WELDING

Welding Safety Precautions:

“Accidents Starts When Safety Ends”

1. Never use oil or grease in any part or assembly of a gas welding plant
2. All inflammable materials should be kept away from the gas welding area
3. Always wear goggles and safety shoes
4. Wear fire resistant clothes, asbestos gloves and an apron
5. Rectify the gas leakages
6. Always keep fire extinguishing devices
7. Do not roll gas cylinders for shifting, always use a trolley to carry
cylinders
8. Do not drop the gas cylinders
9. Close the cylinder valves when not in use or empty
10.Keep the empty cylinders and full cylinders separately
11.Always open the cylinder valves slowly and not more than one and a half
turns
12.Use always the correct size cylinder keys
13.Always keep the cylinders in an upright position
14.Ensure that the hoses do not cross the gang ways
15.Protect the regulators from water, dust, oil etc
16.While igniting the flame point the blow pipe nozzle in a safe direction
17.Check for leakage before using oxy-Acetylene welding equipments
18.Use the spark lighter to ignite the flame to avoid fire hazards
19.While welding wear helmet or shield
20.During chipping off the solified slag always use plain goggles

Sheet Metal Soldering:

Definition: Soldering is the process by which metals are joined with the help of
another alloy called soldering without heating the base metal to be joined. The
melting point of the solder is lower than that of the materials being joined.
Solder is a bonding filler metal used in soldering process

Types of Solder:

1. Soft solder
2. Hard solder
3. Brazing

1
 1. Soft solder: The process of joining metals using tin and lead as a
soldering alloy which melts below 420oC is known as Soft soldering
2. Hard solder: Hard solders whose melting points lie above 450oC, these
are alloys of the materials tin, lead, antimony, copper, cadmium and zinc
and are used for soldering heavy and light metals
3. Brazing: The process of joining metals using copper, zinc and tin alloys
as filler material in which the base metal is heated above 420oC but below
850oC is called brazing

Soldering Iron:
The soldering iron is used to melt the solder. Soldering irons are normally
made copper or copper alloys, so they are also called as copper bits
Soldering iron has the following parts
 Head (copper bit)
 Shank
 Wooden handle
 Edge

Above soldering iron copper tip is heated by a forge

Silver brazing is similar to brazing except that the filler material used in a
silver-copper alloy and the flux used is also different

Electric Soldering Iron:

An electrical soldering iron provides a convenient source of continuous,
uniform heat to the solder and the joint to be soldered
2 basic types of soldering iron:
a) The general purpose electric soldering iron
b) Transformer type electric soldering iron

Composition of Soft Solder:

 Common solder: Tin 50%, Lead 50%-- general sheet metal
 Fine solder: Tin 60%, Lead 40% copper water tank, heater and
 Fine solder: Tin 70%, Lead 30% general electrical work
 Course solder: Tin 40%, Lead 60%-- galvanised iron sheets
 Extra fine solder: Tin 66%, Lead 34%--brass, copper & jewellery
 Eutectic alloy: Tin 63%, Lead 37%--similar to fine solder

Soldering Flux:
This is a chemical compound called flux is applied to the joint

Function of Fluxes:
2
  Remove oxides, prevents corrosion, prevents oxidation and it helps
molten solder to flow easily in the required place

The following criteria are important for selecting a flux

 Working temperature of the solder
 Soldering process
 Material to be joined

Types of Flux:
 Inorganic or corrosive (active)
 Organic or non corrosive (passive)

1. In organic Fluxes
 Hydrochloric acid – other than zinc iron, galvanised sheets
 Zinc chloride – copper, brass & tin sheets
 Ammonium chloride – copper, brass, iron and steel
 Phosphoric acid – stainless steel
2. Organic Fluxes
 Resin: Paste or powder form (pine tree sap) it is used for copper,
brass, bronze, tin plate, cadmium, nickel, silver and some alloys
 Tallow: Form of a animal fat, lead & brass

Hints for successful soldering:

 The metal must be clean
 The correct solder and flux or agent must be clean
 Proper amount of heat must be applied
 You should always wear safety glasses
 Soldering flux must be applied by a swap or brush
 Hold the pieces properly
 Move the soldering iron slowly along with the work making sure that the
solder melts, spreads and penetrates properly
It is the step in soldering that beginners often fail to understand and
remember
WELDING

Definition: Welding is a joining process of similar or dissimilar metals

applications electrical heat. Welding is a permanent joint temperature of arc
welding is 3600oC – 4000oC
3
Types of Joining Process or Method
 Bolting
 Riveting
 Soldering
 Welding

Arc procedure in ultra violet rays it is a dangerous rays

Fundamental Types of Welding or Basic Welding

 Fusion Welding
 Resistance Welding

Fusion is change from solid stage to liquid stage

Arc Welding Definition: When high current passes through an air gap from one
conductor to another, it produces very intense and concentrated heat in the form
of a spark it is called as Arc. Temperature – 4000oC

Resistance Welding Definition: when the joint reaches a plastic stage, sufficient
pressure is applied to produce fusion and get a homogeneous weld

Fusion Welding:
 Arc welding (MMAW, SMAW)
 GMAW (MIG, MAG welding)
 GTAW (TIG welding)
 Submersed Arc Welding (SAW)
 Carbon Arc Welding
 Gas Welding

Types of welding machines:

 AC transformer
 DC generator

AC is Alternative current
DC is Direct current

AC Transformer:
2 types of transformer
 Step-up transformer (high voltage – low amphere) : which gives
increased supply voltage on secondary side of the transformer is called
Step-up transformer
4
  Step-down transformer (low voltage – high amphere) : Transformer
which gives increased supply voltage on secondary side of the
transformer is called Step-down transformer

Welding transformer is low voltage high amphere machine, it is Step-down

transformer

AC: Direction of current flow changes in 50 times per second. It is called AC

DC: Direction of current flows only in one direction. It is called DC

DC Machine:
3 types of DC Machine
 Engine Drive Generator (power supply not enough or need)
 Motor Drive Generator (power supply need)
 Rectifier (power supply need)

AC Transformer:
‘+’ Terminal - 50%
‘-’ Terminal - 50%

DC Machine:
‘+’ Terminal - 65%
‘-’ Terminal - 35%

Welding Tools & Equipments:

Tools:
 Hammer
 Tong
 Tri square
 Bastered file
 Chipping hammer
 Wire brush
 Dot punch
 Scriber
 Chisel
 Grinding machine

Equipments:
 AC or DC Machine
 Holder Cable
 Earth Cable
5
  Electrode

Safety Devices:
 Helmet or Shield
 Hand Gloves
 Apron
 Hand sleeves
 Shoe

Electrode:

Sl. No Sizes of Electrode Current Ranges

1 1.5 mm 30 – 40 Amps
2 2 mm 40 – 60 Amps
3 2.5 mm 60 – 90 Amps
4 3.15 mm 90 – 140 Amps
5 4 mm 140 – 180 Amps
6 5 mm 180 – 220 Amps

1.5 mm, 2 mm, 2.5 mm, 3.15 mm electrode — 350 mm length

3.15 mm, 4 mm, 5 mm electrode --- 450 mm length

3.15 mm electrode is general purpose electrode

It is 2 size of length:
 350 mm length
 450 mm length
Electrode material is Mild Steel (M S)

Code of Electrodes:
 AWS E 6012
 AWS E 6013
 AWS E 7010
 AWS E 7018
 AWS E 8010
 AWS E 8018

AWS - American Welding Society

ISI – Indian Standard Institution
ISO – International Standard Organisation

6
E 60 1 3
E- Electrode
60- Tensile Strength
1-Welding Position
3- Chemical Coating

60- 60,000 PSI (pound per square inch)

80- 80,000 PSI
70- 70,000 PSI

1-All Position Electrode

3- Titania Potassium

Coating of Electrode:

Sl. No Code No Chemical Compound Polarity

1 0 Cellulose Sodium DCEP
2 1 Cellulose Potassium AC or DCEP
3 2 Titania Sodium AC or DCEN
4 3 Titania Potassium AC or DCEP or DCEN
5 4 Iron Powder Titania AC or DCEP or DCEN
6 5 Low hydrogen sodium DCEP
7 6 Low hydrogen Potassium AC or DCEP
8 7 Iron powder + Iron oxide AC or DCEP or DCEN
9 8 Iron powder + low hydrogen AC or DCEP

EP – Electrode Positive
EN – Electrode Negative

What is the purpose of flux coating?

Shielding purpose
It prevents from atmosphere oxygen and nitrogen from the molten metal

ARC LENGTH

Definition: Distance between base metal to electrode tip. It is called as Arc

Length

3 Types of Arc Length:

 Short Arc Length : Less than electrode diameter
 Medium Arc Length : Equal electrode diameter
 Long Arc Length : More than electrode diameter
7
*Medium Arc Length is good welding
Polarity:

Definition: Polarity is a direction of current flow in DC welding circuit

*Polarity system is in DC Machine only

2 types of polarity system

 Straight Polarity
 Reverse Polarity

*Angle is Electrode 70o – 80o

Straight Polarity: + terminal – Earth cable is connected

-terminal – Holder cable is connected

Reverse Polarity: + pole – electrode cable is connected

- pole – earth cable is connected
- pole heat distribution is 1/3 part
+ pole heat distribution is 2/3 part

Types of Positions:
5 types of positions
 Flat or down hand position
 Horizontal position
 Vertical position
 Over head position
 Inclined position(45 degree)

Symbol of Positions:

 Flat ----- 1G, 1F

 Horizontal ------ 2G, 2F
 Vertical ------ 3G, 3F
 Over head ------ 4G, 4F
G- Groove weld
F- Fillet weld

Types of Weld:
4 types of weld
 Butt weld
 Fillet weld
8
  Plug or slot weld
 Spot weld

Types of Joints:
5 types of Joints
 Butt joint
 Fillet joint
 Lap joint
 Corner joint
 Edge joint

Some welding Defects

 Spatters
 Blow hole
 Porosity
 Crack
 Lack of fusion
 Poor penetration
 Over lap
 Distortion
 Arc blow
 Slag inclusion
 Under cut
 Crater

2 types of weld defects:

 Internal defects
 External defects

 Internal defects: Arc blow slag inclusion occurs in DC Machine only

Main welding defects is Distortion
3 types of Distortion
 Longtutional Distortion
 Angular Distortion
 Transerve Distortion

Welding Test:
2types of test

9
  Non Distractive Test(NDT): After the test the job can be used
 Distractive Test(DT): After the test the job cannot be used
N.D.T---- 5 types are there
 Liquid penetrant test
 Magnetic practical test
 ‘X’ Ray test
 Ultra sonic test
 Gamma ray rest

D.T------2 types are there

 Lab test
 Mechanical test

Character of Arc or Metal transfer in Arc welding: 4 types of metal transfer

 Gravity force
 Gas expansion force
 Surface tension (position welding)
 Electro magnetic force

Difference between AC & DC welding:

AC Machine DC Machine
a. Low cost 1. Higher cost
b. Maintenance cost low 2. Maintenance cost high
c. Polarity system nil 3. Polarity system is there
d. No noise 4. Noisy machine
e. Thin sheet, non ferrous metal 5. Possible
welding is impossible

Example:

 Arc welding is---

1. Permanent joint
2. Temporary joint
3. None of them

 Arc welding is---

1. Non fusion welding
2. Fusion welding
3. Pressure welding

10
 Arc welding temperature is---
1. 1000oC
2. 3200oC
3. 4000oC

 Arc welding machine is---

1. Step down transformer
2. Step up transformer
3. None of them

 Arc welding machine supply is---

1. Low voltage high Amph

 Polarity system has---

1. DC machine
2. AC machine
3. None of them

 Arc blow is---

1. Internal defect
2. External defect
3. None of them

 Arc blow occurs in---

1. AC machine
2. DC machine
3. None of them

 Correct Arc length 3.15 electrode is---

1. 4 mm
2. 3.15 mm
3. 4.5 mm

 Ø 2 mm electrode current range is---

1. 40-50 Amps
2. 60-90Amps
3. 90-140Amps

 Magnetic hair line crack founded in---

1. Magnetic practical test
2. ‘X’ ray test
3. None of them

 3G symbol is---
1. Vertical position
11
 2. Horizontal position
3. Flat position

 E 6013 – 3 dianots
1. Chemical compound
2. All position
3. Tensile strength

 Spatter is
1. Weld defect
2. Welding machine
3. Arc length

Match the following:

A. Slag inclusion 1. DC Machine
B. Easy position 2. Fusion Welding
C. Arc blow 3. Flat
D. Arc welding 4. Weld defect
E. Polarity system 5. Magnetic disturb

A B C D E
4 3 5 2 1

Fill in the blanks:

 Arc welding is permanent joint or fusion welding

 1000 mm is 1 meter
 Angle of electrode is 70o – 80o
 Arc welding produce in ultra violet rays
 Over head position in fillet weld is 4F

True or False:

 Main supply is 220v -440v – True

 Medium arc length is good welding – True
 DC welding machine + terminal is more than current – True
 AG 4 grinding wheel is 7 inch – False
 Key hole created is good welding – True

12
 GAS CUTTING

Definition: It is a cutting process of metals with the help of gas flames

Types of Gases: 3 types of gases

 Fuel or combustible gas

 Supporting gas
 Shielding gas

Fuel Gas:

 Acetylene or DA (dissolved acetylene)

 L.P.G (liquid petroleum gas)
 Coal gas
 Hydrogen gas

Supporting Gas:

 Oxygen (O2)

Shielding Gas:

 Carbon di oxide (CO2)

 Argon
 Helium

Difference:

Oxygen Cylinder Acetylene Cylinder

Black colour Maroon
Long cylinder Small cylinder
Moulded cylinder Welded cylinder
No smell More smell
Right hand thread Left hand thread
1800-2000 PSI capacity 7m3 200-250 PSI capacity 6m3 15-
120-150 kg/cm2 16 kg/cm2
Gas Cutting Equipments:

 Oxygen gas cylinder

 Acetylene gas cylinder
 Oxygen regulator
 Oxygen hose (black or blue)
 Acetylene hose (red)
 Cutting blow pipe
13
  Backfire arrestor
 Spark lighter
 Nozzle cleaner
 Cylinder key
 Tong
 Gloves
 3 din goggle
 Gas cutting nozzle

Gas Cutting Chart:

Sl. No Nozzle Size Plate Thickness O2 Pressure

1 8 mm or 1/32” 4 – 10 mm 1 – 1.5 kg/cm2
2 1.2 mm or 3/64” 10 – 20 mm 1.5 – 2 kg/cm2
3 1.6 mm or 1/16” 20 – 50 mm 2 – 3 kg/cm2
4 2 mm or 5/64” 50 – 100 mm 3 – 4 kg/cm2
5 2.4 mm or 7/64” 100 – 150 mm 4 – 4.5 kg/cm2
6 2.8 mm or 3/32” 150 – 200 mm 4.5 – 5 kg/cm2
7 3.2 or 1/8” 200 – 300 mm 5 – 6 kg/cm2

*DA pressure 0.15 kg/cm2 constant

Types of Gas Cutting: 2 types of gas cutting

 Manual gas cutting

 Machine gas cutting

Machine gas cutting:

 PUG cutting
 Profile cutting

PUG or Parallel Uniform Gas Cutting:

 Straight cutting
 Bevel cutting
 Round cutting

Profile Cutting:

 Any shape cutting

14
Types of Metals:

 Ferrous Metals
 Non-Ferrous Metals

1. Iron based metal is Ferrous metal

Ex: Mild steel, cast iron, Tin
2. Which metals are not iron based metal is Non-Ferrous Metals
Ex: Stainless steel, Aluminium

Temperature of Metals:

 Mild steel----------- 1530oC

 Cast iron------------ 1150oC Ferrous Metal
 Tin------------------- 232oC
 Aluminium--------- 650oC
 Brass, Bronze------ 850oC
 Zinc----------------- 410oC Non-Ferrous Metal
 Lead ---------------- 325oC
 Nickel-------------- 1452oC

*Temperature is a when change the solid stage to liquid stage

GAS WELDING :

Definition: Gas welding is joining process of metals with the help of gas flames

Gas Welding Equipments:

 Oxygen gas cylinder

 Acetylene gas cylinder
 Oxygen Regulator
 Acetylene Regulator
 Oxygen hose (black or blue)
 Acetylene hose (red)
 Welding blow pipe
 Backfire arrestor
 Spark lighter
 Nozzle cleaner
 Cylinder key
 Tong
 Gloves
15
  3 din goggle
 Gas cutting nozzle

Types of Gas Flames: 3 types of flames

 Carborising flame (excess acetylene)

 Neutral flame (equal gas)
 Oxidising flame (excess oxygen)

*Gas welding temperature 3100oC-3300oC

Sl. No Metals Flames

1 Mild steel Neutral flame
2 Copper Neutral flame
3 Stainless steel Neutral flame
4 Aluminium Neutral flame
5 Brass, Bronze Oxidising flame
6 Hardening Carbodising flame

* Gas cutting and gas welding used in Neutral flame

Gas Welding Nozzle:
No: 1,3,5,7,9,13,15
GMAW (Gas Metal Arc Welding)

MAG Welding MIG Welding

(Metal Active gas welding) (Metal Active gas welding)
Active gas-CO2 Inert gas-Argon, Helium

MAG CO2 Welding Equipments:

 AC/DC Machine
 CO2 gas
 Wire feeder
 Welding torch assemble
 Earth cable
 Gas regulator
 Heater
 Flow meter
 Spatters spray
 Cylinder key
16
  Wire spool
 Contact tip
 Outer nozzle

*MAG CO2 welding is used in DC reverse polarity only

MAG CO2 welding wire code:

ER-70S6
E--- Electric Welding
R--- Electrode (rode)
70--- 70,000 PSI (tensile strength)
S--- Solid wire
6--- 6% chemical compound

Electrode Size:
0.8 mm, 1 mm, 1.2 mm, 1.6 mm, 2 mm
*1.2 mm electrode current range volt-22, amphere 160 Amps
*MAG, MIG welding used in car manufacturing company
Types of Metal Transfers: 3 types of metal transfers
 Short circuit (or) DIP transfer
 Global transfer
 Spray type transfer

MAG CO2 welding gas flow rate 10hr/min

Stick out – 10 – 15 mm

Stick Out: Distance between conduct tip to surface of weld metal it is called as
stick out.

17