MEE1007 MANUFACTURING PROCESS

L T P J C
2 0 2 0 3

Dr. CHINMAYA P. MOHANTY

Assistant Professor (Senior)
School of Mechanical Engineering,
VIT Vellore, Vellore, TN, India – 632 014.
 WELDING

1. Welding is a process in which two or more parts are

joined permanently at the contact surfaces by a
suitable application of heat and/or pressure.
2. Often a filler material is added to facilitate
coalescence.
3. The assembled parts that are joined by welding are
called a weldment.

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 JOINING PROCESS
Why welding?
1.Permanent joint is produced which will have the same property of
the base metal.
2.Since the added material is minimum, the joint has lighter weight.
3.Welded joints have smooth appearances helps in maintaining
metallic continuity.
4.It is less expensive.
5.Forming a joint in difficult locations is possible through welding
Extensive Applications
1. Constructions repairs and fabrications of bridges, railway tracks
and pipelines.
2.Welding of aerospace materials
3.Machine components viz. Heavy hydraulic turbine shafts, large
gears, pulleys, flywheels, gear housing, steel structures and frames.

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 WELDING

Welding processes are classified into two major groups

1. Fusion welding
2. Solid-state welding
Fusion welding
1. In this process, base metal is melted by means of
heat.
2. Often, in fusion welding operations, a filler metal is
added to the molten pool to facilitate the process
and provide bulk and strength to the joint.
3. Commonly used fusion welding processes are:
arc welding, resistance welding, oxy fuel welding,
electron beam welding and laser beam welding.

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 WELDING

SOLID STATE WELDING

1. In a solid state welding it never requires to reach the
temperature require to melt the two base metals.
2. The process never used any filler material to join the
parts.
3. The weld is created by fully solid diffusion of bond
between the two surfaces.
4. Some of the commonly used solid state welding
process are pressure welding, explosion welding
diffusion welding, friction welding, ultrasonic welding

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 WELDING
ARC WELDING

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 IMPORTANT TERMINOLOGY
Base Metal:
The work pieces to be joined are known as
base metal.
Weld bead: it is the material, which is deposited by the
process of welding. It appears as a separate material from
the base metal in the form of bead. This is also referred to
as bead.
Puddle: it is the portion of the base metals at the joint,
which is melted by the heat during welding.
Weld pass: it is the movement of the welding torch from
one end of the joint to the other end, which results in a joint.
Tack weld: a temporary small weld done at the ends of the
work pieces to hold the work pieces together during
welding.
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 WELDING
TYPES OF WELDED JOINTS
1. Butt Joint
2. Lap joint
3. Tee Joint
4. Edge joint
5. Corner Joint

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 WELDING
ARC WELDING
1. In the arc welding process, the heat required for welding is
obtained through electrical energy.
2. Electrodes carry out the process, which are thin long rods of
metal or' graphite.
3. The electric arc is initiated by striking the tip of an electrode
against the workpiece and then withdrawing it quickly to a
distance to maintain the arc.
4. The arc can produce the temperature of the order of
30,000°C. This heat is sufficient enough to melt the base
metal and a portion of the tip of the electrode.
5. Electrodes used for arc welding process are usually coated.
The function 'of the coating, which acts as flux, is to form a
gaseous shield around the weld to protect the molten metal
from the atmosphere.
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TIG and MIG WELDING
TIG(Tungsten Inert Gas) Welding
The tungsten inert gas welding process is essentially an arc
welding process in which non-consumable tungsten electrode is
used in an externally applied protective inert gas atmosphere.
MIG(Metal Inert Gas) Welding
Metal inert gas welding process is essentially an arc welding technique
in which consumable electrodes are used in an externally applied
protective gas atmosphere. Some times in MIG uses
an electrode covered in a flux that produces carbon dioxide when
consumed for protecting the weld, a semi-inert gas that is an acceptable
shielding gas for welding steel. Then it is called as Shielding Metal
Arc Welding(SMAW).In SMAW during welding arc is not visible due
to presence of granular flux. The technique is quite similar to MIG
welding.
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Tungsten Electrode
Workpiece
DC Power Supply
Argon Gas Cylinder

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 Bare Electrode
Workpiece
DC Power Supply
Argon Gas Cylinder

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 MIG TIG
1. Metal wire is used as electrode. 1. Tungsten rod is used as
electrode.

2. Continuous feed electrode wire 2. Welding rods are used which

is used which are fast feeding. are slow feeding
3. MIG requires consumable 3. It used non consumable
metallic electrode. tungsten electrode
4. Filler metal is compulsory used. 4. Filler metal may or may not be
used.
5. It can weld up to 40 mm thick 5. Metal thickness is limited
metal sheet. about 5 mm.
6. Reverse polarity 6.Straight polarity
7. MIG is comparatively faster than 7.TIG is a slow welding process.
TIG.
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 WELDING
GAS WELDING
1. Gas welding is also a fusion welding process in which the
heat required for fusing the material is obtained by the
combustion of oxygen with other fuel gas such as acetylene,
propane, butane or natural gas.
2. The type of fuel gas to be used is determined by the desired
flame temperature.
3. The most commonly used gas in welding is acetylene, and
hence, the process of gas welding is known as oxy-acetylene
welding
4. The oxy-acetylene flame produces the highest flame
temperature of approximately 3300 °C while oxy-hydrogen
flame gives a maximum temperature of about 2200 °C.
5. Gas welding is very commonly used for repairing the broken
or damaged parts.
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 WELDING

Oxy Acetylene welding

1. The gas welding system consists of two cylinders, one
containing oxygen and other containing acetylene;
hoses for transporting the gases and a torch.
2. The complete combustion of acetylene in an atmosphere
of oxygen is represented by the following summary
reaction:
2C2H2 + 502 > 4CO2 + 2H20 (vapour) + Heat (300
kcal/mole).
1. The temperature generated during the process of oxy-
acetylene welding is of the order 3300 °C.

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 Type of Flames in Oxy Acetylene Flame
Based on the compositions of oxygen and acetylene,
it is possible to obtain three different types of flames
in the gas welding, viz.
1. Carbonizing flame (or reducing flame)
2. Oxidizing flame
3. Neutral flame (or balanced flame).

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Carburising Flame
1. It is obtained when acetylene is in excess.
2. Since it contains excess of acetylene, its flame
temperature is low, and the available carbon is not burnt
completely because of less oxygen; and the leftover
carbon is forced into the molten metal.
3. This excess of carbon gets absorbed in ferrous metals,
making the weld bead hard and brittle.
Oxidising Flame
1. Consists of excess of oxygen.
2. Oxidizing flame produces the hottest flame that can be
produced by any oxygen-fuel source. Since the flame
contains excess of oxygen, it causes the metal to burn or
oxidize quickly.
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Neutral Flame
1. Contains equal proportions of oxygen and acetylene.
2. Unlike carbonizing or oxidizing flame, neutral flame has
little effect on the base metal and it produces sound weld
beads when compared to carbonizing and oxidizing
flames.

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FILLER MATERIALS
1. Filler material is generally added in the gas welding.
2. The filler is melted by the flame and is added to the
molten metal that fills the space between the pieces
being joined.
3. The filler material must be of the same composition as
the base metal.
4. Some metals can be welded without the addition of extra
filler material

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 Flux
1. Flux added to the welded metal, removes oxides from
the surfaces of the parent metals and helps oxides to
float up in the molten metal pool.
2. The common fluxes used in the gas welding are made
of sodium, potassium, lithium and borax.
3. Flux can be applied as paste, powder, liquid, solid
coating or gas during gas welding.

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 RESISTANCE WELDING
1. In resistance welding, the heat required for welding is
produced by means of the electrical resistance
between the two members to be joined. This process is
also known as electric welding.
2. The heat generated in resistance welding is given by
H=I2Rtk
where
H = heat generated, in joules (watt sec)
I = current in amperes
R = resistance in ohms
t = time of current flow in seconds
k = constant to account for losses due to radiation and
conduction. The value of k is normally less than one.
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SPOT WELDING
Spot welding is the
simplest and most
commonly used
resistance welding
process, mostly used to
weld sheets.

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SEAM WELDING
In seam welding, the cylindrical electrodes of spot welding
are replaced by electrode wheels.
With a continuous a.c. power supply, the electrically
conducting electrode wheels produce continuous weld in
two parts whenever the current reaches sufficiently high
level in the a.c. cycle, resulting spot welds at regular
intervals as

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 SEAM WELDING

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Resistance welding applications

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Resistance welding applications

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 ADVANCED WELDING TECHNIQUES
ELECTRON BEAM WELDING
Principle: Fusion of metal plates to be joined occurs due to
conversion of kinetic energy of electron in to thermal energy
when they collide with metals to be welded.
1. It is a fusion welding process in which the metal plates
are joined together by the heat obtained from a high
velocity electron beam.
2. Applications: Aerospace, Automotive and Medical
Industries
Important Components:
1. Vacuum chamber
2. Electron Gun (Cathode)
3. Positioning Diaphragm
4. Electro magnetic lance
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 ADVANCED WELDING TECHNIQUES

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 ADVANCED WELDING TECHNIQUES

Advantages
1. No filler metal is required
2. Produces clean weld
3. Less heat affected jones.
4. Deep penetration.
5. Focus of beam can be controlled by controlling
voltage, current
Disadvantages
1. Equipment cost is high
2. Vacuum chamber size restricts the size of the work
piece to be welded.

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 ADVANCED WELDING TECHNIQUES

LASER BEAM WELDING

The word laser sands for light Amplification by the stimulated
emission of radiation
1. Principle: Light energy is converted into heat energy. Here,
the light energy is produced from the laser source like ruby
rod in the form of monochromatic light.
2. Laser beam welding (LBW) is a welding technique used to join
multiple pieces of metal through the use of a laser.
3. The beam provides a concentrated heat source, allowing for
narrow, deep welds and high welding rates.
Applications: The process is frequently used in high volume
applications using automation, such as in the automotive
industry.

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 ADVANCED WELDING TECHNIQUES
LASER BEAM WELDING

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 ADVANCED WELDING TECHNIQUES
RUBY ROD

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 ADVANCED WELDING TECHNIQUES
Advantages
1. precise working with exact placing of the energy spot
2. welding of complicated joint geometry
3. low heat application, therefore minor changes in
microstructure
4. cavity-free welds
5. low post weld operation times
6. large working distance is possible ( welding up to 500 mm
distance and also to inaccessible parts).
Disadvantages:
1. The welding plants are expensive, depending upon the
equipment.

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 ADVANCED WELDING TECHNIQUES
PLASMA ARC WELDING
Plasma: ionised gas at high temperature
1. Plasma arc welding (PAW) is an arc welding process similar
to gas tungsten arc welding (GTAW)
2. The key difference from GTAW is that in PAW, by
positioning the electrode within the body of the torch, the
plasma arc can be separated from the shielding gas
envelope.
3. The plasma is then forced through a fine-bore copper
nozzle which constricts the arc and the plasma exits the
orifice at high velocities (approaching the speed of sound)
and a temperature approaching 28,000 °C (50,000 °F) or
higher.

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 ADVANCED WELDING TECHNIQUES
PLASMA ARC WELDING
Transferred Arc method
1. Current is transferred from the tungsten electrode (negative)
through the orifice to the workpiece (positive) and back to
the power supply.
2. A transferred arc possesses high energy density and
plasma jet velocity.
3. Ferrous metals and alloys easily welded by this method
Non-Transferred Arc method
1. The arc is formed between the electrode (negative) and the
water cooled constricting nozzle (positive).
2. Arc plasma comes out of the nozzle as a flame.
3. The arc is independent of the workpiece and the workpiece
does not form a part of the electrical circuit.
4. Non metals are welded by this approach
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 ADVANCED WELDING TECHNIQUES
PLASMA ARC WELDING

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 ADVANCED WELDING TECHNIQUES
PLASMA ARC WELDING

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 ADVANCED WELDING TECHNIQUES
PLASMA ARC WELDING
ADVANTAGES
1. Making manual welding is easier in PAW
2. The process provides a complete penetration on a single
pass (about 6 mm thickness for butt weld). So welding is
faster and saving cost and time.
3. The heat affected zone is smaller and the shape of the
welds is more desirable.
4. The plasma arc is more stable and the process is able to
join practically all the commercially available metals

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 ADVANCED WELDING TECHNIQUES
PLASMA ARC WELDING
DISADVANTAGES
1. Special protection safety devices required.
2. Higher equipment cost
3. Need to frequently replace the nozzle surrounding the
electrode
4. Produces unpleasant sound during welding
5. More chances of electrical hazards are associated with this
process.
6. The process is limited to metal thickness of 25 mm and
lower for Butt welds.

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 Thank You for Your Attention !

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