Presented by:
KRISHNA KISHORE PIILI
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WELDING
Definition as per AWS / ASME
A: localised coalescence of metals or non-metals
produced either by heating the materials to the welding
temperature with or without the application of pressure
alone, and with or without the application of filler
material.
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SELECTION OF WELDING PROCESS DEPENDS ON
Thickness & Size of part to be welded
Location and position of weld joints
Joint design
Welding equipment availability
Process and operation requirement
Production cost
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WELDING PROCESSES
Oxy- Gas Welding
Shielded Metal Arc Welding
Gas Metal Arc Welding
Gas Tungsten Arc Welding
Submerged Arc Welding
Flux Cored Arc Welding
Resistance Welding
Electroslag Welding
Thermit Welding
Plasma Arc Welding
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SHIELDED METAL ARC WELDING
SMAW process defined as an arc welding
process which produces coalescence of metals
by heating them with an arc between a covered
metal electrode and the work-piece.
Shielding is obtained from decomposition of
the electrode covering.
Pressure is not used and filler metal is
obtained from the electrode.
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SHIELDED METAL ARC WELDING
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MODE OF OPERATION
Arc melts parent plate and electrode to form a weld
pool which is protected by flux cover.
Operator adjusts electrode feed rate, I.e. hand
movement to keep arc length constant. Slag must be
removed after depositing each bead. Normally a small
degree of penetration, requiring plate edge
preparation. Butt welds in thick plate or large fillets
are deposited in a number of passes.
The process can also be used to deposit metal to form
a surface with alternative properties.
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CONSUMABLES
Metal rods 1.5-8mm diameter with flux covering (1-5mm
radial thickness).
The characteristics of manual metal arc electrodes, I.e. arc
stability, depth of penetration, rate of deposition, position of
welding, depends on the chemical composition of the
electrode coating classified by AWS specifications.
Types of Consumables used in SMAW
Rutile: Titanium Dioxide, Clay , Sodium silicate
Cellulosic: Cellulose( wood pulp), Titanium Dioxide, Sodium
silicate
Basic: Lime stone ( Calcium carbonate ), Titanium Dioxide,
Sodium silicate
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SMAW - OPERATING PARAMETERS
Current range : 75-300 A
Range of Thickness: 2mm upwards
Deposition rate : 2-11 lb/Hr
Types of joint : All
Welding position : all (depending on flux
coating)
Access : Good
Portability : Good
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MATERIALS
MOSTLY CONFINED TO FERROUS ALLOYS,
BUT CAN BE USED FOR SOME OTHERS.
TYPICAL APPLICATIONS
Structural steel work.
Ship Building
Repair and Hardfacing of construction plant.
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OVERALL ADVANTAGES
Low Equipment Cost
Usage possible with restricted access.
OVERALL LIMITATIONS
Skilled operator is required for good quality welds.
Slow, mainly because flux must be chipped away.
SAFETY
Arc emits visible and ultraviolet radiation.
High open circuit voltage present while electrode is fitted
to holder.
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GAS METAL ARC WELDING
GMAW is defined as an arc welding process which
produces coalescence of metals by heating them with an arc
between a continuous filler metal (consumable) electrode and
the work piece.
Shielding is obtained entirely from an externally supplied
gas or gas mixture.
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GAS METAL ARC WELDING
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GAS METAL ARC WELDING
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GAS METAL ARC WELDING(Contd.)
TYPE OF OPERATION : Manual, mechanised or automatic.
EQUIPMENT : Power Source
Wire feed Unit
Welding gun or torch
Gas supply system traveling unit
if mechanised.
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GAS METAL ARC WELDING
An arc is maintained between the end of the bare
wire electrode and the work. The wire is fed at a
constant speed, selected to give the required
current, and the arc length is controlled by the
power source. The operator is not therefore
concerned with controlling the arc length and can
concentrate on depositing the weld metal in the
correct manner. Hence the name ‘semi-
automatic’ for manual operation, in which wire,
gas and power are fed to a hand held gun via a
flexible conduit.
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The process can be operated at high currents
(250-500A) when metal transfer is in the form of
‘spray’ but except for aluminium, this technique is
confined to welding in the flat and horizontal
positions. For welding in the vertical and
overhead positions. Special low-current
techniques must be used, I.e. ‘dip transfer’ or
pulsed arc shielded by a stream of Gas.
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GMAW - OPERATING PARAMETERS
Current range : 65-500 A
Range of Thickness: Dip transfer, pulsed arc –Above 0.5mm
Spray transfer 6mm upwards
Deposition rate :12-10 Kg/Hr (2-20 Lb/Hr)
Types of joint : All including spot welds
Welding position : Dip transfer, pulsed Arc- All Spray
transfer – Flat(TJoints only-H.v) (with aluminum, spray
transfer can be used in all positions)
Access : Fair
Portability : Fair
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Consumables
Electrodes, bare wire (m.s. is normally copper coated) 0.6-1.6mm
dia. Layer wound on sppools 0.5-12 Kg (1-25lb) weight.
Composition of wire selected to suit parent material; wire
specifiations covered by BS 2901. Electrodes, fluxcored are
available for high deposition rate welding.
Shielding gas in cylinders containing compressed gas which will
expand to 7Cu.M (250 [Link]) at atmospheric pressure.
Composition to suit parent material – usually carbon dioxide
(CO2) for mild steel, argon for non-ferrous materials and argon
with 1.5% oxygen or 5-20% CO2 for high strength and corrosion
resisting ferrous [Link] mixtures are used in special
circumstances.
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MATERIALS
Steels, Aluminum alloys and other metal which it is
feasible to produce in the form of wire.
TYPICAL APPLICATIONS
Medium gauge fabrication such as light and
heavy vehicles.
High rate production not suitable for mechanized
welding.
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OVERALL ADVANTAGES
Continuous process
Reduced finishing operations
Thin sheets can be welded in all positions by dip transfer
mode.
OVERALL LIMITATIONS
No independent control of filler addition.
Range of action limited by wire feed.
SAFETY
Arc emits visible and ultraviolet radiation.
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GAS TUNGSTEN ARC WELDING
GTAW is defined as an arc welding process which produces
coalescence of metals by heating them with an arc between a
tungsten (non- consumable) electrode and the work piece.
Gas Tungsten Arc Welding (GTAW) uses a non consumable
tungsten electrode which must be shielded with an inert gas.
The arc is initiated between the tip of the electrode and work
to melt the metal being welded, as well as the filler metal,
when used.
A gas shield protects the electrode and molten weld pool, and
provides the required arc characteristics.
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GAS TUNGSTEN ARC WELDING
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The GTAW welding process uses a non-consumable
tungsten electrode to provide an arc.
Filler metal, when required, is fed from a separate filler rod.
A shielding gas, e.g. argon, is fed through the welding gun
to the weld area and provides a gas shield to prevent
contamination by the atmospheric gases.
No fluxes are used with the process.
When the arc only is used to produce the weld, without
the addition of separately fed filler wire, the process is
known as autogenous GTAW
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GTAW Welding is used for deposition of high quality root
runs on pipe work.
When high quality root runs are needed, a back purge is
used to prevent oxidizing (coking) of the weld metal.
In most cases electrode DC. –Ve polarity is used
D.C. +Ve needs higher voltage and overheat and melt
the tip
The scavenging action achieved with electrode DC +Ve
A compromise is met using AC current so that for 50%
of each current cycle the electrode is positive.
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The Gas shield fulfils two main function
It provides a suitable ionizable atmosphere for the
electric arc.
It protects the weld pool from atmospheric contamination.
Excessive gas pressure can cause rippling of the weld
pool.
Three gases may be considered for GTAW welding: argon, helium
and nitrogen.
Argon Produces a smooth, quiet arc with low arc volts.
The addition of between 1% and 5% of the active gas
hydrogen, will raise the arc voltage and give deeper
penetration.
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The inert gas helium is lighter than argon, therefore
requires higher.
Helium creates a higher arc voltage which is useful
for welding thick sections.
Helium is also more expensive than argon.
Nitrogen is inert at room temperature.
At arc temperature Nitrogen combines with oxygen
and becomes
Active therefore not suitable in most of the cases
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A high o.c.v. of around 90 volts is required for
GTAW welding to ensure arc stability at all times.
The power sources used for GTAW are
generator, transformer , transformer-rectifier.
High frequency current is superimposed at the
start of all [Link] operations.
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OVERALL ADVANTAGES
Superior quality welds
Welds can be made with or without filler metal
Precise control of welding variables (heat)
Free of spatter
Slag free
Low distortion
OVERALL LIMITATIONS
Requires greater welder dexterity than MIG or stick welding
Lower deposition rates
More costly for welding thick sections
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SUBMERGED ARC WELDING
SAW is defined as an arc welding process which produces
coalescence of metals by heating them with an arc or arcs
between a bare metal electrode or electrodes and the work
piece.
Pressure is not used and filler metal is obtained from the
electrode and sometimes from a supplementary welding rod.
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SUBMERGED ARC WELDING
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OVERALL ADVANTAGES
High weld metal Quality
Smooth and uniform weld bead with no spatters.
Extremely high deposition rate and welding speed.
High Arc time can be achieved through automation.
Minimum operator fatigue.
OVERALL LIMITATIONS
High initial cost
Limited welding positions.
Requirement of special jigs and fixtures.
Difficulty in welding low thickness metals.
Full penetration weld joints not 1possible from single side. 37
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Thermit Welding
Thermit Welding usually uses the exothermic reaction of a mixture
of iron oxide and aluminum powder or other similar mixtures to
weld or repair large forgings and castings, and join pipes and
railroad rails.
The parts are aligned and a ceramic or sand mold is built around
the joint to be formed. The thermitic mixture reaction is initiated
with a special compound (an oxidizing agent) heating quickly to
the desired temperature which melts the ends of the parts to be
joined. After the weld cools, excess material is removed by
machining, grinding, or other cutting methods
Heat source
chemical reaction between thermit mixture components
Iron oxide and aluminum powder
ignition fuse required 1 40
Thermit Welding
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