RESEARCH/LIBRARY WORK IN

STEEL

SUBMITTED BY:
CAPULONG RANIEL G.
SUNGLAO, CINDY C.
SUBMITTED TO:
ENGR. MARC NEIL ADIZAS
SECTION: CE-501
DATE: MARCH 06, 2020
1. What are the types of metal arc welding? Also define and differentiate.

Metal Arc Welding

-The metal arc welding (MAW) process mainly uses a metal electrode for the
welding process. This metal electrode can be either consumable otherwise non-
consumable based on the requirement. Most of the used consumable electrode can be
covered with flux, and the main benefit of this type of welding process is that it requires
low temperature compared with others.
a. Shielded metal arc welding (SMAW)

It is the simplest, least expensive, and mostly widely used arc welding process. It
is often referred to as ‘stick welding’ or manual metal arc welding. This process
produces coalescence of metals by heating them with an arc between a covered metal
electrode and the base metal work piece. Shielding is provided by decomposition of the
electrode covering. The main function of the shielding is to protect the arc and the hot
metal from chemical reaction with constituents of the atmosphere. The electrode
covering contains fluxing agents, scavengers, and slag formers.
b. Manual Metal Arc welding (MMA)

It is often referred to as Shielded Metal Arc Welding (SMAW) or stick electrode

welding. It was the predominant form of fusion welding until the beginning of the 1980s.
It uses electrode rods consisting of a wire core with an external coating containing
mixtures of substances such as chemicals, minerals and iron powder. They are made in
a range of core diameters, with each diameter being intended for a particular current
range. Welding involves striking an arc between the electrode and the workpiece, with
the heat of the arc melting the electrode coating which forms a protective slag. The weld
metal is produced both by the core electrode wire and iron powder in the coating.
c. Gas metal arc welding (GMAW)

It is a high-speed, economical process that is sometimes referred to as

metal inert gas (MIG) welding. In this process, an arc is struck between the base metal
and a continuously supplied consumable electrode, which provides filler metal for the
weld. The electrode is bare, containing no coating or core. The shielding, to protect the
molten metal from reacting with constituents of the atmosphere, is supplied by an
external gas, usually containing one of a mixture of the following: helium, argon, or
carbon dioxide. A significant amount of fume can be generated when welding with this
process. Most of the fume generated during GMAW is derived from the consumption of
the electrode and not from the base metal.
2. What are factors affecting the quality of welding.
From cars to planes and bridges to buildings, welding keeps our economy
moving. It's the backbone of our world. While we don't always notice every weld under
the hood or behind the walls, welding plays an integral role in keeping people safe and
advancing our quality of life. It’s both an art and a science. From basic fabrication to
advanced robotics, modern welders blend trade skills with technology to work smarter,
not just harder. Because welding is an essential component in so many industries and
art forms, the demand for welders is at an all-time high. This means that the choice to
specialize is yours.  Weld quality assurance is the use of technological methods and
actions to test or assure the quality of welds, and secondarily to confirm the presence,
location and coverage of welds. In manufacturing, welds are used to join two or more
metal surfaces.
3. Methods in checking the actual condition of welded joints.
Visual inspection is probably the most underrated, and often misused, method of
welding inspection. Because of its simplicity, and the absence of sophisticated
equipment, the potential of this method of inspection is quite often underestimated.
Visual inspection of welding can often be the easiest to perform and is usually the least
expensive to conduct. If carried out correctly, this type of inspection can often be an
extremely effective method of maintaining acceptable welding quality and preventing
welding problems. There are many areas within the welding operation that can be
verified and evaluated by this method of inspection. A good pre-weld inspection plan
may provide us with an excellent opportunity to prevent welding problems before they
start, through the detection and correction of situations that may cause welding
problems or welding discontinuities. Inspection conducted during the welding operation
can often detect problems before they escalate and also help to provide confidence in
the final welded product. Post-weld inspection can often provide an economical method
of determining a weld’s acceptability with regard to many surface discontinuities. 
i. Pre weld inspection - This inspection is conducted prior to the start of the
welding operation. This type of inspection is typically associated with
checking the preparation of the welding joint and verification of parameters
that would be difficult or impossible to confirm during or after welding. This
is the area of inspection where we can best introduce controls that may
prevent defective welding. Some areas of pre-weld inspection are joint
preparation inspection/pre-weld setup. 
ii. Inspection during welding- This is the inspection that is carried out
during the welding operation and is concerned mainly with the
requirements of the welding procedure specification (WPS). This
inspection includes such items as interpass cleaning methods, interpass
temperature control, welding current settings, welding travel speed,
shielding gas type, gas flow rate, and welding sequence, if applicable.
Also, any environmental conditions that may affect the quality of the weld
such as, rain, wind, and extreme temperatures.
iii. Post-weld inspection- This inspection typically conducted to verify the
integrity of the completed weld. Many non-destructive testing (NDT)
methods are used for post-weld inspection. However, even if the weld is to
be subjected to NDT, it is normally wise to conduct visual inspection first.
One reason for this is that surface discontinuities, which may be detected
by visual inspection, can sometimes cause misinterpretation of NDT
results or disguise other discontinuities within the body of the weld. The
most common welding discontinuities found during visual inspection are
conditions such as undersized welds, undercut, overlap, surface cracking,
surface porosity, under fill, incomplete root penetration, excessive root
penetration, burn through, and excessive reinforcement.
4. Types of welded joints.
A welded joint is a point or edge where two or more pieces of metal or plastic are
joined together. They are formed by welding two or more workpieces (metal or plastic)
according to a particular geometry. There are five types of joints referred to by
the American Welding Society: butt, corner, edge, lap, and tee. These configurations
may have various configurations at the joint where actual welding can occur.
 a. butt joint
A butt joint is a technique in which two pieces of material are joined by
simply placing their ends together without any special shaping. The name 'butt
joint' comes from the way the material is joined together. The butt joint is the
simplest joint to make since it merely involves cutting the piece to the appropriate
length and butting them together. 
b. corner joint
The parts in a corner joint form a right angle and are joined at the center of
the angle.
c. lap joint
Lap joint consists of two overlapping parts.
d. tee joint
In a Tee-joint, one joint is the right angle to the other joint in the approximate
shape of the letter “T”.
e. edge joint
The parts in edge joint are parallel with at least one of their edges in
common and the joint is made at the common edge(s).
5. Types of welding process.
When you start learning to weld, it’s easy to be overwhelmed by the sheer
amount of information available on the subject. It can be difficult to begin your welding
journey without knowing about the different welding types that exist. 
a. TIG Welding

TIG welding also goes by the names of Heliarc and gas tungsten arc
welding (GTAW). With this type of welding, the electrode is non-consumable and made
of tungsten. It is one of the few types of welding that can be done with no filler metal,
using only the two metals being welded together. You can add a filler metal if you
desire, but you will have to feed it by hand.
b. Flux-Cored Arc Welding (FCAW)

This type of welding is similar to MIG welding. In fact, MIG welders can often
perform double duty as a FCAW welder as well. Just like in MIG welding, a wire that
serves as the electrode and the filler metal is fed through your wand. This is where
things begin to differ. For FCAW, the wire has a core of flux that creates a gas shield
around the weld. This eliminates the need for an external gas supply.
c. Stick (Shielded-Metal Arc Welding)
 This process of welding started in the 1930s but continues to be updated and
improved today. It has remained a popular form of welding because it is simple and
easy to learn, as well as low cost to operate. However, it doesn’t create the neatest
welds, since it splatters easily. Cleanup is usually necessary.
d. MIG Welding

MIG welding is a simple form of welding that can easily be performed by new
welders. MIG stands for metal inert gas, though it is sometimes called gas metal arc
welding (GMAW). It is a quick process that involves the filler metal being fed through the
wand, while gas is expelled around it to shield it from outside elements. This means it’s
not great for outdoor use. Still, it’s a versatile process and can be used to weld many
different types of metal at different thicknesses.
e. Laser Beam Welding

This type of welding can be used on metals or thermoplastics. As the name

implies, it involves the use of a laser as a heat source to create the welds. It can be
used on carbon steels, stainless steel, HSLA steels, titanium, and aluminum. It is easily
automated with robotics and is therefore used often in manufacturing, such as in the
automotive industry.
f. Electron-Beam Welding

This is a type of welding where a high-velocity beam of electrons creates heat

through kinetic energy, welding two materials together. This is a highly sophisticated
form of welding that is performed by machine, generally in a vacuum.
g. Plasma Arc Welding

Plasma arc welding is similar to GTAW, but it uses a smaller arc, increasing the
precision of the weld. It also uses a different torch, achieving much higher temperatures.
Gas is pressurized inside the wand, creating plasma. The plasma is then ionized,
making it electrically conductive. This allows the arc to be created, producing incredibly
high temperatures that can melt the base metals.
h. Atomic Hydrogen Welding
Atomic hydrogen welding is an extremely high-heat form of welding that used to
be known as arc-atom welding. This type of welding involves using hydrogen gas to
shield two electrodes made of tungsten. It can reach temperatures above those of an
acetylene torch and can be performed with or without a filler metal. This is an older form
of welding that has been replaced by MIG welding in recent years.
i. Electroslag
This is an advanced process of welding that is used to join the thin edge of two
metal plates together vertically. Instead of the weld being applied to the outside of a
joint, it will take place in between the edges of the two plates.
6. Types of welds.
a. Fillet Welds

A fillet weld joins two surfaces at an approximate right angle to each other. There
are several types of fillet weld.
b. Groove Welds

The groove weld refers to beads that are deposited in a groove between two
members to be joined.
c. Surfacing Weld

These are welds composed of one or more strings or weave beads deposited on
an unbroken surface to obtain desired properties or dimensions. This type of weld is
used to build up surfaces or replace metal on worn surfaces. It is also used with square
butt joints.
d. Plug Weld

Plug welds are circular welds made through one member of a lap or tee joint
joining that member to the other. The weld may or may not be made through a hole in
the first member; if a hole is used, the walls may or may not be parallel and the hole
may be partially or completely filled with weld metal.
e. Slot Weld

This is a weld made in an elongated hole in one member of a lap or tee joint
joining that member to the surface of the other member that is exposed through the hole
f. Flash Weld
Flash welding is referred to as a resistance welding process where fusion is
produced over the entire abutting surface.
g. Seam Weld

A weld made by arc seam or resistance seam welding where the welding
process is not specified.
h. Spot Weld

A spot weld is a weld made by arc spot or resistance spot welding where the
welding process is not specified
i. Upset Weld

An upset weld is a resistance welding process where fusion occurs progressively

along a joint of over the entire abutting surface.
7. Draw standard welding symbols