19MEE202

MANUFACTURING PROCESS - I
AMRITA SCHOOL OF ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
COIMBATORE CAMPUS
Dr.A.Shanmugasundaram (Section-A)
 Welding - Definition

Welding is a joining process that produces

coalescence (form into a mass or whole) of
materials by heating them to welding
temperature, with or without the application of
pressure or by the application of pressure
alone, and with or without the use of filler
materials.
 INTRODUCTION
Welding is a process for joining same or different
materials.
The large bulk of materials that are welded are
metals & their alloys and also applied to the joining
of other materials such as thermoplastics.
Welding joins different metals / alloys with the help
of a number of processes in which heat is applied
either electrically or by means of a gas torch.
In order to join two or more pieces of metal
together by one of the welding processes, the most
essential requirement is Heat, Pressure and Filler
Materials may also be employed depending upon
the processes
 Early Developments in Welding

• Edmund Davy discovered acetylene at beginning

of nineteenth century
• Sir Humphrey Davy discovered the electric arc
in 1801
– Concerned with use of arc for illumination
– Demonstrated possible to maintain high voltage arc
for varying periods of time by 1809
• Workable electrical generating devices invented
and developed on practical basis by 1850
 History of Fusion Welding
• First documented instance done by
Auguste de Meritens in 1881
– Welded lead battery plates together with
carbon electrode
• Two of Auguste's pupils, N. Benardos and
S. Olszewski continued work and issued
patent for welding process using carbon
electrodes and electric power source four
years later
– Primary goal was repair welding
 Bare Metal Electrode Welding
• Introduced in 1888 by N. G. Slavianoff (Russian)
– Discovery first recognized in western Europe in 1892
• C. L. Coffin was pioneer of welding industry in United
States
– 1889 received patent on equipment and process for
flash-butt welding
– 1890 received additional patents for spot welding
– 1892 received patent for bare metal electrode arc
welding process
• Without knowledge of Slavianoff's work
 History of Welding
• Foresche and Picard developed first
commercial oxyacetylene welding torch at
turn of the century
• Electric arc welding method used in US
until about 1920
– Handicapped because of welds produced by
these electrodes not as strong as metal being
welded
• Welding arc very unstable
 History of Welding
• In 1907 Kjellberg (Swedish engineer) received
patent covering electrode-coating process
– Coating thin and acted only as stabilizer of arc
– Produced welds little better than bare electrodes
• In 1912 Kjellberg received another patent for
electrode with heavier coating made of asbestos
with binder of sodium silicate
• In 1908, Benardos patented electroslag process
of welding thick plates in one pass
 History of Welding
• Technology of welding progressed slowly
until World War I
– Demands of war called for improved methods
of fabrication
– End of war, welding widely accepted
• Research on coated electrodes through
1920s resulted in electrode coatings and
improved core wire
 Broad Classification of welding

Gas welding (4)

Arc welding (8)
Resistance welding (6)
Solid state welding (6)
Thermo-Chemical welding (2)
Radiant Energy welding (2)
 Sub Classification of welding

Gas welding
 Air-Acetylene welding
 Oxy-Acetylene welding
 Oxy-Hydrogen welding
 Pressure gas welding
 Sub Classification of welding

Arc welding
 Carbon arc welding
 Shield metal arc welding (SMAW)
 Flux cored arc welding (FAW)
 Submerged arc welding (SAW)
 Metal Inert Gas welding (MIG or GMAW)
 Tungsten Inert Gas welding (TIG or GTAW)
 Electroslag welding (ESW)
 Plasma arc welding (PAW)
 Sub Classification of welding

Resistance welding Solid state welding

• Spot welding (RSW) • Cold welding (CW)
• Seam welding (RSEW) • Diffusion welding (DFW)
• Projection welding • Explosive welding (EXW)
• Resistance butt • Forge welding (FOW)
welding • Friction welding (FRW)
• Flash butt welding • Ultrasonic welding (USW)
(FW)
• Percussion welding
 Sub Classification of welding

Thermo-Chemical welding process

• Thermit welding
• Atomic hydrogen welding
Radiant Energy welding process
• Electron beam welding
• Laser beam welding
CLASSIFICATION OF WELDING
PRACTICAL APPLICATIONS OF WELDING

Welding has been employed in Industry

as a tool for:
(a) Regular fabrication
(b) Repair and maintenance work
 Regular fabrication applications

Aircraft construction
(a) Welded engine mounts.
(b) Turbine frame for jet engine.
(c) Rocket motor fuel and oxidizer tanks.
(d) Ducts, fittings, cowling components, etc.
Space craft
• Fuel tanks
• Space structures
• Supporting structures
Automobile construction
(a) Arc welded car wheels.
(b) Steel rear axle housing.
(c) Frame side rails.
(d) Automobile frames, brackets, etc.
Bridges
(a) Section lengths.
(b) Shop and field assembly of lengths,etc.
Buildings
(a) Column base plates.
(b) Trusses.
(c) Erection of structure, etc
Pressure vessels and tanks
Clad and lined steel plates.
Shell construction.
Joining of nozzle to the shell, etc.
Storage Tanks
Oil, gas and water storage tanks.
Rail Road Equipment
Under frame.
Air receiver.
Engine.
Front and rear hoods, etc.
• Piping and Pipelines
Rolled plate piping.
Open pipe joints.
Oil, gas and gasoline pipe lines, etc.
• Ships
Shell frames.
Deck beams and bulkhead stiffeners.
Girders to shells.
Bulkhead webs to plating, etc.
• Trucks and trailers.
• Machine tool frames, cutting tools and dies.
• Household and office furniture.
• Earth moving machinery and cranes.
 Repair and Maintenance work:

• Repair of broken and damaged

components and machinery such as tools,
punches, dies, gears.
• shear press and machine tools frames.
• Hard facing and rebuilding have worn out
or undersized (costly) parts rejected
during inspection.
• Fabrication of jigs, fixtures, clamps and
other work holding devices.
 Five Types of Welds
• Surface

• Groove

• Fillet

• Plug

• Slot
 Surface Welds
Surface welds are welds were material has
been applied too and/or blended with the
surface of the work piece.
Two common applications are for hard
surfacing and padding.

Surface weld nomenclature

A: Electrode wire
B: Electrode flux
C: Arc
D: Weld puddle
E: Bead
F: Slag
G: Gas shield
 Groove Welds
Groove welds are used to fuse the sides or
ends of two pieces of metal.
The primary use of groove welds is to complete
butt joints.

Groove weld nomenclature

A: Toe
B: Width
C: Face reinforcement
D: Toe
E: Joint preparation
F: Joint gap
G: Root reinforcement
H: Joint face
I: Base metal
• Fillet welds have a
triangular cross section
Fillet Welds
and are used to fuse
two faces of metal that
are at a 90 degree
angle to each other. T Lap Corner

• Three common types Fillet weld nomenclature

are:

A: Reinforcement
B: Toe
C: Face
D: Throat
E: Toe
F: Leg
G: Root
H: Base metal
I: Leg
 Plug Welds
Plug welds are used
to attach two
surfaces together
when a complete
joint is not required
The holes can be made
and the design does with a drill bit.
not allow for any
The weld is completed by
weld bead outside establishing the arc on the bottom
the dimensions of plate and then continuing to weld
until the hole is full.
the metal.
 Slot Welds
Slot welds are identical to plug welds except
for the shape of the holes.
For slot welds, slots are machined or stamped
in the upper plate.

They are
completed the
same as plug
welds.
 Five Types of Joints

Corner
Butt

Lap

T
Edge
 Types of Weld Joints
There are five types of weld joints

– Butt Joint parts lie in the same plane

and are joined along their edges

– Corner Joint parts are joined at the

corner

– Lap Joint two overlapping parts are

joined

– Tee Joint in this joint, the parts form

the English letter T

– Edge Joint parts are parallel and at

least one of their edges are parallel
Types of joints
 Butt Joints
• Used to attach two metal faces together.
• Joint can be completed with the faces
square or beveled.

Edge Joints
• Used to weld two
surfaces at 180
degrees.
 Butt Joint--Multipass
Three examples for 1/8 inch
SMAW electrode:
1/4 inch and less; single pass,
single side.

1/4 inch to 3/8’s inch; single pass, two

sides or joint prep and one side.

3/8’s inch to 3/4 inch; joint prep

and multiple pass.
 Corner Joints
• Three common types:
Joint Weld

– Closed Groove weld

– Partially open Fillet weld

– Fully open Fillet weld

Lap Joints
• Lap joints are use to
attach metal that
overlaps.
• A lap of three times
metal thickness
provides maximum
strength.
• Welding both sides
increases strength in
both directions.
 Welding Joints

Examples of joints that can be made through the various joining processes
Welding Joints - Types
 Welding Joints - Selection

Categorize the joint by the four factors as below:

 Fast fill (high deposition rate)
 Fast freeze (out-of-position joint : overhead /
vertical)
 Fast follow (high arc speed & small welds)
 Penetration (weld depth)
 - A joint can also be characterized by the
combination of different categories.
 - Choose the process based on the joint
requirement.
Nomenclature of Welds
Nomenclature of Welds
 Welding Positions

Vertical Overhead

As well as flat
and horizontal
Welding Positions
Five Welding Positions

Flat Horizontal

Vertical down
Vertical up

Overhead
Welding Positions
Welding Positions - GROOVE WELDS IN PLATE
Welding Positions - FILLET WELDS IN PLATE
Welding Positions - FILLET WELDS IN PLATE
Welding Positions – GROOVE WELDS IN PIPE
Welding Positions – FILLET WELDS IN PIPE
Welding Positions – FILLET WELDS IN PIPE
 Welding symbol

Primary Reference -
• ISO 2553:1992
Secondary References -
• AWS A2.4:1998
Welding symbol
Generalized Welding Symbol

FAR SIDE Field weld

DETAILS Weld Geometry symbol

Electrode D L1- Weld all-

L2 around for
Material D L1- pipes, etc.
L2
ARROW SIDE D = Weld Depth (usually equal to plate
thickness)
DETAILS
L1 = Weld Length
L2 = Distance between centers for
The Field Weld Symbol is astitched welds
guide for installation. Shipyards
normally do not use it, except in modular construction.
Examples: Fillet Welds on T-Joints

Copyright © The McGraw-Hill Companies, Inc. Permission required for

 Weld-All-Around Symbol
• Used when weld is to extend all way around joint or series
of connected joints
• Symbol: circle viewable at junction of reference line and
arrow

Copyright © The McGraw-Hill Companies, Inc. Permission required for

V-groove Weld on Butt Joint

Copyright © The McGraw-Hill Companies, Inc. Permission required for

Contour Symbol and Letters Which
Indicate Finishing Method

Copyright © The McGraw-Hill Companies, Inc. Permission required for

Weld Symbols (Butt Joints)

Backing
 Weld Symbol
(Corner Joints)

Weld Symbol
(Fillet Joints)

58
 Welding symbol
Elementary Weld Symbols

• Most common are fillet, square groove

and flare bevel weld joints
 Welding symbol
Supplementary Weld Symbols

• Contour symbols
 Electrical Terms
• Electricity- the flow of electrons through a
conductor
• Electron – the negatively charged part of an
atom
• Polarity – the direction of the flow of electrons
Basic Electricity and the Science of Welding
Voltage – The electrical potential or pressure that
causes current to flow
Actual voltage for a welding current is 18 to 36 volts
 Measured in Volts
Current – The movement of charged particles in a
specific direction. When an electrical current moves
through a wire heat is generated by the resistance. The
greater the flow the greater the resistance.
• Arc-electricity jumping from an air gap between
electrode and the base metal.
• Arc temp- 6000ºF to 10,000ºF
 Measured in Amps
 Alternating
Current
(AC)
The current
reverses its
direction of flow
120 times per
second, it
requires 1/60 of
a second to
complete a cycle
or hertz.
The frequency
is indicated as
25, 40, 50, and
60 cycles per
second.
Direct Current (DC)
Direct Current Straight Direct Current Reverse
Polarity – DCSP “or” Polarity - DCRP
“or”
Direct Current Electrode
Negative –DCEN Direct Current Electrode
Positive - DCEP
 Basic Electricity and the Science of Welding
Polarity
 DC- (Direct Current
Electrode Negative)
 DC+ (Direct Current
Electrode Positive) AC (Alternating Current)

DC - AC DC+

Straight
Polarity Reverse
Polarity
 Basic Electricity and the Science of Welding
• Polarity is important because it has a direct
relationship with the amount of heat
generated within the base metal.
• Polarity does not affect AC welding situations
• DCRP will generate more heat within the base metal
• Reverse Polarity is also used for making some welds in the
vertical & horizontal positions.
• One way to know if you have the right polarity setting is the
sharp crackling sound of the arc.
• An incorrect polarity setting will cause the arc to give off a
hissing sound & will make it difficult to control the welding
bead.
• DCSP will concentrate more heat through the electrode
and a smaller area within the base metal.
 Types of Welding Machines - Transformer
• Produces AC current
– Least expensive to purchase
– Lightest & smallest
– Current may be changed by plugging leads into
sockets or by rotating a hand wheel
– No moving parts
 Types of Welding Machines - Rectifier
• Rectifier or commonly called “Inverter”
– Basically a transformer containing an electrical device which changes AC into
DC currents
– They produce both AC or DC currents with the ability to produce straight or
reverse polarity. Steep slopping
volt-amp curve
– Very efficient
– Basically quiet operation
– HI & LOW range setting
– Not very mobile 36
volts
– Few moving parts

Beginning Weld Ending Weld

Constant Potential (MIG)
– Maintains approximately the same voltage regardless of the amount of current
drawn. Unlike a constant current machine (stick welding) where there is a
steep slope or drop-off of amps
– If the wire (or electrode) is fed at a faster rate the current increases, if it is
slowed down it decreases.
– Easier to train an operator
– Achieve good welds
– Not very mobile
– Less splatter
– Continuous welds
– Shielding Gas
– Moving Parts
36
volts

Beginning Ending Weld

Weld
Types of Welding Machines - Motor-Generator
– Welder powered by a gasoline motor
– Provides DCSP or DCRP & AC
– Expensive
– Many moving parts
– Loud
– Very mobile
– Alternative power source
 Duty cycle

 Duty cycle is the percentage

of a 10 minute period that a
welder can operate at a given
current setting
 60 per-cent duty cycle can be
operated safely for six
minutes of a ten minute cycle
repeated indefinitely.