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CWIT, PUNEGENERAL ENGINEERING
PRACTICAL 5 : WELDING AND WELDING SYMBOLSINTRODUCTION:
Welding may be described as a process of uniting two pieces of metal or alloy byraising the temperature of the surfaces to be joined so that they become plastic or molten. This may be done with or without the application of pressure and with or without the use of added metal.
DIFFERENT METHODS OF WELDING
There are numerous methods of welding, but they can be grouped broadly into twocategories.
 Forge
 
welding 
is the term covering a group of welding processes in which the partsto be joined are heated to a plastic condition in a forge or other furnace, and arewelded together by applying pressure or impact, e.g. by rolling, pressing, or hammering.
 Fusion welding 
is the process where the surfaces to be joined are melted with or without the addition of filler metal. The term is generally reserved for those processes in which welding is achieved by fusion alone, without pressure. Forgewelding will be dealt with first.
 Pressure
 
welding 
is the welding of metal by means of mechanical pressure whilstthe surfaces to be joined are maintained in a plastic state. The heating for this process is usually provided by the process of 
resistance welding 
, where the piecesof metal to be joined are pressed together and a heavy current is passed throughthem.
 Projection welding 
is a resistance-welding process in which fusion is produced bythe heat obtained from the resistance to flow of electric current through the work  parts, which are held together under pressure by the electrodes providing thecurrent. The resulting welds are localized at predetermined points by the design of the parts to be welded. The localization is usually accomplished by projections or intersections.
Spot welding 
is a resistance-welding process of joining two or more overlapping parts by local fusion of a small area or ‘spot’. Two copper-alloy electrodes contacteither side of the overlapped sheets, under known loads produced by springs or air  pressure.
Stitch welding 
is spot welding in which successive welds overlap.
Seam
 
welding 
is a resistance-welding process in which the electrodes are discs.Current is switched on and off regularly as the rims of the discs roll over the work,with the result that a series of spot welds is at such points. If a gas-tight weld is
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CWIT, PUNEGENERAL ENGINEERING
required, the disc speed and time cycle are adjusted to obtain a series of overlapping welds.
 Flash-butt welding 
is a resistance-welding process which may be applied to rod, bar, tube, strip, or sheet to produce a butt joint. After the current is turned on, thetwo parts are brought together at a predetermined rate so that discontinuous arcingoccurs between the two parts to be joined. This arcing produces a violent expulsionof small particles of metal (flashing), and a positive pressure in the weld area willexclude air and minimize oxidation. When sufficient heat has been developed byflashing, the parts are brought together under heavy pressure so that all fused andoxidized material is extruded from the weld. Fusion-welding processes can now bedealt with. The heat for fusion welding is provided by either gas or electricity.
Gas welding 
is a process in which heat for welding is obtained from a gas or gases burning at a sufficiently high temperature produced by an admixture of oxygen.Examples of the gases used are acetylene (oxy-acetylene welding), hydrogen (oxyhydrogen welding), and propane (oxy-propane welding).In
air-acetylene welding 
, the oxygen is derived from the atmosphere by induction.Electrical fusion welding is usually done by the process of ‘arc welding’.
Metal-arc welding 
is welding with a metal electrode, the melting of which provides thefiller metal.
Carbon arc welding 
is a process of arc welding with a carbon electrode (or electrodes), in which filler metal and sometimes flux may be used.
Submerged-arc welding 
is a method in which a bare copper-plated steel electrode isused. The arc is entirely submerged under a separate loose flux powder which iscontinually fed into and over the groove which is machined where the edges to bewelded are placed together. Some of the flux powder reacts with the molten metal: part fuses and forms a refining slag which solidifies on top of the weld deposit; theremainder of the powder covers the weld and slag, shielding them fromatmospheric contamination and retarding the rate of cooling.
Welding symbols:
When welds are specified on engineering and fabrication drawings, a cryptic set of symbols issued as a sort of shorthand for describing the type of weld, its size, andother processing and finishing information. The purpose of this practical is tointroduce you to the common symbols and their meaning
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