MEE1007 MANUFACTURING PROCESS

L T P J C
2 0 2 0 3

School of Mechanical Engineering,

VIT Vellore, Vellore, TN, India – 632 014.
 Module - II

Joining Processes
Introduction to 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,
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.
Definition

• Welding is a metallurgical fusion process where interface of

the two parts to be joined are brought to a temperature above
the melting point and then allowed to solidify so that a
permanent joining takes place.
• The weld joint strength is equal to or sometimes more
than that of the parent metal.
• Products obtained by the process of welding are called
weldments.
Fabrication process can be classified as:-
1. Mechanical joining by means of bolts, screws and rivets
2. Adhesive bonding by employing synthetic glues such as epoxy
3. Welding, brazing and soldering

The choice of fabrication method depends on:

1. Types of assembly—permanent, semi-permanent or temporary
2. Materials being joined—steels, cast irons, aluminum, similar or dissimilar
metals
3. Economy achieved.
4. Types of service required—such as assembly subjected to heavy
loading, impact loading, high temperatures etc.
 JoiningProcesses
Bolted joint
• Joints obtained by bolts and screws is temporary.
• Rivets are semi-permanent fastening devices.
• Mechanical fastening involve making holes in the mating
parts.
• Adhesive bonding generally have less strength.
• Adhesive bonding helps in joining awkwardly shaped
parts or thin sheets.
• Metals and non metals can be joined by adhesive bonding.
(Eg. brake shoe linings)
• Sandwich structure construction for damping structural
vibration, relies on the damping capability of the adhesive.
Classification

-Fusion welding processes

-Solid state welding processes
-Advanced welding techniques
Joining of materials by heating,
with or without the
application of pressure.
 Fusion Welding
Gas Welding is further classified as follows:
1.OXY-Acetylene Gas Welding
2.Air-Acetylene Gas welding
3.OXY-Hydrogen Gas welding
4.Atomic Hydrogen Gas Welding

ARC Welding is further classified as follows:

1.AC Welding
2.DC Welding – Classified as DCSP/DCRP
3.TIG Welding – Tungsten Inert Gas Welding
4.MIG Welding – Metal Inert Gas Welding
5.SAW Welding-Submerged Arc Welding
6.Shielded metal arc welding (SMAW)
7.Electroslag welding (ESW),
Types of Welded Joints
Welding Positions
Butt-Joint Edge Preparation Methods
 Butt-Joint Edge Preparation Methods
• Joint surfaces must be thoroughly cleaned before welding is attempted.
• To remove the oily substances from the surface, organic solvents such as
acetone and carbon tetrachloride are to be used. Foreign substances
should be removed by cleaning with a rag soaked in the solvent.
• The heavier oxide films may be removed by acid pickling, wire brushing or
emery.
• When organic solvents are used for cleaning, care must be taken to see
that the solvent is completely evaporated from the interfaces. Otherwise,
highly poisonous gases such as phosgene may be formed.
• Oxides present on the surface must be eliminated by use of fluxes.
• Filler metal is used to fill gap between the parts.
• The composition of filler metal should be same as that of the base metal
Terminology of Welding
 Terminology of Welding
Backing It is the material support provided at the root side of a weld to aid in
the control of penetration.
Base metal The metal to be joined or cut is termed the base metal.
Weld Bead Bead is the metal added during a single pass of welding.
Crater In arc welding, a crater is the depression in the weld-metal pool at the
point where the arc strikes the base metal plate.
Deposition Rate The rate at which the weld-metal is deposited per unit time is
the deposition rate and is normally expressed as kg / h.
Fillet Weld The metal fused into the corner of a joint made of two pieces placed
at approximately 90 degrees to each other is termed fillet weld.
Penetration It is the depth up to which the weld metal combines with the base
metal as measured from the top surface of the joint.
 Terminology of Welding
Puddle The portion of the weld joint that is melted by the heat of welding is
called puddle.
Root

It is the point at which the two pieces to be joined by welding are nearest.
Tack Weld
A small weld, generally used to temporarily hold the two pieces together during
actual welding, is the tack weld
Toe of Weld
It is the junction between the weld face and the base metal.
Torch
In gas welding, the torch mixes the fuel and oxygen and controls its delivery
to get the desired flame.
 Terminology of Welding
Weld Face
It is the exposed surface of the weld.
Weld Metal
The metal that is solidified in the joint is called weld metal. It
may be only a base metal or a mixture of base metal and filler
metal.
Weld Pass
A single movement of the welding torch or electrode along the
length of the joint which results in a bead is a weld pass.
Fillet welds
Tack Weld
 Fusion Welding : Gas Welding

Definition
Gas Welding or oxy-fuel gas welding (OFW), derives heat from the combustion of fuel
gas such as acetylene in combination with oxygen.

Normally used fuel gas is acetylene because it generates high temperature.

The process is called Oxy Acetylene Welding (OAW).
In Oxy Acetylene Welding, the combustion takes place in two stages.

C2 H2 + O2  2 CO + H2 + 448 KJ/mol

4 CO + 2 H2 + 2 O2  4 CO2 + 2 H2O + 812 KJ/mol

Gas Welding
• Gas welding is a fusion welding process in which
welding is done by heating the work piece with
flames obtained from fuel–oxy gas
 Oxyacetylene Flames Used in Welding

Figure 27.1 Three basic types of oxyacetylene flames used in oxyfuel-gas welding and cutting
operations: (a) neutral flame; (b) oxidizing flame; (c) carburizing, or reducing, flame. The gas
mixture in (a) is basically equal volumes of oxygen and acetylene.
Types of flames

1) Neutral flame
2) Reducing flame
3) Oxidizing flame
Types of flames
Neutral flame
• Oxygen and Acetylene mixed in equal amounts
• A short inner cone and a longer outer envelope
characterize a neutral flame
• For most metals a neutral flame is used.
• Addition of little more oxygen give a bright whitish
cone surrounded by the transparent blue envelope
is called Neutral flame (It has a balance of fuel gas
and oxygen) (3200ºC)
• Used for welding steels, aluminium, copper and
cast iron
Reducing Flame
• Excess acetylene is used
• Combustion of acetylene is incomplete
• A greenish acetylene feather between the inert cone
and the outer envelope characterizes a reducing flame
• Desirable for welding aluminum alloys and high-carbon
steels.
• Oxygen is turned on, flame immediately changes into a
long white inner area (Feather) surrounded by a
transparent blue envelope is called Carburizing flame
(30000c)
Oxidizing flame
• Excess oxygen is used
• A short white inner cone characterizes an oxidizing
flame.
• This flame is preferred when welding brass because
copper oxide covers the weld pool and thus prevents
zinc from evaporating from the weld pool.
• If more oxygen is added, the cone becomes darker and
more pointed, while the envelope becomes shorter and
more fierce is called Oxidizing flame
• Has the highest temperature about 34000c
• Used for welding brass and brazing operation
Oxy-Acetylene Welding Equipment
 Oxy-Acetylene Welding Equipment

• The oxygen is stored in strong cylinders at a pressure from 13.8 Mpa to

18.2 MPa.
• The acetylene is available in the following two forms:
• Acetylene storage cylinder, and
• Acetylene generator

• Free acetylene is highly explosive if stored at a pressure more than 200

kPa.
• Acetylene is stored in cylinder filled with 80 to 85% porous material such
as calcium silicate and then filled with acetone which can absorb up to
420 times its volume of acetylene at a pressure 1.75 MPa.
• The rate of consumption of acetylene should be less than the rate of
release, otherwise acetone may come out.
 Oxy-Acetylene Welding Equipment

Acetylene is produced by a
reaction between calcium
carbide and water.

The generator is permitted

to a safe pressure of 100 kPa.

Chemical Reaction
CaC2 + 2 H2O  C2H2 + Ca(OH)2
Oxy-Acetylene Welding Equipment
• The acetylene valve on the torch is opened slightly and lighted with the
help of a friction spark lighter.
• The flame draws oxygen from atmospheric air and results in reducing
flame.
• The oxygen valve is slowly opened till the intermediate flame feather of
the reducing flame recedes into the inner white cone.
• The actual adjustment of the flame depends on the type of material to
be joined.
• The choice of the torch size depends on the thickness of the metal to be
joined.
• For thicker metals, welding rod is to be used to obtain a strong weld.
 Alternative Gases for OFW

• Methylacetylene - Propadiene (MAPP)

• Hydrogen
• Propylene
• Propane
• Natural Gas
• The torch tip should be positioned above metal plate with the white cone is
at a distance of 1.5 to 3.0 mm from the plate The torch should be held at
an angle of 30◦ to 45◦ degrees from the horizontal plane.
• The torch movement along the joint should be either oscillating or
circular.
• In forehand welding, the torch is moved in the direction of the tip. This
preheats the metal before the white cone of the tip melts it.
• In backhand welding, the torch moves backwards. The outer blue flame is
directed on the already welded joint.
• Welding rod is to be held at a distance of 10 mm from the flame and 1.5
to 3.0 mm from the surface of the puddle (weld-metal pool).
• Thicker plates require more than one pass of the gas torch along the length
to complete the joint. This is called multi pass welding.
Advantages
Oxy-Acetylene welding equipment is versatile.
The same equipment with a range of torches is used for oxygen cutting,
brazing and braze welding.

It is used in general purpose shops.

Disadvantages
Oxy-welding operation is slower when compared to production welding
methods such as electric arc welding.
 Oxyacetylene flame cutting
• For cutting plate in straight line shear cutter is used up
to thickness 40mm.
• If thicker plate and to be cut in a specific contour
shear cutter can’t work.
• Oxy-fuel gas cutting is used (Up to 2 meter can be cut
with special precautions)
Typical
Portable
Oxygen/ Fuel
Cutting Rig
 Green = Oxygen
Red = Fuel

Oxygen/ Fuel Hose

Oxy-acetylene cutting/Gas cutting
Cutting Tip

Welding Tip

Heating Tip
Oxy-acetylene cutting
Gas cutting similar as oxy-acetylene
gas welding; except torch tip.

Provision for pre heating and

providing oxygen jet.
The tip has central hole for oxygen jet with surrounding holes for
preheating flames as shown figure. The cutting hole should be
chosen properly for different thickness.
GAS CUTTING

• Ferrous metal is heated in to red hot condition and a jet of pure oxygen
is projected onto the surface, which rapidly oxidizes
• Oxides having lower melting point than the metal, melt and are blown
away by the force of the jet, to make a cut
• Fast and efficient method of cutting steel to a high degree of accuracy
• Torch is different from welding
• Cutting torch has preheat orifice and one central orifice for oxygen jet
• PIERCING and GOUGING are two important operations
• Piercing, used to cut a hole at the centre of the plate or away from the
edge of the plate
• Gouging, to cut a groove into the steel surface
Different size of orifice determines the amount of
preheating and amount of jet flow required for cutting.

Larger size orifice than required produce wider kerf

width and more oxygen will be consumed.
Annexure - II
• Questions
1) Define welding.
2) How mechanical joints are differ from welded
joints.
3) Why neutral flame extensively used in oxy-
acetylane gas welding
4) Name the most widely used gases in gas welding
processes
5) List out the parameters used in selection of
welding processes.