Welding Metallurgy

Module-1
Lecture 1: Introduction of Welding

Dr. Riya Mondal

Department of Metallurgy and Material Engineering
NIAMT Ranchi
Contents:
 Syllabus of the course
 Definition of welding
 History of welding
 Common welding base material
 General advantage of welding
 General disadvantage of welding
 Welding as compared to casting
 Welding as compared to riveting
 Practical applications of welding
 Text Books

 Dr. O. P. Khanna, Welding Technology, Reprint: 2002.

 A. O. Brien, Welding Handbook: Welding Processes, Part 1, Vol.2, AWS,2004.

 J. F. Lancaster (Ed), The Physics of welding, Pergamon, 1986.

 R.W. Messler, Principles of Welding, John Wiley and Sons,1999.

 V. M. Radhakrishnan, Welding Technology and Design, New age. 2002.

 Introduction
Definition of Weld:
“A localized coalescence of metals or nonmetals produced either by heating the
materials to the welding temperature, with or without the application of pressure, or
by the application of pressure alone and with or without the use of filler material”
Definition of Welding:
“Welding refers to an extensive group of manufacturing processes.” A joining
process that produces a coalescence of metals by heating them to the welding
temperature. With or without the application of pressure and with or without the use
of filler metals.
The weldability of a material refers to its ability to be welded. Many metals and thermoplastics
can be welded, but some are easier to weld than others. It greatly influences weld quality and is
an important factor in choosing which welding process to use.

 The large bulk of materials that are welded are metals and their alloys. The welding is also
applied to the joining of other material such as thermoplastics.
 In welding heat is supplied either by electrical arc or by a gas torch or by some other
means.
 The most essential requirement is Heat but in some processes Pressure is also employed.
 The joining bond is metallurgical (involving some diffusion) rather than just mechanical,
as with riveting and bolting.
 Welding produce permanent joint between the parts to be assembled.
 History of Welding
 Middle Ages: Blacksmiths of the Middle Ages welded various types of iron tools by
hammering. The welding methods remained more or less unchanged until the dawn of the 19th
century.
 Late 19th Century
Engineers/scientists apply advances of electricity to heat and join metals (Joule, Le Chatelier,
etc.)
 Early 20th Century
Prior to 1st World War welding was not trusted as a method to join two metals due to crack
issues.
 1930’s & 40’s
Industrial welding gains acceptance and is used extensively in the war effort to build tanks,
aircraft, ships etc. The use of welding in today’s technology is extensive. It is a remarkable rise
since about 1930.
 19th Century (1800): In this century, major weldings were made.

1830: Englishman Edmund Davy discovered acetylene in 1836 and acetylene was soon utilized by the welding
industry.
1880: In 1881, French scientist Auguste De Meritens succeeded in fusing lead plates by using the heat generated
from an arc.
1890: During the 1890's, one of the most popular welding methods was invented i.e. carbon arc welding. In this
time, thermite welding was also invented in 1893.

 20th Century (1900):

1900:
Coated metal electrode was first introduced by Strohmenger. A coating helped the arc to be much more stable.
A number of other welding processes were developed during this period i.e. seam welding, spot welding, flash
butt welding, and projection welding.
1919:
After the end of World War I, the American Welding Society was established by Comfort Avery Adams. The aim
of the society was the advancement of welding processes.
1920:
Automatic welding was first introduced which was invented by P. O. Nobel. In 1920, an early predecessor of
GMAW was invented by P. O. Nobel of General Electric.
 History of Welding (cont.)
1930: The New York Navy Yard developed stud welding. Stud welding was increasingly used for
the construction industry and also for shipbuilding.
1940: The GTAW was another significant milestone in the history of welding which was
developed in Battelle Memorial Institute in 1948.
1960: There were several advancements in the welding industry during the 1960's. Electroslag
welding and Plasma arc welding were invented during this time.
1990: In 1991, Welding Institute invented FSW. It is a solid state joining process which utilizes
frictional heat of a rotating tool and stirring effect of the tool probe for solid state joining.
The use of welding in today’s technology is extensive. This growth is faster than the general
industrial growth.
Module-2
Lecture 3: Oxy-Fuel Gas Welding
Gas welding (Process, Equipment and Applications):
Principle of the Process:
 Heat required for welding is obtained from the flame generated due to oxy-fuel mixture combustion.
 The flame resulting at the tip of the torch is sufficient to melt and join the parent metal.
 A filler metal rod is generally added to molten metal pool to build up the seam slightly for greater strength.
 This welding does not require the components to be forced together under pressure until the weld forms and
solidifies.

Oxyacetylene welding (OAW):

In this case, welding is performed by a flame formed
by the combustion of oxygen and acetylene. The
flame comes from a torch. A filler rod coated with
flux is used sometimes which prevents oxidation,
creating a better joint. Acetylene is a famous fuel
because it is capable of generating a temperature
of 3500°C.
Oxyacetylene Combustion OR Reactions:
As the oxygen-acetylene mixture burns from the tip of the welding torch, it displays several clearly recognizable zones of
combustion. The overall chemical equation for the complete combustion of acetylene is:
2C2H2 + 5O2 → 4CO2 + 2H2O ............................................(1)
Combustion takes place in two stages:
The first stage: In the first stage the oxygen uses for combustion is supplied from the oxygen cylinder. The reaction can be seen
as the small inner cone of the flame. The highest temperature is at the point of this cone.
2C2H2 + 2O2 → 4CO + 2H2 .................................................(2)
The second stage:
4CO + 2H2 + 3O2 → 4CO2 + 2H2O.....................................(3)
uses the oxygen supplied from the air surrounding the flame. This combustion zone constitutes the outer envelope of the flame.
Oxy-acetylene flames
The type of flame produced depends upon the ratio of oxygen to acetylene in the gas mixture which leaves the torch tip.
There are three distinct types of oxy-acetylene flames, usually termed:

i. Carburizing flame (Excess Acetylene flame)

ii. Neutral flame
iii. Oxidizing flame (Excess Oxygen flame)

Acetylene Flame: When acetylene alone is burned in air, it produces a flame that varies in color from yellow near the torch tip
to orange-red at the outer extremity.
 Depending upon the presence of excess acetylene in oxy-acetylene flame it can be categories as:
(i)Carburizing Flame
As the oxygen valve in the torch is progressively opened and the ratio of oxygen to acetylene increases, the flame
becomes generally bright. Then, the bright portion contracts toward the welding tip, forming a distinct bright zone
within a blue outer envelope.
This is a carburizing flame because it has a large excess of acetylene; it is sometimes described as a soft flame
because it has very little force.
Application: It has a relatively low temperature and is used in silver brazing and soldering, as well as in the welding
of lead. It is generally used for carburizing (surface hardening) purposes.
Note: Reducing Flame: (Max. temperature is about 3040°C): The flame is as a slightly excess acetylene or
reducing flame but less than the carburizing flame. As more oxygen is introduced, the bright zone of the flame
contracts further and is seen to consist of two parts:
• A bright inner cone and
• A pale-green feather,
The feather is caused by a slight excess of acetylene.
For welding steel, the length of the feather should be about one-eighth to one-quarter, but never more than one-half,
the length of the inner cone. It should not be called a carburizing flame because it does not carburize the metal, but it
does ensure the absence of the oxidizing condition.
Application: It is used in Low alloy steel, non-ferrous metals that do not tend to absorb carbon. It is very well used
for high carbon steel.
ii) Neutral flame (Max. temperature is about 3260 °C):
Equal amounts of oxygen and acetylene are burning, neither excess acetylene nor excess oxygen
is present at the high-temperature tip of the inner cone. For this reason, this flame is called neutral
flame and the gas mixture is often described as an acetylene-to-oxygen ratio of 1 to 1. So, when
the presence of carbon must be strictly avoided. When the oxidizing condition is unacceptable, as
in the case of stainless steel welding, the use of a neutral flame is essential for good results. It has
a light blue inner cone with a darker blue outer envelope. A neutral flame is named so because
it effects no chemical changes in the molten metal and therefore will not oxidize or carburize the
metal. Neutral flames are commonly used to weld: Mild steel, Stainless steel, Cast iron,
Aluminum, Copper.
iii) Oxidizing Flame (Max. temperature is about 3315°C):
It is produced when more than one volume of oxygen is mixed with one volume of acetylene. It
has a small white cone which is much shorter, much bluer in colour and more pointed than that of
neutral flame.
The flame should be sufficiently rich in oxygen to ensure that a film of oxide slag forms over the
weld to provide shielding for the weld pool. Here the oxygen-to-acetylene ratio is about 1.5/1.
An oxidizing flame should never be used in welding steel.
It is used only in welding copper, certain copper-base alloys and zinc-base material.
Oxy-Acetylene Welding Setup OR Equipment:
The simplest and most frequently used OAW system consists of:
i) Compressed gas cylinders

ii) Gas pressure regulators

iii) Hoses, and

iv) A welding torch

The gas regulator attached to each cylinder, whether fuel gas or oxygen, controls the pressure at which the gas flows to the
welding torch
 Oxygen and acetylene gases are stored in separate cylinders.
 At the torch, the gas passes through an inlet control valve, through tubes within the handle, and into the mixing chamber of
the welding nozzle attached to the welding torch.
 The mixed gases then pass through the welding tip and produce the flame at the exit end of the tip.
 Filler metal, when needed, is provided by a welding filler rod that is melted progressively along with the surfaces to be

joined.
Gas pressure regulators
Gas pressure regulators are employed for regulating the supply of acetylene and oxygen gas from cylinders. A
pressure regulator is connected between the cylinder and hose leading to welding torch. The cylinder and hose
connections have left-handed threads on the acetylene regulator while these are right handed on the oxygen
regulator. A pressure regulator is fitted with two pressure gauges, one for indication of the gas pressure in the
cylinder and the other for indication of the reduced pressure at which the gas is going out.
Welding torch
Figure shows the construction of the welding torch. It is a tool for mixing oxygen and acetylene in correct
proportion and burning the mixture at the end of a tip. Gas flow to the torch is controlled with the help of two needle
valves in the handle of the torch. There are two basic types of gas welding torches:
(1) Positive pressure (also known as medium or equal pressure), and
(2) Low pressure or injector type
The positive pressure type welding torch is the more common of the two types of oxyacetylene torches.
Torch tips
It is the portion of the welding apparatus through which the gases pass just prior to their ignition and burning. A great variety of
interchangeable welding tips differing in size, shape and construction are available commercially. The tip sizes are identified by
the diameter of the opening. The diameter of the tip opening used for welding depends upon the type of metal to be welded.
Hose pipes
The hose pipes are used for the supply of gases from the pressure regulators. The most common method of hose pipe fitting both
oxygen and acetylene gas is the reinforced rubber hose pipe. Green is the standard color for oxygen hose, red for acetylene, and
black hose for other industrially available welding gases.
Goggles
These are fitted with colored lenses and are used to protect the eyes from harmful heat and ultraviolet and infrared rays.
Gloves
These are required to protect the hands from any injury due to the heat of welding process.
Spark-lighter
It is used for frequent igniting the welding torch.
Filler rods
Gas welding can be done with or without using filler rod. When welding with the filler rod, it should be held at
approximately 900 to the welding tip. Filler rods have the same or nearly the same chemical composition as the base
metal. Metallurgical properties of the weld deposit can be controlled by the optimum choice of filler rod. Most of the
filler rods for gas welding also contain deoxidizers to control the oxygen content of weld pool.

Fluxes
Fluxes are used in gas welding to remove the oxide film and to maintain a clean surface. These are usually employed
for gas welding of aluminium, stainless steel, cast iron, brass and silicon bronze. They are available in the market in
the form of dry powder, paste, or thick solutions.
Applications:
 It can be used for preheating, post heating, welding, braze welding, and torch brazing, and it is readily converted
into oxygen cutting.

 The process can be adapted to short production runs, field work and repairs.

 Metals that can be oxy-fuel gas welded: Most ferrous and nonferrous metals can be oxy fuel gas welded.
Oxyfuel gas welding can be used to join thin carbon steel sheet and carbon steel tube and pipe.

 Oxyfuel gas welding is frequently used for repairs and alterations because the equipment is portable, welding
can be done in all positions, and acetylene and oxygen are readily available.
Advantages of OAW
 The equipment is low cost, versatile, self-sufficient and usually portable. Besides welding the oxyacetylene can be
used for welding, brazing, soldering, preheating, post-heating and metal cutting etc.
 It requires little maintenance, and can be used with equal facility in the field and in the factory.
 It can weld most common materials.
 The gas flame temperature is lower and easily controllable which is necessary for delicate work. Therefore
oxyacetylene welding is extensively used for sheet metal fabrication and repairs.
 The rate of heating and cooling is relatively low. In some cases this is an advantage.
 Since the source of heat and the filler metal are separate, the welder has control over filler metal deposition rates.
Heat can be applied preferentially to the base metal and the filler metal.
 Oxyfuel gas welding is capable of joining small-diameter carbon steel pipe (up to about 75 mm diameter) with
resulting weld quality equal to competitive processes and often with greater economy.
 Pipe with wall thickness up to 4.8 mm ( 3/16 inch) can be welded in a single pass.
Disadvantages of OAW
 Oxygen and acetylene gases are expensive.
 There are safety problems involved in their handling and storing.
 The flame takes considerably longer for the metal to heat up. Due to this, oxyacetylene welding is not suitable for
thick sections.
 Because the flame is not concentrated and it needs prolonged heating of the joint which result in a larger heat
affected area . This often leads to increases grain growth, more distortion and in some cases loss of corrosion
resistance.
 Flame temperature is less than the arc temperature. Gas flame takes a long time to heat up the metal than arc.
 Refractory metals like Columbium, Tantalum, Molybdenum, Tungsten and the reacting metals such as Titanium
and Zirconium cannot be welded by this process.
 More safety problems are associated with the handling and storing of gases.
Module-3
Lecture 4: Arc Welding
 Principle of the Process
 Heat required for welding is obtained from the arc struck between a coated electrode and the workpiece. The arc
temperature and thus the arc heat can be increased or decreased by employing higher or lower arc currents.
 A high current arc with a smaller arc length produces a very intense heat. The arc reaches temperatures of around
10,000°F. The arc melt the electrode and the job.
 Both work piece and electrode is connected to different terminals of AC or DC supply.
 An electric arc is formed whenever current is passed between two metallic electrodes separated by a short
distance.
 Whenever electrode first touches the plate, a large short circuit flows and as it withdrawn later, current continues
to flow in the form of spark across the air gap. Due to this spark, air gets ionized and air becomes conducting and
so, current is able to flow across the gap.
 Material droplets are transferred from electrode to the job, through the arc and are deposited along the joint to be
welded.
 The flux coating melts, produces a gaseous shield and slag to prevent atmospheric contamination of the molten
weld metal.
Types of arc welding:

 Unshielded arc welding: When a large electrode or filler rod is used for welding, it is said to be un- shielded arc
welding.

 Shielded arc welding: When the welding rods coated with fluxing material are used, then it is called shielded arc
welding.

Electrodes: An electrode is a tool used in arc welding to produce electric arc.

Based on their characteristics, arc welding electrodes can be broadly classified into two types. They are:

 Consumable Electrode: If the melting point of an arc welding electrode is less, it melts and fills the gap in the
workpiece. Such an electrode is called consumable electrode.

 Non-consumable electrode: If the melting point of the arc welding electrode is high, it does not melt to fill the
gap in the workpiece. Such an electrode is called non-consumable electrode.
Welding Electrodes:
An electrode is a piece of wire or a rod of a metal or alloy, with or without coatings. An arc is set
up between electrode and workpiece. Welding electrodes are classified into following types-
i. Consumable Electrodes ii. Non-consumable Electrodes
1. Bare Electrodes 1. Carbon or Graphite Electrodes
2. Coated Electrodes 2. Tungsten Electrodes
Consumable electrode is made of different metals and their alloys. The end of this electrode
starts melting when arc is struck between the electrode and workpiece. Thus consumable
electrode itself acts as a filler metal. Bare electrodes consist of a metal or alloy wire without any
flux coating on them. Coated electrodes have flux coating which starts melting as soon as an
electric arc is struck. This coating on melting performs many functions like prevention of joint
from atmospheric contamination, arc stabilizers etc.
Non-consumable electrodes are made up of high melting point materials like carbon, pure
tungsten or alloy tungsten etc. These electrodes do not melt away during welding. But practically,
the electrode length goes on decreasing with the passage of time, because of oxidation and
vaporization of the electrode material during welding. The materials of non-consumable
electrodes are usually copper coated carbon or graphite, pure tungsten, thoriated or zirconiated
tungsten.
 Shielded Metal Arc Welding (SMAW):
Shielded metal arc welding (SMAW), also known as manual metal arc welding (MMA or MMAW), flux shielded
arc welding or informally as stick welding, is a manual arc welding process that uses a consumable electrode
covered with a flux to lay the weld.

SMAW Set up
 Arc welding Power source
 Electrode
 Workpiece
 Electrode holder
 Electrode lead cable
 Welding table
 Current flows through the electrode cable, to the electrode holder, through
 Workpiece lead (cable)
the electrode, and across the arc.
 Input power lead (cable)
 On the work side of the arc, the current flows through the base material to
the work clamp and back to the welding machine.
 Details of SMAW Process
Different constituents of a SAMW process:

1.Electrode
2.Weld puddle
3.Arc
4.Shielding gas
5.Solidified weld metal
6.Slag
Process: Shielded metal arc welding (SMAW) is a process that melts and joins metals by heating them with an arc
established between a sticklike covered electrode and the metals. It is often called stick welding. The electrode holder
is connected through a welding cable to one terminal of the power source and the workpiece is connected through a
second cable to the other terminal of the power source. The core of the covered electrode, the core wire, conducts the
electric current to the arc and provides filler metal for the joint. For electrical contact, the top 1.5 cm of the core wire
is bare and held by the electrode holder. The electrode holder is essentially a metal clamp with an electrically
insulated outside shell for the welder to hold safely. The heat of the arc causes both the core wire and the flux
covering at the electrode tip to melt off as droplets. The molten metal collects in the weld pool and solidifies into the
weld metal. The lighter molten flux, on the other hand, floats on the pool surface and solidifies into a slag layer at the
top of the weld metal. i. Turn power supply on iv) Adjust output
a. Polarity
ii. Connect work clamp
b. Amperage
iii. Select electrode v) Insert electrode into electrode holder
(Type & Diameter)
Advantages of SMAW process are: Limitations of SMAW process are:
1) Simple, portable and inexpensive welding 1) Lower consumable efficiency
equipment
2) Difficult to weld very thin materials
2) Both filler metal, arc and molten metal
shielding are provided by the electrode. 3) Frequent restarts

3) Can be used in areas of limited access. 4) Higher operator skill required for SMAW than some
other processes
4) Low initial cost.
5) Deposition rates are generally lower than other
5) All position capabilities. welding process such as GMAW.

6) Suitable for most of the commonly used 6) Maximum current that can be used is limited by the
metals and alloys. electrical resistance of the core wire.

7) Excessive current may overheat the electrode

breaking down the flux coating.

8) Deteriorates arc behavior and shielding.

Applications of SMAW:
 Suitable for most of the commonly used metals and alloys.

 SMAW is used both as fabrication process and maintenances. It is also used in repair jobs. The
process finds applications in

i) ship building

ii) pipes joining

iii) automotive and aircraft industry

iv) building and bridge construction

v) air receiver, tank , boiler

vi) pressure vessel fabrications.

Module-3
Lecture 5: Submerged Arc Welding
 Submerged are welding (SAW):
Introduction of SAW

 Heat for fusion is generated from an arc between a continuous consumable electrode and the base metal.

 The filler metal is a bare consumable electrode wire, fed through a wire feeder.

The arc, end of the electrode and molten pool remain completely hidden and are invisible being submerged under a blanket of
granular flux.
Basic Features

 Arc fully submerged in flux.

 Heat loss is minimum. Thermal efficiency as high as 80-90%.
 Produces no visible arc light

 Welding is spatter free

 High deposition
Downhand welding process
Principle of SAW

 In SAW process, instead of a flux covered electrode, granular

flux and bare (or copper coated) electrode is used.

 Arc between the electrode and job is the heat source and remains
buried/ suppressed under the flux.

 The flux serves as shield and protects the molten weld pool from
atmospheric contamination.

The process may be semi-automatic or fully-automatic.

Process of SAW:

 Flux is fed directly on the arc from a hopper. The submerged arc welding flux feeds through the hopper tube and continuously
distributes itself over the seam a short distance ahead of the welding zone.

 Electrode acts as the filler wire and Fed continuously by a wire-feeding mechanism. The wire feed mechanism begins to feed
the welding into the joint at a controlled rate.

 An electric arc is established as the current flows between the electrode and the work.

 The carriage is started (manually or automatically) to travel along the seam.

 Arc heat burns some of the flux, electrode tip and the adjacent edges of the base metal, creating a pool of molten metal below a
layer of liquid slag (burnt flux)

 Slag floats on the molten metal and thus completely shields the molten zone from the atmosphere.

 It also dissolves impurities in the base metal and electrode and floats them up to the surface.

Slag shield results in a slower cooling rate for the deposited weld metal and thus provides an annealing effect to the weld deposit.
 Process variants

According to material thickness, joint type and size of component,

varying the following can increase deposition rate and improve
bead shape.
v) Electrode diameter
i) Welding current
vi) Electrode extension (length of stick out)
ii) Polarity
vii) Type of flux
iii) Welding voltage
viii)Width and depth of flux layer
iv) Welding speed
ix) Wire feed rate
Flux:

 Apart from shielding it also provides:

 Stability of the arc.

 Chemical composition of the weld metal.

 Mechanical properties of weld deposit.

Granular fusible minerals containing oxides of manganese, silicon, titanium, aluminum, calcium, zirconium,
magnesium and other compounds such as calcium fluoride. (short form MSC MA TZ). The flux is specially
formulated to be compatible with a given electrode wire type so that the combination of flux and wire yields desired
mechanical properties. All fluxes react with the weld pool to produce the weld metal chemical composition and
mechanical properties. It is common practice to refer to fluxes as 'active' if they add manganese and silicon to the
weld, the amount of manganese and silicon added is influenced by the arc voltage and the welding current level.
The main types of flux for SAW are:

i) Bonded Flux: Bonded with a low melting compound such as sodium silicate. Contain metallic deoxidisers,
Help to prevent weld porosity. These fluxes are effective over rust and mill scale.

ii) Fused fluxes: Produced by mixing the ingredients, then melting, cooling and grinding. Smooth stable arcs,
with welding currents up to 2000A. The flux prior to use should be backed (around 900°C) to remove moisture.
Moisture, if present in the flux, will cause porosity in the weld deposit.
Wire:
SAW is normally operated with a single wire on either AC or DC current. Common variants are:

1. Twin wire

2. Multiple wire (tandem or triple)

3. Single wire with hot or cold wire addition

4. Metal powder addition

5. Tubular wire

All contribute to improved productivity through a marked increase in weld metal deposition
rates and/or travel speeds. A narrow gap process variant is also established, which utilizes a
two or three bead per layer deposition technique.
 Advantages:
i) This gives consistently high quality welds with minimum operator skills. Molten flux provides very suitable conditions for high current to
flow.
ii) Minimum of welding fume and of arc visibility (radiation).
iii) Well suited to welding thick sections. Practically, no edge preparation is necessary for materials under 12 mm in thickness.
iv) Suitable for welding carbon, low alloy and alloy steels.
v) This process can be used for welding in exposed areas with relatively high winds.
vi) Because of high heat concentration, considerably higher welding speed can be used.
vii) Relatively high metal deposition rates. The rate of deposition of material is very high, about 45 kg/h. The ability to produce high quality,
defect free welds.
viii)With submerged arc welding, strong welds are readily made with good process design and control.
ix) SAW gives deep weld penetration.
x) With submerged arc welding process, high speed welding of thin sheet steels up to 5 m/min. is possible.
xi) In mechanized applications, SAW gives high operation factor.
xii) Submerged arc welding process is suitable for both indoor and outdoor applications.
xiii)In case of SAW, 50 % to 90 % of the flux is recoverable.
xiv)Distortion is much less with the submerged welding process.
 Disadvantages:
i) Weld may contain slag inclusions.

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

iii) In small thickness (i.e. less than 4.8mm) burn through is likely to occur.

iv) Weld metal chemistry is difficult to control.

v) A change in welding variables especially when using alloyed fluxes may affect weld metal composition adversely. Submerged
arc welding process requires relatively troublesome flux handling systems.

vi) Cast iron, Al-alloy, Mg-alloy, Pb and Zn cannot be welded.

vii) SAW can only be used for welding of ferrous materials like steel or stainless steel and some nickel based alloys.

viii)Submerged arc welding process requires inter-pass and post weld slag removal.

ix) The residues of flux and slag can present the health and safety concerns.
x) SAW is limited to the 1F, 2F and 1G welding positions only.
Application:

i) SAW is widely used for welding carbon, carbon manganese, alloy and stainless steels.

ii) It is also used for joining some nickel based alloys.

iii) Fabrication of pipes, pressure vessels, boilers, structural shapes, rail road, crane, bridge, girders, under structures of railway
coaches, locomotives etc.

iv) It is widely used in automotive, aviation (aero-plane), ship-building and nuclear power industries.

v) High deposition rates and with deep weld penetration makes the SAW process highly suitable for all mechanized and automatic
welding and surfacing applications.

vi) It is widely used for cladding carbon and alloy steels with stainless steel and nickel alloy deposits.

vii) It is also used in hard facing tractor rollers & idlers and crane pulleys