Professional Documents
Culture Documents
Welding Processes - PPT
Welding Processes - PPT
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
WELDING PROCESSES
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
WELDING
• Welding is a materials joining process which produces
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
IMPORTANT TERMS
• Autogenous welding: The process of joining similar metals by
melting the edges together, without the addition of filler metal.
• Homogeneous welding: The process of joining similar metals
with the help of filler metal or rod of same material.
• Heterogeneous welding: The process of joining dissimilar
metals using filler rod.
• Weldability: weldability of a metal is the ease with which two
similar or dissimilar metals are joined by fusion with or without
the application of pressure and with or without the use of filler
material.
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
• Puddle: The portion of the weld joint that is melted by the heat of
welding .
• Root: It is the point at which the two pieces to be joined by welding
are nearest to each other.
• Tack weld: A small weld, generally used to temporarily hold the two
pieces during actual welding.
• Toe of weld: It is the junction between the weld face and the base
metal.
• Weld metal: The metal that is solidified in the joint is called weld
metal. It may be only base metal or a mixture of base metal and filler
metal.
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
• Welded joints are more brittle and therefore their fatigue strength is
less than the members joined.
• Due to uneven heating & cooling of the members during the
welding, the members may distort resulting in additional stresses.
• Skilled labor and electricity are required for welding.
• No provision for expansion and contraction is kept in welded
connection & therefore, there is possibility of cracks.
• The inspection of welding work is more difficult and costlier than the
riveting work.
• Defects like internal air pocket, slag inclusion and incomplete
penetration are difficult to detect.
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
WELDABILITY
• The ease with which welding of a give material can be
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
WELDING POSITIONS
• All welding is done in one of four positions:
➢ Flat
➢ Horizontal
➢ Vertical
➢ Overhead
The most common type of weld you will do is a Fillet weld and a
Groove weld, and you can accomplish these welds in all four
positions. But you also do surface welds in all four positions as
well, thought you will not do this type of weld very often.
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
• 1 = Flat Position
• 2 = Horizontal Position
• 3 = Vertical Position
• 4 = Overhead Position
• In addition there are letters that designate the type of weld you
will do in that position. For example:
• F = Fillet Weld
• G = Groove Weld
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
GAS WELDING
• Oxy-fuel welding (commonly called oxyacetylene welding, oxy
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
metals.
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PRINCIPLE OF OPERATION
• When acetylene is mixed with oxygen in correct
proportions in the welding torch and ignited, the flame is
produced which is sufficiently hot to metal and join the
parent metal.
greater strength.
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
FUEL GASES
• Oxy-fuel processes may use a variety of fuel gases, the
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
carbide, :
• C2H2+O2 → 2CO+H2+Heat
• 4CO+2H2+3O2 → 4CO2+2H2O+Heat
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
GAS WELDING (OXY-ACETYLENE)
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
welding torch
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
FLAME DEFINITION
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
Types Of flame
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
ADVANTAGES AND DISADVANTAGES OF
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
OXY-ACETYLENE WELDING
• Advantages of Oxy-Acetylene Welding
➢It's easy to learn.
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
➢ Refractory metals (W, Mo, Ta etc.) and reactive metals (Ti, Zr ) cannot
be gas welded.
➢ Storage of gas is not safe. More safety is needed.
➢ Gas flame takes a long time to heat up the metal than an arc.
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
OXY-HYDROGEN WELDING
• Oxy-hydrogen is a mixture of Hydrogen (H2) and oxygen
(O2) gases.
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
FLAME CUTTING
• The oxy-fuel process is the most widely applied industrial
• There are several fuel gas and nozzle design options that
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
• Process fundamentals
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
• Purity of oxygen
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
POLARITY
• Polarity is defined as the type of potential given to the
workpiece or electrode.
• In case of DC power source, positive and negative
terminals are fixed whereas in case of AC power source,
positive and negative terminals are not fixed I.e. the
terminal which is positive during one half of cycle
becomes negative in another half.
• So, polarity principle is applicable only in case of DC
power source.
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
ELECTRODES
• The electrodes are used for providing heat input in arc welding.
1. consumable or Non-consumable electrode
2. Bare or coated electrodes
Consumable electrode:
➢ when the arc is obtained with consumable electrodes, the weld metal
and the tip of the electrode also get melted under the arc.
➢ The molten metal from the electrode and the base metal get mixed
under the arc and provides the necessary joint.
➢ The electrode is continuously consumed and serving as the
purpose of filler rod as well as heat input the joint.
➢ It is made of various materials depending on the purpose and
chemical composition of the metals to be welded.
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
• Non-consumable electrode:
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
• Bare electrode:
➢ if the electrode is not coated with flux, it is called the bare electrode.
➢ Bare electrodes are used in carbon arc welding and tungsten arc
welding.
• Coated electrode:
➢ One of the major concerns with the coated electrodes, is the moisture
pick up by the coating. This moisture, dissociate into oxygen and
hydrogen being absorbed by the liquid metal and subsequently
released during solidification, causing porosity.
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
FLUX
➢During welding if the metal is heated/melted in air, oxygen from
the air combines with the metal to form oxides which results in
poor quality, low strength welds and in some cases, may even
make welding impossible.
➢Sometimes the flux will be added separately.
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
• Gas forming: The gas forming components are organic matters such as starch,
wood pulp etc. which form gas layer, thus isolating the welding zone from the
ambient air.
• Slag forming: The slag forming components are chinaclay, felspar, manganese
and titanium ores etc. These components enhance slag formation. The slag
covering the molten metal prevents it from coming into contact with the ambient
air.
• Reducing: The reducing components are such as ferro-silicon, ferro-titanium,
ferro-manganese reduces the oxides.
• Alloys: The alloying components such as ferro-silicon, ferro-manganese, ferro-
chromium, chromium-oxide are used for rendering this metal heat proof.
• Binding: The binding components will be added so that covering should have
proper binding with bare electrode.
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
• Shielding gases:
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
• Polarities:
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
• High level of visibility when working due to low levels of smoke. Visibility is
excellent because no smoke or fumes are produced during welding, and there is
no slag or spatter that must be cleaned between passes or on a completed weld.
• TIG welding also has reduced distortion in the weld joint because of the
• As in oxyacetylene welding, the heat source and the addition of filler metal can be
separately controlled.
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
DISADVANTAGES OF TIG WELDING
ac ac
k e r- s o ft w a k e r- s o ft w a
• Takes practice
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
welding process.
welding process.
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
• Welding current
• Welding voltage
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
WELDING CURRENT
• The welding current is the electrical amperage in the
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
WELDING VOLTAGE
• voltage setting directly controls the arc length.
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
must be lowered.
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
• Easy to learn
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
metals
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
APPLICATIONS
• Structural steel
• Aluminum sections
• Stainless steel and nickel alloys
• Ferrous and non-ferrous metals.
• Welding tool steels and dies.
• Metal fabrication industries, ship building, automobiles,
pressure vessel industries etc.
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
• The molten flux reacts with the impurities in the molten weld metal to
form slag which floats over the surface of the weld metal.
• Layer of slag over the molten weld metal results:
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
• Welding head
• Flux Hooper
• Flux recovery unit
• Welding power sources (AC transformer or DC generator)
• Flux
• Electrodes
• Controls
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
under 12 mm in thickness.
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
➢ Since the operator cannot see the welding being carried out, he cannot judge the progress of
welding accurately. Therefore accessories like jigs and fixtures, pointers, light beam focusing
devices or roller guides may be used for proper welding at the joint.
➢ The flux needs replacing of the same on the joint which is not always possible.
➢ The progress is limited to welding in flat position and on the metal more than 4.8 mm thick. In
➢ The process requires edge preparation and accurate fit up on the joint. Otherwise the flux
may spill through the gap and arc may burn the workpiece edges.
➢ Weld metal chemistry is difficult to control. A change in welding variables especially when
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
APPLICATIONS
• Welding of bridge girders, railroads, structural shapes,
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
RESISTANCE WELDING
• Resistance welding is a joining process in which heat is
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
• The current passing through the two overlapping work pieces causes
work pieces by the formation of weld without the use of filler material
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
MATERIALS TO BE WELDED
• The following metals may be welded by Resistance
Welding:
Welding
• Aluminum alloys
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
SPOT WELDING
• Resistance spot welding (RSW) is a process in which contacting metal surfaces
• Typically the sheets are in the 0.5 to 3 mm (0.020 to 0.118 in) thickness range.
• The process uses two shaped copper alloy electrodes to concentrate welding
current into a small "spot" and to simultaneously clamp the sheets together.
• Forcing a large current through the spot will melt the metal and form the weld.
• The attractive feature of spot welding is that a lot of energy can be delivered to
the spot in a very short time (approximately 10–100 milliseconds).That permits the
welding to occur without excessive heating of the remainder of the sheet.
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
PROJECTION WELDING
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
• Projection welding is often used to weld studs, nuts, and other screw
machine parts to metal plate.
• It is also frequently used to join crossed wires and bars.
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
• There are limitations to some material weldability but proper settings and
process control can solve most of these problems. The main issues that
might be associated with projection welding technique are
➢ Costlier Equipments
➢ Projections cannot be made in thin work pieces as they cannot
withstand the electrode pressure
➢ Additional work is required to form projections apart from welding
➢ Chances of harmful fume emission while welding coated steels or
when oil or organic materials are present
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
• Unlike spot welding the disc shaped electrodes are not separated
after each weld, but maintain continues pressure over the work
pieces.
• The electrode current is timed to flow in pulses so that a row of welds
is produced along the interface.
• Copper alloy electrodes are used to keep the heat at the electrode
contact surface to a minimum.
• The motion of the electrodes and current impulses are so arranged
that the weld nuggets overlap forming a gas or liquid pressure tight
weld.
• After the welding is over the electrodes and work pieces are flooded
with water to dissipate the heat.
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
• Relatively higher current is thus required for seam welding than for
spot welding.
• The work pieces to be welded are over lapped sufficiently to prevent
metal flowing out from the edges of the pieces during welding under
pressure.
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
seam weld).
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
and control.
rods etc.
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
FLASH WELDING
• Flash welding (FW) is a resistance welding process that
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
hange E hange E
XC di XC di
F- t F- t
PD
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
parts
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a
PD
or
or
!
!
W
W
O
O
N
N
Y
Y
U
U
B
B
to
to
ww
ww
om
om
k
k
lic
lic
C
C
.c
.c
w
w
tr re tr re
.
.
ac ac
k e r- s o ft w a k e r- s o ft w a