Welding
Welding is the process for joining two similar or dissimilar
metals with application of heat and pressure or without the
application of pressure.
It joins different metals with or without use of filler metal.
The fusion of metal takes place by means of heat.
The heat may be generated either from combustion of gases,
electric arc, electric resistance or by chemical reaction.
Welding provides a permanent joint
Types of welding joint
Gas welding process
Oxyacetylene welding, commonly referred to as gas welding. It is
a process which relies on combustion of oxygen and acetylene.
When mixed together in correct proportions within a hand-held
torch or blowpipe, a relatively hot flame is produced with a
temperature of about 32000C. The chemical action of the
oxyacetylene flame can be adjusted by changing the ratio of the
volume of oxygen to acetylene.
Equipments
Conti..
The blue flame will be divided into 3 different color regions - a
long yellowish tip, a blue middle section, and a whitish-blue
intense inner section.
There are three types of flames as described below :
Neutral Flame - This type of flame is the one you will use most
often in the metalwork room. It is called “neutral” because it has
no chemical effect upon the metal during welding. It is achieved
by mixing equal parts oxygen and acetylene and is witnessed in
the flame by adjusting the oxygen flow until the middle blue
section and inner whitish-blue parts merge into a single region.
Reducing / Carburising flame - If there is excess acetylene, the
whitish-blue flame will be larger than the blue flame. This flame
contains white hot-carbon particles, which may be dissolved
during welding. This “reducing” flame will remove oxygen from
iron oxides in steel.
Oxidizing flame - If there is excess oxygen, the whitish-blue
flame will be smaller than the blue flame. This flame burns
hotter. A slightly oxidizing flame is used in brazing, and a more
strongly oxidizing flame is used in welding certain brasses and
bronzes.
Types of Flames
Advantages of Gas Welding
Gas welding is probably portable and most versatile process.
Gas welding provides better control over the temperature of
the metal in the weld zone by controlling the gas flame.
This provides better control over filler-metal deposition rate.
The cost and maintenance of the gas welding equipment’s is
low as compared to some other welding processes.
Disadvantages
Oxy acetylene weld lines are much rougher in appearance than
other kinds of welds, and require more finishing.
Oxy acetylene welds have large heat affected zones.
(HAZ- area around the weld line that have had their mechanical
properties adversely affected by the welding process)
Electric arc welding processes
The process, in which an electric arc between an electrode and
a work-piece or between two electrodes is utilized to weld
base metals, is called an arc welding process.
Most of these processes use some shielding gas while others
employ coatings or fluxes to prevent the weld pool from the
surrounding atmosphere.
The temperature produced by the electric arc is about 4500°C
to 5500°C.
Both direct current (D.C.) and alternating current (A.C.) are
used for arc welding.
Working procedure
Electric arc welding is a process in which metal melts and joins
by heating them with an arc established between a covered
electrode and the metals. The core wire conducts the electric
current to the arc and provides filler metal for the joint. 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 melts the core wire and the flux covering at the electrode
tip into metal droplets. Molten metal in the weld pool solidifies
into the weld metal while the lighter molten flux floats on the top
surface and solidifies as a slag layer.
Advantages
The welding equipment is portable.
It has the ability to weld on porous and dirty metals.
Its equipment is inexpensive.
It is a fast welding process when compared to others.
It offers strong joint.
Arc welding beads can be used to create designs on fine
metals.
Its power supply can be use where there is electricity and the
alternative can use be if there is no electricity but generator.
Disadvantages
Increase of project costs as wastage is inevitable during the
process.
Well trained and skillful operator is needed for the task.
Not all thin metals can weld on arc welding.
