Welding Processes

Gautam singh (M.E 4th yr)

10030104014

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.

Types of Welding

Fusion Welding Homogeneous Heterogeneous

Pressure Welding Friction Welding

Gas Welding
Electroslag High Energy Beam Electric Arc

Brazing
MIG

Soldering

TIG
Shielded Metal Arc Stick

Fusion Welding Principles

Base metal is melted Filler metal may be added Heat is supplied by various means
Oxyacetylene gas Electric Arc Plasma Arc Laser

Fusion Welding

ELECTRODE COATING CORE WIRE WELDING ATMOSPHERE ARC STREAM ARC POOL SOLIDIFIED SLAG PENETRATION DEPTH WELD

BASE METAL

Weld Fluxes
Typical fluxes
SiO2, TiO2, FeO, MgO, Al2O3 Produces a gaseous shield to prevent contamination Act as scavengers to reduce oxides Add alloying elements to the weld Influence shape of weld bead during solidification

Inert Gases
Argon, helium, nitrogen, and carbon dioxide Form a protective envelope around the weld area Used in
MIG TIG Shield Metal Arc

Types of Fusion Welding

Oxyacetylene Cutting/Welding Shielded Metal Arc (Stick) Metal Inert Gas (MIG) Tungsten Inert Gas (TIG)

Oxyacetylene Welding
Flame formed by burning a mix of acetylene (C2H2) and oxygen
TORCH TIP 2300 deg F

Inner Cone: 5000-6300 deg F

Combustion Envelope 3800 deg F

Fusion of metal is achieved by passing the inner cone of the flame over the metal Oxyacetylene can also be used for cutting metals

Gas Welding (Oxy-acetylene)

A number of welding processes use a flame produced by burning a mixture of fuel gas and oxygen. The gas usually used is Acetylene but other gases are also used.
Separate cylinders and a hose pipe from each cylinder transports the gases to a torch. Gas and fuel mix in the torch

burns @ 3100C.

Metal Inert Gas (MIG)

Uses a consumable electrode (filler wire made of the base metal) Inert gas is typically Argon DRIVE WHEELS CONSUMABLE
ELECTRODE POWER SOURCE

SHIELDING GAS

ARC COLUMN

BASE METAL

PUDDLE

Tungsten Inert Gas (MIG)

Tungsten electrode acts as a cathode A plasma is produced between the tungsten cathode and the base metal which heats the base metal to its melting point Filler metal can be added to the weld pool
TUNGSTEN ELECTRODE TUNGSTEN ELECTRODE

POWER SOURCE

(CATHODE)

++
SHIELDING GAS ARC COLUMN

++

--BASE METAL (ANODE)

BASE METAL

PUDDLE

Submerged Arc Welding (SAW)

Similar to MIG welding, SAW involves formation of an arc between a continuously-fed bare wire electrode and the workpiece

Applications
SAW welding taking place in the flat position. Ideal for heavy workpieces Carbon-manganese steels,low alloy steels and stainless steels

Welding Positions
INCREASING DIFFICULTY

FLAT HORIZONTAL

OVERHEAD

VERTICAL

Weld Symbols (Butt Joints)

Backing

Weld Symbol (Fillet Joints)

Weld Symbol (Corner Joints)