UNIT-3

WELDING
 SYLLABUS
• A) WELDING : Classification of welding
processes types of welds and welded joints
and their characteristics, design of welded
joints, Gas welding, ARC welding, Forge
welding, resistance welding, Thermit welding
and Plasma (Air and water ) welding.
• B) CUTTING OF METALS: Oxy – Acetylene Gas
cutting, water plasma. Cutting of ferrous, non-
ferrous metals
 Introduction
• Welding is a process of joining two similar or dissimilar metals
with the help of heat or pressure or by some other means. The
cost of welding is very less as compared to other processes and
forms a strong joint.
• For this reason it is largely used in the following fields of
engineering:
1. Manufacturing of machine tools, auto parts, cycle parts, etc.
2. Fabrication of farm machinery & equipment.
3. Fabrication of buildings, bridges & ships.1
4. Construction of boilers, furnaces, railways, cars, aero planes, rockets
and missiles.
5. Manufacturing of television sets, refrigerators, kitchen cabinets, etc.
Classification of welding processes
• Many types of welding processes have been developed
depending upon the field of their applications. But the
welding is broadly divided into following two groups.

1. Forge or Pressure Welding (Under pressure without

additional filler metal)
(a) Friction welding
(b) Electric resistance welding
(c) Blacksmiths forge welding
(d) Cold pressure welding
Classification of welding processes
2. Fusion or non-pressure welding (With
additional filler material)
(a) Gas welding (Heat created by Gas)
(b) Electric arc welding (Heat created by electrically)
(c) Thermit welding (Heat created by chemical
Reaction)
Types of welds and welded joints and their
characteristics:
• Types of Welds:
• There are many types of welds. Some of the common
types you will work with are
Bead,
Groove,
Fillet,
Surfacing,
Tack,
Plug,
Slot, and
Spot
Seam.
 Weld bead:
• The first type of weld you will learn to produce
is called a weld bead, also referred to simply
as a bead.
 Weld bead:
• A weld bead is only a weld deposit produced by a single
pass with one of the welding processes.
• It may be narrow or wide, depending on the amount of
transverse oscillation (side to- side movement) you use.
• If you use a great deal of oscillation, the bead is wide; if
you use little or no oscillation, the bead is narrow.
• A narrow weld bead made without much weaving
motion is often referred to as a stringer bead; a weld
bead made with side-to-side oscillation is called a
weave bead.
 Groove welds
• Groove welds are made in the groove
between two members of a work piece and
are adaptable to a variety of butt joints of
varying thicknesses.
 Groove welds
• If two or more beads are deposited in the
groove, the weld is made with multiple pass
layers, as shown in Figure 3-24.
 Fillet weld:
• A fillet weld is used to join two surfaces at
approximately right angles to each other in a
lap, tee, or corner joint. The shape of a fillet
weld’s cross-sectional view is triangular
Fillet weld
 Surface weld
• Surfacing is a welding process used to apply a hard,
wear-resistant layer of metal to surfaces or edges of
parts as either a preventative to wear, or a remedy
for already worn parts (Figure 3-27).
• It is one of the most economical methods of
conserving and extending the life of machines, tools,
and construction equipment.
• Sometimes known as hard facing or wear facing, a
surfacing weld is composed of one or more stringer
or weaves beads.
Surface weld
 Tack weld
• A tack weld is a temporary weld made to hold parts of
an assembly in proper alignment until the final welds
are made (Figure 3-28).
• Although the sizes of tack welds are not specified,
they are normally between 1/2 to 3/4 inch in length,
but never more than 1 inch in length.
• In determining the size and number of tack welds you
need for a specific project, you need to consider the
thicknesses of the metals being joined and the
complexity of the object being assembled.
Tack weld
 Plug welds and slot welds
• Plug welds and slot welds are welds made through holes
or slots in one member of a lap joint (Figure 3-29).
• These welds are used to join the member with holes to the
surface of another member exposed through the hole.
• The hole may or may not be completely filled with weld
metal.
• These types of welds are often used to:
• Join face-hardened plates from the backer soft side
• Install liner metals inside tanks
• Fill up holes in a plate
Plug welds and slot welds
 Spot weld, Seam weld
• Spot weld:
• In spot welding resistance welding process
is used, the welding takes place at the
interface of two base metals.
• Seam weld:
• This is a continuous spot welding process
which will takes place at the interface of two
surfaces.
Spot weld, Seam weld
 Types of welding joints
• Basic types of welding joints are classified as
under:
(a) Butt Joint
• In this type of joint, the edges are welded in
the same plane with each other. V or U shape
is given to the edges to make the joints strong.
Some examples of butt joints are shown in the
figure.
(a) Butt Joint
 (b) Lap Joint
• This type of joint is used in joining two
overlapping plates so that the corner of each
plate is joined with the surface of other plate.
Common types of lap joints are single lap,
double lap or offset lap joint. Single welded
lap joint does not develop full strength as
compared to double welded lap.
(b) Lap Joint
 (c) T-Joint
• When two surfaces are to be welded at right
angles, the joint is called T-Joint. The angle
between the surfaces is kept 90°.
 Corner Joint
• In this joint, the edges of two sheets are
joined and their surfaces are kept at right
angle to each other. Such joints are made in
frames, steel boxes, etc.
 (e) Edge Joint
• In this joint two parallel plates are welded
edge to edge.
 (f) Plug Joint
• Plug joints are used in holes instead of rivets
and bolts.
 Welding Positions
• In horizontal position it is very easy to weld.
But many times it is impossible to weld the job
in horizontal position. Other positions are
classified as under:
(a) Flat Position
(b) Horizontal Position
(c) Vertical Position
(d) Overhead Position
 (a) Flat Position

• In flat positions the work piece is kept in

nearly horizontal position.
• The surface to be worked is kept on upper
side. The welding is done as illustrated in the
fig 7.18.
(a) Flat Position
 Horizontal Position
• In this position, the work piece is kept as in
the fig 7.19.
• Two surfaces rest one over the other with
their flat faces in vertical plane. Welding is
done from right side to left side. The axis of
the weld is in a horizontal plane and its face in
vertical plane.
Horizontal Position
 Vertical Position
• In this position, the axis of the weld remains in
approximate vertical plane. The welding is
started at the bottom and proceeds towards
top. Welding process is illustrated in figure.
Vertical Position
 Overhead Position
• As shown in the figure, the work piece
remains over the head of the welder. The
work piece and the axis of the weld remain
approximate in horizontal plane. It is the most
difficult position of welding.
Overhead Position