UNIVERSITY OF ENERGY AND NATURAL RESOURCES

MANUFACTURING TECHNOLOGY MECH 216

UE20028713

WELDING
Welding is the process of joining two similar or dissimilar metals by fusion. The
process of joining the metals can either be;
a) With or without pressure
b) With or without a filler metal
In both processes the fusion of the metals is achieved by means of heat which may
be generated from combustion of gases, electric arc, and electric resistance or by
chemical reactions. The welding process provides a permanent joint.
Before welding is done one important property of the metal called weldability
(property of a material which indicates the ease with which it can be welded with
other similar o dissimilar metals) must be first investigated. This involves the
metallurgical changes that occur due to welding, changes in hardness in and around
the weld, gas evolution and absorption, extent of oxidation, and the effect on
cracking tendency of the joint.
WELDING JOINTS
There are two main types of welding types namely butt joint and lap joint.
Lap weld joint: This is a weld in which the ends of the pieces are overlapped and
joined by welding. There are three main types of lap weld joint and this include
single-lap joint, double-joint and a tee fillet weld.
Butt weld joint: This is a joint that joins the end of pieces of metals with similar
cross-section without overlapping. There are two main types of butt weld, single-vee
butt weld and double-vee butt weld.
WELDING POSITIONS
There are four main types of welding positions, which include:
a)
b)
c)
d)

Flat or down hand position

Horizontal position
Vertical position
Overhead position
ADVANTAGES OF WELDING

1. Welding is more economical and is much faster as compared to other

processes such as riveting, bolting, casting, etc.
2. Welding if properly controlled results permanent joints having strength equal
or sometimes more than the base metal.
3. It allows large number of similar and dissimilar metals or alloys to be joined.
4. General welding equipment is not costly.

5. Welding permits considerable freedom in design.

DISADVANTAGES OF WELDING
1.
2.
3.
4.
5.

It usually results in residual stresses and distortion of work pieces.

Welded joints need stress relieving and heat treatment.
Welding gives out harmful radiations, spatter and fumes.
Edges preparations of the welding materials are required before welding.
Jigs and fixers may also be needed to hold and position the parts to be
welded.
CLASSIFICATION OF WELDING

Welding processes can be classified in several ways. Based on the sources of heat,
the processes can be classified as blacksmith fire, flame, arc, etc. Based on the type
of interaction it can be classified as liquid/liquid (fusion welding) or solid/solid (solid
state welding). However, the general classification of welding and allied processes is
given as under
a) Welding Processes
1. Oxy-Fuel Gas Welding Processes
I.
Air-acetylene welding
II.
Oxy-hydrogen welding
III.
Oxy-acetylene welding
IV.
Pressure gas welding
2. Arc Welding Processes
I.
Carbon Arc Welding
II.
Shielded Metal Arc Welding
III.
Submerged Arc Welding
IV.
Gas Tungsten Arc Welding
V.
Gas Metal Arc Welding
VI.
Plasma Arc Welding
VII.
Electro-slag Welding
VIII.
Atomic Hydrogen Welding
IX.
Stud Arc Welding
X.
Electro-gas Welding
3. Resistance Welding
I.
Spot Welding II. Seam Welding III. Projection Welding IV.
Resistance Butt Welding V. Flash Butt Welding VI.
Percussion Welding VII. High Frequency Resistance
Welding VIII. High Frequency Induction Welding
4. Solid-State Welding Processes
I.
Forge Welding
II.
Cold Pressure Welding
III.
Friction Welding
5. Thermit Welding Processes
I.
Thermit Welding II. Pressure Thermit Welding
6. Radiant Energy Welding Process

I.

Laser Welding II. Electron Beam Welding

ALLIED PROCESSES
This consist basically of metal joining or Metal Depositing Processes
(i.e. soldering, brazing, braze welding, adhesive bonding, metal
spraying, surfacing) and thermal cutting processes (i.e. gas cutting and
arc cutting).
WELDING FLAMES
In welding, the type of flame is very essential to get the desire
welds needed. The shape, size and condition of the flame are the
factors that need to be considered critically for maximum efficiency.
There are three types of welding (oxy-acetylene) flames which
include;
i. Neutral welding flame (acetylene and oxygen in equal
proportions). The temperature is of about 3260C.Its used for the
welding of mild steel, stainless steel, cast iron, etc.
ii. Carburizing welding flame (excess of acetylene). It occurs at a
temperature of 3038C. It is used for the weld of lead and for
carburizing purpose.
iii. Oxidizing welding flame (excess of oxygen). This occurs at a
temperature as high as 6300F. it is used in the welding of copperbase metals, zinc-base metals and some ferrous metals such as
manganese steel and cast iron.
Some basic components of a welding device include the gas
pressure regulators (regulates the supply of acetylene and oxygen
gas from cylinders), welding touch (it mixes the oxygen and
acetylene in correct proportion at the end of the tip), torch tips (it is
the part through which the gases passes just before ignition and
burning), hose pipes (they supply gases from the pressure
regulator) green is the standard color for oxygen hose and red for
acetylene, spark-lighter (it is used for igniting the welding torch),
filler rods, goggles (they are filled with colored lenses and protect
the eyes from heat and ultraviolet an infrared rays), gloves (they
protect the hands from injury), fluxes( they are used to remove
oxide film to maintain clean surface).
EFFECTS OF WELDING HEAT
1. Metallurgical effect; The base metal after welding sometimes
have metallurgical changes due to the welding heat and this
region is called heat affected zone.
2. Mechanical effect; this involves the distortion and residual stress
resulting from welding.
DEFFECTS OF WELDING

1.
2.
3.
4.
5.
6.

Lack of penetration
Lack of fusion
Porosity
Undercuts
Slug inclusion
Cracks

BRAZING: Is a process of joining metals without melting the base

metal. During this process liquids with temperature above 450C
and below the solidus of the base metals are used as fillers. This
method can be used for most metals except aluminum and
magnesium.
METHODS OF BRAZING
i.
ii.

Torch brazing
Furnace brazing

SOLDERING: Is a method of joining similar or dissimilar metals by

heating them to a suitable temperature and by means of a filler
metal having liquidus temperature not exceeding 450C