Professional Documents
Culture Documents
Welding Technology Notes
Welding Technology Notes
CLASSIFCATION:
V U
BEVEL
Prof. G. R. C. PRADEEP 6 Email: grcpradeep@gmail.com
Gas Welding:
It is the process of generating the heat required for melting
the joint by burning a combustible gas with air/oxygen in a
concentrated flame at high temp. It can weld most
common materials.
(a) Oxy-Acetylene Welding:
This is suitable for joining metal sheets and plates having
thickness of 2 to 50 mm. Additional metal called filler
metal is added to the weld in the form of welding rods
whose composition is same as the part being welded. Oxygen
is stored at a pressure of 14 MPa. Acetylene is dissolved in
acetone and stored in the cylinder as it decomposes in to
carbon and hydrogen if stored as a gas and increases the
pressure which may cause explosion.
Video
1,2
Types of Flames:
1. Neutral Flame: When oxygen and acetylene are supplied
in nearly equal volumes, this is produced having a max.
temperature of 3200oC. This is desired in most welding
operations. It has sharp brilliant Inner cone and outer cone
faintly luminous with bluish colour. Used for most welding
applications for many metals like Mild steel, Stainless steel,
Cast Iron, Copper, Aluminium etc.
Prof. G. R. C. PRADEEP 9 Email: grcpradeep@gmail.com
Carburizing Flame:
There is excess of acetylene. This has 3 zones, sharp inner
cone, intermediate whitish cone, bluish outer cone. The
length of the intermediate cone is an indication of the
proportion of excess acetylene. If little excess of acetylene
is used it is called reducing condition and is used for welding
High carbon steel, Ni, non-ferrous Alloys, low alloy steel etc.
If more excess of acetylene is used it is called carburizing
condition and is used for low carbon steels for carburizing
heat treatment purpose.
Rightward Welding
Video
3
Video
4,5
Principle of Arc:
An Arc is generated between two conductors of Electricity,
Cathode and Anode, when they are touched to establish the
flow of current and then separated by a small distance. An
arc is a sustained electric discharge through the ionized gas
column called plasma between the two electrodes. The
electrons liberated from the cathode strike the anode at high
velocity, generating large amount of heat (6000oC). About
65% to 75% of total heat is liberated at anode.
Prof. G. R. C. PRADEEP 19 Email: grcpradeep@gmail.com
With AC the cathode and anode change continuously and as
a result temp. across the arc would be more uniform
compared to a DC arc.
Video
8
1)
3) 4)
Prof. G. R. C. PRADEEP 35 Email: grcpradeep@gmail.com
2. Globular / Drop Transfer: It occurs at higher currents than
the first. The melted tip forms a big size drop (twice the
wire dia) at tip which is pinched by electromagnetic forces
and pulled by gravity in to the weld pool. It causes
excessive spatter hence usually avoided mode of transfer. It
may sometimes cause short circuit also.
3. Spray Transfer: It occurs at higher currents than the
second. Here the molten metal is detached from tip by the
increased electromagnetic pull irrespective of gravity force.
It produces very little spatter & used for thick plates (>6 mm)
in flat and horizontal positions only. Wire diameters are more.
4. Pulsed Spray Transfer: The current is pulsed between spray
transfer range and nearer to globular range cyclically so that
it is suitable for all positions of welding. It is mainly used for
S.S as it reduces distortion and inter granular corrosion.
Prof. G. R. C. PRADEEP 36 Email: grcpradeep@gmail.com
Tungsten Inert Gas (TIG) welding:
This process was invented for welding Al as Al forms an
oxide layer immediately on exposing to atmosphere. DCEP
was used in welding Al as it causes peeling of oxide layer
(Cathode cleaning process). A.C. was later found to give
better result. Filler material can be used if required in TIG
welding by feeding as if in Gas welding. Pure tungsten is
used for DCEN for welding most of the metals. Thoriated
tungsten or Zirconated tungsten is used for A.C and DCEP
for welding Al and Mg alloys.
This process is being widely used
for thin sheets for precision
welding in nuclear, air craft, space craft,
chemical industries.
Duty Cycle:
Duty cycle is the ratio of arcing time to the weld cycle time
expressed as percentage. If arcing time is continuously 5
minutes then as per European standard it is 100% duty cycle
and 50% as per American standard. At 100% duty cycle
minimum current is to be drawn. The welding current which
can be drawn at a duty cycle can be evaluated from the
following equation:
Video
1
RPW
Video
4,5,6,7,8,9
RSW
BRIDGE GIRDER
Video
6
Video
7,8
BRAZING OF
WATCH ASSEMBLIES, CONNECTORS IN AUTOMOBILES