Welding seminar
INTRODUCTION OF WELDING
What is welding?
Welding is a fabrication process that joins materials usually
metals or thermoplastics, by using high heat to melt the parts
together and allowing them to cool, causing fusion. Welding
is distinct from lower temperature techniques such as
brazing and soldering, which do not melt the base metal.
Origin
Late 19th Century
- Scientist/engineers apply advances in electricity to heat and/or
join metals (Le Chatelier, Joule, etc.)
Early 20s Century
- Prior to WWI welding was not trusted as a method to join two
metals due to crack issues.
1930s and 1940s
- Industrial welding gains acceptance and is used extensively in the
war effort to build tanks, aircraft, ships.
Modern Welding
- the nuclear/space age helps bring welding from an art to a
science.
TYPES OF WELDING PROCESS
Carbon Arc Welding
Carbon arc welding (CAW) is a process
which produces coalescence of metals by
heating them with an arc between a non-
consumable carbon (graphite) electrode ...
Arc Welding
Arcwelding is a type of welding process using
an electric arc to create heat to melt and join
metals. A power supply creates an electric arc
between a consumable or non-consumable
electrode and the base material using either
direct (DC) or alternating (AC) currents.
Plasma Arc Welding
Plasma arc welding is a method that strikes
a plasma arc between the electrode and
base material and uses it for welding. It is
classified as a non-consumable electrode type
and, as with TIG welding, it uses a tungsten
rod for the electrode.
Gas metal arc welding (GMAW)
Gas metal arc welding (GMAW) is an arc
welding process in which the source of heat is an arc
formed between consumable metal electrode and the
work piece with an externally supplied gaseous shield
of gas either inert such as argon, carbon
dioxide(CO2) /or helium.
Flux cored arc welding
Flux cored arc welding uses heat generated
by an electric arc to fuse base metal in the
weld joint area. This arc is struck between the
metallic workpiece and the continuously-fed
tubular cored consumable filler wire, with both the
wire and the metallic workpiece melting together
to form a weld joint.
Welding Position
A welding position is a technique that allows a welder to join metals in
the position in which they are found or the position in which a
specific component will be used.
Welding Defects
Welding Defects can be defined as the irregularities formed in the given weld metal
due to wrong welding process or incorrect welding patterns, etc. The defect may
differ from the desired weld bead shape, size, and intended quality. Welding defects
may occur either outside or inside the weld metal. Some of the defects may be
allowed if the defects are under permissible limits but other defects such as cracks
are never accepted.
Types of Welding Defects
• Slag Inclusions.
• Porosity.
• Undercut.
• Weld Crack.
• Incomplete Fusion.
• Incomplete Penetration.
• Spatter.
Slag Inclusions
Slag inclusions are nonmetallic particles trapped in the weld metal or
at the weld interface. Slag inclusions result from faulty welding
technique, improper access to the joint, or both. Sharp notches in joint
boundaries or between weld passes promote slag entrapment.
Weld Porosity
Welding porosity is a welding defect that results from unwanted
gasses being trapped within the molten weld puddle during
solidification, which causes pockets or pores on the surface or
within the bead. Porosity can occur on the surface of a weld or
within the weld bead.
Undercut
Is a groove in the base metal along both sides
of the weld that is not completely filled during
the welding process.
Weld cracks are severe flaws that
usually require rework or repair. A
welded joint experiences a dramatic reduction in
strength as soon as the crack forms, hence the need
to address them in most cases.
Incomplete fusion is a weld discontinuity in
which fusion did not occur between weld metal and
fusion faces or adjoining weld beads. This absence
of fusion may occur at any location within the weld joint
and may be present in fillet welds and/or groove welds.
Incomplete penetration is described as a joint
root condition in a groove weld in which
weld metal does not extend through the joint
thickness. It is the failure of filler metal or base
metal to completely fill the root of the weld.
