Unit 3

MANUFACTURING TECHNOLOGY UNIT-III WELDING
UNIT-3
WELDING
SYLLABUS
A) WELDING : Classification of welding processes types of welds and welded joints and their
characteristics, design of welded joints, Gas welding, ARC welding, Forge welding, resistance welding,
Thermit welding and Plasma (Air and water ) welding.
B) CUTTING OF METALS: Oxy – Acetylene Gas cutting, water, plasma Cutting of ferrous, non-
ferrous metals
Welding:
Welding is a process of joining two similar or dissimilar metals with the help of heat or pressure
or by some other means. The cost of welding is very less as compared to other processes and forms
a strong joint.
For this reason it is largely used in the following fields of engineering:
1. Manufacturing of machine tools, auto parts, cycle parts, etc.
2. Fabrication of farm machinery & equipment.
3. Fabrication of buildings, bridges & ships.1
4. Construction of boilers, furnaces, railways, cars, aeroplanes, rockets and missiles.
5. Manufacturing of television sets, refrigerators, kitchen cabinets, etc.
Classification of welding processes:

Many types of welding processes have been developed depending upon the field of their
applications (Table 7.1). But the welding is broadly divided into following two groups.
1. Forge or Pressure Welding (Under pressure without additional filler metal)

(a) Friction welding
(b) Electric resistance welding
(c) Blacksmiths forge welding
(d) Cold pressure welding
2. Fusion or non-pressure welding (With additional filler material)

(a) Gas welding (Heat created by Gas)
(b) Electric arc welding (Heat created by electrically)
(c) Thermit welding (Heat created by chemical Reaction)
PBR VITS –DEPARTMENT OF MECHANICAL ENGINEERING II-B.TECH,II-SEM

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Types of welds and welded joints and their characteristics:

Types of Welds:
There are many types of welds. Some of the common types you will work with are bead, groove,
fillet, surfacing, tack, plug, slot, and resistance.
Weld bead:
 The first type of weld you will learn to produce is called a weld bead, also referred to simply as a
bead.
 A weld bead is merely a weld deposit produced by a single pass with one of the welding
processes.
 It may be narrow or wide, depending on the amount of transverse oscillation (side to- side
movement) you use.
 If you use a great deal of oscillation, the bead is wide; if you use little or no oscillation, the bead
is narrow.

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 A narrow weld bead made without much weaving motion is often referred to as a stringer bead; a
weld bead made with side-to-side oscillation is called a weave bead.
Groove welds:
Groove welds are made in the groove between two members of a work piece and are adaptable to
a variety of butt joints of varying thicknesses.
 If two or more beads are deposited in the groove, the weld is made with multiple pass layers, as
shown in Figure 3-24.

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Fillet weld:
 A fillet weld is used to join two surfaces at approximately right angles to each other in a lap, tee,
or corner joint. The shape of a fillet weld’s cross-sectional view is triangular
Surface weld:
Surfacing is a welding process used to apply a hard, wear-resistant layer of metal to surfaces or
edges of parts as either a preventative to wear, or a remedy for already worn parts (Figure 3-27).
 It is one of the most economical methods of conserving and extending the life of machines, tools,
and construction equipment.
 Sometimes known as hard facing or wear facing, a surfacing weld is composed of one or more
stringer or weaves beads.
Figure 3-27 — Example of surfacing (hardfacing/wearfacing) welds.
Tack weld:
A tack weld is a temporary weld made to hold parts of an assembly in proper alignment until the
final welds are made (Figure 3-28).
 Although the sizes of tack welds are not specified, they are normally between 1/2 to 3/4 inch in
length, but never more than 1 inch in length.
 In determining the size and number of tack welds you need for a specific project, you need to
consider the thicknesses of the metals being joined and the complexity of the object being
assembled.

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Plug welds and slot welds:

Plug welds and slot welds are welds made through holes or slots in one member of a lap joint
(Figure 3-29).
 These welds are used to join the member with holes to the surface of another member exposed
through the hole.
 The hole may or may not be completely filled with weld metal.
 These types of welds are often used to:
Join face-hardened plates from the backer soft side
Install liner metals inside tanks
Fill up holes in a plate

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Spot weld:
In spot welding resistance welding process is used, the welding takes place at the interface of
two base metals.
Seam weld:
This is a continuous spot welding process which will takes place at the interface of two surfaces.
Types of welding joints:

Basic types of welding joints are classified as under:
(a) Butt Joint
In this type of joint, the edges are welded in the same plane with each other. V or U shape is
given to the edges to make the joints strong. Some examples of butt joints are shown in the figure.

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(b) Lap Joint

This type of joint is used in joining two overlapping plates so that the corner of each plate is
joined with the surface of other plate. Common types of lap joints are single lap, double lap or offset lap
joint. Single welded lap joint does not develop full strength as compared to double welded lap.
(c) T-Joint:
When two surfaces are to be welded at right angles, the joint is called T-Joint. The angle between
the surfaces is kept 90°.
(d) Corner Joint

In this joint, the edges of two sheets are joined and their surfaces are kept at right angle to each
other. Such joints are made in frames, steel boxes, etc.
(e) Edge Joint

In this joint two parallel plates are welded edge to edge.

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(f) Plug Joint

Plug joints are used in holes instead of rivets and bolts.
Welding Positions:
In horizontal position it is very easy to weld. But many times it is impossible to weld the job in
horizontal position. Other positions are classified as under:
(a) Flat Position
(b) Horizontal Position
(c) Vertical Position
(d) Overhead Position
a) Flat Position:
• In flat positions the work piece is kept in nearly horizontal position.
• The surface to be worked is kept on upper side. The welding is done as illustrated in the fig 7.18.
(b) Horizontal Position:

• In this position, the work piece is kept as in the fig 7.19.
• Two surfaces rest one over the other with their flat faces in vertical plane. Welding is done from
right side to left side. The axis of the weld is in a horizontal plane and its face in vertical plane.
c) Vertical Position:
In this position, the axis of the weld remains in approximate vertical plane. The welding is
started at the bottom and proceeds towards top. Welding process is illustrated in figure.

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(d) Overhead Position:

As shown in the figure, the work piece remains over the head of the welder. The work piece and
the axis of the weld remain approximate in horizontal plane. It is the most difficult position of welding.
Basic Weld Symbols:

The basic weld symbols according to IS : 813 – 1961 (Reaffirmed 1991) are shown in the following table.
.
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Elements of a Welding Symbol:

A welding symbol consists of the following eight elements:
1. Reference line,
2. Arrow,
3. Basic weld symbols,
4. Dimensions and other data,
5. Supplementary symbols,
6. Finish symbols,
7. Tail, and
8. Specification, process or other references.
Standard Location of Elements of a Welding Symbol:

According to Indian Standards, IS: 813 – 1961 (Reaffirmed 1991), the elements of a welding
symbol shall have standard locations with respect to each other.
The arrow points to the location of weld, the basic symbols with dimensions are located on one
or both sides of reference line. The specification if any is placed in the tail of arrow. Fig. 10.5 shows
the standard locations of welding symbols represented on drawing.

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Design of welded joints:

• Design of fillet weld joint
• Design of butt(groove) weld joint
Design of fillet weld joint:
Design of parallel fillet weld joint:
Design of Transverse fillet weld joint

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Design of combined transverse and parallel fillet weld:
Design of butt weld:

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Design of axially loaded unsymmetrical welded joints
GAS WELDING:
 It is a fusion welding in which strong gas flame is used to generate heat and raise temperature
of metal pieces localized at the place where joint is to be made.
 In this welding metal pieces to be joined are heated. The metal thus melted starts flowing
along the edges where joint is to be made.
 A filler metal may also be added to the flowing molten metal to fill up the cavity at the edges.
 The cavity filled with molten metal is allowed to solidify to get the strong joint.
 Different combinations of gases can be used to obtain a heating flame.
 The popular gas combinations are oxy-hydrogen mixture, oxygen-acetylene, etc. different
mixing proportion of two gases in a mixture can generate different types of flames with
different characteristics.
Oxy-Acetylene Welding:

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 Oxy-acetylene welding can used for welding of wide range of metals and alloys.
 Acetylene mixed with oxygen when burnt under a controlled environment produces large amount
of heat giving higher temperature rise.
 This burning also produces carbon dioxide which helps in preventing oxidation of metals being
welded. Highest temperature that can be produced by this welding is 3300 oC.
 The chemical reaction involved in burning of acetylene is
o
 on the basis of supply pressure of gases oxy-acetylene welding is categorized as
• High pressure welding
• Low pressure welding
High pressure welding:
 In this system both gases oxygen and acetylene supplied to welding zone are high pressure
from their respective high pressure cylinders.
Low pressure welding:
 The other one is low pressure welding in which oxygen is supplied from high pressure
cylinder but acetylene is generated by the action of water on calcium carbide and supplied at
low pressure.
 In this case high pressure supply of oxygen pulls acetylene at the welding zone.
Comparison:
 A comparison can be drawn between low pressure and high pressure welding. High pressure
welding equipment is handy, supplies pure acetylene at constant pressure, with better control
and low expenses as compared to low pressure welding.
Flame formation and its different types:
 Flame is established by burning (controlled) of the two gases mixture at the outlet of blow
pipe or torch.
 The proportion of gasses in the mixture is controlled by controlling the flow rate of each of
the two gasses.
 Here, it should be clear that burning of acetylene generates heat and oxygen only supports
acetylene in burning.
 Insufficient supply of oxygen leaves acetylene un burnt in atmosphere creating pollution and
adding cost of waste acetylene.
 A general nomenclature of the flame established in oxy-acetylene welding is given in Figure
5.1.
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The flame can be divided into three zones. Zone ‘1’ is very near to the outlet of torch, where oxygen
reacts with acetylene and burning of two gases takes place.
 Zone ‘2’ produces carbon monoxide and hydrogen in ratio 2 : 1 by volume. This zone gives
the highest temperature of the flame.
 This zone is suppose to consume the oxygen available here and contribute reducing properly
to the flame.
 Zone ‘3’ is the outermost zone of the flame. Temperature of this zone is comparatively low.
 This zone converts CO to CO2 and H2O vapors.
Types of flames:
 On the basis of supply proportion of acetylene and oxygen, flames can be divided into three
categories, neutral flame, carburizing flame and oxidizing flame. These are described here.
• Neutral Flame
• Carburizing Flame
• Oxidizing Flame
Neutral Flame:
 A neutral flame is obtained when equal amount of O2 and C2H2 are mixed and burnt at the
outlet of welding torch.
 The flame consists of two sharply defined zones inner white flame cone outer envelope of
blue colour as shown in Figure 5.2.
 In this flame none of two gasses is supplied in excess.
 This flame is of white cone and has the maximum use for successful welding of many metals.
Carburizing Flame:
 This flame is obtained when excess of acetylene is supplied than which is theoretically
required.
 This flame is identified by three zones the inner cone which is not sharply defined, an outer
envelope as same in case of neutral flamed and middle zone surrounds inner one extended to
outer envelope.
 It is white in colour due to excess acetylene. Larger the excess of acetylene larger will be its
length.
 To get a neutral flame a systematic procedure is to make carburizing flame first and then
increase oxygen supply gradually till the excess acetylene zone disappears.
 The resulting flame is a carburizing flame.
 Its temperature generation range is 3100oC to 3300oC.
 It is used for the welding of metals where risk of oxidation at elevated temperature is more
like aluminium, its alloys and lead and its alloys.
 The metals which have tendency to absorb carbon should not be welded by carburizing flame
as they become brittle localized.
Oxidizing Flame:
 This flame as an excess of oxygen over that required for a neutral flame.
 The ratio O2 : C2H2 = 1.15 to 1.50.
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 To have this flame set carburizing flame first convert it to neutral flame and than reduce the
supply of acetylene to get oxidizing flame.
 Its inner cone is relatively shorter and excess oxygen turns the flame to light blue colour.
 It burns with a harsh sound.
 It is used for metals which are not oxidized readily like brasses and bronzes.
Gas welding tools and equipments:

 Equipment for gas welding as well as for gas cutting are almost similar.
 It consists of two large steel cylinders, one containing oxygen at high pressure and other
dissolved acetylene also at high pressure.
 In addition to tools and equipments some consumables are also used in gas welding.
 Major tools and equipment and consumables are listed below followed by their brief
description.
(a) Gas cylinders (two)
(b) Hose pipes and valves
(c) Cylinder pressure gauge
(d) Outlet pressure gauge
(e) Pressure regulators
(f) Blow pipe or torch and spark lights
(g) Welding screens
(h) Goggles, screens, gloves and apron
(i) Wire brush, trolley, chipping hammer.
Consumables:
(a) Oxygen gas
(b) Acetylene gas
(c) Filler metal (rod or wire)
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(d) Fluxes.
Gas Cylinders:
 Two large steel cylinders, capable to withstand high pressure are needed to keep oxygen and
acetylene separately.
 Cylinders are painted with different colours :oxygen cylinder in black colour and acetylene
cylinder in maroon or red colour.
 Oxygen is filled at pressure to 2000 pound per square ich (PSI).
 Large weight of acetylene is kept dissolved in acetone. Acetylene cylinder should not be
exposed to higher temperature for safety reasons.
Pressure Regulators:
 Each of the cylinders should be equipped with pressure regulator at the top.
 Pressure regulator maintains supply pressure at a constant value which have to be much less
than the pressure at which gas has been filled in the cylinder.
 This way supply pressure can be controlled and maintained to different values as per the
requirement.
 Value of supply pressure depends upon inside diameter of outlet nozzle, supply flow rate of
gas.
Gas welding torch or Blow pipe:
 Blow pipes are used in welding or cutting.
 These are made in different design and size to suit the work.
 Both the gases are mixed in a chamber of blow pipe and then driven out through the orifice
of the blow pipe nozzle and burnt by spark lighter.
 Blow pipes are classified as high pressure torch used in gas cutting and low pressure torch
used in gas welding.
 In case of high pressure blow pipe acetylene is supplied at high pressure as compared to low
pressure blow pipe.
 Construction of a blow pipe is given below in Figure 5.3.
Welding Rods:
 These are also called filler metals.
 Filler metal is typically in the form of rod, 90 mm long and diameter ranging from 1.6 mm to
9.5 mm.
 Composition of filler metal must be same as that of base metal. Two types of welding rods
are generally available.
 One is coated welding rods, which have coating of flux.
 Others are bare welding rods having no coating of flux.
 Different types of welding rods are used for welding of different metals. Some examples are
given below.

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Metal to be welded
(a) Iron rich steels
(b) Stainless steel
(c) Copper
(d) Aluminium and its alloy
Composition of Welding Rod
(a) More ‘C’ Si, Mn less ‘P’ and ‘S’
(b) Should have ‘Cr’ and ‘V’.
(c) Copper rods with phosphorus.
(d) Rods of same metal containing some silicon.
Flux
 Flux is used in every welding operation.
 Mild steel is exceptional to this.
 Flux is used to prevent oxidation of hot metal.
 It converts the oxides and nitrides to slag that can be removed from welding zone easily.
Formation of oxides and nitrides make weldment weak.
 Different fluxes are used for welding of different metals.
 For the welding of copper and its alloy sodium nitrate, sodium carbonates are used as flux.
 For welding of aluminium or its alloy chloride of sodium, potassium, lithium or barium are
used.
Applications:
 It is used to join thin metal plates.
 It can used to join both ferrous and non-ferrous metals.
 Gas welding mostly used in fabrication of sheet metal.
 It is widely used in automobile and aircraft industries.
Advantages:
 It is easy to operate and does not require high skill operator.
 Equipment cost is low compare to other welding processes like MIG, TIG etc.
 It can be used at site.
 Equipment’s are more portable than other type of welding.
 It can also be used as gas cutting.
Disadvantages:
 It provides low surface finish. This process needs a finishing operation after welding.
 Gas welding have large heat affected zone which can cause change in mechanical properties
of parent material.
 Higher safety issue due to naked flame of high temperature.
 It is Suitable only for soft and thin sheets.
 Slow metal joining rate.
 No shielding area which causes more welding defects.

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ARC WELDING:
The welding in which the electric arc is produced to give heat for the purpose of joining two
surfaces is called electric arc welding.
Principle
 Power supply is given to electrode and the work. A suitable gap is kept between the work and
electrode.
 A high current is passed through the circuit.
 An arc is produced around the area to be welded.
 The electric energy is converted into heat energy, producing a temperature of 3000°C to
4000°C.
 This heat melts the edges to be welded and molten pool is formed. On solidification the
welding joint is obtained.
Electric Power for Welding:

 AC current or DC current can be used for arc welding. For most purposes, DC current is
preferred.
 In D.C. welding, a D.C. generator or a solid state rectifier is used. D.C. machines are made
up to the capacity range of 600 amperes.
 The voltage in open circuit is kept around 45 to 95 volts and in closed circuit it is kept 17 to
25 volts. D.C. current can be given in two ways:
• (a) Straight polarity welding.
• (b) Reverse polarity welding.
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a) Straight polarity welding:

 In straight polarity welding work piece is made anode and the electrode is made cathode as
shown in the fig 7.13.
 Electrons flow from cathode to anode, thus, heat is produced at the materials to be welded.
(b) Reverse polarity welding:

 In reverse polarity system the work is made cathode and the electrode is made anode. This
welding is done specially for thin section.
Effect of Arc Length:

 Arc length is the distance from the tip of the electrode to the bottom of the arc.
 It should vary from 3 to 4 mm. In short arc length, the time of contact will be shorter and will
make a wide and shallow bead.
 The penetration is low as compared to long arc lengths.
Equipment used for Arc Welding:
1. D.C. Welding Equipment
(a) AC Motor - Generator set
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(b) Diesel Engine - Generator set

(c) Transformer - Rectifier welding set
2. AC Equipment
(a) Welding transformer set
3. Equipment accessories
(a) Leads
(b) Holder
(c) Connectors
(d) Ground Clamps
4. Operator’s tool
(a) Chipping hammer
(b) Wire brush
(c) Arc shield
(d) Closed shoe
AC Motor Generator:
 In this a generator is driven by a suitable AC motor.
 The average voltage of the generator is 25 volt. The current ranges from 25 to 100 amperes.
 The voltage in the generator is variable. The voltage can be set to the desired value with the
help of rheostat
Diesel Engine Generator Set:
 In this set, the drive is given by a diesel engine.
 Rest of the system is same as in case of A.C. motor generator.
 Diesel engine generator sets are used in the areas when electricity is not available.
Transformer Rectifier Set:

 It allows the current to flow through it only in one direction because it has a one way valve or
solid rectifier installed on the electrode side of the secondary coil.
 The set can supply straight polarity and reverse polarity power supply. The rectifier, are of
two types
• (a) Silicon diode
• (b) Selenium plate
5. Cables or Leads: These leads are made up of copper or aluminium wire. The wires are insulated with
rubber & cloth fibre. A heavy insulation is necessary for these cables.
6. Face Shield: When arc is produced around the job, infrared rays and ultraviolet rays are produced. To
protect the face and eyes from these dangerous rays, a shield is necessary.

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7. Other Accessories & Tools: Other accessories & tools used for arc welding are shown in the fig
7.17.
Types of Electrodes:
Electrodes are of two types
1. Coated electrodes: Coated electrodes are generally applied in arc welding processes. A metallic
core is coated with some suitable material. The material used for core is mild steel, nickel steel,
chromium molybdenum steel, etc. One end of the coated core is kept bare for holding.
2. Bare electrodes: Bare electrodes produce the welding of poor quality. These are cheaper than
coated electrodes. These are generally used in modern welding process like MIG welding.
Electrode Size:
 Electrodes are commonly made in lengths 250 mm, 300 mm, 350 mm, 450 mm,
and the diameters are 1.6 mm, 2 mm, 2.5 mm, 3.2 mm, 4 mm, 7 mm, 8 mm and
9 mm.
Functions of Coatings:
The coating on an electrode serves the following functions:
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1. To prevent oxidation.
2. Forms slags with metal impurities.
3. It stabilizes the arc.
4. Increases deposition of molten metal.
5. Controls depth of penetration.
6. Controls the cooling rate.
7. Adds alloy elements to the joint.
FORGE WELDING:
 Forge welding is a solid state welding process in which metal joint is created due to inter-
molecular diffusion.
 As we know, forging is a technique of shaping any metal by application of high pressure and
temperature.
 This welding process uses fundamental technique of forging to weld similar or dissimilar
metals. it has been used from a very old period to join iron or steal work pieces.
 It was a simplest process of joining two metals in ancient time but now it has replaced by
other more suitable and simplest welding processes like arc welding and gas welding.
Principle:
 Forge welding is a solid state welding process in which both the plates are heated quite
below its melting temperature.
 This heating deforms the work pieces plastically. Now a repeated hammering or high
pressurize load is applied on these plates together.
 Due to this high pressure and temperature, inter-molecular diffusion takes place at the
interface surface of the plates which make a strong weld joint.
 One of the basic requirements of these types of welding is clean interface surface which
should be free from oxide or other contaminant particles.
 To prevent the welding surface from oxidation, flux is used which mixes with the oxide and
lower down its melting temperature and viscosity. This allow to flow out the oxide layer
during heating and hammering process.

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Working:
 Forge welding was one of the most applied welding method in ancient time. This is a
fundamental welding process of all solid state welding. Its working can be summarized as
follow.
 First both the work plates heated together. The heating temperature is about 50 to 90% of its
melting temperature.
 Both the plates are coated with flux.
 Now manual hammering is done by a blacksmith hammer for making a joint. This process is
repeated until a proper joint is created.
 For welding large work pieces, mechanical hammering is used which is either driven by
electric motor or by using hydraulic mean. Sometime dies are used which provides finished
surface.
Application:
 It is used to join steel or iron.
 It is used to manufacture gates, prison cells etc.
 It is widely used in cookware.
 It was used to join boiler plates before introduction of other welding process.
 It was used to weld weapon like sword etc.
 Used to weld shotgun barrels.
Advantages:
 It is simple and easy.
 It does not require any costly equipment for weld small pieces.
 It can weld both similar and dissimilar metals.
 Properties of weld joint are similar to base material.
 No filler material required.
Disadvantages:
 Only small objects can be weld. Larger objects required
 Large press and heating furnaces, which are not economical.
 High skill required because excessive hammering can damage
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 The welding plates.

 High Welding defects involve.
 It cannot use as mass production.
 Mostly suitable for iron and steel.
 It is a slow welding process.
ELECTRIC RESISTANCE WELDING:

 The electric resistance welding is commonly used. It can be applied to any metals.
 Electric current passes through the materials being joined.
 The resistance offered to the flow of current results in raising the temperature of the two metal
pieces to melting point at their junction.
 Mechanical pressure is applied at this moment to complete the weld. Two copper electrodes of low
resistance are used in a circuit.
 The mechanical pressure or force required after the surfaces are heated to a plastic temperature is
approximately 0.3 N/m2 at the welded surface.
 This method of welding is widely used in modern practice for making welded joints in sheet metal
parts, bars and tubes etc.
Parameter Affecting Resistance Welding:
 Successful application of Resistance welding process depends upon correct application and
proper control of the following factors.
1. Current: Enough current is needed to bring the metal to its plastic state of welding.
2. Pressure: Mechanical pressure is applied first to hold the metal pieces tightly between the
electrodes, while the current flows through them called weld pressure, and secondly when the metal has
been heated to its plastic state, to forge the metal pieces together to form the weld, called forge pressure.
3. Time of Application: It is the cyclic time and the sum total of the following time period allowed
during different stages of welding
a. Weld Time :Time period during which the welding current flow through the metal pieces to raise
their temp.
b. Forge Time: Time period during which the forge pressure is applied to the metal pieces.
c. Hold Time: Time period during which the weld to be solidify.
d. Off Time: The period of time from the release of the electrodes to the start of the next weld cycle.
4. Electrode contact area: The weld size depends on the contact area of the face of the electrodes
Types of resistance welding:
1. Spot welding
2. Seam welding
3. Butt welding
4. Flash welding
5. Projection welding
6. Percussion welding
1. Spot Welding:
 It is used for joining two or more sheets of metal.
 The sheets to be welded are held overlapping between the two electrodes, one moveable and the
other fixed. Heavy current is passed through the electrodes.
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 Pressure is applied from the top electrode by moving it downward.
 The fusion of material takes place at the spot.

 The sheet is then moved to have another spot weld at the desired place.
 The time period for each weld may be 1/100th of a second or more.
 The current may be of the order of 5000 amperes or more.
 The voltage between electrodes about 2 volts.
 The open circuit voltage is less than 12 volts.
 Fig. 4.4 shows how spot welding is done.
 Rods, wires and small pieces can also be welded by this method.
 For the sheets the time required is about 1/50sec. for each 0.25 mm of total thickness of the
two sheets to be welded.
Spot Welding Machine:
 A spot welding machine is shown in Fig. 4.5 AC supply is given to the primary of the welding
transformer through the timer which controls the time for which the current flows. The primary
has got tappings and a particular tapping is selected by the selector switch S depending upon the
current required for welding.
 For maximum welding current the selector switch should be kept in position No. 1. The
secondary is connected to the two electrodes made of copper or bronze and they are cooled by
water. When pressure is not applied on the foot pedal, the electrodes are kept apart by the spring.
 The sheets to be welded are placed over-lapping each other between the two electrodes and
pressure is applied by pressing the foot pedal.
 The spot weld is made between the sheets. Thickness and composition of the plates determine
the duration and magnitude of the current.
 It varies from 1000 to 10,000 amperes and may flow for a fraction of a second to some seconds.
Spot welding is mostly employed in the manufacture of automobiles, refrigerators and other
metal stamping assemblies.
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Advantages of Spot Welding:

1. It has low initial cost.
2. Higher productivity.
3. Less skilled worker can operate this welding.
4. Edge preparation is not required.
5. Operation may be made automatic or semi-automatic
Disadvantages of Spot Welding:
1. Job of more thickness cannot be welded.
2. High initial cost of equipment.
3. Skilled labor is required for maintenance purpose.
Applications of Spot Welding:
1. It can be frequently used in automobile and aircraft industries.
2. It is used for making containers.
3. Fabrication of steel household furniture.
2. Seam welding:
 In Fig. 4.7 shows how seam welding is carried out. In this case wheel or roller type electrodes
are used and the pressure between them remains constant.
 The seam welding is done in order to produce a continuous joint which may be required for the
construction of tanks, transformer’s refrigerators, gasoline tanks, air craft, containers and
cylindrical pieces.
 Seam weld is actually a series of overlapping spot welds.
 Usually numbers of spots obtained per meter of the joint are between 200 to 400.
 The two sheets on which seam welding is required are placed over-lapping each other.
 The current is passed between the two moving electrodes as shown in Fig. 4.7.

29
 The electrodes are to be shape of continuously rotating wheel which also applies pressure on the
job.
 It is used when a continuous joint required between two overlapping metal sheets.
Advantages of Seam Welding:

(i) Less overlap than spot or projection welds.
(ii) Several parallel seams may be produced.
(iii) Gas tight or liquid tight joints can be produced.
Disadvantages of Seam Welding:
(i) High cost of equipment as compared to spot welding set.
(ii) It is difficult to weld thickness greater than 3 mm.
(iii) Welding can be done only along a straight line.
Applications of Seam Welding:
It is used for welding of stainless steel, aluminium and its alloys nickel and its alloys etc.
3. Butt welding:
 In Fig.4.8 shows how butt welding is done. The welding transformer has a comparatively larger
number of turns on the primary and lesser number of turns on the secondary because heavy
current is required on the secondary side.
 The two parts to be welded together are placed touching each other end to end so as to form a
butt joint.
 A pressure is also applied in the axial direction of weld. The jobs are securely clamped and
heavy current is passed through them.
 The heat produced is sufficient to raise the temperature of material to plastic state and fusion
takes place at the points of contact when pressure is applied on both sides.
 This method is used for welding pipes, wires and rods etc.

30
 The voltage required for welding is 2 to 10 volts and current varies from 50 A to several
hundred amperes, depending upon the material and the area to be welded at a time.
4. Flash Butt Welding:

 This is similar to butt welding except that the parts to be welded are joined together under light
pressure and a heavy current passed through the joint.
 Due to poor contact at the joint arcing takes place.
 When sufficient heat has been produced the two parts are suddenly pressed together and the
current is simultaneously stopped.
 A thin film is produced around the joint which is subsequently removed to give a weld of this
type.
 It is used for welding chains, rail ends, shaft axles etc.
 Flash Butt Welding
 Note: Resistance welding can be applied to iron and steel, brass, copper, aluminium and certain
other metals with eminently satisfactory results
Advantages of Flash Butt Welding:
(i) It is a faster process.
(ii) Preparation of weld surface is not required.
(iii) Power requirement is less.
(iv) Many dissimilar metals with different melting temperatures can be flash welded.
(v) The process is cheap.
(vi) It offers strength factor upto 100%.
Disadvantages of Flash Butt Welding:
(i) More chances of fire hazards.
(ii) Metal is lost during flashing and upsetting.

31
(iii) Concentricity and straightness of the work pieces during welding process is often difficult to
maintain.
Applications of Flash Butt Welding:
(i) It is used for welding metal sheets, bars, rods fittings etc.
(ii) Flash welding finds applications in automotive and air craft products.
(iii) It is also employed in household appliances, refrigerators and farm implements.
5. Projection Welding:
 It is infact a modified form of the spot welding. One of the pieces to be welded this way has
projections produced by pressure.
 The electrodes are flat.
 The electrodes are placed on work piece and current passed between them.
 Heat is produced at the contacts and work piece gets welded at these points.
 It is easy to weld certain parts which cannot be welded by spot welding.
 When two plates to be welded are of different cross-section then in order to obtain desirable
strength it is necessary to have the projections on the thicker plate.
Advantages of Projection Welding:
(i) More than one spot can be weld at a given time.
(ii) Proper heat balance can be obtained easily.
(iii) The welds may be placed closer than spot welding.
(iv) Electrode life is much longer than the life of electrode in spot welding.
Disadvantages of Projection Welding:
1. Metals, which cannot support projection, cannot be welded satisfactory.
2. To make projection is an extra operation.
3. The initial cost of the equipment required for projection welding is high as press type
machines are required for this type of welding.
Applications of Projection Welding:
1. It is usually employed on punched where the projection automatically exists.
2. Small fasteners, nuts etc. can be welded to larger components.
3. Projection welding is used for welding of refrigerator condensers, crossed-wire welding grills
etc.
4. Welding of stainless steel parts.

32
THERMIT WELDING:
 Aluminum has greater affinity to react with oxygen; it reacts with ferric oxide to liberate pure
iron and slag of aluminum oxide.
 Aluminum oxide floats on top of molten metal pool in the form of slag and pure iron (steel)
settled below, because of large difference in densities
 Thermit welding process is essentially a casting and foundry process, where the metal obtained
by the Thermit reaction is poured into the refractory cavity made around the joint.
Steps involved in thermit welding:

1. The two pieces of metal to be joined are properly cleaned and the edge is prepared.
2. Then the wax is poured into the joint so that a wax pattern is formed where the weld is to be
obtained.
3. A moulding box is kept around the joint and refractory sand is packed carefully around the wax
pattern as shown in Fig. 7.40, providing the necessary pouring basin, sprue, and riser and gating
system.
4. A bottom opening is provided to run off the molten wax. The wax is melted through this opening
which is also used to preheat the joint. This makes it ready for welding.
5. The Thermit is mixed in a crucible which is made of refractory material that can withstand the
extreme high heat and pressure, produced during the chemical reaction.
6. The igniter (normally barium peroxide or magnesium) is placed on top of the mixture and is
lighted with a red hot metal rod or magnesium ribbon.
7. The reaction takes about 30 seconds and highly super-heated molten iron is allowed to flow into
the prepared mould cavity around the part to be welded.
8. The super-heated molten metal fuses the parent metal and solidifies into a strong homogeneous
weld.
9. The weld joint is allowed to cool slowly.

33
Applications:
 Welding pipes
 Cables
 Conductors
 Shafts
 Broken machinery frames
 Rails
 Repair of large gear tooth.
Advantages:
 No external power source is required (heat of chemical reaction is utilized);
 Very large heavy section parts may be joined.
Disadvantages:
 Only ferrous (steel, chromium, nickel) parts may be welded;
 Slow welding rate;
 High temperature process may cause distortions and changes in Grain structure in the weld
region.
 Weld may contain gas (Hydrogen) and slag contaminations.
PLASMA ARC WELDING:

Principle:
 The hot ionized gases are known as plasma. When a sufficient amount of energy provided to any
inert gas, some of its electrons breaks free from its nucleus but travel with it. After the electrons
leave, the atoms are converted into hot ionized state. It is most common state of matter which is
known as fourth state of matter. These ionized atoms have high heat contain which is further used to
join two plates.
 This is basic principle of plasma arc welding. This welding is extended form of TIG welding in
which, a non-consumable tungsten electrode is used to produce arc. This arc heats up the inert gases
which are provided from inner orifice around tungsten electrode. The heating temperature is about
33000 0c at which the gas converts into ionized form. This hot ionized gas further used to create a
welding joint by fusion.

34
Equipment used:
 Power supply
 Plasma console
 Plasma torch
 Shielding gas
 Plasma gas
 Cooling system
 Filler material
Power supply:
 PAW process needed a high power DC supply to generate electric spark in between tungsten
electrode and welding plates (For transferred PAW Process) or in between tungsten electrode
and discharge nozzle (For Non-transferred PAW process).
 One of the main features of plasma arc welding which make it different from TIG, is its low
ampere welding capability.
 This welding can weld at low ampere of about 2 amp and maximum current which it can handle
is about 300 amp. It needs about 80 volts for proper working.
 The power source consist transformer, rectifier and control console.
Plasma console:
 A control console is required for plasma arc welding. The plasma arc torches are designed to
connect to the control console rather than the power source.
 The console includes:
 A power source for the pilot arc
 A delay timing system for transferring from the pilot arc to the transferred arc
 Water and gas valves
 Separate flow meters for the plasma gas and the shielding gas.

35
Plasma torch:
 This is most important part of PAW process. This torch is quite similar as used in TIG welding
but too complex.
 It consist four main parts which are tungsten electrode, collets, inner nozzle, and outer nozzle.
 The tungsten electrode is hold by the collet.
 The collet is available in varying diameters.
 The inner gas nozzle supply inert gases inside the torch to form plasma.
 The outside nozzle supply shielding gases which protect the weld area from oxidation. These
nozzles wear out rapidly.
 PAW torches are water cooled because arc is contained inside the torch which produces high
heat, so a water jacket is provided outside the torch
Shielding and Plasma Gas Supply:
 Generally, plasma gas is same as shielding gas which is supplied by a same source. Mainly inert
gases like argon, Helium etc. are used as both inert and shielding gases. This gas is supplied at
both inert and outer nozzles.
Filler Material:
 Mostly no filler material is used in this welding process.
 If filler material is used, it is directly feed into weld zone.
Types of PAW:
Mainly plasma arc welding can be classified into two types.
A. Transferred plasma arc welding:
B. Non-transferred plasma arc welding:
Transferred plasma arc welding:

 This process also uses straight polarity DC current.
 In this process, the tungsten electrode is connected to the negative terminal and the work piece is
connected to the positive terminal.
 The arc is produces between tungsten electrode and work piece.
 In this process both plasma and arc transferred to the work piece which increases the heating
capacity of process.
 It is used to weld thick sheets.
Non-transferred plasma arc welding:
 In this welding process, straight polarity
36
 DC current is used. In this process, the tungsten electrode is connected to the negative and the
nozzle is connected to the positive pole.
 The arc produces between tungsten electrode and nozzle inside the torch.
 This will increase the ionization of gas inside the torch.
 The torch transfers this ionized gas for further process.
 It is used to weld thin sheets.
Working:
 This welding works on same as TIG instead, plasma is used to heat up the parent material.
 First the work pieces are properly cleaned. The power source supply power which produces arc
between tungsten electrode and nozzle, or tungsten electrode and work-piece.
 The tungsten electrode gives a high intense arc which is used to ionization of gas particles and
converts orifice gases into plasma.
 This hot ionized gas is supplied to the welding plates from a small orifice.
 The shielding gases like argon etc. are supplied through pressure valve and regulating valve to
the outer nozzle of welding torch.
 These gases create a shield around the welding area which protects it from atmospheric gases
like oxygen, nitrogen etc.
 The plasma strikes the welding plates and fuses it into one piece.
 Next the welding torch is moved in the direction of welding.
 If the welding required filler material, it is fed by the welder manually.
Advantages:
 Constricted opening
 Good arc stability
 Permits deeper penetration
 Narrow weld bead obtained
 Less distortion
 Rapid welding speed
 It can work low amperage
 Low power consumption for same size weld
 The distance between tool and work-piece does not effects
Disadvantages:
 Orifice replacement is necessary
 Expensive welding process
 Nozzle get melt
 More noise level around 100db
 Excessive ultra violet and infrared radiation
 High skill labour required
 High maintenance cost
Applications:
 Aeronautical industry
 Precision instruments industry
 Jet engine manufacturing
 Steel and titanium tube manufacturing
 Butt weld of wall tubes
 Medical setup and thin electronic chips
 Repair tools, dies, and molds
 Coating or welding of turbine blades

37
CUTTING OF METALS
Introduction:
Cutting of metals implies severing or removal of metal. Cutting is the process of separating
metals, i.e., a metal piece is separated or split into two parts. Cutting of metals is an everyday practice in
industry.
It is employed for the following purposes:
 Cutting desired lengths and shapes of (rolled) metal pieces for assembly and other processing
operations to be carried out on different machine tools and presses. Many times it is required to
cut a gear blank from a plate or a blank is cut from a plate for subsequent forming operations.
 For preparing the edges of plates for welding them together.
 For cutting gates and risers from the castings.
 For salvage work
OXY-FUEL GAS CUTTING:
It is an oxygen cutting process wherein the severing of metals is effected by means of the
chemical reaction of oxygen with the base metal at elevated temperatures, the necessary temperature
being maintained by means of a gas flame obtained from the combustion of a fuel gas (such as
acetylene, hydrogen, propane, etc.) and oxygen.
There are four basic requirements for oxy-fuel cutting:

 The ignition temperature of the material must be lower than its melting point otherwise the
material would melt and flow away before cutting could take place
 The oxide melting point must be lower than that of the surrounding material so that it can be
mechanically blown away by the oxygen jet
 The oxidation reaction between the oxygen jet and the metal must be sufficient to maintain the
ignition temperature
 A minimum of gaseous reaction products should be produced so as not to dilute the cutting
oxygen.

38
Equipment:
A conventional OAW outfit is readily converted to perform light to heavy OAC by exchanging
the welding nozzle on the torch handle to a cutting accessory head fitting into the handle
Cutting torch:
 A cutting torch is made up of a yellow brass body.
 Mixes acetylene and oxygen and carries the gas mixture to the orifices where it is ignited to
produce preheating flames.
 Carries cutting oxygen to the central orifice from where as it emerges, it oxidizes the metal and
blows the same away to form an open slot (kerf).
There are two types of cutting torches:
1. The injector type, in which the acetylene is delivered to the torch at pressures below 1 psi. The
acetylene is drawn into the torch with the help of an injector. Acetylene and oxygen for the
preheating flames are mixed in the tip of the cutting torch.
2. The equal pressure type, in which oxygen and acetylene are delivered at pressures above 1 psi.
The mixing of the gases takes place within the torch (and not in the tip).

39
1. Cutting oxygen tube

2. Pre-heat oxygen tube
3. Cutting oxygen valve lever
4. Oxygen valve
5. Acetylene valve
6. Acetylene tube
7. Cutting oxygen orifice
8. Preheat orifices
Gas pressure regulators:
Gas pressure regulators, etc., are similar in design to those used for oxy acetylene welding.
Principle of operation:
 The oxy acetylene flame cutting process makes use of a cutting torch.
 The mixes the acetylene and the oxygen in correct proportions to produce a preheating flame and
also the torch supplies a uniformly concentrated stream of high purity oxygen (known as cutting
oxygen) to the reaction zone.
 After a spot area along the line of cut is heated to ignition temperature (900°C), i.e., reddish
yellow colour by the preheat flames, keeping the flame cones 1.5 to 3 mm above the surface of
material, to be cut, a thin jet of high purity oxygen is then directed or shot at this heated spot.
 The jet quickly penetrates through the steel. The iron and oxygen combine to form iron oxide.
 The oxygen jet blows the reaction products from the joint and thus the torch moves progressively
forward over the metal surface, cutting a narrow slot or kerf along the desired line of severance.
In actual practice, the top surface of the material is frequently covered with mill scale or rust.
 They must be melted away by the preheating flame to expose a clean metal surface to the oxygen
jet.
 The cutting action is self progressing provided the (cutting) oxygen jet is sustained and the pre
heating flame is maintained on the top surface of the metal object being cut.
Summary:
 Oxy acetylene flame preheats the metal to the ignition point at the place to be cut. It also
provides a protective shield between the cutting oxygen stream and the atmosphere.
40
 Cutting oxygen combines with iron to form iron oxide.

 Cutting oxygen jet blows away molten iron and iron oxide thereby cutting a narrow slit or kerf in
the metal object.
Applications:
 To prepare edges of plates for bevel and groove weld joint designs.
 To cut small sized work pieces from bigger plates for further processing.
 To cut rivets gates and risers from castings.
 To cut many layers of thin sheets at the same time (stack cutting) to reduce both time and cost
for production work.
 To pierce holes and slots in steel plates.
 For salvage work
Advantages:
 Shapes and sizes difficult to be machined by mechanical methods can be easily cut by flame
cutting.
 The process is faster than mechanical cutting methods.
 The cost of flame cutting is low as compared to that on a machine tool, i.e. mechanical cutting
machine.
 Flame cutting equipment being portable also, can be used for the field work.
 Multi torch machines can cut a number of pieces simultaneously.
Disadvantages
 Flame cutting is limited to the cutting of steels and cast iron.
 As compared to mechanical cutting, the dimensional tolerances are poor.
 The place of cutting needs adequate ventilation and proper fume control.
 The expelled red hot slag and other particles present fire and burn hazards to plant and workers.
Metals can be cut using flame cutting

 Plain Carbon Steel.
 Low Alloy Steel.
 Manganese Steel.
 Low-content Chromium Steel.
Metals cannot be cut by flame cutting

 Stainless Steel.
 Carbon Steel.
 Aluminium.
 Non-ferrous Metals.

41
WATER JET MACHINING:

Principle:
This process works on the basic principle of water erosion. In this process, a high-speed well-
concentrated water jet is used to cut the metal. It uses the kinetic energy of water particle to erode metal
at the contact surface. The jet speed is almost 600 m/s. It does not generate any environmental hazards.
For cutting hard materials, abrasive particles are used in the water jet. These abrasive particles erode
metal from the contact surface.
Hydraulic Pump:
In the water jet machining process a hydraulic pump is used to pump the water from the storage
tank for the machining process. It is connected to an electric motor of about 100 Horsepower.
Hydraulic Intensifier:
As the name implies, it is used to increase the water pressure for further process. Hydraulic
intensifier accepts water from the pump at a small pressure about 4 bar. The water pressure at the outlet
of the intensifier is about 3000-4000 bars.
Hydraulic Accumulator:
A hydraulic accumulator is used when a large amount of pressure energy is required for an
instant. It used to eliminate pressure fluctuation. It supplies fluid at high pressure when required.

42
Tubing System:
Tubes are used to supply high-pressure water to the nozzle for further cutting process. It
increases the kinetic energy of the fluid. Its diameter is about 10-14 mm. It provides flexible movement
and does not allow any significant loses.
Flow regulator:
Flow regulators are used to regulating the flow according to cutting requirement. For high
cutting load, high pressurized water is supplied at the high rate.
Abrasive:
Abrasive particles are used in abrasive water jet machining for machine hard material. Generally
Aluminium oxide, Silicon carbide etc. used as abrasive particles.
Nozzle:
As we know, nozzles are used to convert pressure energy into kinetic energy. This nozzle
converts high pressure of water into a high-velocity jet. This high-speed water jet strikes at work surface
which is used for machining. There is a possibility of erosion at the orifice of the nozzle due to high-
pressure water jet. Therefore high wear resistance material is used for the nozzle. The size of the nozzle
is about 0.2 – 0.4 mm. If abrasive water-jet machining is used, abrasive particles mixed in water stream
before entering into the nozzle.

43
Drain and Catcher-

The drain and catcher system is used to remove debris and other machined particle form water. It
separates metal particle from water and this water is further sent to the reservoir. It also used to reduce
noise associated with WJM.
Working:
The working of waterjet machining can be summarized as follows-
 First water is filled in the water reservoir. It provides water for cutting operation.
 A pump sucks water from the water reservoir and sends it to intensifier.
 Intensifier increases the water pressure from 4 bar to 4000 bars. It sends water to an accumulator
which store some pressurize water.
 This high-pressure water now sends through tubing system to the nozzle. The water passes
through flow regulator valve which regulates the flow.
 Now, this high-pressure water enters into the nozzle. Nozzle converts some pressure energy of
water into kinetic energy.
 A high-speed high pressurize water jet is available at the nozzle exit.
 This water jet sends to strike at the work surface. It erodes metal from the contact surface. Thus
metal removal takes place.
 This is a whole working process of waterjet machining.
Applications:
 It is used in aerospace industries.
 Abrasive jet machining is used to cut hard metal like stainless steel, titanium, Inconel etc.
 It is used for machining or cutting reinforced plastic.
 Use to cut stone which reduces dust in the environment.
 Used to machining PCB.
Advantages:
 It does not change mechanical properties of the workpiece. It is useful for machining heat
sensitive material.
 It is environment-friendly because it does not form any dust particle and used water as cutting
fluid.
 Good surface finish.
 No physical tool is required.
 It can cut both soft and hard material. For machining soft materials, water jet machining is used
and for machining hard materials, abrasive water jet machining is used.
 It is ideal process for laser reflective materials where laser beam machining cannot be used.
 Lower cost of machining.
Disadvantages:
 It cannot be used for machining material which degrades in presence of water.
 Low metal removal rate.
 High initial cost.
 The thick material cannot be machined easily.

44
PLASMA ARC CUTTING:

It is an arc cutting process wherein the severing of the metal is obtained by melting a localized
area with a constricted arc and removing the molten material with a high velocity jet of hot, ionized gas
issuing from the orifice.
Principle of operation:
 Plasma arc cutting makes use of DCSP (electrode -ve) with a constricted transferred arc struck
between a tungsten electrode situated within the torch and the workpiece to be cut.
 The cutting arc between the electrode and the workpiece is initiated by a pilot arc established
between electrode and nozzle.
 The nozzle is connected to ground (+) through a current limiting resistor and a pilot arc relay
contact.
 The pilot arc is initiated by a high frequency generator connected to the electrode and nozzle.
Ionized orifice gas from the pilot arc is blown through the constricting nozzle orifice.
 This forms a low resistance path to ignite the main arc between the electrode and the workpiece.
 Once the main arc is ignited the pilot arc goes off. A high-frequency electric arc thus established is
passed through a stream of inert gas (usually nitrogen) the latter is ionized.
 Both the ionized gas column and the arc are forced through a small orifice in the torch nozzle.
 The nozzle, having a relatively small orifice, constricts the arc and thus increases current density
and arc temperature.
 This high temperature arc is localized and concentrated upon a small area of the plate where its
intense heat melts the metal to the cut.
 The gas which is heated by the arc cannot expand due to the constriction of the nozzle orifice and it
emerges in the form of a supersonic jet.
 The base metal continuously melted by the intense heat of the arc is removed by the jet-like gas
stream (issuing from the torch nozzle) to form a narrow kerf and smooth surface.
 The combined heat and force of the arc stream produce a high quality, saw-like cut.
45
Following are some of the parameters involved in PAM that you must consider are:
 Current: Up to 500A
 Voltage: 30-250V
 Cutting speed: 0.1-7.5 m/min.
 Plate thickness: Up to 200mm
 Power require: 2 to 200 KW
 Material removal rate: 150 cm3/min
 Velocity of Plasma: 500m/sec
 Material of workpiece: As previously stated, you can use any metal as material of workpiece. For
instance, aluminium and stainless steel are highly recommended for this process.
Applications of plasma arc:
1. Plasma cutting is used to cut particularly those nonferrous and stainless metals that cannot be cut
by the usual rapid oxidation induced by ordinary flame torches.
2. Plasma cutting can be used for stack cutting, plate bevelling, and shape cutting and piercing.
3. With some modifications, plasma arc cutting can be used under water.
4. Plasma arc cutting finds applications in many industries such as shipyard, chemical, nuclear and
pressure vessel.
5. It is used for removing gates and risers in foundry.
6. It cuts hot extrusions to desired length.
7. It is used to cut any desired pipe contour.
8. It is also employed for gouging applications.
9. It finds use in the manufacture of automotive and railroad components.
Advantages:
1. It cuts carbon steel up to 10 times faster than oxy-fuel cutting, with equal quality more
economically.
2. It leaves a narrower kerf.
3. Plasma cutting being primarily a melting process can cut any metal.
4. Arc plasma torches give the highest temperature available from many practicable sources.
Disadvantages:
1. High initial cost of the equipment.
2. This entire machining process consumes a high amount of inert gases.
3. Production of narrower surfaces takes place which is unnecessary.
4. The most harmful part of PAM is that metallurgical changes takes place on the surface.
5. The operator or person handling the whole process must take proper precautions. This process
can affect human eyes so a proper googles or helmet must be worn by an operator.

46

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MANUFACTURING TECHNOLOGY UNIT-III WELDING

Classification of welding processes:

1. Forge or Pressure Welding (Under pressure without additional filler metal)

2. Fusion or non-pressure welding (With additional filler material)

PBR VITS –DEPARTMENT OF MECHANICAL ENGINEERING II-B.TECH,II-SEM

Types of welds and welded joints and their characteristics:

PBR VITS –DEPARTMENT OF MECHANICAL ENGINEERING II-B.TECH,II-SEM

PBR VITS –DEPARTMENT OF MECHANICAL ENGINEERING II-B.TECH,II-SEM

Figure 3-27 — Example of surfacing (hardfacing/wearfacing) welds.

PBR VITS –DEPARTMENT OF MECHANICAL ENGINEERING II-B.TECH,II-SEM

Plug welds and slot welds:

PBR VITS –DEPARTMENT OF MECHANICAL ENGINEERING II-B.TECH,II-SEM

Types of welding joints:

PBR VITS –DEPARTMENT OF MECHANICAL ENGINEERING II-B.TECH,II-SEM

(b) Lap Joint

(d) Corner Joint

(e) Edge Joint

PBR VITS –DEPARTMENT OF MECHANICAL ENGINEERING II-B.TECH,II-SEM

(f) Plug Joint

(b) Horizontal Position:

PBR VITS –DEPARTMENT OF MECHANICAL ENGINEERING II-B.TECH,II-SEM

(d) Overhead Position:

Basic Weld Symbols:

PBR VITS –DEPARTMENT OF MECHANICAL ENGINEERING II-B.TECH,II-SEM

Elements of a Welding Symbol:

Standard Location of Elements of a Welding Symbol:

PBR VITS –DEPARTMENT OF MECHANICAL ENGINEERING II-B.TECH,II-SEM

PBR VITS –DEPARTMENT OF MECHANICAL ENGINEERING II-B.TECH,II-SEM

Design of welded joints:

Design of fillet weld joint:

Design of parallel fillet weld joint:

Design of Transverse fillet weld joint

PBR VITS –DEPARTMENT OF MECHANICAL ENGINEERING II-B.TECH,II-SEM

Design of combined transverse and parallel fillet weld:

Design of butt weld:

PBR VITS –DEPARTMENT OF MECHANICAL ENGINEERING II-B.TECH,II-SEM

Design of axially loaded unsymmetrical welded joints

PBR VITS –DEPARTMENT OF MECHANICAL ENGINEERING II-B.TECH,II-SEM

Gas welding tools and equipments:

PBR VITS –DEPARTMENT OF MECHANICAL ENGINEERING II-B.TECH,II-SEM

PBR VITS –DEPARTMENT OF MECHANICAL ENGINEERING II-B.TECH,II-SEM

Electric Power for Welding:

a) Straight polarity welding:

(b) Reverse polarity welding:

Effect of Arc Length:

(b) Diesel Engine - Generator set

Transformer Rectifier Set:

PBR VITS –DEPARTMENT OF MECHANICAL ENGINEERING II-B.TECH,II-SEM

PBR VITS –DEPARTMENT OF MECHANICAL ENGINEERING II-B.TECH,II-SEM

 The welding plates.

ELECTRIC RESISTANCE WELDING:

 Pressure is applied from the top electrode by moving it downward.

 The fusion of material takes place at the spot.

Advantages of Spot Welding:

PBR VITS –DEPARTMENT OF MECHANICAL ENGINEERING II-B.TECH,II-SEM

Advantages of Seam Welding:

PBR VITS –DEPARTMENT OF MECHANICAL ENGINEERING II-B.TECH,II-SEM