Welding Process

Prepared by : - Shyam Bihari Sah

Dy. Manager (PM)

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 Contents

• Introduction
• Process
• SMAW
• Position
• Joint
• Electrode specification
• Application

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 Introduction
Welding is a fabrication or sculptural process that joins materials, usually 
metals or thermoplastics, by using high heat to melt the parts together and
allowing them to cool, causing fusion. Welding is distinct from lower
temperature metal-joining techniques such as brazing and soldering, which
do not melt the base metal.
 वेल्डन, निर्माण (fabrication) की एक प्रक्रिया है जो चीजों को जोडने के काम आती है। झलाई द्वारा मुख्यतः धातुएँ
 तथा थर्मोप्लास्टिक जोड़े जाते हैं। इस प्रक्रिया में सम्बन्धित टुकड़ों को गर्म करके पिघला लिया जाता है और उसमें एक 
फिलर सामग्री को भी पिघलाकर मिलाया जाता है। यह पिघली हुई धातुएं एवं फिलर सामग्री ठण्डी होकर एक मजबूत जोड़
बन जाता है। झलाई के लिये कभी-कभी उष्मा के साथ-साथ दाब का प्रयोग भी किया जाता है।

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 Process

A method of performing welding, such as:

1. Shielded metal arc welding

2. Submerged arc welding
3. Gas metal arc welding
4. Gas tungsten arc welding
5. Oxyacetylene welding

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 Shielded metal arc welding

Diagram of arc and weld area, in shielded metal arc welding. 1. Coating Flow 2. Rod
3. Shield Gas 4. Fusion 5. Base metal 6. Weld metal 7. Solidified Slag

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 Welding position

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 Joint

Root:-The first pass in the weld, usually

made without any appreciable weaving
motion
Hot Pass:-The weld pass that
immediately follows the stringer (root)
pass “V” Groove
Filler:-The weld passes that follow the
hot pass and fill the weld groove flush or
almost flush with the surface of the work
pieces.
Cap:- The weld pass that finishes the
welded joint. The cover bead is higher
than the adjacent surface and overlaps
the groove.

“U” Groove
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 Welding Electrode Specification

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 Mill roller Arcing
Arcing has been done on a fresh roller mounted over lathe machine by welders
came from our Group Units, on following parameters:-
a) RPM of Lathe Machine : 1.25
b) Arcing Type : Dynamic
c) Current : 260Amp
d) Electrode used :-
For Teeth Side Face Arcing : Azucar-80, Dimension : 4.0 X 400MM
For Tip arcing : Azucar-100, Dimension : 3.25 X 350MM

Dynamic Arcing Video (on Lathe).mp4 Dynamic Arcing Video (on Lathe)_2.mp4

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 Application
s.no Electrode name Application
1 Azucar-80 Teeth Side Face Arcing

2 Azucar-100/ESSEN 100 Tip arcing

3 E 6013 E7013,E8013 welding sheet metals ,mild steels

4 E309 M.S to S.S

5 E308 ,E304 S.S to S.S

6 L&T electrode 2b build-ups prior to hard facing and for sideways

wheel crowns guides, couplings, rope winches
and brake drums
7 L&T electrode 6006 Conveyor screws, scraper blades, digging teeth

8 C.I (Machinable & Non Motor housings, machine bases, levers and
Machinable) cams, farm machinery castings
Machinable is called of Nickel-Iron based
electrode (Without heating)
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 What is polarity in welding
Polarity:- The term 'polarity' is used to describe the electrical connection of the
electrode in relation to the terminal of a power source.
Polarity: - 'polarity' शब्द का प्रयोग किसी विद्युत स्रोत के टर्मिनल के संबंध में इलेक्ट्रोड के विद्युत कनेक्शन का
वर्णन करने के लिए किया जाता है।

2 Types of Polarity in Welding

1. Reverse Polarity (DCEP)

2.Straight Polarity(DCEN)

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 1.Reverse Polarity (DCEP)

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 2.Straight Polarity(DCEN)

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 DHAMPUR SUGAR MILL LIMITED

Thank You…!

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