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Fusion Welding and Types: Lecture # 23 Manufacturing Processes-I (ME322)

The document discusses different types of welding processes. It classifies welding into solid state welding and fusion welding. Fusion welding involves melting materials while solid state welding does not. The document focuses on arc welding, a type of fusion welding. It describes four common arc welding processes: shielded metal arc welding, gas metal arc welding, flux-cored arc welding, and submerged arc welding. Each process uses different electrode and shielding gas combinations.

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70 views17 pages

Fusion Welding and Types: Lecture # 23 Manufacturing Processes-I (ME322)

The document discusses different types of welding processes. It classifies welding into solid state welding and fusion welding. Fusion welding involves melting materials while solid state welding does not. The document focuses on arc welding, a type of fusion welding. It describes four common arc welding processes: shielded metal arc welding, gas metal arc welding, flux-cored arc welding, and submerged arc welding. Each process uses different electrode and shielding gas combinations.

Uploaded by

Hammad
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Fusion Welding and Types

Lecture # 23
Manufacturing Processes-I
(ME322)

3/31/2015 H.A. Qazi, Lecturer ME DSU, ME322, SP15 1


Lecture 23 Outline

Welding Process
Classification of Welding Process
Solid State Welding
Fusion Welding
Arc Welding
Classification of Arc Welding
Shielded Metal Arc Welding
Gas Metal Arc Welding
Fluxed Core Arc Welding
Submerged Arc Welding

3/31/2015 H.A. Qazi, Lecturer ME DSU, ME322, SP15 2


Classification of Manufacturing
Processes
Solidification processes

Particulate processing
Shaping processes
Deformation processes

Material removal
Processes
operations Property enhancing
Heat treatment
processes
Cleaning & surface treatment
Surface enhancement &
protection Processes
Manufacturing Coating and deposition processes
processes
Welding
Permanent joining
Brazing and soldering
processes
Joining &
Adhesive bonding
Assembly
operations Threaded fasteners
Mechanical fastening
Permanent fastening methods

3/31/2015 H.A. Qazi, Lecturer ME DSU, ME322, SP15 3


Welding Processes
Welding is a material joining process in which two
or more parts are coalesced at their contacting
surfaces by suitable application of heat and/or
pressure.
Only Heat
Only Pressure
Combination of Heat
and Pressure

Discussion is limited
to welding of metals
only. However welding
of plastic is also a
practiced in the industry.

3/31/2015 H.A. Qazi, Lecturer ME DSU, ME322, SP15 4


Classification of Welding

Arc Welding

Resistance
Welding
Fusion Welding
Oxy-fuel gas
Welding

Welding Other Fusion


Welding
Processes

Solid State
8 Different types
Welding

3/31/2015 H.A. Qazi, Lecturer ME DSU, ME322, SP15 5


Fusion Welding

In Fusion Welding coalescence is accomplished by melting


the two parts to be joint, in some cases adding filler metal
to the joint.

Solid State Welding

In Solid-State Welding heat and/or pressure are used to


achieve coalescence, but no melting of the base metals
occur, and no filler metal is added

3/31/2015 H.A. Qazi, Lecturer ME DSU, ME322, SP15 6


Arc Welding (AW)

Arc Welding is a fusion welding process in which


coalescence of the metals is achieved by the heat from an
electric arc between an electrode and the work.

3/31/2015 H.A. Qazi, Lecturer ME DSU, ME322, SP15 7


AW Process Explanation

An electric arc is a discharge of electric current across a


gap in a circuit.
The arc is sustained by the presence of a thermally
ionized surrounding of gas (called the plasma).
To initiate the arc in an AW process, the electrode is
brought into contact with the work, and then quickly
separated from it by a short distance.

3/31/2015 H.A. Qazi, Lecturer ME DSU, ME322, SP15 8


AW Process Explanation
The electric energy from the arc thus formed produces
temperature of 5500oC or higher (sufficiently hot to melt any
metal)
A pool of molten metal, consisting of the base metal(s) and
filler metal (if one is used) is formed near the tip of the
electrode.
As the electrode is moved along the joint, the molten weld
pool solidifies in its wake.

3/31/2015 H.A. Qazi, Lecturer ME DSU, ME322, SP15 9


Components in AW Process

Electrodes: Electrodes used in AW Processes are


classified into two categories.

1. Consumable Electrode: These electrode provide the


source of the filler metal in AW processes.

2. Non-Consumable Electrode: These electrodes are


made up of tungsten (or carbon, rarely) which resist
melting by arc.

3/31/2015 H.A. Qazi, Lecturer ME DSU, ME322, SP15 10


Components in AW Process

Arc Shielding: In nearly all AW processes, the electrode


tip, arc, and the molten weld pool is covered by a blanket of
gas or flux, or both, which inhabit their exposure to the air.
Common shielding gasses include argon, and helium.
CO2 is also used usually in combination with Ar and
/or He.
During Welding, the flux melts and become a liquid
slag, covering the operation and protecting the molten
weld metal.
The slag hardens upon cooling and must be removed
later by chipping or brushing.

3/31/2015 H.A. Qazi, Lecturer ME DSU, ME322, SP15 11


AW Process Classification

Shielded Metal Arc Welding

Gas Metal Arc Welding


Consumable
Electrodes
Flux-Cored Arc Welding

Arc Welding
Submerged Arc Welding
Processes

Gas Tungsten Arc Welding


Non Consumable
Electrodes
Plasma Arc Welding

3/31/2015 H.A. Qazi, Lecturer ME DSU, ME322, SP15 12


Shielded Metal Arc Welding

It is an AW process that uses a consumable electrode


consisting of a filler metal rod coated with chemical that
provide flux.
Sometimes called Stick Welding
The bare metal end of the welding stick (opposite to
the welding tip) is clamped in an electrode holder

3/31/2015 H.A. Qazi, Lecturer ME DSU, ME322, SP15 13


Gas Metal Arc welding

It is a AW process in which the electrode is a consumable


bare metal wire, and shielding is accomplished by flooding
the arc with a gas.
Gases used for shielding include inert gasses such as
argon and helium, and active gases such as CO2
MIG: Metal Inert Gas
MAG: Metal Active Gas.

3/31/2015 H.A. Qazi, Lecturer ME DSU, ME322, SP15 14


Fluxed-Cored Arc Welding

It is an AW process in which the electrode is a continuous


consumable tubing that contain flux in its core.

3/31/2015 H.A. Qazi, Lecturer ME DSU, ME322, SP15 15


Submerged Arc Welding

It is an AW Process that uses a continuous, consumable


bare wire electrode, and are shielding is provided by a
cover of granular flux.

3/31/2015 H.A. Qazi, Lecturer ME DSU, ME322, SP15 16


Expected Learning

Welding Process
Classification of Welding Process
Solid State Welding
Fusion Welding
Arc Welding
Classification of Arc Welding
Shielded Metal Arc Welding
Gas Metal Arc Welding
Fluxed Core Arc Welding
Submerged Arc Welding

3/31/2015 H.A. Qazi, Lecturer ME DSU, ME322, SP15 17

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