Description W B S

1. Joint strength Strongest Medium Weakest

2. Melting of base Melt & Fuse Lesser metallurgical effect No MOBM
material
3. Composition of filler Similar to base metal Not similar (Cu based alloy) Not similar (Sn & Pb based
alloy)
4.Use of filler metal Not always needed Required Required
5.Flow of filler metal Pool of molten metal Capillary action Capillary action
6.Heat affected zone High Less Negligible
7.Surface finish Requires finishing Good Not required
8.Operating Temperature 4000^C to 6000^C 500^C to 1000^C 300^C to 600^C
9.Pieces to be joined Same material Maybe dissimilar Maybe dissimilar
10.
Thickness of base Thick metals can be joined Moderately thick Sheet metals
material
COMPARISON B/W WELDING, BRAZING AND SOLDERING

WELDING
Welding is a metallurgical process of joining two similar or dissimilar metallic components with the application of heat,
with or without the application of pressure and with or without the use of filler metal.

Welding process is broadly classified into two types

i. plastic welding.

ii. Fusion welding

1. Plastic welding (Pressure Welding) :

Plastic welding also called as pressure welding. In plastic welding, the metal parts to be joined are heated to the plastic
state, or slightly above, and the fused together by applying external pressure. In this process filler materials are not
used.

Eg: Forge welding, Friction welding, Resistance welding, etc.

2. Fusion welding: In fusion welding, the parts to be joined are heated above their melting temperatures and then
allowed to solidify by cooling. A filler metal may or may not be used during the welding process.

Eg: Arc Welding, Gas Welding, Laser Welding, etc.

ARC WELDING

 The arc welding operates under the principle that when two conductor of an electric circuit are touched together
momentarily and then instantaneously separated slightly, assuming that there is sufficient voltage ( 80 to 100 V) in
the circuit to maintain the flow of current ( 100 to 400 A), an electric arc is formed.

❖ Concentrated heat is produced throughout the length of the arc at a temperature of about 5000 to 6000°C.

❖ In arc welding, usually the work piece/parts to be welded are wired as one pole of the circuit, and the electrode held
by the operator forms the other pole.

❖ When the arc is produced, the intense heat quickly melts the work piece metal which is directly under the arc,
forming a small molten metal of the electrode is carried over by the arc to the molten metal.
❖ The molten metal in the pool is agitated by the action of the arc, thoroughly mixing the base and the filler metal. A
solid joint will be formed when the molten metal cools and solidifies.

❖ The flux coating over the electrode produces an inert gaseous shield surrounding the arc and protects the molten
metal from oxidizing by coming in contact with atmosphere. Flux materials like calcium fluoride, cellulose, iron oxide
etc..

Advantages Of Arc Welding

1. Strength of the arc welded joints are high.

2. Almost all metals can be arc welded.

3. No need of highly specialized equipment.

4. Cost per unit of welding is comparatively less.

5. It can be widely applied for domestic, industrial and specialized use.

Applications of Arc Welding

▪ Building and bridge construction,

▪ Ship building

▪ Boiler and pressure vessel fabrication

▪ Joining of large pipes and penstock

▪ In almost all repair and maintenance work.

GAS WELDING

Gas welding is a fusion type welding operations that burn various fuels mixed with oxygen.

▪ Oxy Fuel Welding employs several types of gases, which is the primary distinction among the members of this group,
Gas mixtures that can be used are:

1. Oxygen – Acetylene mixture and

2. Oxygen – Hydrogen mixture

As in Arc Welding, Filler metal is sometimes added & the Composition must be similar to that of the base metal. Filler
rod often coated with flux to clean surfaces and prevent oxidation.

Two large cylinders: one containing oxygen at high pressure, and the other containing acetylene gas.

Two pressure regulators: fitted on the respective cylinders to regulate or control the pressure of the gas flowing from
the cylinders to the welding torch as per the requirements.

❖ Welding torch, used to mix both oxygen and acetylene gas in proper proportion and burn the mixture at its tip.

❖ By adjusting the pressure regulators, suitable proportions of oxygen and acetylene gases enter into the welding torch.

❖ The gases get mixed in the torch and are issued from the torch to burn in atmosphere.

❖ The resulting flame at the torch tip has a temperature ranging from 3100°C to 3500 °C and this heat is sufficient
enough to melt the work piece metals.

❖ A filler metal may be used to supply the additional material to fill the gap.
❖ The molten metal of the filler metal combines with molten metal of the work piece, and upon solidification from a
single piece of metal.

Advantages Of Oxy-acetylene Welding

• Most versatile process with wide range of applications.

• Low cost of equipment and low maintenance cost.

• Heat source and the filler are separated; hence the filler material deposition rate can be controlled.

• Equipment are portable and multi-functional.

Disadvantages Of Oxy-acetylene Welding

• Costlier while welding heavier sections.

• Handling and storing gases is difficult.

• It takes long time to heat up the metal pieces compared to arc welding.

• It may lead to safety hazards since gases are used.

Applications of Oxy acetylene welding

• Oxy acetylene welding is preferred for joining thin metals, both ferrous and non ferrous, in automotive, aerospace and
manufacturing industries.

• It is used in the fabrication of sheet metal parts and for joining materials that require relatively slow rate of heating
and cooling.

Types of oxy-acetylene flames

Neutral Flame: When oxygen & acetylene are supplied to the torch in nearly equal volumes, a neutral flame is produced
having a maximum temperature of 3100o C. It has little effect on the base metal and sound welds are produced when

compared to other flames. Neutral flame is used for welding – MS, CI, Al, Cu, Stainless steel .

Oxidizing Flame: In an oxidizing flame excess of oxygen is present. The flame has a inner white cone somewhat small,
giving rise to higher tip temperature (3300o C). Excess of oxygen in the oxidizing flame causes the metal to burn or
oxidize quickly. Oxidizing flame is useful for welding some nonferrous alloys such as copper and zinc base alloys.
Oxidizing flame is used for welding – Copper-base metals, Zinc-base metals, ferrous metals such as Mn steel, CI, etc.

Carburizing Flame: In a carburizing flame or reducing flame excess of acetylene is present. The temperature of this flame
is 2900o C. The excess unburnt carbon is absorbed in ferrous metals, making the weld hard and brittle. In between the
outer blue flame and inner white cone, an intermediate flame feather exists, which is reddish in color. The length of the
flame feather is an indication of the excess acetylene present. Carburizing flame is used for welding – low alloy steel
rods, non-ferrous metals, high carbon steel, cast iron, etc.