WELD ING

1H MANUFAKTUR MSU
Abidzar Al-Ghiffari
M. Fadlan alamsyah
Otter Sorbo
Hani
Ardi
Mind Mapping of Welding
 Welding ( Processes & Information )

What is Welding?

Welding is nothing more than the art of joining metals together. By

comparison, wood is joined by nails, bricks are held together with mortar;
metal is joined by welding! What makes welding such a big deal is that the
world’s infrastructure depends on it! Everything you touch everyday that
is made of metal is most likely welded in one form or another. It is one of
the most valuable technologies that played a huge part in the industrial
revolution, and is the backbone to the world’s militaries.

Welding today is comprised of three main ingredients which are required

to join metals together:
1. An electrical power source to produce an arc.
2. Some form of shielding to protect the weld from the air.
3. Filler material to fill the weld joint.

The ways these three ingredients work together are:

1. The weld area needs to be shielded from any air around it. This is
important because oxygen and other gasses in the air make welds brittle
and porous.
2. Electricity to produce an arc. An electrical arc melts metal in fractions
of a second and is hot enough to melt any known metal!
3. Filler metal is added… which is how two pieces of metal become one.

Types of Welding
MIG Welding
MIG welding is one of the easier types of welding for beginners to learn.
MIG welding is actually two different types of welding. The first uses bare
wire and the second flux core. Bare wire MIG welding can be used to join
thin pieces of metal together. Flux core MIG welding can be used outdoors
because it does not require a flow meter or gas supply. MIG welding is
usually the welding of choice for DIY enthusiasts and hobby welders who
don’t have the money to spend on expensive equipment.
Stick Welding
Stick welding, also known as Arc welding, is doing it the old fashioned way.
Stick welding is a bit harder to master than MIG welding, but you can pick
up a stick welding equipment for very little if you want to have a go at
home. Stick welding uses a stick electrode welding rod.

TIG Welding
TIG welding is extremely versatile, but it is also one of the more difficult
welding techniques to learn and Lincoln Electric TIG welders are skilled
individuals. Two hands are needed for TIG welding. One hand feeds the
rod whilst the other holds a TIG torch. This torch creates the heat and arc,
which are used to weld most conventional metals, including aluminum,
steel, nickel alloys, copper alloys, cobalt and titanium.

Plasma Arc Welding

Plasma arc welding is a precision technique and is commonly used in
aerospace applications where metal thickness is 0.015 of an inch. One
example of such an application would be on an engine blade or an air
seal. Plasma arc welding is very similar in technique to TIG welding, but
the electrode is recessed and the ionizing gases inside the arc are used to
create heat.

Electron Beam and Laser Welding

Electron beam and laser welding are extremely precise, high energy
welding techniques.

Gas Welding
Gas welding is rarely used anymore and has been largely superseded by
TIG welding. Gas welding kits require oxygen and acetylene and are very
portable. They are still sometimes used to weld bits of car exhaust back
together.

There is currently a huge shortage of skilled welders in the US and the

rest of the world, so for young people who do decide to take up a career
as a welding technician, the job prospects are good.
 MIG WELDING PLASMA ARK
WELDING

STICK WELDING ELECTRON BEAM

WELDING
 TIG WELDING GAS WELDING

Classification of Welding

Welding processes can be classified based on following criteria;

1. Welding with or without filler material.

2. Source of energy of welding.

3. Arc and Non-arc welding.

4. Fusion and Pressure welding.

1. Welding can be carried out with or without the application of filler

material. Earlier only gas welding was the fusion process in which
joining could be achieved with or without filler material. When
welding was done without filler material it was called ‘autogenous
welding'. However, with the development of TIG, electron beam
and other welding processes such classification created confusion
as many processes shall be falling in both the categories.

2. Various sources of energies are used such as chemical, electrical,

light, sound, mechanical energies, but except for chemical energy
all other forms of energies are generated from electrical energy
for welding. So this criterion does not justify proper classification.

3. Arc and Non-arc welding processes classification embraces all the

arc welding processes in one class and all other processes in other
class. In such classification it is difficult to assign either of the
class to processes such as electroslag welding and flash butt
 welding, as in electroslag welding the process starts with arcing
and with the melting of sufficient flux the arc extinguishes while in
flash butt welding tiny arcs i.e. sparks are established during the
process and then components are pressed against each other.
Therefore, such classification is also not perfect.

4. Fusion welding and pressure welding is most widely used

classification as it covers all processes in both the categories
irrespective of heat source and welding with or without filler
material. In fusion welding all those processes are included where
molten metal solidifies freely while in pressure welding molten
metal if any is retained in confined space under pressure (as may
be in case of resistance spot welding or arc stud welding)
solidifies under pressure or semisolid metal cools under pressure.
This type of classification poses no problems so it is considered as
the best criterion.
Welding Tools and Equipments

Auto-Darkening Welding Helmet

Auto darkening welding helmets are
great welding tools for beginners
because they allow you to easily see the
work piece before starting your welds,
which means more accuracy and less
frustration.

Welding Gloves

Obviously you have to have

welding gloves, unless of course
you already have nerve damage
on your fingers. In that case you
won’t need them.

Safety Glasses
When you’re using angle grinders, you
need to have some safety glasses on.
Those sparks you see flying off the
grinding disk are small pieces of
metal, and if one hits you in the eye,
you’re done with.

Safety Shoes
A steel-toe boot (also known as a
safety boot, steel-capped boot or
safety shoe) is a durable boot or
shoe that has a protective
reinforcement in the toe which
protects the foot from falling
objects or compression, usually
combined with a mid sole plate
to protect against punctures from
below.