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Unit 3

The document provides information about various welding processes and their principles. It discusses gas welding, arc welding techniques like shielded metal arc welding and gas metal arc welding. It describes the equipment, terminology and principles involved in different welding methods. Various types of electrodes, fluxes, power sources and edge preparations for welding are also explained.

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0% found this document useful (0 votes)
54 views71 pages

Unit 3

The document provides information about various welding processes and their principles. It discusses gas welding, arc welding techniques like shielded metal arc welding and gas metal arc welding. It describes the equipment, terminology and principles involved in different welding methods. Various types of electrodes, fluxes, power sources and edge preparations for welding are also explained.

Uploaded by

kartik gupta
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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UNIT 3

WELDING

Bharati Vidyapeeth College of Engineering


WELDING
 Welding is a materials joining process which
produces joint of materials by heating them to
suitable temperatures with or without the application
of pressure and with or without the use of filler
material.

 Welding is used for making permanent joints.


 It is used in the manufacture of automobile bodies, aircraft
frames, railway wagons, machine frames, structural works,
tanks, furniture, boilers, general repair work and ship building.

Bharati Vidyapeeth College of Engineering


TYPES
 Plastic Welding or Pressure Welding

 Fusion Welding or Non-Pressure Welding

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Bharati Vidyapeeth College of Engineering
Bharati Vidyapeeth College of Engineering
Classification of welding processes:
(i). Arc welding
 Carbon arc (iv)Thermit Welding
 Metal arc
 Metal inert gas (v)Solid State Welding
 Tungsten inert gas Friction
 Plasma arc Ultrasonic
 Submerged arc Diffusion
 Electro-slag Explosive
 Atomic Hydrogen Forge
(ii). Gas Welding (vi)Newer Welding
 Oxy-acetylene
 Air-acetylene Electron-beam
 Oxy-hydrogen Laser
(iii). Resistance Welding (vii)Related Process
 Butt Oxy-acetylene cutting
 Spot Arc cutting
 Seam Hard facing
 Projection Brazing
 Percussion Soldering
Bharati Vidyapeeth College of Engineering
Terminologies associated with welding
process
 Base metal – Work pieces to be joined
 Weld bead – Material deposited by the
process of welding
 Puddle – Portion of the base material which
is melted by the heat of welding.
 Weld pass – Movement of welding torch
from one end of the joint to the other.
 Tack weld – Temporary weld done at the
ends of the work pieces.
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Types of Weld joints

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EDGE PREPARATION IN WELDING

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EDGE PREPARATION IN WELDING
 To ensure complete penetration and sound weld ,
edge preparation is essential.

70 to 90 degrees
Root

(a) Square faces (b) Single V

(c) Double V (d) Single U (e) Double U


TYPE OF EDGES
Bharati Vidyapeeth College of Engineering
GAS WELDING
 Gas welding is called an oxy-fuel gas welding as heat is derives from
combustion of acetylene with oxygen.

 Fuel is generally used is acetylene because of high temperature


generated during the process is i.e 31000c

Bharati Vidyapeeth College of Engineering


GAS WELDING PRINCIPLE
When acetylene is mixed with oxygen in correct proportion in the
welding torch and ignited, the flame is produced which is sufficiently
hot to melt and join the parent metal. A filler rod is generally added
to build up the seam for greater strength. It may be classified as:-

1. High Pressure oxy-acetylene welding:- Acetylene is supplied from


acetylene cylinder in compressed form

2. Low pressure oxy-acetylene welding:- In this acetylene gas is supplied


from generator at low pressure. In the generator calcium carbide is added in
the chamber in which water is already present. Acetylene starts forming and
collected from top of water and used for further welding.

CaC 2 + 2 H 2 O → C 2 H 2 + Ca(OH) 2

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Bharati Vidyapeeth College of Engineering
TYPES OF FLAMES

 Neutral flame
 Oxidizing flame
 Carburizing flame

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CHEMISTRY IN GAS WELDING
Stage 1
2C2H2 + 2O2 = 4CO + 2H2
Stage 2
4CO + 2H2 + 3O2 = 4CO2 + 2H2O
Stage 3

2C2H2 + 5 O2 = 4CO2 + 2H20 (vapour) + 1284.57 k J / mol

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GAS WELDING EQUIPMENT...
1. Oxygen Gas Cylinders- coloured (Black)
2. Acetylene Gas Cylinders- coloured (Maroon)
Pressure
Oxygen – 140 bar
Acetylene – 15 bar
3. Regulators
4. Pressure Gauges
5. Hoses
6. Welding torch
7. Check valve
8. Non return valve
9. Gas lighter
10. Protective clothing

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Oxy-Acetylene welding

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Pressure Regulator & Gauges

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Welding Torch

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Goggles or Eye Protection

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Protective Clothing & Gloves

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Arc welding
 Arc welding is a type of welding process using an
electric arc to create heat to melt and join metals. A
power supply creates an electric arc between a
consumable or non-consumable electrode and the
base material using either direct (DC) or alternating
(AC) currents.
 The welding area is usually protected by some type
of shielding gas, vapor, or slag. Arc welding processes
may be manual, semi-automatic, or fully automated.

Bharati Vidyapeeth College of Engineering


Power supplies
 To supply the electrical energy necessary for arc
welding processes, a number of different power
supplies can be used.
 The most common classification is
constant current power supplies and
constant voltage power supplies.
 In arc welding, the voltage is directly related to the
length of the arc, and the current is related to the
amount of heat input.

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 Constant current power supplies are most often used for
manual welding processes such as gas tungsten arc
welding and shielded metal arc welding, because they
maintain a relatively constant current even as the voltage
varies.
 This is important because in manual welding, it can be
difficult to hold the electrode perfectly steady, and as a
result, the arc length and thus voltage tend to fluctuate.
 Constant voltage power supplies hold the voltage
constant and vary the current, and as a result, are most
often used for automated welding processes such as gas
metal arc welding, flux cored arc welding, and
submerged arc welding. In these processes, arc length is
kept constant, since any fluctuation in the distance
between the wire and the base material is quickly rectified
by a large change in current.
Bharati Vidyapeeth College of Engineering
Metal Arc welding
 Equipments:
 A welding generator (D.C.) or Transformer (A.C.)
 Two cables- one for work and one for electrode
 Electrode holder
 Electrode
 Protective shield
 Gloves
 Wire brush
 Chipping hammer
 Goggles

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Electrodes
 Filler rods are used in arc welding are called electrodes.
 Metallic wires having same composition as the metal to be weld.
 Coated uniformly with a protective coating called flux. e.g
titanium oxide, potassium oxide, cellulose, iron or manganese,
Ferro silicates, carbonates, gums, clays, asbestos etc…

Bharati Vidyapeeth College of Engineering


Types of Fluxes
Gas forming- Isolating welding zone from ambient air. e.g
organic matter like wood pulp

Slag forming- china clay, felspar, manganese, & titanium


ores

Reducing- ferro silicon,ferro titanium,ferro manganese


reduces oxides

Stabilizing- Ionized the zone b/w electrode and part to be


weld and ensuring stable burning.

Binding- so that covering should have proper binding with


bare electrode. Bharati Vidyapeeth College of Engineering
ARC WELDING PROCESS

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Bharati Vidyapeeth College of Engineering
Bharati Vidyapeeth College of Engineering
Shielded Metal Arc Welding (SMAW): “Stick welding”
• Arc temperature is nearly 5500°C
• The electrode is also the filler rod
• Only for steel
• Strong welds if done properly (but often not)
• Very high heat input: good for thick parts, bad for grain growth and
distortion

Kalpakjian

Bharati Vidyapeeth College of Engineering


Welding Tool Equipments

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Gas Metal Arc Welding (GMAW): “MIG” (Metal-Inert-Gas)
• Complex mechanism but simple to perform and easy to
automate
• The consumable electrode is used and fed continuously from
a spool. It melts in the arc.
• For steel or aluminum
• Low skill level can achieve good weld
• Medium heat input: distortion and grain growth are significant
•DCRP is used
•Inert gas (He, Ar, CO2) is used
•E.g used for Domestic cylinder part joining

Bharati Vidyapeeth College of Engineering Kalpakjian


Gas Metal Arc Welding (GMAW): “MIG” (Metal-Inert-Gas)

Bharati Vidyapeeth College of Engineering Kalpakjian


MIG Welding

Bharati Vidyapeeth College of Engineering


Gas Metal Arc Welding (GMAW): “MIG” (Metal-Inert-Gas)
Advantages of Metal Inert Gas Welding (MIG, GMAW):

•Continuous weld may be produced (no interruptions);


•High level of operators skill is not required;
•Oxide form on the surface cleaned automatically;

Disadvantages of Metal Inert Gas Welding (MIG, GMAW):

•Expensive and non-portable equipment is required;


•Outdoor application are limited because of effect of wind,
dispersing the shielding gas.

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Gas Tungsten Arc Welding (GTAW): “TIG” (Tungsten-Inert-
Gas)
• The electrode is tungsten (not consumed)
• The filler rod is separate and fed manually
• High skill level required to achieve good weld
• Difficult to automate
•He and Ar are used as inert gas
• Low heat input and small weld bead: distortion and grain growth are minimized
•AC power supply is used for welding of Al, Mg and its alloys in which half of the
cycle more heat is produced on the work-piece and remaining half of the cycle
cleaning of oxides take place.
•DCSP is used for all materials to be welded except Al, Mg and its alloys

Kalpakjian
Bharati Vidyapeeth College of Engineering
Gas Tungsten Arc Welding (GTAW): “TIG” (Tungsten-Inert-
Gas)

Kalpakjian
Bharati Vidyapeeth College of Engineering
Gas Tungsten Arc Welding (GTAW): “TIG” (Tungsten-Inert-Gas)

ADVANTAGES:-

• Weld composition is close to that of the parent metal;


• High quality weld structure
• Slag removal is not required (no slag);

DIS-ADVANTAGES:-

• Low welding rate;


• Relatively expensive;
• Requires high level of operators skill.

Bharati Vidyapeeth College of Engineering


CARBON ARC WELDING (CAW)
A process in which heat is generated by
an electric arc struck between an carbon
electrode and the work piece. The arc heats
and melts the work pieces edges, forming a
joint.

Carbon arc welding is the oldest welding


process.

Bharati Vidyapeeth College of Engineering


CARBON ARC WELDING (CAW)
ADVANTAGES:-

• Low cost of equipment and welding operation;


• High level of operator skill is not required;
• The process is easily automated;
• Low distortion of work piece.

DIS-ADVANTAGES:-

• Unstable quality of the weld (porosity);


• Carbon of electrode contaminates weld material with
carbides.

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SUBMERGED ARC WELDING (CAW)
Submerged Arc Welding is a welding process, which utilizes a bare
consumable metallic electrode producing an arc between itself and the
work piece within a granular shielding flux applied around the weld.

Since the electrode is submerged into the flux, the arc is invisible. The flux
is partially melts and forms a slag protecting the weld pool from oxidation
and other atmospheric contaminations.

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Bharati Vidyapeeth College of Engineering
Bharati Vidyapeeth College of Engineering
SUBMERGED ARC WELDING (CAW)
ADVANTAGES:-

•Very high welding rate;


•The process is suitable for automation;
•High quality weld structure

DIS-ADVANTAGES:-

•Weld may contain slag inclusions;


•Limited applications of the process - mostly for welding
horizontally located plates.

APPLICATIONS:-
• Ship building, longitudinal pipe welding, circumferential
welding in wind tower fabrication
Bharati Vidyapeeth College of Engineering
Resistance Spot Welding (RSW): “SPOT WELDING”
• No filler rod: electrical current is passed through metal under pressure
• Distortion and grain growth are minimized
• Low skill level required
• Easy to automate
• Low heat input and no weld bead

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Resistance Spot Welding (RSW): “SPOT WELDING”

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Bharati Vidyapeeth College of Engineering
Bharati Vidyapeeth College of Engineering
Resistance Spot Welding (RSW): “SPOT WELDING”
ADVANTAGES:-

• Low Cost
• Less skilled worker required
• Higher productivity

Disadvantages:-
Leak proof joint can not be made

APPLICATIONS:-

• Automobiles and aircraft industries


• Utensils and container
• Used for the welding of HSS, Low carbon steel, Cu, Ni
& Ni alloys
Bharati Vidyapeeth College of Engineering
Resistance SEAM Welding (RSW): “SEAM WELDING”
Seam welding is similar to spot welding except that the components to be joined
are gripped between revolving, circular copper rollers The welding current is
applied in a series of pulses resulting in a corresponding series of overlapping
spot welds being made along the seam

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Resistance SEAM Welding (RSW): “SEAM WELDING”

Bharati Vidyapeeth College of Engineering


Bharati Vidyapeeth College of Engineering
Resistance SEAM Welding (RSW): “SEAM WELDING”
ADVANTAGES:-

• Produce gas or liquid tight joints.


• Several parallel seams can be produced.
• Overlap can be less than spot welding.

DIS-ADVANTAGES:-

• Cost of equipments is high.


• Welding can be done only along straight line.
• Difficult to weld thickness greater than 3mm.

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Resistance Welding (RSW): “PROJECTION WELDING”
In this process the electrodes act as
locations for holding the parts to be joined
and are, therefore, job-specific.

The joint is so designed that projections are


preformed on one of the parts to be joined.

Projection welding enables the welding


pressure and the heated weld zone to be
localized at predetermined points.

This technique is largely used for small,


precision components that need to be
accurately located.

Bharati Vidyapeeth College of Engineering


Resistance Welding (RSW): “PROJECTION WELDING”

ADVANTAGES:-

• It is possible to weld more than one spot at a given time.


• Life of electrode is much longer than spot welding electrode.
• The uniformity and appearance of weld is better as compared to spot welding

DIS-ADVANTAGES:-

• Making of projections is an extra operation.


• All projection should be of same height.
• Metal which cannot support projection, cannot be weld.

APPLICATIONS:-

• Used for welding refrigerator condensor

Bharati Vidyapeeth College of Engineering


Resistance Welding (RSW): “BUTT OR UPSET WELDING”

The two ends of the rods are brought


together with just sufficient force to
ensure the current can flow without
arcing.
The resistance of the joint interface
ensures that local heating will take
place on the passage of a heavy
electric current at low voltage.

When the metal in the joint zone has


reached its welding temperature, the
current is switched off and the axial
force on the joint is increased to
complete the weld.

Bharati Vidyapeeth College of Engineering


Resistance Welding (RSW): “BUTT OR UPSET WELDING”

APPLICATIONS:-

• In wire drawing
Industries
• For producing butt
joint in tubes, pipes
& rods etc.

Bharati Vidyapeeth College of Engineering


Wire Drawing

Bharati Vidyapeeth College of Engineering


Resistance Welding (RSW): “FLASH BUTT WELDING”

Flash butt welding is similar to


upset butt welding except that
the heat required for melting is
obtained by means of an arc
rather than the simple resistance
welding.

Bharati Vidyapeeth College of Engineering


Resistance Welding (RSW): “BUTT OR UPSET WELDING”

ADVANTAGES:-

• It consumes less welding


current

• Process is cheap.

• Process is fast.

• It offers 100% strength


factor.

• Preparation of weld
surface is not required.
Bharati Vidyapeeth College of Engineering
Soldering
 It is a low temperature joining process in
which fusible alloy or metal is introduced
in a liquid state between work piece to be
joined It is performed at temperatures
below 450ºC for joining. The filler metal is
called SOLDER
 Soldering is used for,
 Sealing, as in automotive radiators
or tin cans
 Electrical Connections

 Joining thermally sensitive


components
 Joining dissimilar metals

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Types of Solder & Fluxes
 Soft solder- Lead 37% and Tin 63%
 Medium solder- Lead & Tin each 50%
 Electrician solder- Lead 58% and Tin 42%
 Plumber solder- Lead 70% and Tin 30%

Flux available in the form of powder, liquid or


in paste form.
 Inorganic flux(Corrosive flux)- It consist of zinc
& ammonium chloride
 Organic flux(Mild flux)- Lactic acid, stearic acid,
benzoic acid, glutamic acid etc
 Rosin(Non corrosive flux)- gum extruded from
pine trees

Bharati Vidyapeeth College of Engineering


Soldering Method
1. Soldering Iron Method 2. Torch Method
3. Spray Method 4. Induction Method
5. Dip & Wave Method 6. Resistance Method
7. Ultrasonic Method 8. Condensation Method

APPLICATIONS:-
 Connection in radios & T.V sets etc
 Radiator brass tubes for motor cars
 Sometime used for repairing utensils
 Wiring joint in electrical connections, battery and other
terminals

Bharati Vidyapeeth College of Engineering


Brazing
 It is a joining process of two metal piece
in which a non-ferrous alloy is introduced
in a liquid state between work piece to be
joined It is performed at temperatures
above 450ºC for joining.
 The filler metal is distributed by capillary
action.
 The capillary action between base metal
and filler metal is higher than that
between base metal and flux.
 Application of flux is by spraying,
brushing

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Brazing
FILLER METAS
•Aluminium silicon
•Copper zinc
•Magnesium
•Nickel
•Copper Phosphorus

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Brazing
APPLICATIONS:-

 Used for Fastening of pipes fittings, tanks, carbide tip on


tools, radiators, heat exchangers etc.
 It can join Cast metal to wrought metal and dissimilar
metals.

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Brazing
ADVANTAGES:-

 Dissimilar metals which can not be welded can be joined by brazing


 Very thin metals can be joined
 Metals with different thickness can be joined easily

DISADVANTAGES:-

 Brazed joints have lesser strength compared to welding


 Joint preparation cost is more

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“WELDING DEFECTS”
1. Lack of Penetration
It is the failure of the filler metal to penetrate
into the joint. It is due to
(a) Incorrect edge penetration
(b) Incorrect welding technique.

2. Lack of Fusion
Lack of fusion is the failure of the filler metal to
fuse with the parent metal. It is duo to
(a) Too fast travel
(b) Incorrect welding technique
(c) Insufficient heat

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“WELDING DEFECTS”
3. Undercuts
These are grooves or slots along the edges of
the weld caused by
(a) Too fast travel
(b) Bad welding technique
(c) Too much heat build-up.

4. Cracking
It is the formation of cracks either in the weld
metal or in the parent metal. It is due to
(a) Unsuitable parent metals used in the weld
(b) Bad welding technique

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5. Overlays
“WELDING DEFECTS”
These consist of metal that has flowed on to the parent metal without fusing with it.
The defect is due to
(a) Contamination of the surface of the parent metal
(b) Insufficient heat

6. Blowholes
These are large holes in the weld caused by
(a) Gas being trapped, due to moisture.
(b) Contamination of either the filler or parent metals.

7. Burn Through
It is the collapse of the weld pool due to
(a) Too much heat concentration
(b) Poor edge preparation.

8. Excessive Penetration
It is where the weld metal protrudes through the root of the weld. It is caused by
(a) Incorrect edge preparation
(b) Too much heat concentration
(c) Too slow travel. Bharati Vidyapeeth College of Engineering

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