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Manufacturing Processes – ME 205 11
 What is Welding?
 Welding is the process of joining two or more parts
permanently

 Fusion welding, in its simplest form, involves melting the

parts to be joined in the localized area where they meet,
and then letting the molten metal mixture within the joint
area resolidify.

 In gas welding, and most arc welding processes, an

additional element called filler metal is usually required.

 The strength of welded joint should be more or at least

equal to that of the material of the parts being joined.

Manufacturing Processes – ME 205 2

 Types of Weld Joints

Manufacturing Processes – ME 205 3

 Types of Weld Joints

Manufacturing Processes – ME 205 4

 Fusion-Weld Zone

Its Characteristics in oxy-fuel and arc welding

Manufacturing Processes – ME 205 5

 Welding Defects

Manufacturing Processes – ME 205 6

 Welding Defects

Manufacturing Processes – ME 205 7

 Welding Processes
 Gas Welding (GW)
 Oxyacetylene Welding (OAW)
 Electric Arc Welding
 Shielded Metal Arc Welding (SMAW)
 Submerged Arc Welding (SAW)
 Metal Inert Gas Welding (MIG, GMAW)
 Tungsten Inert Gas Welding (TIG, GTAW)
 Electric Resistance Welding
 Spot Welding (RSW)
 Seam Welding (RSEW)
 Projection Welding (RPW)
 Solid State Welding (SSW)
 Friction Welding (FRW)
 Electromagnetic pulse welding
 Ultrasonic welding
Manufacturing Processes – ME 205 8
 Gas Welding
 Gas Welding is a welding process, utilizing heat of the flame from
a welding torch.
 The torch mixes a fuel gas with oxygen in the proper ratio and
flow rate.
 The hot flame fuses the edges of the welded parts, which are
joined together forming a weld after solidification.

The flame temperature is

determined by a type of the
fuel gas and proportion of
oxygen in the combustion
mixture: (2500°C -
3500°C).

Manufacturing Processes – ME 205 9

 Advantages and Disadvantages

Advantages of gas welding Disadvantages of gas welding

 Versatile processes  High skill operator is required
 Low cost  Flame temperature is lower
 Portable equipment than in arc welding

 Electric supply is not required  Fumes due to shielding fluxes

 Some metals cannot be welded
(reactive and refractory metals)

Manufacturing Processes – ME 205 10

 Oxyacetylene Welding (OAW)
 Oxyacetylene welding combines
oxygen (blue) and acetylene (red)
gasses to provide a high
temperature flame for welding.

 This flame provides enough heat

to melt most metals (3300°C)

 Oxyacetylene welding is a manual

process (the welder must
personally control the torch
movement and the filler rod).
Manufacturing Processes – ME 205 11
 Torch Design

Manufacturing Processes – ME 205 12

 Flame Types
 The type of flame obtained depends on the ratio of oxygen to
acetylene being burnt:
 Neutral flame used for welding steel, cast iron, copper, aluminum.
(Neutral flames are used in most welding applications).
 Oxidizing flame used for welding brass and bronze
 Carburizing flame used for welding white metals, nickel, alloy
steel

Manufacturing Processes – ME 205 13

Manufacturing Processes – ME 205 14
 Oxyacetylene Welding (Video)

Manufacturing Processes – ME 205 15

 Shielded Metal Arc Welding (SMAW)
 An electric arc, between a metal electrode (covered with flux)
and the base metal, is used to generate heat.

 Heat from the electric arc melts both the end of the electrode
and the base metal to be joined.

The rest of the covering

melts to form a slag which
covers the completed
weld.

The slag layer protects 5500 oC

the hot metal from
oxidizing while it cools.

Manufacturing Processes – ME 205 16

 Details of SMAW

Manufacturing Processes – ME 205 17

 Metal Inert Gas Welding (MIG)
 An electric arc between a continuously fed metal electrode and
the base metal produces heat.
 An electrode feeding device supplies metal electrode
continuously.
 The arc is shielded by
a gas (Argon or Helium).

Manufacturing Processes – ME 205 18

 Metal Inert Gas Welding (MIG)
 The machine is equipped with controls to adjust
the wire feed speed and shielding gas volume.

 No slag to remove.

 Expensive, non-portable equipment required.

 Continuous weld may be produced.

Manufacturing Processes – ME 205 19

 MIG / GMAW

Manufacturing Processes – ME 205 20

 Tungsten Inert Gas Welding (TIG)
 Gas tungsten arc welding
uses the heat of an electric
arc between a tungsten
electrode and the base
metal.

 A separate welding filler rod

is fed into the molten base
metal.

 A shielding gas (Argon or

Helium) flows around the arc
to keep away air and other
harmful materials.

Manufacturing Processes – ME 205 21

 TIG Welding
 This process is particularly desirable when welding
stainless steel, aluminum, and many other
nonferrous metals.

 Weld composition is close to parent metal.

 No slag to remove.

 Relatively expensive.

Manufacturing Processes – ME 205 22

 TIG Welding

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 Submerged Arc Welding (SAW)
 The arc is submerged in a granular flux.
 Some of the flux melts and forms a shielding slag over the
weld and the rest melts and forms a slag.

Manufacturing Processes – ME 205 24

 Submerged Arc Welding (SAW)
 The chemical composition of the flux will affect the
composition of the completed weld.
 alloying elements can be added to the weld by adding
them to the flux.
 Often used with thick plates.
 Automatic equipment.
 Very high welding rate.
 Limited for welding
horizontally located plates.

Manufacturing Processes – ME 205 25

 SAW

Manufacturing Processes – ME 205 26

 Resistance Spot Welding (RSW)
 A high amperage electric current passes through the metal.
 Resistance to the electrical current flow heats the metal to
welding temperature.
 The process is used to weld together two or more
overlapping pieces.

Manufacturing Processes – ME 205 27

 Spot Welding
 The process is well suited for automatic welding.

 The weld is made between two electrodes (made of copper

alloys) which press the metals together.

 The process is controlled by the amperage, the electrode

pressure, and the timing.

 High welding rate (very cost effective).

 Thickness of welded sheets is limited (about 6 mm).

Manufacturing Processes – ME 205 28

 Resistance Projection Welding

Manufacturing Processes – ME 205 29

 Spot Welding (Video)

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 Resistance Seam Welding (RSEW)
 Resistance seam welding is a special application of spot
welding often used to weld joints in products which require
an airtight seam.
 The electrodes are wheels, the work to be welded is
passed between the revolving wheel electrodes.

Manufacturing Processes – ME 205 31

 Seam Welding
 A timing device turns on the welding current at rapidly
repeating intervals.
 The rapidly repeating current flow makes a series of
overlapping spot welds which appear to be a continuous
line of welding

Manufacturing Processes – ME 205 32

 Seam Welding

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 Friction Welding (FrW)
 Friction welding uses friction
to create enough heat to fuse
two pieces of metal together.

 One of the pieces is made to

revolve. The ends of the parts
to be joined are then lightly
pressed together.

 The resulting friction develops

the required heat.

 As the metal surfaces reach

the plastic state, they are
forced together under a much
greater pressure.
Manufacturing Processes – ME 205 34
 Friction Welding
 This process is used mainly in welding large round rods or
cylinders.

 Thorough surface preparation is required (degreasing,

oxides removal, etc.).

 No consumable material required (filler material, fluxes,

shielding gases).

Manufacturing Processes – ME 205 35

 Friction Welding

Manufacturing Processes – ME 205 36