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Welding

Introduction:
Joining two or more parts to make single part is termed as fabrication process. Eg. Aircraft or
Ship bodies, bridge, building trusses etc. It is known as secondary manufacturing process
because in this process we work on the raw material obtained by one of the primary
manufacturing process such as rolling, extrusion, casting etc.
Welding which is the process of joining two metallic components for the desired purpose, can be
defined as the process of joining two similar or dissimilar metallic components with the
application of heat, with or without the application of pressure and with or without the use of
filler metal. Heat may be obtained by chemical reaction, electric arc, electrical resistance,
frictional heat, sound and light energy. If no filter metal is used during welding then it is termed
as Autogenous Welding Process'.
The fabrication process can be classified:
1. Mechanical Joining: Bolts, Screw & Rivets etc.
2. Adhesive bonding by employing synthetic glue such as epoxy resins.
3. Welding, Brazing & Soldering.
Parameter to choose a welding process:
1. Types of assembly: Permanent, Semi-permanent or Temporary.
2. Material being joined: Steel, Cast Iron, Al, similar or dissimilar material.
3. Economy achieved
4. Types of service required: such as assembly subjected to heavy loading, impact loading,
high temperature etc.
Permanent joints are preferred where the load is high and the durability plays an important role.
Some advantages are high load bearing capacity, higher yield strength of the combined structure,
and better distribution of stresses through the material. There is also a decreased chance that the
parts will separate. The main drawback, of course, is that the joint has to be broken if any
alterations are needed and sometimes installation is tricky, requiring complicated instruments,
shields, etc. The two main types of permanent joints are welding and riveting (It is a type of semi
permanent joints).

The temporary joint can be also as strong but it is a type which can be modified according to
the alteration required. The parts can be dismantled and assembled with ease thereby making it
easy to transport. In addition, temporary joints are, in general, fairly easy to facilitate and do not
involve extreme technical know-how. The strength of the joint could be varied by locating the
joint in the optimum place and by choosing the optimum method to join the same. Ex. Bolted
Joints, Screw Joints.

Welding
Welding is a metallurgical fusion process. The interface of 2 parts to be joined are brought to a
temperature above the melting point and then allowed to solidify so that a permanent joining
takes place. Because of the permanent nature of the joints, its strength is generally equal or
sometimes greater than the parent material. The products obtained by process of welding are
called weldments.
A welded joint is obtained when 2 clean surfaces are brought into contact with each other and
either pressure or heat or both applied to obtain the bond. The inter diffusion between the
materials to be joined and the tendency of atoms to be bond are the fundamental basis of
welding.
Heat alone: GTAW (Gas Tungsten Arc Welding), SMAW (Shielded Metal Arc Welding), SAW
(Submerged Arc Welding) etc.
Pressure alone: Ultrasonic welding, Thermite welding etc.
Both Heat and Pressure: Resistance welding, Friction Welding etc.
Types Of welded Joints:

Gas Welding:
It is Also called as oxy-fuel gas welding (OFW), derives the heat from the combustion of a fuel
gas such as acetylene in combination with oxygen. It is a fusion welding process wherein the
joint is completely melted to obtain the fusion. The heat produced by the combustion of gas is
sufficient to melt any metal and as such is universally applicable
The oxygen is normally stored in strong cylinders at a pressure ranging from 13.8 MPa to 18.2
MPa. Acetylene is normally made available in the following two forms:
Acetylene storage cylinder, and
Acetylene generator.
In all the oxy-fuel gas welding processes, the combustion takes place in three stages.
CaC2 + 2H2O C2H2 + Ca(OH)2
Acetylene is explosive so generated through calcium carbide. Acetylene produced is used to
generate carbon monoxide which is used for further reaction.
The first reaction takes place when the fuel gas such as acetylene and oxygen mixture burn
releasing intense heat.
C2H2 + O2 2CO + H2 + 18.75 MJ/m3

The carbon monoxide (CO) and hydrogen produced in the first stage further combine with the
atmospheric oxygen and give rise to the outer bluish flame, with the following reaction.
4 CO + 2H2 + 3O2 4CO2 + 2H2O + 35.77 MJ/m3

Arc Welding:
An arc is generated between two conductors of electricity, cathode and anode, when they are
touched to establish the flow of current and then separated by a small distance. An arc is a
sustained electric discharge through the ionised gas column called plasma between the two
electrodes.

The arc is struck between a flux covered stick electrode and the workpieces. The workpieces are
made part of an electric circuit, known as welding circuit. It includes welding power source,
welding cables, electrode holder, earth clamp and the consumable coated electrode.
Figure shows the fine molten droplets of metal and molten flux coming from the tip of the coated
electrode. The flux melts along with the metallic core wire and goes to weld pool where it reacts
with molten metal forming slag which floats on the top of molten weld pool and solidifies after

solidification of molten metal and can be removed by chipping and brushing. Welding power
sources used may be transformer or rectifier for AC or DC supply. The requirement depends on
the type of electrode coating and sometimes on the material to be welded.

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