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BASIC GUIDE TO WELDING
Welding is a process of joining two metal elements by the application of
heat. This heat may be applied different form (by Gas flame or by electric
arc or by electric resistance or by gas plazma). Welding are widely used in
industries for manufacturing/fabrication of pipe works, structures, vessels,
tanks and various repairing works. Welding has become a very important
process in any industry. Welding of Critical components should be done by
competent welders according to various standards (e.g. IBR approved or
AWS-American Welding Society).
The AWS has defined master charts of welding procedures for different
materials and applications. These are called WPS(Welding procedure
specifications).WPS covers the design of the joint, base metals, filler wire
or electrodes and their domestic name with AWS numbers, amount of
current, technique of welding, heat treatment if any, pre- heating post
heating etc. Once the WPS is selected it should be followed in toto for the
particular welding system. For different materials different WPS shall be
required. Proper welding electrodes or filler metal wires shall be used for
specific base metal. Size (Diameter) of the electrode or filler wire is very
important as the welding current and OCVs are accordingly selected. If the
correct welding rod or filler metal wire is not selected then welding joint
produce between two elements may not of full strength and quality, which
may fail in the destructive testing. Welding joints are designed for 100%
equivalent to the base metals.
Non-destructive testing of welding joints is done by Radiography, Die
Penetrating Test and Ultra Sonic flaw detective techniques. According to
criticality of the service welding joint quality is ensured. This is called QAP
or quality assurance plan. QAP gives the total requirement of the NDTs
and DTs for the particular job. Destructive tests are performed on the
samples or production coupens.
There are many welding process in applications in industries. e.g. Metal
Arc Welding,(MMAW and AMAW) Oxy-acetylene gas Welding, Tungsten
Inert gas Arc Welding (TIGAW), Metal inert gas Arc Welding (MIGAW),
electreon beam welding, Electric resistance welding, Plasma Welding etc.
In any welding process basically the metal parts at the joint are heated
over a range of fusion temperature, which cause moten metal to flow in
presence of flux or inert gas to prevent of oxidation, and the two molten
metal elements get fused along with the filler metal if any. The heating
and cooling rate of the metal parts affects the metallurgical and
mechanical properties of the base metals as well as the weld met. In
critical application where alloying elements are present in the metal to be
welded, to re-gain the properties at par with the parent metal, welding
joints passes through pre-heat treatment or post weld heat treatments so
that detrimental effects of welding procedure are nullify and to restore the
original properties of the base metal.
Distortion and residual stresses developed during welding procedures and
their magnitude depends upon the metal and welding procedures. Due to
Gas Welding:
In case of gas welding temperature is generated with Oxyacetylene gas
torch flame and filler wire is fed separately.
Oxyacetylene welding is commonly referred as gas welding in which hot
flame is produced of about 3200 degree Cent. There are three type of
flame setting as neutral, oxidizing and carburising which can be set by
varying the proportion of Oxygen and Acetylene. The oxidizing flame is
obtained by increasing the oxygen flow and carburizing flame is set
through in acetylene flow. The action of the oxyacetylene flame on the
surface of the material to be welded can be adjusted to produce a soft,
harsh or violent reaction by varying the gas flows.
Welding of Different Material:
Welding of Cast Iron:
Cast Iron is suppose to be difficult to weld material as the carbon content
in cast iron is high as 2~4%. Generally cast iron parts involves repair
(cracks) and rarely joining of two cast iron parts. The widely used grade of
cast iron is grey cast iron which is present in most of the machine parts.
The high carbon contents(roughly 10 times as compare to most steel
deposit similar or better then the base metal and to responds to post-heat
treatment in some manner as the base metal.
Some common welding electrodes AWS (American welding Society)
numbers are given below for ready reference:
AWS
AWS
AWS
AWS
AWS
AWS
AWS
E
E
E
E
E
E
E