WELDING PROCESSES

Presented by
Parveen Kumar{05110}
INROD!CION

As we all know that whatever the product

that is impossible to manufacture as a
single piece.

Welding is a process which is used to join

the two parts to get a desired product.

Welding is a joining process. The types of

welding processes are:-
"#nt$$$%
Diversity of welding processes
welding
Solid state welding Soldering and brazing Fusion welding
Electrical energy Chemical energy
Other processes Non consumable
electrode
Consumable electrode
Resistance
welding
Cold welding
Friction welding
Diffusion welding
Flash welding
Ultrasonic welding
Explosion welding
Gas metal arc welding
Shielded metal arc welding
Submerged arc welding
Flux cored arc welding
Electrogas welding
Electroslag welding
Gas tungsten arc welding
Atomic hydrogen welding
lasma arc welding
!xyacetylene welding
!xyfuel gas welding
"aser beam welding
#hermit welding
Electron beam welding
Soldering
$ra%ing
&!SION WELDING

It is defined as the melting of two

material parts by attaching together by
means of heat

eat may be supplied by chemical or

electrical means.

In this filler metal may or may not be

use .

!"#I$% W&'(I%)
*$+,-I#&#:-

$.yfuel gas welding

Arc welding processes

/. *onsumable electrode
0. %onconsumable electrode

Thermit welding

&lectron beam welding

'aser beam welding

O'(&!EL G)S WELDING

$.yfuel gas welding is the welding

process that use a fuel gas combined
with o.ygen to produce a flame.

This frame is the source of the heat

that is used to melt the metal at the
point of joint.

The most common gas welding process

which is o.yacetylene welding and is
used for automotive bodies1 and various
other repair works.
"#nt$

In this process1 heat is generated in

two steps:-
*% Pr+mary "#mbust+#n ,r#"ess:-
In this process1 acetylene reacts with $2
and give *$ and 2 and it produces
3:4 of the total heat generated in the
flame.
*% Se"#ndary "#mbust+#n ,r#"ess:-
It consist of further burning of 2 and
*$ with $2 and this reaction
produces about 2:4 of the total heat.
The temp. developed in the flame is
about 4455*.

y,es #- -.ame:-
2. When there is no e.cess o.ygen1 then it is
known as neutra. -.ame.
4. If the o.ygen is notin large amount1 then it
is known as #/+d+0+n1 -.ame.

This is harmful for steel1 because it o.idi6es

the steel.

It is used only for *u and *u alloys because

in those cases1 a thin protective layer of
slag forms over the molten metal.
4. If the ratio of $2 is deficient1 then the flame
becomes redu"+n1 -.ame.
The temp. of reducing flame is lower1 so it is
suitable for applications re7uiring low temp.
$89A*&T9'&%& !'A+&# "#&( I%
W&'(I%)
$89A*&T9'&%& T$-* A%( #&T",
&ILLER 2E)LS

!iller metals are used to supply additional

material to the weld 6one during welding.

They are available as rod or wire made of

metals compatible with those to be
welded.

These consumable filler rods may be

coated with flu. .

The function of the flu. is to retard

o.idation of the surface of the parts being
welded by generating a gaseous shield
around the weld 6one.
A-* W&'(I%)

Arc welding processes use a welding

power supply to create and maintain
an electric arc between an
electrode and the base material to
melt metals at the welding point.

They can use either direct (DC) or

alternating (AC) current, and
consumable or non-consumable
electrodes.

The welding region is sometimes

protected by some type of inert or
semi-inert gas, known as a shielding
gas, and filler material is sometimes
used as well.
y,es #- ar" 3e.d+n1:-
1%S4+e.ded meta. ar" 3e.d+n1:-

#hielded metal arc welding is one of the

oldest1 simplest and most versatile
welding process.

The electric arc is generated by touching

the tip of a coated electrode against the
work piece and then withdrawing it 7uickly
to a distance sufficient to maintain the arc.

The electrode arc in the shape of thin1

long stick1 so this process is also known as
stick welding.

Abare section at the end of the

electrode is clamped to one terminal of
the power source 1 while the other
terminal is connected to the work piece
being welded.

The current usually ranges from 05A to

455A1power re7uirements are generally
less then 35:W.

The current may be dc or ac . !or sheet

metal welding dc is preferred because
of the steady arc it produces .
C#nt$$

The polarity of the dc current is

important and its selections is depend
upon the metal to be welded 1 types of
electrode and the depth of the heated
6one.

In straight polarity 1 the work piece is

positive and electrode is negative.

It is preferred for sheet metals 1

because it produces shallow penetration
1 and for joints with very wide gaps.

In reverse polarity 1 the electrode is

positive and deeper weld penetration is
possible
#I&'(&( +&TA' A-*
W&'(I%)
#+AW #9#T&+ #&T",

Adantages - The process is ery ersatile, re!uiring

little operator training and ine"pensie e!uipment.

Disadantages # $. the process is generally limited to

welding ferrous materials, though speciality
electrodes hae made possible the welding of cast
iron, nickel, aluminium, copper, and other metals.
A%%&'CAT'()* -- *+A, is often used to weld
carbon steel, low and high alloy steel, stainless steel,
cast iron, and ductile iron.
- ,hile less popular for nonferrous materials, it can
be used on nickel and copper and their alloys and, in
rare cases, on aluminum.
- The thickness of the material being welded is
bounded on the low end primarily by the skill of the
welder, but rarely does it drop below .../in
($./mm). )o upper bound e"ists1 with proper 2oint
preparation materials of irtually greater thickness
S!52ERGED )RC
WELDING

In this process1 the weld arc is shielded by a

granular flu.1 consisting of lime1 silica1 +n$21
*a!21and other compounds.

The thick layer of the flu. completely covers

the molten metal.

The flu. also acts as a thermal insulator1

promoting deep penetration of heat into the
work piece.

The consumable electrode is a coil of bare

round wire ;3.0-35<mm dia.

&lectrical current ranges from 455-2555a and

the voltage is up to /55v.
G)S 2E)L )RC WELDING

This process is also known as +I)

welding.

In this process1 the weld area is shielded

by an inert atmosphere of Ar1 e1 *$2 or
various other gas mi.tures.

The consumable bare wire is fed

automatically through a no66le into the
weld arc.

(eo.idi6ers are usually present in the

metal itself1 in order to prevent o.idation of
the molten weld puddle.

In this process1 metal can be transferred

In s,ray trans-er 1 small droplets of

molten metal from the electrode are
transferred to the weld area at a rate of
several hundred droplets per seconds.

The transfer is spatter free and very

stable.

igh dc current and voltages and

large diameter electrodes are used 1
with argon rich gas mi.ture used as a
shielding gas.

In 1.#bu.ar trans-er 1 carbon dio.ide

gas are used 1 and globules propelled
by the forces of electric arc transfer the
metal 1 with considerable spatter.

In s4#rt "+r"u+t+n1 1 the metal is

transferred in individual droplets 1
more than 05 per second.

As electrode tip touches the molten

metal and short circuit.

'ow current voltages are utili6ed 1

with carbon dio.ide rich gases and
with electrodes made of small
diameter wires.

The power re7uired is about 2 kw.

C#nt$$$
+I) $,&-ATI$%
)+AW WI-& !&&( "%IT
GMAW torch nozzle cutaway image. (1) Torch handle, (2) Molded phenolic dielectric
(shown in white and threaded metal nut insert (yellow, (3) !hielding gas nozzle,
(4) "ontact tip, (5) #ozzle output face
)+AW #9#T&+ #&T",
AD3A)TA45* # $. Can be applied to non-ferrous metals
6. automated7semi-automated process with good
speed
D'*AD3A)TA45* # $. %orosity due to gas entrapment
when the gas is not pure 6. Cannot be used outdoors
or under water due loss of shielding gas in such
conditions
A%%&'CAT'()* - 4+A, is commonly used in industries
such as the automobile industry, where it is
preferred for its ersatility and speed. A related
process, flu" cored arc welding, often does not utili8e
a shielding gas, instead employing a hollow electrode
wire that is filled with flu" on the inside.
&L!' CORED )RC
WELDING

4+s ,r#"ess +s s+m+.ar t# 1as meta. ar"

3e.d+n1 6 3+t4 t4e e/"e,t+#n t4at t4e
e.e"tr#de +s tubu.ar +n s4a,e and +s -+..ed
3+t4 -.u/%

C#red e.e"tr#de ,r#du"e a m#re stab.e

ar" 6 +m,r#ve 3e.d "#nt#ur 6 and ,r#du"e
better me"4an+"a. ,r#,ert+es #- t4e 3e.d
meta.%

Se.- s4+e.ded "#red e.e"tr#des are a.s#

ava+.ab.e%

4ese e.e"tr#des d#n7t re8u+res e/terna.

1as s4+e.d+n1 6 be"ause t4ey "#nta+n
ELECROG)S WELDING

This process is used primarily for

welding the edges of sections vertically
in one pass 1 with the piece placed edge
to edge .

It is known as machine welding process

because it re7uire special e7uipment .

The weld metal is deposited into a

weld cavity between the two pieces to
be joined.

The space is enclosed by the two water

cooled copper dams to prevent the

#ingle or multiple electrodes are fed

through a conduit 1 and a continuous
arc is maintained using flu. cored
electrodes .

The current ranges from /55-=05

amp.

,ower re7uirement is about 25 kw.

#hielding is done by the means of an

inert gas such as argon and it depends
upon the type of material being
welded.
ELECROSL)G WELDING

The application of this process are

similar to electrogas welding .

The main difference is that the arc is

started between the tip and the bottom
of the part to be welded.

!lu. is added and then melted by the

heat of arc.

After the molten slag reaches the tip of

electrode 1 the arc is e.tinguished .

eat is then produced by the

continuously by the electrical resistance
)RC WELDING PROCESSES
NON CONS!2)5LE

In these processes generally tungsten

electrode is used.

As one pole of the arc 1 it generates the

heat re7uired for welding .

A shielding gas is supplied from an

e.ternal sources to protect the welding
6one from atmospheric effects.

These are the following processes

which come under this category.
C#nt$$$$%%
G)S !NGSEN )RC
WELDING

It is also called TI) welding .

The filler metal is provided from the

filler wire 1 because the tungsten
electrode is not consumed in this
operation.

A constant and stable arc gap is

maintained at a constant current
level.

In tig welding filler metal may or

may not be used e.g in the welding of

The power supply may be ac or dc

type depending upon the metal to be
welded.

Ac is used for al 1 mg 1 because the

cleaning action of ac remove o.ides
and improves weld 7uality.

,ower re7uirement ranges from >-25

kw.

There is one major disadvantage of

this process is that the contamination
of tungsten electrode is taking place
by the molten metal.
C#nt$$%%
)TAW #9#T&+ #&T",
)TAW W&'( A-&A

AD3A)ATA45* # $. most preferred method for non

ferrous metals 6. best !uality welds are produced

D'*AD3A)TA45* # $. comple" techni!ue re!uires

skilled labour 6. costly (re!uires shielding gas and
filler material)
A%%&'CAT'()*- $. The aerospace industry is one of
the primary users of gas tungsten arc welding , it is
used e"tensiely in the manufacture of space
ehicles, and is also fre!uently employed to weld
small-diameter, thin-wall tubing.
6. 'n maintenance and repair work, the process is
commonly used to repair tools and dies, especially
components made of aluminum and magnesium.
9. The welds it produces are highly resistant to
corrosion and cracking oer long time periods, 4TA,
is the welding procedure of choice for critical welding
PL)S2) )RC WELDING

In this process a concentrated

plasma arc is produced and is aimed
to the weld area .

The arc is stable and reaches temp.

as high as 44555 c.

A plasma is a ioni6ed hot gas 1

combination of e7ual number of
electrons and ions.

The plasma is initiated between the

tungsten electrodes and the orifice

$perating current is usually below 355A1 but

they can be higher for special applications.

There are 2 methods of plasma arc

welding:---
4. In the transferred arc method the
workpiece being welded is part of the
circuit current.

The arc transfers from the electrode to the

workpiece.
2. In the non transferred method the arc
occurs between the electrode and the
no66le.

eat is carried to the workpiece by the

plasma gas.
9ER2I WELDING

This process involves e.othermic reaction

between metal o.ides and metallic reducing
agents.

The heat of the reaction is the utili6ed in

welding.

The most common mi.ture of material used

in welding steel and cast iron is finally divided
particles of iron o.ides1 !e1 Al.

This non e.plosive mi.ture produces a

temperature of 4255 * in less a minute.

This welding process involves the alignment

of the parts to be joined1 but with a gap

If the parts are thick1 the mold cavity may

be preheated to improve welding and to
dry the mold.

(rying of the mold is very important

otherwise superheated steam trapped in
the mold can cause e.plosions.

The superheated product of the reaction

are allow to flow into the gap1 melting the
edge of the parts being joined.

This welding suitable for welding and

repairing castings and thick steel structural
sections.
C#nt$$$%%
ELECRON:5E)2
WELDING

In this process the heat is generated by

high velocity narrow beam electrons.

The kinetic energy of the electrons is

converted into heat as they strike
workpiece.

The process re7uires special e7uipments

to focus the beam on the workpiece in the
vacuum.

The higher the vacuum1 more the beam

penetrates and greater depth to width
ratio.

This process is used for workpiece whose

L)SER 5E)2 WELDING

This welding process utili6es high power

laser beam as the source of heat to
produce fusion weld?

In this beam can be focused on very small

area which is being welded.

It has high energy density1 so it has high

penetrating capability.

This process is suitable for welding deep

and narrow joints.

In this1 the depth to width ratio is ranging

from /:35.
C#nt$$$$%%

Its application is in automotive

industry for welding of transmission
components.

The power level is up to 355 kw.

'aser beam welding process

produces welds of good 7uality1 with
minimum shrinkage and distortion.
C#nt$$$%%
-eferences:--
v
+anufacturing engg.
And tech. by
:alpakjian

thanks