Manufacturing technology

MEC205
Fusion Welding processes
Welding positions
WELDING PROCESSES

1. Arc Welding
2. Resistance Welding
3. Oxyfuel Gas Welding
4. Other Fusion Welding Processes
5. Solid State Welding
6. Weld Quality
7. Weldability
8. Design Considerations in Welding
 Arc Welding (AW)

• An arc is generated between two

conductors (Electrodes), cathode and
anode( direct current DC).
• For arc generation- Contact has been
made between these two and then
separated to maintain optimum gap.
• An Arc is a “sustained electric discharge”
which results of ionization of gap
column
• The arc temperature may reach 5500°C-
6000 °C
• Electrons are liberated from cathode
moves towards anode(wp) and
accelerated in their movement
Arc welding
Principle of Arc
• electrons when they strike the anode(workpiece) at high velocity, a
large amount of heat generated.
•They collide with the positive ions in arc column .
•A temperature of the order 6000 degree is generated at the anode.
•Larger air gap requires higher potential difference to produce an arc.
•If too large air gap, arc may extinguished.
•AC may be preferred.
•Most AW processes add filler metal to increase volume and strength
of weld joint
Arc welding

•A pool of molten metal is formed near electrode tip, and as

electrode is moved along joint, molten weld pool solidifies in its
wake
Arc welding equipments
1. Power source
Direct current (DC) vs. Alternating current (AC)
2. AC machines less expensive to purchase and operate, but
generally restricted to ferrous metals
3. DC equipment can be used on all metals and is generally noted
for better arc control
3. DC rectifier or generator can be used to supply the required DC
power.
4. DC arc is more expensive than AC arc welding.
5. 70 % heat is liberated near anode in DC arc welding.
Arc welding equipments
1. Power source
•If more heat is required at the workpiece side such as thicker sheet
or the work material which have high thermal conductivity such as
Aluminium, copper , then the workpiece can be made anode.
• This is term as straight polarity( electrode negative)
•For thinner material where less heat is required the polarity could be
reverse polarity.
Arc welding equipments
Set up of arc welding
Arc welding equipments
2.Electrodes
Electrodes used in arc welding are of two type
a. Consumable- are made of various material depending upon
purpose and chemical composition of the metal to be welded.
• These can be either bare or coated with flux(stick electrode).
a. Non consumable- electrode used carbon, graphite or tungsten
Function of coated electrode
1. The coating gives off inert gases such as CO2 which shield the
molten metal pool and protect it from oxidation.
2. It mixed with oxides and other impurities present in the puddle
and forms slag.
3. It is used to stabilize the arc.
4. Special alloying elements can be introduced through these
coating to improve strength and physical properties of the weld
metal.
5. Coating act as insulator and thus permit electrode to reach in
narrow grooves.
Arc welding equipments
2.Electrodes
•Electrodes are generally available in diameter 3.2,4,5, 6,8 and 9
mm.
•Limitation of coated electrode- it absorb moisture.
Consumable Electrode AW Processes
1. Shielded Metal Arc Welding
2. Gas Metal Arc Welding(MIG)
3. Flux‑Cored Arc Welding
4. Electrogas Welding
5. Submerged Arc Welding
Arc welding equipments
1. Shielded Metal Arc Welding/manual metal arc welding
• is the most widely used of the various arc welding processes
• Welding is performed with the heat of an electric arc that is
maintained between the end of a coated metal electrode and the
work piece
Arc welding equipments
1. Shielded Metal Arc Welding/manual metal arc welding

• This flux burns off during the process,

creating a gaseous envelope around the
arc and oxidizes the metals being joined
together
• The flux also creates a black layer of
slag that needs to be chipped off after
each weld
• This process is primarily used on steels.
Stick requires low capital investment,
with low deposition rates on welds
Arc welding equipments
1. Shielded Metal Arc Welding/manual metal arc welding
Equipment
1. Welding power source
2. Electrode
3. Electrode holder
4.Welding cables and connectors
5.Accessory equipment (chipping hammer, wire brush)
6.Protective equipment (helmet, gloves, etc.)
Arc welding equipments
1. Shielded Metal Arc Welding/manual metal arc welding
Equipment
1. Welding power source
• SMAW may utilize either alternating current (AC) or direct
current (DC), but in either case, the power source selected must
be of the constant current type
• SMAW consists of a step-down transformer( voltage 17 -45V)
and
• Current ( around 600 A)
Arc welding equipments
1. Shielded Metal Arc Welding/manual metal arc welding
Equipment
2. Electrode
• The choice of electrode for SMAW depends on a number of
factors, including the weld material, welding position and the
desired weld properties
• The composition of the electrode core is generally similar and
sometimes identical to that of the base material.
• Electrode coatings can consist of a number of different
compounds, including rutile(Tio2), calcium fluoride, cellulose
2. GMAW -Gas Metal Arc Welding/Metal inert gas welding (MIG)

•An arc welding process that uses an arc between a continuous

filler metal electrode and the weld pool to produce a fusion
(melting) together of the base metal
•Very popular among fabrication industry because of advantages
over other types of welding
•Electric arc is established between wire electrode and work
piece
•The process is used with a shielding gas(Ar,He,Co2) supplied
from an external source without pressure
2. Gas Metal Arc Welding (GMAW)/MIG

• Wire is fed continuously and automatically from a spool

through the welding gun
• Shielding gases include inert gases such as argon and
helium for aluminum welding, and active gases such as
CO2 (most economical)for steel welding

• Bare electrode wire plus shielding gases eliminate slag on

weld bead - no need for manual grinding and cleaning
of slag
2. Gas Metal Arc Welding (GMAW)/MIG
2. Gas Metal Arc Welding (GMAW)/MIG
•Both argon and helium can be used with AC and DC welding power
sources.
•However, CO2 is normally used with DC with electrode positive. As
CO2 electrode tend to cause large electron spatter and unstable arc.
•GMAW is approximately 92% - 98% efficient
•GMAW requires a shielding gas
Equipments of MIG
1. Power Supply
Direct Current Electrode Positive (DCEP)
(Electrons flow from – to +)
2. Wire Feeder
Electrical mechanical device that feed required amount of filler
material at a constant rate of speed
Equipments of MIG
3. Welding filler electrode
Small diameter consumable electrode that is supplied to the welding
gun by the roller drive system
4. Shielding Gas
• Gas used to protect the molten metal from atmospheric
Contamination
• 75%Argon (inert gas) & 25% Carbon Dioxide most common gas
used for GMAW
GMAW Advantages over SMAW
• Better arc time because of continuous wire electrode
– Sticks must be periodically changed in SMAW
• Better use of electrode filler metal than SMAW
– End of stick cannot be used in SMAW
• Higher deposition rates
• Eliminates problem of slag removal
• Can be readily automated
• High weld quality
• Less work piece distortion
Arc welding equipments
Consumable Electrode AW Processes
3.Gas tungsten arc welding(TIG)

• heat is generated by an electric arc

struck between a tungsten non-
consumable electrode and the
work piece.
• The weld pool is shielded by an
inert gas (Argon, helium,
Nitrogen) protecting the molten
metal from atmospheric
contamination.
Arc welding equipments
Consumable Electrode AW Processes
3.Gas tungsten arc welding(TIG)

• The heat produced by the arc

melts the work pieces edges and
joins them. Filler rod may be
used, if required.
• Tungsten Inert Gas Arc Welding
produces a high quality weld of
most of metals. Flux is not used
in the process.
Arc welding equipments
Consumable Electrode AW Processes
3.Gas tungsten arc welding(TIG)
Advantages of Tungsten Inert Gas Arc Welding (TIG, GTAW):
1. Weld composition is close to that of the parent metal;
2. High quality weld structure
3. Slag removal is not required (no slag);
4. Thermal distortions of work pieces are minimal due to
concentration of heat in small zone.
Arc welding equipments
Consumable Electrode AW Processes
3.Gas tungsten arc welding(TIG)
Disadvantages of Tungsten Inert Gas Arc Welding (TIG, GTAW):
1. Low welding rate;
2. Relatively expensive;
3. Requires high level of operators skill.