By: Prof.

Huzaifa Fidvi
 Classification of welding
Welding Process

Plastic / Pressure Welding Fusion / Non Pressure Welding

The work pieces are heated The material at the joint is

to plastic state and then
joined together by applying
external pressure without
use of additional filler
material
heated to molten state and
then allowed to solidify with
the use of additional Filler
material.
Fusion / Non - Pressure Welding
 Electric Arc Welding - Introduction
• Arc welding process is fusion method of welding that utilizes the
high intensity of the arc generated by the flow of current to melt
the workpieces.
• A solid continuous joint is formed upon cooling.
• Arc welding is the most common method of welding metals
 Electric Arc Welding - PRINCIPLE
• The source of heat for arc welding process is an 'electric arc'.
• Electrical Energy is converted into Heat Energy.
• An arc is generated between two electrically conducting
materials.
• One pole of the electric circuit is connected to 'electrode',
while the other to the workpiece.
• When the tip of the electrode material is brought in contact
with the workpiece material and momentarily separated by
small distance of 2-4 mm, an arc is generated.
• In the Arc, the current flows through a path of ionized
particles which acts as a high resistance conductor,
generating heat.
 Electric Arc Welding - PRINCIPLE
• The high heat of the arc
melts the edges of the
work pieces and a pool of
molten metal is formed.
• Coalescence (fusion)
takes place and when the
coalesced liquid solidifies,
the two work pieces join
together to form a single
component.

Approx 1 KWH of electricity

creates 250 calories (1000 J) and
temperatures ranging from
6000 oC to 7000 oC.
 Electric Arc Welding - Types
 1. Carbon Arc Welding
 2. Shielded Metal Arc Welding - SMAW
 3. Submerged Arc Welding - SAW
 3. Inert Gas Welding
 Tungsten Inert Gas Welding –TIG
 Metal Inert gas Welding - MIG
 4. Electro Slag Welding
 5. Atomic Hydrogen Welding
Advantages and Disadvantages of Arc Welding
 Advantages
  Most efficient way to join metals
  Lowest-cost joining method
  Affords lighter weight through better utilization of materials
  Joins all commercial metals
  Provides design flexibility
 Disadvantages
  Manually applied, therefore high labor cost.
  Need high energy causing danger
  Not convenient for disassembly.
  Defects are hard to detect at joints.
 Electric Arc Welding - Equipment
General Welding Equipment:
 A welding generator (D.C.) or Transformer (A.C.)
 Two cables- one for work and one for electrode
 Electrode holder
 Electrode
 Protective shield
 Gloves
 Wire brush
 Chipping hammer
 Goggles
Electric Arc Welding – Equipment SET UP
 Power Source
 DC Generator –
 It is run by an electric motor or by diesel engine if electricity
is not available.
 Voltage supplied – 15 to 50 volts
 Current - 200 to 600 A

 AC Transformer
 It changes high voltage low amperage in to low Voltage high
amperage.

 In order to strike the arc an open circuit voltage of between 60

to 70 volts is required.
 For maintaining the arc 17 to 25 volts are necessary.
 A.C. Welding D.C. Welding
1. At higher currents AC gives a smoother
arc.
1.DC arc is more stable.
2. Once established the arc can be easily
2.DC is preferred for
maintained and controlled.
welding certain non-ferrous
3. It is suitable for welding thicker sections. metals and alloys.
4. AC is easily available. 3. It has lower open circuit
5. AC welding power source has no rotating voltage and therefore is safer.
parts. 4. ARC heat can be regulated
6. It is noiseless. (i.e., through DCRP and DCSP)
7. It occupies less space 5. A DC welding equipment is a
self contained unit. It can be
8. It is less costly to purchase and maintain.
operated in fields where power
9. It possesses high efficiency (0.8). supply is not available
10.It consumes less energy per unit weight 6.DC welding power source is
of deposited metal. a transformer-rectifier unit or a
11.Melting rate of electrode cannot be DC generator (motor or engine
controlled in AC as equal heat generates at driven
electrode and job.
 Polarity in DC
 Applicable to only DC power
source. (In AC terminals are not
fixed and keep changing every half
cycle.)
 It is the potential given to the
workpiece and electrode.
 Heat generated during
welding is
 67 % at the positive terminal
(Anode)
 33 % at negative terminal
(Cathode)
 Polarity in DC
 Two Types:
 1. DCSP – DC Straight Polarity
 +ve terminal (Anode)–Workpiece
 -ve terminal (Cathode)-Electrode

 2. DCRP – DC Reverse Polarity

 +ve terminal (Anode)Electrode
 -ve terminal (Cathode)- Workpiece
Polarity in DC
 FLUX SHIELDED METAL ARC WELDING - SMAW
• It is an arc welding process wherein coalescence is
produced by heating the workpiece with an electric arc
set up between a flux coated electrode and the
workpiece. Temperatures of 2400 oC to 2600 oC are obtained
• The flux covering decomposes due to arc heat and
performs many functions, like arc stability, weld metal
protection.
• The electrode is consumable and supplies the
necessary filler metal.
SMAW Process
 Principle of the process: SMAW
• Heat required for welding is obtained from the arc struck
between a coated electrode and the workpiece.
• The arc temperature and thus the arc heat can be
increased or decreased by employing higher or lower arc
currents.
• A high current arc with a smaller arc length produces very
intense heat. The arc melts the electrode end and the job.
• Material droplets are transferred from the electrode to the
job, through the arc, and are deposited along the joint to
be welded.
• The flux coating melts, produces a gaseous shield and slag
to prevent atmospheric contamination of the molten weld
metal.
 FLUX SHIELDED METAL ARC WELDING - SMAW
• AC transformers and DC generators or rectifiers can be
employed for welding with covered electrodes.
• Both AC and DC power sources produce good quality
welds, but depending upon welding situation one may
be preferred over the other.
•
• The most commonly used power source for AC welding
is a transformer. A transformer may be operated from
the mains on single phase, two phases or three phases.
A typical specification for the transformer is as follows:
– Current range up to 600 Amps.
– Open circuit voltage 70 to 100 volts.
Advantages of Shielded Metal Arc Welding (SMAW)
1. SMAW is the simplest of all the arc
welding processes.
2.The equipment can be portable
3.Cost is fairly low.
4. This process finds innumerable
applications, because of the availability
of a wide variety of electrodes.
5. A big range of metals and their alloys
can be welded.
6. Welding can be carried out in any
position with highest weld quality.
 Disadvantages of Shielded Metal Arc Welding -
(SMAW)
• Because of the limited length of each electrode and brittle flux
coating on it, mechanization is difficult.
• In welding long joints (e.g., in pressure vessels), as one
electrode finishes, the weld is to be progressed with the next
electrode. Unless properly cared, a defect (like slag inclusion or
insufficient penetration) may occur at the place where welding
is restarted with new electrode.
• The process uses stick electrodes and thus it is slower as
compared to MIG welding.
• Because of flux coated electrodes, the chances of slag
entrapment and other related-defects are more as compared
to MIG or TIG welding.
 Applications of Shielded Metal Arc Welding -
(SMAW)
• Today, almost all the commonly employed metals and their alloys
can be welded by this process.
• Shielded metal arc welding is used both as a fabrication process
and for maintenance and repair jobs.
• The process finds applications in
– Air receiver, tank, boiler and pressure vessel fabrications;
– Shipbuilding;
– Pipes and Penstock joining;
– Building and Bridge construction;
– Automotive and Aircraft industry, etc.
Thank You