Metal joining Processes

and Manufacturing Practices

18ME331
DR. K. CHOCKALINGAM M.E., M.B.A., Ph. D., FIE.
Professor and Head
Department of Mechanical Engineering
Thiagarajar College of Engineering
Madurai- 625 020
kcmech@tce.edu
 Syllabus
• Metal joining Process - Introduction:
• Solidification of the weld metal, base metal, heat
affected zone, weld metal, shielding gases, filler
metal, fluxes.
• Fusion welding: Oxy-fuel gas Welding, Arc welding,
SMAW, Flux core arc welding, SAW ,MIG welding, TIG
welding, Co2 Welding, Thermit welding, Plasma arc
welding, Electron Beam welding, Laser Beam
welding.
• Solid State welding: Resistance Welding-spot, seam,
projection welding , friction welding, friction stir
welding, diffusion bonding, ultra sonic welding,
explosion welding.
 Syllabus
•Defects in welding: Crack, Distortion (Distortion and residual stresses,
Concept of distortion, Types of distortion, Control of welding distortion),
Incomplete Penetration, Inclusions, Porosity and blowholes, Poor fusion,
Poor weld bead appearance, Spatter, Under-cutting and over lapping,
causes and remedies of defects.
•Testing and Inspection of welding : Weldability, Hot Cracking Tests, Root
Tracking Tests, Inspection and Testing of welds, Stages of weld inspection
and testing, Destructive testing of welds, Non- destructive testing of welds
and visual Inspection.
•Brazing and soldering: Principle of Operation, advantages, Limitations
and application
 Learning Resources
• Serope Kalpakjian and Steven R.Schmid, “Manufacturing
Engineering and Technology”, Sixth Edition, PHI, 2010.
• Mikell P.Groover “Fundamental of Modern Manufacturing”,
Wiley India Edition, Third Edition, Reprint, 2012.
• Philip F. Oswald, and Jairo Munoz, “Manufacturing Process
and Systems”, John Wiley India Edition, 9th Edition, Reprint
2008.
• E. Paul DeGarmo, J.T. Black and Ronald A. Kohser, “Degarmo’s
Materials and Processes in Manufacturing “, John Wiley &
Sons, 11th Edition 2011.
• Richard.L,LittIe, “Welding and Welding Technology” -
McGraw Hill Education (India) Private Limited , New Delhi,
42nd Reprint 2013.
 Learning Resources
• AWS Welding Handbook, Volume 1, Welding Science & Technology,
American Welding Society, 2001.
• AWS Welding Handbook, Volume 2, Welding Processes, Part 1, American
Welding Society, 2004.
• AWS Welding Handbook, Volume 3, Welding Processes, Part 2, American
Welding Society, 2004.
• https://npteI.ac.in/courses/113106067/Week1/Overview.pdf- Dr. G.
Phanikumar Professor, Dept. of MME, IIT Madras.
• https://npteI.ac.in/courses/112107090/- COURSE CO-ORDINATED BY : IIT
ROORKEE
• http://textofvideo.npteI.ac.in/112107089/Iec3.pdf- Prof. Dr. D. K. Dwivedi
Department of Mechanical and Industrial Engineering Indian
Institute of Technology, Roorkee
• https://ocw.mit.edu/courses/materials-science-and-engineering/3-37-
welding-and-joining- processes-fall-2002/lecture-notes/ - COURSE CO-
ORDINATED BY MIT
WELDING
• Welding is the permanent joining of two materials, usually metals, by
coalescence, which is induced by a combination of temperature, pressure,
and metallurgical conditions.
• The particular combination of these variables can range from high
temperature with no pressure to high pressure with no increase in
temperature.
• Because welding can be accomplished under a wide variety of conditions, a
number of different processes have been developed.
• Welding is the dominant method of joining in manufacturing, and a large
fraction of metal products would have to be drastically modified if welding
were not available.
Types of welding
Fusion welding
• Fusion welding is defined as melting together
and joining materials by means of heat.

• Filler metals, which are metals added to the

weld area during welding, also may be used.

• Fusion welds made without the use of filler

metals are known as autogenous welds.
Five basic joints in fusion welding
Various weld procedure to produce
welded joints
 Oxy fuel–gas Welding
• Oxy fuel–gas welding (OFW) is a general term
used to describe any welding process that uses a
fuel gas combined with oxygen to produce a
flame.
• The flame is the source of the heat that is used
to melt the metals at the joint. The most
common gas welding process uses acetylene;
the process is known as oxyacetylene–gas
welding
• (OAW) and is typically used for structural metal
fabrication and repair work.
Oxy fuel–gas Welding
• Developed in the early 1900s, OAW utilizes
the heat generated by the combustion of
acetylene gas in a mixture with oxygen.
• The heat is generated in accordance with a pair
of chemical reactions.
• The primary combustion process, which occurs
in the inner core of the flame, involves the
following reaction:
• C2H2 + O2 2CO + H2 + Heat.
Oxy fuel–gas Welding
• This reaction dissociates the acetylene into
carbon monoxide and hydrogen and produces
about one-third of the total heat generated in
the flame
• The secondary combustion process is
• 2CO + H2 + 1.5O2 2CO2 + H2O + Heat
• This reaction consists of the further burning of
both the hydrogen and the carbon monoxide
and produces about two-thirds of the total heat
Oxy fuel–gas Welding
• The temperatures developed in the flame can
reach 3300°C
• Oxy fuel–gas welding can be used with most
ferrous and nonferrous metals for almost any
work piece thickness,
• but the relatively low heat input limits the
process to thicknesses of less than 6 mm
Typical Oxy acetylene flame and
associated temperature distribution
Types of oxy acetylene flames

At a ratio of 1:1 (i.e., when there is no excess oxygen), the

flame is considered to be neutral (Fig. 30.1a). With a greater
oxygen supply, the flame can be harmful (especially for steels),
because it oxidizes the metal.
Types of oxy acetylene flames

flame with excess oxygen is known as an oxidizing flame (Fig.

30.1b). Only in the welding of copper and copper-based alloys is an
oxidizing flame desirable, because in those cases, a thin protective
layer of slag (compounds of oxides) forms over the molten metal.
 Types of oxy acetylene flames

If the oxygen is insufficient for full combustion, the flame is known as

a reducing, or carburizing, flame (a flame having excess acetylene);
The temperature of a reducing flame is lower; hence, such a flame is
suitable for applications requiring low heat, such as brazing, soldering,
and flame-hardening operations.
Other fuels in Oxy fuel gas welding
• Other fuel gases (such as hydrogen and methyl acetylene
propadiene) also can be used in oxy fuel–gas welding.
• However, the temperatures developed by these gases are lower
than those produced by acetylene.
• Hence, they are used for welding
(a) metals with low melting points (such as lead) and
(b) parts that are thin and small.
• The flame with pure hydrogen gas is colorless; therefore, it is
difficult to adjust the flame by eyesight.
Principle of Oxy fuel gas welding
Filler metals
• Filler metals are used to supply additional metal
to the weld zone during welding.

• They are available as filler rods or wire and may

be bare or coated with flux.

• The purpose of the flux is to retard oxidation of

the surfaces of the parts being welded by
generating a gaseous shield around the weld zone.
Filler metals
• The flux also helps to dissolve and remove oxides
and other substances from the weld zone, thus
contributing to the formation of a stronger joint.

• The slag developed (compounds of oxides, fluxes,

and electrode-coating materials) protects the
molten puddle of metal against oxidation as it
cools.
Welding torch
Welding torch
Basic equipment used in
oxy fuel–gas welding
General points to be noted
• The acetylene valve is opened first. The gas is lit with a spark
lighter or a pilot light. Then the oxygen valve is opened and the
flame adjusted
• To ensure correct connections, all threads on acetylene fittings are
left handed, whereas those for oxygen are right handed.
• Oxygen regulators usually are painted green and acetylene
regulators red.
• The acetylene is usually obtained in portable storage tanks that
hold up to 8.5 m3 (300 ft3) at 1.7 MPa (250 psi) pressure
General points to be noted

• Welding rods come in standard sizes, with

diameters from 1.5 to 9.5 mm (1/16 to 3/8 in.)
• Lengths from 0.6 to 0.9 m (24 to 36 in.).
• They are available in standard grades that
provide specified minimum tensile strengths
or in compositions that match the base metal.
Process summery of Oxy fuel gas
welding
Heat source : Fuel gas—oxygen combustion
Protection : Gases produced by combustion
Electrode :None
Material joined : Best for steel and other ferrous metals
Rate of heat input : Low
Weld profile : (Depth/Width) 1/3
Max. penetration : 3 mm
Assets :Cheap, simple equipment, portable, versatile
Limitations :Large HAZ, slow