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Fundamentals of Welding Tech Day 1
Fundamentals of Welding Tech Day 1
Fundamentals of Welding Tech Day 1
Definition :
A localized Joining of material with or without the use of
filler and also with or without the application of pressure.
or
Bringing two perfectly smooth & clean material surfaces to
an intimate contact, which is an atomic distance, indeed,
between the two, is known as welding.
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Welding Joint Terminology
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Types of Common Welded Joints
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Types of Common Welded Joints
• Butt Joint
• Fillet Joint
• Lap Joint
• Open Corner Joint
• Closed Corner Joint
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Types of Fillet Welds
• Mitre Fillet
• Convex Fillet
• Concave Fillet
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Leg Hieght
Face
Leg length
Reinforcement
Designed throat
Actual Throat
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Weld Positions
• Weld Slope
• Weld Rotation
• Flat Position
• Horizontal Vertical Position
• Horizontal Position
• Over Head Position
• Vertical Up Position
• Vertical Down Position
• Inclined Position
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G - Positions on Plate
1G
2G
3G
4G
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G - Positions on Pipe
1G
2G
5G
6G
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F - Positions on Plate
1F
2F
3F
4F
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F - Positions on Pipe
1F
2F
2FR
4F
5F
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Welding Processes
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OXY-GAS WELDING
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OXY-GAS WELDING
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OXY-GAS WELDING
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OXY-GAS WELDING
Process Technique
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OXY-GAS WELDING
There are three distinct flame used in this method
The neutral flame
• Equal quantities of oxygen and acetylene
• Distinct inner white cone with a rounded tip
• Suitable for all carbon steel, cast irons, low alloy steels and
aluminum
The carburizing (carbonizing) flame
• Slight excess of acetylene.
• Feather around the inner white cone.
• Used for welding of high carbon steels and for hard surfacing.
The oxidizing flame
• Has an excess of oxygen
• Inner white cone is shorter and sharper than the neutral cone.
• This flame is suitable for brass, bronze, zinc applications,
• Used for bronze welding and brazing
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Three Distinct Flame
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Manual Metal Arc Welding
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Manual Metal Arc Welding
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Effect of Amperage too low
Poor penetration or fusion,
unstable arc,
irregular bead shape,
slag inclusion,
porosity,
electrode freezes to the weld,
possible stray arc strikes.
Effect of Amperage too high
Excessive penetration,
burn through,
porosity,
spatter,
deep craters,
undercut,
electrode overheats,
high deposition (positional welding difficult).
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Effect of Voltage too low
Poor penetration,
Electrode freezes to work
Possible stray arcs
Fusion defects
Slag inclusions
Unstable arc
Irregular bead shape.
Effect of Voltage too high
Porosity
Spatter
Irregular bead
Slag inclusion
Very fluid weld pool
positional welding difficult.
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Travel speed too slow
Excessive deposition
Cold laps
Slag inclusions
Irregular bead shape.
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An electrode connected to the d.c.+ve pole will have two thirds of
the available energy.The remaining one third of the energy in the
parent material
It will result in:
wide and shallow weld pool
Broad HAZ
Slow Rate of Cooling
Hydrogen Intrapment
An electrode connected to the d.c. –ve pole has One third of the
energy develops at the electrode and two thirds of the energy in the
parent material.
This will result in
Weld pool which is narrow, deep and fast freezing
limited h.a.z.
May lead to hydrogen entrapment and a brittle metallurgical structure
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In A.C. The polarity is reversing 100 times per second (50 c.p.s.).
Effect of equalizing the heat distribution
Heat at the electrode and half in the parent material.
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The m.I.g./m.a.g. welding process
uses a bare wire consumable
electrode .
The wire, typically 0.8-1.6 mm
diameter, is continuously fed from
a coil through a specially designed
welding gun.
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Eliminate the possibility of atmospheric contamination by
introducing a shielding gas.
Argon is an efficient shielding gas, being inert, it doesnot
chemically react with the weld metal.
When an inert gas is used for shielding the welding process is
know as metal inert-gas (m.i.g.) welding.
Deoxidizers must exist in the wire.
This process is widely referred to as CO2 welding is also called
metal active-gas (m.a.g.) welding.
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Spray or free flight transfer
The weld metal transfers across the arc in the form of a fine
spray.
High deposition rates and deep penetration welds.
Suited to thick materials,
The flat or horizontal welding positions.
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For m.I.g./m.a.g. welding is usually electrode d.c. +ve of a flat
Characteristic.
Advantages
minimal wastage of consumable electrode,
no frequent changing of consumable electrode,
little or no interpass cleaning required (no slag produced)
heavier weld beads are produced, faster welding process,
low hydrogen process – preheat may not be required.
Disadvantages
increased risk or porosity – due
to displacement of the gas shield, more maintenance of plant
involved, high risk of lack or fusion.
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