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WELDING- INTRODUCTION &

CLASSIFICATION
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Definition
American Welding Society Defines WELDING
“A localised joining together of metals or non-metals
produced either by heating the materials to suitable
temperatures ,with or without the application of pressure, or
by application of pressure alone,and with or without the use
of filler material.”
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Overview of joining methods

 Mechanical methods
 Screwed fasteners, rivets (Some of these methods allow
for easy disassembly)
 Brazing and Soldering
 Base metal does not fuse.
 Molten filler drawn into close-fit joints by capillary
action (surface tension forces).
 Brazing filler melts >450°C, solder <450°C
 Welding
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Soldering
Joining process in which a filler metal with Tm less
than or equal to 450°C (840°F) is melted and
distributed by capillary action between faying
surfaces of metal parts being joined
 No melting of base metals, but filler metal wets and combines
with base metal to form metallurgical bond
 Filler metal called solder
 Closely associated with electrical assembly
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Soldering
Advantages:
 Lower energy than brazing or fusion welding
 Variety of heating methods available
 Good electrical and thermal conductivity in joint
 Easy repair and rework
Disadvantages:
 Low joint strength unless reinforced mechanically
 Joint weakens or melts at elevated temperatures
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Brazing
Joining process in which a filler metal is melted and
distributed by capillary action between faying
surfaces of metal parts being joined
 No melting of base metals occurs
 Only the filler melts
 Filler metal melting temperature is greater than
450C (840F)
 But less than melting temperature of base metal(s) to be joined
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Brazing
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Brazing
 Any metals can be joined, including dissimilar metals
 Can be performed quickly and consistently,
permitting high production rates
 Multiple joints can be brazed simultaneously
 Less heat and power required than FW
 Problems with HAZ in base metal are reduced
 Joint areas that are inaccessible by many welding
processes can be brazed
 Capillary action draws molten filler metal into joint
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Brazing Limitations
 Joint strength is generally less than a welded joint
 Joint strength is likely to be less than the strength of
the base metals
 High service temperatures may weaken a brazed
joint
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Weld

 A joint produced by heat or pressure or both

So there is continuity of material.

 Filler (if used) has a melting temperature

close to the base material
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Welding processes

 Fusion welding
 Welding in the liquid state with no pressure
 Union is by molten metal bridging
 Solid phase welding
 Carried out below the melting point without filler additions
 Pressure often used
 Union is often by plastic flow
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Basic Requirements of Welding Process

Source of Heat
Chemical Reaction
Electrical - Arc, Resistance, Induction
Mechanical

Protection from Atmosphere

Gas Shielding
Flux
Mechanical Expulsion
Vacuum
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Fusion welding heat sources

Electric Electric Chemical Power

arc resistance reaction beams

SMAW Spot, seam & Oxyfuel Laser

GTAW projection gas Electron
SAW welding welding beam
GMAW
FCAW
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 SMAW - Shielded metal arc welding

 GTAW - Gas tungsten arc welding (TIG)
 SAW - Submerged arc welding
 GMAW - Gas-metal arc welding (MIG, MAG)
 FCAW - Flux cored arc welding
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Shielded Metal Arc Welding (SMAW)

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Shielded Metal Arc Welding

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 Shielded Metal Arc Welding

Heat source - arc between metal and a
flux coated electrode (1.6- 8 mm
diameter)
 Current 30-400A (depends on
electrode size)
 AC or DC operation
 Power 1 to 12 kW
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Shielded Metal Arc Welding

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Shielded Metal Arc Welding

Minimum equipment

 Power source (ac or dc, engine driven or mains transformer)

 Electrode holder and leads
 May carry up to 300 amps
 Head shield with lens protects face & eyes
 Chipping hammer to remove slag
 Welding gloves protect hands from arc radiation, hot material and
electric shock
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Shielded Metal Arc Welding

Process features

 Simple portable equipment

 Widely practiced skills
 Applicable to wide range of materials, joints, positions
 About 1kg weld deposited per arc-hour
 Portable and versatile
 Properties can be excellent
 Benchmark process
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Shielded Metal Arc Welding

Covered electrodes
 Core wire
 Solid or tubular
 2mm to 8mm diameter, 250
to 450mm long
 Coating
 Extruded as paste, dried to
strengthen
 Dipped into slurry and dried
(rare)
 Wound with paper or chord
(obsolete)
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Shielded Metal Arc Welding

Functions of coating

 Slag protects weld pool from oxidation

 Gas shielding also protects weld pool
 Surface tension (fluxing)
 Arc stabilising (ionising)
 Alloying and deoxidation
 Some ingredients aid manufacture (binder and extrusion aids)
Shielded Metal Arc Welding
AWS A5.1 classification

E XXXX - H
Tensile Strength Hydrogen level
in KPSI (HmR)
H = 5 ml / 100g of WM
R = low moisture pick-
up
Useable positions Flux type
1=all positions 20 = Acidic (iron oxide)
2=flat + horizontal 10, 11 = Cellulosic
4=vertical down 12, 13 = Rutile
24 = Rutile + iron powder
27 = Acidic + iron powder
16 = basic
18, 28 = basic + iron powder
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Shielded Metal Arc Welding

Applications
 Wide range of welded products:
 light structure & Heavy steel structures
 Workshop and site
 High integrity (nuclear reactors, pressure equipment)
 Ideal where access is difficult - construction site,
inside vessels, underwater
 Joins a wide range of materials
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Shielded Metal Arc Welding

Limitations

 Low productivity
 Low power
 Low duty cycle (frequent electrode changes)
 Hydrogen from flux coatings
 Electrode live all the time
 Arc strike, stray current and electric shock risks
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Shielded Metal Arc Welding

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Gas shielded arc process

Tungsten Inert Gas welding (TIG)
Gas tungsten arc welding (GTAW)
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Gas Tungsten Arc Welding

 Alternative names -
GTAW,TIG (Tungsten Inert
Gas), Argonarc

 Heat source is an electric

arc between a non-
consumable electrode and
the workpiece

 Filler metal is not added or

is added independently
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Gas Tungsten arc welding

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Gas Tungsten Arc Welding

Heat source - arc between a tungsten tip

and the parent metal
30-400A, AC or DC
10-20V
0.3-8kW
Inert gas shielding
Consumable filler rod can be used (1 to
4mm diameter)
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Gas Tungsten Arc Welding - Process features

 Excellent control
 Stable arc at low power (80A at 11V)
 Independently added filler
 Ideal for intricate welds eg root runs in pipe or thin sheet
 Low productivity 0.5kg/h manual
 High quality
 Clean process, no slag
 Low oxygen and nitrogen weld metal
 Defect free, excellent profile even for single sided welds
Gas Tungsten Arc Welding - Equipment

 Welding power source with constant current characteristic

 DC for most metals, AC for Al
 Arc starting by high frequency (5000V, 0.05A)
 Sequence timers for arc starting, arc finishing & gas control
 Water- or gas-cooled torch with tungsten electrode
 Electrode may contain thoria or zirconia, etc
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Gas Tungsten Arc Welding - Shielding gases

 Torch is fed with an inert or reducing gas

 Pure argon - widespread applications
 Argon-helium - Higher arc voltage, inert
 Argon-2% hydrogen - Cu alloys & austenitic steel
 Torch gas must not contain oxygen or CO2
 Backing (or purge) gas
 Used for all single-sided welds except in carbon steel
 Argon, nitrogen
 Supplementary shielding
 Reactive metals: Ti, etc
 Gas filled chambers or additional gas supply devices
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Gas Tungsten Arc Welding - Filler metals

 Autogenous welding (no filler)

 Filler wire or rod of matching composition
 C-Mn & low alloy steel
 Stainless Steel
 Al, Mg, Ti
 Cu & Ni
 Consumable inserts - filler preplaced in joint
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Gas Tungsten Arc Welding

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Submerged arc welding

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Submerged arc welding

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ubmerged arc welding

Submerged arc welding - Features

 High productivity
 2 to 10 kg/hour
 Up to 2m/min
 Bulky, expensive and
heavy equipment
 Flat and horizontal
positions only
 Thicker sections (3mm
and above)
 Mostly ferrous materials
(also Ni alloys)
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Submerged arc welding - Equipment

 Power source
 Welding head and
control box
 Welding head travel
 Flux recovery system
(optional)
 Positioners and
Fixtures
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Submerged arc welding - Applications

 Long straight welds in heavier material

 Vessel longitudinal and circumferential welds
 Flange to web joints of I beams
 Flat or horizontal position
 Flux has to be supported
 Access has to be good
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TIG Welding root

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Arc Welding
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Piping joints
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Structural welding
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Solid-State Welding

 Heat
 Pressure
 Time
 NO Melting
 NO Filler Material
 Intimate Contact
Usually Requires Deformation
 Works with Dissimilar Metals
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Resistance Welding
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Friction Welding
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Oxy-Acetylene Welding
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Oxy-acetylene Cutting &

Gouging
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Oxy-acetylene Cutting &

Gouging
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Questions?