EXPERIMENT-I

and
weld joint designs
EXPERIMENT: To study about welding processes,

AIM OF TiuE

welding symbols.

OBJECTIVES:
variousjoining methods.
To study and classify
joinis and temporary Joints.
To compare permanent
and cdge preparation
To study various weld joint designs, wclding positions

techniques.
used terms and symbols related to welding
T o familiarize with
various commonly

processes.
Important safcty tips.

or more elements are put or bring

THEORY: Joining is a fabrication procesS where two
and
It is normaly called as secondary manufacturing process
together to make a single part.
can be classified as:

Mechanical Joining (Mechanical Forces)

Adhesive Bonding (Chemical Forces)
Welding (Physical Forces)

process which produces coalescence of

Welding Processes: Wclding is a material joining
materials by heating them to suitable temperatures with or without the application of pressure

or by the application of pressure alone and with or without the use of filler material. In general,

various welding processes can be grouped as:

Fusion Welding Processes

Pressure or Solid-State Welding Processes

Under Fusion Welding Processes heat is primarily used for melting of the faying surfàces to

produce the joint. Some examples of fusion welding processes are: gas wclding, arc welding,
plasma arc welding. clectro slag & electro gas welding, laser beam welding and clectron beanm

welding.

In
Pressure or Solid-State Welding Processes pressure is primarily applied (with little or no

application of heat for softening of metal up to plastic state) to produce the joint. Some
 CXamples of pressure welding processes arc: resistance wclding, ultrasonic wciding, diffusion

welding, explosive welding, and fricticon welding.

Weld Joint Design: Some common welding joints arc shown in Figure-1 and they are as

follows:

Butt Joint Tec Joint

- Lap Joint » Edge Joint

Corner Joint

Butt Joint
Lap Joint

Corner Joint Edge Joint Tee Joint

Figure 1: Five basic types of weld joint designs.

Welding Positions: As shown in Figure-2, there are four types of welding positions, which
are given as:

Flat or down hand position - Vertical position

Horizontal position
Overhead position

a) flat (6) horizontal (c) vertical (d) overhead

Figure 2: Four basic welding positions
Flat or Down-hand Welding Position: The flat
position or down hand position is one in which
the welding is
performed from the upper side of the
joint and the face of the weld is
approximately horizontal.
 llorizontal WeldinR P'osition: ln houzontal posiluon, the plane ol the workpicce Vcrtical

and the deppsiled weld head is horisontal This posilion of weldng is nod coninonily usced i

wedng vesels and reservoirs

Vertical Welding l'osition: In verlical position, the plane of the work-picce is vcrtical and the

weld is deposited upon a vertical sur face. I is diflicull to produce satislactory welds in this

position due to the effect of the force of gravity on the molten melal.
Overhead Welding Position: The overhead povition is probably even more diflicult to weld

than the vertical position. Here the pull of gravity against the molten metal is much greater.

Edge Preparations: Fdge preparation is very important for wclding thicker sheets/plates,
the
heavy pipes and solid material. Sive and shape of edge preparation or groove depends on
material type and joint design. Various cdge preparation techniques uscd for but-wclding are

shown in Figure-3.

Singe Square Groove Snge Sevel Gioove Double Bevel Groove

nge-v Groove o v o V Groove

Snoe Groov

DoubleGrove SingeU Groove Double-U Groove

Figure 3: Various cdge preparation techniques for butt-welding.

Important Terminologies: Some of the commonly used terms related to welding processes
are given below:
Base Metal: The material which the welder is
expected to join.
Filler Metal: The material which the welder applies to the base metal.
Groove Weld: A weld made by depositing filler melt in a groove between two metals to be

joined [Figure 4(a)].

Fillet weld: The metal fused into the corner of a joint made of two pieces placed at
approximately 90degrees to each other is termed as fillet weld [Figure-4(a)].
Penetration: The maximum depth at which molten metal penetrates on base metal and then
combines them. It is measured from the top surface of the
joint.
Root: The bottom side of weld where filler
metal and base metal touches.
Tack Weld: A small
temporary welding
to hold
workpicce together during the actual welding.
Toe of Weld: The
top side of weld where filler metal and base metal touches.
Weld Face: The face of the weld
looking from top side of the weld.
usiO 701e: lhe area eof base metal and filler mclted as determincd on the cross section of a

Wel.

lleat Altected 7one: That pOrtion ol the base mctal whose struclurc or properiCs navc Cen

changed by the heat of welding.

AICIKAI

or MON
PLL.1DL THK
or LD 18to
riiaza PDETRATICNI

POOT ATRO

Weld
Fillet Weld

Figure-4: (a) Groove weld and (b) Fillet weld.

Safety Tips: Observe the following safety to avoid injury to yourself and co-workers:
Be well dressed i.e., avoid loose
garments, wear cotton clothes, roll up sleeves, put on
suitable footwear and remove
watch and ring.
Keep the work place neat and clean i.e., place the tools at
proper position. The scraps and
chips should be dropped in waste bins
Concentrate on
your job and avoid
talking with co-workers.
The shops are no place to play. Running and pushing in the shop may cause accidents.
Understand the use of tools and machines before
handling.
Never use dull tools. The use may damage the tools
completely or
may lead to injury.
In case in
you are doubt, contact the instructor.
Always check the fitting of the handle in the hammerhcad.
Be familiar with the locations
of First Aid Box and Fire Extinguisher in the shop. In case
of
emergency, one should reach them quickly.
Laziness and carelessness are your deadly cnemies. Always be active and careful in the
shop