Welding

EE541/L - Industrial Electronics

What is welding?
Welding defined
- Welding is the process of joining together two pieces of
metal so that bonding takes place at their original
boundary surfaces.
- When two parts to be joined are melted together, heat or
pressure or both is applied and with or without added
metal for formation of metallic bond.
Welding defined
- It is the process of fabrication that joins materials, usually
metals or thermoplastics by causing coalescence.
- Coalescence is carried out by melting the work pieces or
different metal parts and adding a filler material between
them to form a pool of molten material that cools down to
become a strong joint.
Need for Welding
Welding is an essential part of everyday life. From cars to high rise office
buildings, airplanes to rockets, pipelines, highways, none of it would be
possible without welding.

With ever increasing demand for both high production rates and high
precision, fully mechanized or automated welding processes have taken a
prominent place in the welding field.
Risk Factors
Risk Factors
- It can be dangerous and unhealthy if the needed
precautions are not taken
- The risk of burns and fire is very high (hot work process)
- The brightness of the weld area leads to a condition called
arc eye or flash burns in which ultraviolet light causes
inflammation and can burn the retinas of the eyes.
Risk Factors
- Welders are often exposed to dangerous gases and
particulate matter as in the processes like flux cored arc
and shielded metal arc welding smoke containing particles
of various types of oxides is released.
- Carbon Monoxide, Hydrogen Fluoride, Nitrogen Oxides,
Oxygen Deficiency, Ozone
Classifications of Welding
Plastic Welding or Pressure Welding
Fusion Welding or Non-Pressure Welding
 When the metal piece acquires
plastic state on heating, external
pressure is applied. In this
process, externally applied
forces play an important role in
the bonding operation.

Plastic Welding or
Pressure Welding
 The material at the joint is
heated to a molten state
and allowed to solidify.
Fusion Welding or
Non-Pressure
Welding
Difference of Plastic and
Fusion Welding
Personal Protective Equipment
and Clothing
 Protects from:
Welding helmet, hand
● radiation
shield, or goggles ● flying particles, debris
For the eyes and face. ● hot slag, sparks
● intense light
● irritation and chemical burns

Wear fire resistant head coverings

under the helmet where appropriate
 Respirators
For the lungs (breathing).
Protects against:

● fumes and oxides

Ear muffs, ear plugs Protects against

For the ears (hearing). ● noise

Use fire resistant ear muffs where

sparks or splatter may enter the
ear, rather than plugs.
 Boots, gloves
Protects against
For the feet and hands.
● electric shock
● heat
● burns
● fires
Welding Devices
3-in-1 MIG TIG STICK Welder
C.M.T Pitbull Ultra-Portable 100-
Amp Electric Arc Welder - 110V -
Arc Welding Equipment
Miller Big Blue 350 PipePro®

Rated Output 400 A, 100% bij 24

VDC

Voltage Range 14 - 40 VDC

Amperage Range 20-400 A

Generator power 12 kVA peak

Generator output 120 VAC 1ph,

240 VAC 1ph

Weight 482 kg
SIMADRE TITAN2000DI 3IN1 IGBT
SYNERGIC DIGITAL MIG/TIG/MMA
WELDING MACHINE

Input Voltage (VAC) 1 phase

220V(15%)

Input current (A) 29

Power capacitance (KVA)) 6.4

Output current range (A) 50-200

MMA Current 30-200

Output voltage (VDC) 15-26

MATWELD 350 MIG
TRANSFORMER/RECTIFIER WELDER

Weight 143Kg

Output Current Range 60 - 360A

Input Power Voltage

Three Phase AC 380V ± 10%

Rated Input Power Capacity

15.9 KVA
 Shielded metal arc welding
(SMAW), also known as manual
metal arc welding (MMA or
MMAW), flux shielded arc welding
or informally as stick welding, is a
manual arc welding process that
uses a consumable electrode
covered with a flux to lay the
weld.
SMAW is a welding process that uses a flux
covered metal electrode to carry an electrical
current. The current forms an arc that jumps a
gap from the end of the electrode to the work.
The electric arc creates enough heat to melt
both the electrode and the base material(s).
Molten metal from the electrode travels across
the arc to the molten pool of base metal where
they mix together. As the arc moves away, the
mixture of molten metals solidifies and becomes
one piece. The molten pool of metal is
surrounded and protected by a fume cloud and a
covering of slag produced as the coating of the
electrode burns or vaporizes. Due to the
appearance of the electrodes, SMAW is
commonly known as ‘stick’ welding.
 Gas metal arc welding (GMAW),
sometimes referred to by its subtypes
metal inert gas (MIG) welding or
metal active gas (MAG) welding, is a
welding process in which an electric
arc forms between a consumable MIG
wire electrode and the workpiece
metal(s), which heats the workpiece
metal(s), causing them to melt and
join.
In the GMAW process, an arc is established between a continuous wire
electrode (which is always being consumed) and the base metal. Under the
correct conditions, the wire is fed at a constant rate to the arc, matching the
rate at which the arc melts it. The filler metal is the thin wire that’s fed
automatically into the pool where it melts. Since molten metal is sensitive to
oxygen in the air, good shielding with oxygen-free gases is required. This
shielding gas provides a stable, inert environment to protect the weld pool as it
solidifies. Consequently, GMAW is commonly known as MIG (metal inert gas)
welding. Since fluxes are not used (like SMAW), the welds produced are
sound, free of contaminants, and as corrosion-resistant as the parent metal.
The filler material is usually the same composition (or alloy) as the base metal.
 Gas tungsten arc welding (GTAW),
also known as tungsten inert gas
(TIG) welding, is an arc welding
process that uses a non-consumable
tungsten electrode to produce the
weld.
GTAW
● In the GTAW process, an arc is established between a tungsten electrode
and the base metal(s). Under the correct conditions, the electrode does not
melt, although the work does at the point where the arc contacts and
produces a weld pool. The filler metal is thin wire that’s fed manually into the
pool where it melts. Since tungsten is sensitive to oxygen in the air, good
shielding with oxygen-free gas is required. The same inert gas provides a
stable, inert environment to protect the weld pool as it solidifies.
Consequently, GTAW is commonly known as TIG (tungsten inert gas)
welding. Because fluxes are not used (like SMAW), the welds produced are
sound, free of contaminants and slags, and as corrosion-resistant as the
parent metal.
GTAW
● Tungsten’s extremely high melting temperature and good electrical
conductivity make it the best choice for a non-consumable electrode. The arc
temperature is typically around 11,000° F. Typical shielding gasses are Ar,
He, N, or a mixture of the two. As with GMAW, the filler material usually is
the same composition as the base metal.
● GTAW is easily performed on a variety of materials, from steel and its alloys
to aluminum, magnesium, copper, brass, nickel, titanium, etc. Virtually any
metal that is conductive lends itself to being welded using GTAW. Its clean,
high-quality welds often require little or no post-weld finishing. This method
produces the finest, strongest welds out of all the welding processes.
However, it’s also one of the slower methods of arc welding
 ● Squeeze interval
Welding
● Weld interval
Sequence ● Hold interval
● Release
● Standby interval
 Squeeze Interval
Welding ● Once the electrode have
Sequence engaged the metal, they are
allowed to press against the
surface for a short time before
the welding current is turned
on.
 Weld Interval
● About 2 to 10 seconds, during this
interval, the welding transformer is
Welding energized, current flows and
create weld. The current is not
Sequence continuous, but on and off in short
burst called pulsations.

○ Heat Subinterval – the current is

on

○ Cool Subinterval – the current is

off
 Welding Hold Interval
Sequence ● Electrode pressure is
maintained on the metal
surfaces, but the welding
current is turned off.
 Welding Release
Sequence ● The welding electrode
cylinders are retracted,
releasing the wheel from the
electrodes.
 Standby
Welding ● The lift cylinder is retracted,
Sequence lowering the finished wheel
from the welding location. The
system remains standby until a
new wheel is loaded to the
lifting cradle.