Presentation on welding Process

Presented by Submitted to
suman kumar saurabh (1) Prof. Prabha Chand (2) Dr US Yadav
Research scholar NIT Jamshedpur Senior scientific officer-I
ME2019RSME011 Mechanical Engineering Department HAL ,Kanpur
Welding
Welding is a joining process of two similar or dissimilar materials by the application of
heat with or without pressure and with or without application of filler materials. It is a
permanent joint. It is essential for manufacturing industry.
in welding heat is supplied either by electrical arc or by gas torch or by other sources.
Advantages
 It is used for repair work.
 Strength of joint is greater than equal to parent material.
 They have high corrosion resistance.
 Different types of joints can be done.
 Welding is economical and cost efficient.
Welding
Disadvantages
• Highly skilled operator is required
• It produce harmful radiations.
• It produce internal stresses distortion and change in micro structure in welding
region.
• Initial investment is more
Applications
• Automobile parts.
• Aircraft and ship construction.
• Machine frames.
• Pipelines.
• Tanks and vessels.
Joining process
Two types of joining process-
1. Mechanical bonding
2. Atomic bonding
Mechanical bonding

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I. Temporary joint- with screw elements

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II. Permanent /semi-
Rivets, staples, stitches, shrink-fit
Atomic bonding- Welding is main categories
Classification of welding
Welding can be classified based on the following aspects-
I. Source of heat
II. Application of pressure
III. Depending upon the different phase of base material and

M P Groover, Fundamentals of
©2010 John Wiley & Sons, Inc.
filler material.

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IV. Depending upon compos of the joints
V. Depending upon the pos of electrode
VI. Mechanism
 Classification of welding

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M P Groover, Fundamentals of
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Classification of Welding Processes

Fusion welding - Fusion welding is a process that uses heat to join or fuse two or
more materials by heating them to melting point. The process may or may not
require the use a filler materials.
Examples: arc welding, resistance spot welding, gas welding

Solid state welding - Solid state welding is a group of welding processes which
produces coalescence at temperatures essentially below the melting point of the
base materials being joined, without the addition of brazing filler metal. Pressure
may or may not be used.
These processes are sometimes erroneously called solid state bonding processes
Examples: cold welding, diffusion welding, explosion welding, forge welding,
friction welding, hot pressure welding, roll welding, and ultrasonic welding.
Welding classifications
Acetylene gas welding
• In this process oxygen and acetylene gas is used for welding process.
• It rises the temperature of metal above melting point.
• Filler material is used for joining.
• Operation
• In this process oxygen and acetylene is used for the welding.
• Oxygen supports the combustion and acetylene gas generate high temp.
• Operation starts with placing the part togather which is to be join.
• Oxiacetylene flame heat the metal temp produced is about 3200°c.
• Filler metal is added to the join which join the parts by melting it self.
• filler material is copper coated steel, carbon steel.
• chemical reaction at tip is as followed.
• 2C²H²+5O²→4CO²+2H²O
Welding processes

• Advantages.
• It is used for all types of joints.
• Oxyacetylene flame can be easily controlled.
• Suitable for thin metal sheets.
• Equipment is portable & versatile.
• Limitations.
• Method is slower.
• Distortion of work piece is more.
Types of flames
• Natural flame.
1. All gas is burn
2. Gives 100% heat.
3. Ideal flame used in gas welding.
• Reducing flame.
1. It consist of inner core intermediate feather and outer flame.
2. It is also called as carburising flame.
3. strong reduction in higher zone due to high amount of acetylene .
• Oxidizing flame.
1. It contain more oxygen than any other flame.
2. This is used for oxidizing metal like brass,Zink etc.
3. It is similar to natural flame.
Arc welding
• In this process heat generation takes place by an electric arc.
• Both work piece and electrode is connected to different terminals of AC or DC
supply.
• small gap bet work piece and electrode arc is generated.
• It produces temp about 3600°c.

M P Groover, Fundamentals of
©2010 John Wiley & Sons, Inc.
It having following types.

1. Carbon Arc welding.

2. Shielded metal arc welding.
3. Gas shielded arc welding.
4. Plasma arc welding.
Carbon arc welding
• It is new welding process.
• Electric is made of carbon.
• Electrics are soft and not suitable for high temp.
• Electric consumption slowly & requires filler material.
• Arc is generated between electrode and w/p.
• DC supply is used Electrode is negative & w/p is positive.
• It is used for thick material.
Shielded metal arc welding
• In this electric arc is used for the welding purpose.
• flux coated electrode is used for the welding.
• flux gives stability to protection to weld metal.
• during welding electrode is melt and serve as filler material.
• flux over the electrode is also get melt to form coating over the weld material.

Advantages.
• Simple process.
• welding equipments are portable and less costly.
• Metal and alloy can be welded.
• Applicable in any position.

Disadvantages.
• Automatic welding is difficult because of short electrode.
• Process is slow.
• Welding defects are more during replacement of electrode.
Tungsten inert gas
welding(TIG)
• It is also called as gas tungsten arc welding.
• inert gas is act as shield and keep contaminant away from welded metal.
• Electrod does not melt during welding.it is non consumable electrod.
• filler material added separately.
• Inert gas used is argon.
• Advantages.
• Slag free operation due to absence of flux.
• different materials can be welded.
• no cleaning requires.
• Disadvantages.
• Equipment cost is high.
• slow process.
• Filler material requires
Metal inert gas welding (MIG)
• It is also known as Gas metal arc welding (GMAW).
• In this process weld joint is produced by heating the metal with electric arc.
• The filling wire is continuously feed from wire reel at constant rate.
• wire is feed though the rollers at constant rate.
• Instead of flux ineart gas is supplied through welding torch.
• welding torch is connected to cylinder of unwary gas like argon
• Advantages.
• slag inclusion are not occurs.
• Continuous feed makes process faster.
• Less skilled operator is required.
• thick sheets can be welded.
•
MIG ….
• Disadvantages.
• Process is complicated.
• setup is complicated.
• Initial cost is high..
• Applications.
• For welding of commercial
• metals like Nickel,killed steel.
Plasma arc welding
• Plasma is heated ionized gas enable it to conduct electric current.
• Plasma arc is narrow restricted electric arc passes through water cooler orifice.
• It consist of non consumable tungsten electrod and shielding gas like argon.
• Argon gas flows through the orifice to form plasma.
• the temperature of plasma is about 10000°c.
• Advantages.
• Weld uniform throughout.
• greater depth of welding with less distortion.
• proper control on heat.
• metal disposition rate is high.
•
Plasma arc welding
• Limitations.
• Welding equipments are expensive.
• frequent replacement of nozzle.
• Applications
• Stainless steel welding.

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• Nickel alloy in aero plane.
• Aluminium or graphite nozzles for rocket
Resistance welding
• In these process heat and pressure is applied on joint.
• No additional filler or flux material required.
• joint is obtained by means of electrical resisitance.
• During process heavy current about 15000A is passed over joint with limited
area for short time.
• Heavy current heat joint up to plastic state.

M P Groover, Fundamentals of
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• due to high pressure metal get fused and forms joint.
• Heat generated is given as bellow H= CI2Rt
• It is classified as
1. Spot Welding
2. Seam Welding
3. Projection welding
4. Upset Welding
Spot Welding

• It is first type of resistance welding and widely used for lap joint of thin metal sheet.
• It is consist of two electrodes in which bottom electrode is fixed and upper is used for apply
pressure.
• Sheets to be weld are kept in the two electrode .
• The pressure is applied over the sheets and current is passed though it so that they
get weld.
• Welding is done due to high current is passed through the metal plates which produce heat.
• Applications
• For mass production.
• For Ferrous and Non ferrous metals.
• Used to weld sheets of 10mm thick
Seam Welding

• It is used for special purpose

• In this process disk type electrodes are used.
• It is used to produce continuous type of welding between two sheets.
• Disk are made up of cupper and current is applied through it
• Current is applied in pulse form with proper time interval
• Disks are rotate continuously so that metal sheets moves forward.
• Current can be regulated by timer to produce continuous seam.
• Applications.
• For gas or water tight joints
• To manufacture seam welded pipes
Projection Welding
• It is modification of spot welding.
• In this type one of the sheet is provided with projections and other is plane.
• These projections are in circular form.
• There diameter is equal to thickness of plate.
• Current and pressure is get concentrated at projection areas during process.
• During this process sheets to welded are kept between electrodes which made of
cupper .
• Pressure is applied by upper
movable electrode and lower
is fixed .
• By passing current these
projections are get melted and
welding is done.
Others Fusion Welding Processes

Others FW processes that cannot be classified as arc,

resistance, or oxyfuel welding. In this fusion welding used unique technologies
to develop heat formelting
Applications are typically unique
 Electron beam welding

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 Laser beam welding

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 Electroslag welding
 Thermit welding
EBW
• EBW is Fusion welding process in which heat for welding is
provided by a highly-focused, high-intensity stream of
electrons striking work surface.
• Electron beam gun operates at High voltage (e.g., 10 to 150
kV typical) to accelerate electrons Beam currents are low

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(measured in milliamps)
• Power in EBW not exceptional, but power density
• Is low
 EBW…

©2010 John Wiley & Sons, Inc.

M P Groover, Fundamentals of
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EBW Advantages and
Disadvantages
Advantages:

 High-quality welds, deep and narrow profiles

 Limited heat affected zone, low thermal distortion
 No flux or shielding gases needed

M P Groover, Fundamentals of
©2010 John Wiley & Sons, Inc.

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Disadvantages:

High equipment cost

 Precise joint preparation & alignment required
 Vacuum chamber required
Safety concern: EBW generates x-rays