Introduction
Welding : In general, it is a process of joining 2 material
plates and make an integrated one.
The large bulk of materials that are welded are metals and
their alloys. The welding is also applied to the joining of other
materials such as thermoplastics(during heating it melts or
plasticise ex. Pvc,nylon and during cooling it solidifies).
In welding heat is supplied either by electrical arc or by gas
torch or by some another means.
The most essential requirement is heat but in some processes
Pressure is also applied.
History of welding
Middle ages :
Blacksmith of the middle ages welded various types of iron tools by hammering. The welding methods
remained more or less unchanged until the dawn of the 19 th century.
Late 19th century
Engineers/ scientists apply advances of electricity to heat and join metals
Early 20th century
Prior to 1st world war welding was not trusted as a method to join two metals due to crack issues(due to
metallurgical changes).
1930’s & 40’s
Industrial welding gains acceptance and is used extensively in the war effort to build tanks, aircraft, ships
etc.
1890
one of the most popular welding methods was invented i.e. carbon arc welding. In this time, thermite
welding was also invented in 1893.
1900 :
Coated metal electrode was first introduces by strohmenger. Coating help arc to be much more stable.
Other welding processes i.e. seam welding, spot welding, flash butt welding and projection welding.
1920:
Automatic welding was first introduced and invented by P.O. Nobel.
1930:
The new York navy yard developed stud welding. Stud welding was increasingly used for the construction
industry and also for ship building.
1940:
The GTAW was another significant milestone in the industry of welding developed in Battle memorial
institute in 1948.
1960:
Electroslag welding and plasma arc welding were invented during this time.
1990:
In 1991, welding institute invented FSW. It is solid state joining process which utilises frictional heat of a
rotating tool and stirring effect of the tool probe for solid state joining.
The use of welding in today’s technology is extensive. This growth is faster than the general industrial
growth.
welding classification
Depending upon the source of heat
Depending upon the application of pressure
Depending upon the different phases of base and filler material
Depending upon the composition of the joint
Depending upon the position of electrode
Depending upon the mechanism
Depending upon the source of heat
(i) Arc welding (ii) Gas welding (iii)Resistance welding (iv)Thermo-chemical welding
Carbon arc welding (CAW) Oxy-acetylene butt Thermit welding
Metal arc (SMAW) Air acetylene spot Atomic hydrogen welding
Tungsten inert gas(TIG/GTAW) Oxy-hydrogen seam
Metal inert gas(MIG/GMAW) Pressure gas projection
Plasma arc (PAW) percussion
Submerged arc (SAW) flash butt
Electro-slag (ESW)
Electro gas
(v) Mechanical energy welding (vi) Radiant energy welding
Friction eletro beam
ultrasonic laser beam
diffusion
forge
roll
explosive
Pressure welding : The pieces of metal to be joined are heated to a plastic state and forced together by external pressure.
Non pressure welding : The material at the joint is heated to a molten state and allowed to solidify.
Welding
Fusion welding Pressure welding
arc solid state
gas
radiation energy
downhand or flat welding process is the
easiest welding process as filler material is to
be deposited towards the gravity. while in
overhead we have to deposit filler material
against the gravity. horizontal- movement of
material in horizontal direction. while in
vertical - movement of material in vertical
direction.
• Depending upon the mechanism
1. Manual welding : In manual welding both feeding of filler material and
welding speed(how much molten material need to be deposited in the
welding region) are controlled manually. Example: SMAW
2. Semi-automatic : Ei
Power density and welding
parameters
Fusion welding processes can be looked into on the basis of range of
energy density which they can apply for melting the faying surfaces of
base metal for joining. Heat required for fusion of faying surfaces of
components being welded comes from different sources in different fusion
welding processes (gas, arc and high energy beam). Each type of heat
source has capability to supply heat at different energy densities
(kW/mm2).Even for a given arc power (arc current I X arc voltage V),
different welding processes provide heat at different energy densities due
to the fact that it is applied over different areas on the surface of base
metal in case of different processes. Energy density (kW/mm2) is directly
governed by the area over which heat is applied by a particular process
besides welding parameters.
