
• Pressure gauge and Pressure regulator
• Hose and hose fitting
• Goggles, gloves and spark lighter
• Gas cylinder: oxygen cylinder black
colour(15400KN/m2) and acetylene moron
colour (100KN/m2)
Types of flames
• The nature and properties of gas flame have the maximum
effect on oxy-acetylene welding
• Proper adjustment of flame leads efficient welding
• This adjustment is made in regard to characteristics and power
of flame by regulating the pressures of oxygen and acetylene
• A flame in which only acetylene burns is yellow in color which
has no commercial use
– It is because of its incapability to develop high temperature
• The types of flames used in engineering works are
1. Oxidising flame
2. Neutral flame
3. Carburising flame
Gas flame
Neutral flame
• Equal volume of oxygen and acetylene
• Maximum temp 32000C.
• Used to weld steel, stainless steel, cast iron, copper.
Oxidized flame
• Excess of oxygen.
• Used in welding of Brass.
• Used for cutting metals.
• In steel, this will result in a large grain size, increased brittleness
• with lower strength.
Carburizing flame
• Excess of acetylene.
• Increases carbon content in steel resulting in a hard and brittle
weld generally used for welding Nickel, Monel etc.
Gas welding technique:
• Left ward or forward (right to left)
• Right ward or backward (left to right)
• Vertical.
Flux
• Chemicals which deoxidise from the metal
surfaces and provide inert atmosphere around the
molten metal are known as fluxes
Function
• To prevent oxides from the hot surfaces
• To reduce the viscosity of the molten metal
Filler
• Rod which provide additional metal in completing
the welding is known as filler
• The composition of the filler metal should be the
same as that of the metals to be welded.
High pressure system Low pressure system
1. The pressure of acetylene used is high 1. The pressure of acetylene used is low i.e.,
i.e., above atmospheric (max. up to 2 bar). below atmospheric (0.1 bar)
2. This process uses acetylene gas which is 2. This process uses acetylene which is
already filled in commercially available produced on the spot with the help of
cylinder. acetylene generator by reaction of calcium
carbide and water
3. Acetylene gas obtained from commercial 3. The cost of production of acetylene is low
cylinders is costly and hence this process is suitable where
large amount of acetylene is required
4. High pressure gas welding plant is 4. Low pressure gas welding plant is not
obviously portable portable, as the number of equipment’s
used are more.
5. A constant acetylene pressure is available 5. This process has disadvantage of pressure
from the cylinder. fluctuation of acetylene. This results in
unsteady gas flame
