+0)26-4

1
lntroduction to WeIding TechnoIogy
1.1 DEFlNlTlON AND CLA55lFlCATlON
WoIdIng Is n rocoss of ormnnonf joInIng fwo mnforInIs (usunIIy mofnIs) fhrough IocnIIsod
conIosconco rosuIfIng from n suIfnbIo combInnfIon of fomornfuro, rossuro nnd mofnIIurgIcnI
condIfIons. oondIng uon fho combInnfIon of fomornfuro nnd rossuro from n hIgh fom-
ornfuro wIfh no rossuro fo n hIgh rossuro wIfh Iow fomornfuro, n wIdo rnngo of woIdIng
rocossos hns boon dovoIood.
Classification of Welding Process
AmorIcnn WoIdIng SocIofy hns cInssIfIod fho woIdIng rocossos ns shown In IIg. l.l. VnrIous
woIdIng rocossos dIffor In fho mnnnor In whIch fomornfuro nnd rossuro nro combInod nnd
nchIovod.
WoIdIng Irocossos cnn nIso bo cInssIfIod ns foIIows (bnsod on fho sourco of onorgy):
l. Cns WoIdIng
OxyncofyIono
Oxy hydrogon
2. Arc WoIdIng
Cnrbon Arc
MofnI Arc
Submorgod Arc
Inorf-gns-WoIdIng
TIC nnd MIC
IInsmn Arc
IIocfro-sIng
3. !osIsfnnco WoIdIng
Sof
Sonm
IrojocfIon
2 WeldingScienceandTechnology
Iuff WoIdIng
InducfIon WoIdIng
4. SoIId Sfnfo WoIdIng
IrIcfIon WoIdIng
!IfrnsonIc WoIdIng
IxIosIvo WoIdIng
Iorgo nnd IffusIon WoIdIng
5. Thormo-chomIcnI WoIdIng
ThormIf WoIdIng
AfomIc H
2
WoIdIng
(nIso nrc woIdIng)
6. !ndInnf Inorgy WoIdIng
IIocfron Ionm WoIdIng
!nsor Ionm WoIdIng
In ordor fo obfnIn conIosconco bofwoon fwo mofnIs fhoro musf bo n combInnfIon of rox-
ImIfy nnd ncfIvIfy bofwoon fho moIocuIos of fho Iocos boIng joInod, suffIcIonf fo cnuso fho
formnfIon of common mofnIIIc crysfnIs.
IroxImIfy nnd ncfIvIfy cnn bo Incronsod by InsfIc doformnfIon (soIId-sfnfo-woIdIng) or
by moIfIng fho fwo surfncos so fhnf fusIon occurs (fusIon woIdIng). In soIId-sfnfo-woIdIng fho
surfncos fo bo joInod nro mochnnIcnIIy or chomIcnIIy cIonnod rIor fo woIdIng whIIo In fusIon
woIdIng fho confnmInnnfs nro romovod from fho moIfon ooI by fho uso of fIuxos. In vncuum or
In oufor snco fho romovnI of confnmInnnf Inyor Is quIfo onsy nnd woIds nro formod undor IIghf
rossuro.
1.2 CONDlTlON5 FOR OTAlNlNG 5ATl5FACTORY WELD5
To obfnIn snfIsfncfory woIds If Is dosIrnbIo fo hnvo:
n sourco of onorgy fo cronfo unIon by I!SIO or I!ISS!!I
n mofhod for romovIng surfnco COTAMIATS
n mofhod for rofocfIng mofnI from nfmoshorIc COTAMIATIO
confroI of woId MITA!!!!CY
1.2.1 Source of Energy
Inorgy suIIod Is usunIIy In fho form of honf gonornfod by n fInmo, nn nrc, fho rosIsfnnco fo
nn oIocfrIc curronf, rndInnf onorgy or by mochnnIcnI monns (frIcfIon, uIfrnsonIc vIbrnfIons or
by oxIosIon). In n IImIfod numbor of rocossos, rossuro Is usod fo forco woId rogIon fo InsfIc
condIfIon. In fusIon woIdIng fho mofnI nrfs fo bo joInod moIf nnd fuso fogofhor In fho woId
rogIon. Tho word fusIon Is synonymous wIfh moIfIng buf In woIdIng fusIon ImIIos unIon. Tho
nrfs fo bo joInod mny moIf buf nof fuso fogofhor nnd fhus fho fusIon woIdIng mny nof fnko
Inco.
IntroductiontoWeldingTechnology 3
1.2.2 Surface Contaminants
Surfnco confnmInnnfs mny bo orgnnIc fIIms, nbsorbod gnsos nnd chomIcnI comounds of fho
bnso mofnI (usunIIy oxIdos). Honf, whon usod ns n sourco of onorgy, offocfIvoIy romovos orgnnIc
fIIms nnd ndsorbod gnsos nnd onIy oxIdo fIIm romnIns fo bo cIonnod. IIuxos nro usod fo cIonn
fho oxIdo fIIm nnd ofhor confnmInnnfs fo form sIng whIch fIonfs nnd soIIdIfIos nbovo fho woId
bond rofocfIng fho woId from furfhor oxIdnfIon.
Solid
state
welding
ISSWI
Arc
welding
(AW)
Brazing
(B)
Welding
processes
Soldering
(S)
Other
welding
Resistance
welding
(RW)
Oxyfuel
gas
welding
(OFW)
Thermal
spraying
(THSP)
Allied
processes
Adhesive
bonding
(ABD)
Oxygen
cutting
(OC)
Thermal
cutting
(TC)
Arc
cutting
(AC)
Other
cutting
atomic hydrogen welding.........AHW
bare metal arc welding............BMAW
carbon arc welding..................CAW
gas.....................................CAW.G
shielded..............................CAW.S
twin.....................................CAW.T
electrogas welding...................EGW
flux cored arc welding..............FCAW
coextrusion welding............CEW
cold welding........................CW
diffusion welding.................DFW
explosion welding...............EXW
forge welding......................FOW
friction welding....................FRW
hot pressure welding..........HPW
roll welding..........................ROW
ultrasonic welding...............USW
dip soldering........................OS
furnace soldering.................FS
induction soldering...............IS
infrared soldering.................IRS
iron soldering.......................INS
resistance soldering.............RS
torch soldering.....................TS
wave soldering.....................WS
flash welding.....................FW
projection welding.............PW
resistance seam welding..RSEW
high frequency............RSEW.HF
induction......................RSEW.I
resistance spot welding.....RSW
upset welding....................UW
high frequency............UW.HF
induction......................UW.I
electric arc spraying........EASP
flame spraying.................FLSP
plasma spraying..............PSP
chemical flux cutting...........FOC
metal powder cutting..........POC
oxyfuel gas cutting..............OFC
oxyacetylene cutting.....OFC.A
oxyhydrogen cutting.....OFC.H
oxynatural gas cutting..OFC.N
oxypropane cutting.......OFC.P
oxygen arc cutting..............AOC
oxygen lance cutting..........LOC
gas metal arc welding.............GMAW
pulsed arc.........................GMAW.P
short circuiting arc.............GMAW.S
gas tungsten arc welding........GTAW
pulsed arc.........................GTAW.P
plasma arc welding.................PAW
shielded metal arc welding.....SMAW
stud arc welding......................SW
submerged arc welding...........SAW
series.................................SAWS
arc brazing......................AB
block brazing..................BB
carbon arc brazing.........CAB
diffusion brazing.............DFB
dip brazing......................DB
flow brazing....................FLB
furnace brazing..............FB
induction brazing............IB
infrared brazing...............IRB
resistance brazing..........RB
torch brazing...................TB
electron beam welding......EBW
high vacuum................EBW.HV
medium vacuum..........EBW.MV
nonvacuum.................EBW.NV
electrostag welding...........ESW
flow welding......................FLOW
induction welding..............IW
laser beam welding...........LBW
percussion welding...........PEW
thermit welding..................TW
air acetylene welding......AAW
oxyacetylene welding.....OAW
oxyhydrogen welding.....OHW
pressure gas welding.....PGW
air carbon arc cutting..........AAC
carbon arc cutting...............CAC
gas metal arc cutting..........GMAC
gas tungsten arc cutting.....GTAC
metal arc cutting.................MAC
plasma arc cutting..............PAC
shielded metal arc cutting..SMAC
electron beam cutting..........EBC
laser beam cutting...............LBC
air...................................LBC.A
evaporative....................LBC.EV
inert gas.........................LBC.IG
oxygen...........................LBC.O
Fig. 1.1 Master Chart of Welding and Allied Processes
4 WeldingScienceandTechnology
1.2.3 Protecting Metal From Atmospheric Contamination
To rofocf fho moIfon woId ooI nnd fIIIor mofnI from nfmoshorIc confnmInnnfs, socInIIy fho
oxygon nnd nIfrogon rosonf In fho nIr, somo shIoIdIng gnsos nro usod. Thoso gnsos couId bo
nrgon, hoIIum or cnrbon-dIoxIdo suIIod oxfornnIIy. Cnrbon dIoxIdo couId nIso bo roducod by
fho burnIng of fho fIux confIng on fho consumnbIo oIocfrodo whIch suIIos fho moIfon fIIIor
mofnI fo fho woId ooI.
1.2.4 Control of Weld Metallurgy
Whon fho woId mofnI soIIdIfIos, fho mIcrosfrucfuros formod In fho woId nnd fho honf-nffocfod-
zono (HAZ) rogIon doformInos fho mochnnIcnI roorfIos of fho joInf roducod. Iro-honfIng
nnd osf woIdIng honf-fronfmonf cnn bo usod fo confroI fho cooIIng rnfos In fho woId nnd HAZ
rogIons nnd fhus confroI fho mIcrosfrucfuro nnd roorfIos of fho woIds roducod. ooxIdnnfs
nnd nIIoyIng oIomonfs nro nddod ns In foundry fo confroI fho woId-mofnI roorfIos.
Tho forogoIng dIscussIon cIonrIy shows fhnf fho sfnfus of woIdIng hns now chnngod from
skIII fo scIonco. A scIonfIfIc undorsfnndIng of fho mnforInI nnd sorvIco roquIromonfs of fho
joInfs Is nocossnry fo roduco succossfuI woIds whIch wIII moof fho chnIIongo of hosfIIo sorvIco
roquIromonfs.
WIfh fhIs brIof InfroducfIon fo fho woIdIng rocoss Iof us now consIdor Ifs Imorfnnco fo
fho Indusfry nnd Ifs nIIcnfIons.
1.3 lMFORTANCE OF WELDlNG AND lT5 AFFLlCATlON5
1.3.1 Importance of Welding
WoIdIng Is usod ns n fnbrIcnfIon rocoss In ovory Indusfry Inrgo or smnII. If Is n rIncInI
monns of fnbrIcnfIng nnd ronIrIng mofnI roducfs. Tho rocoss Is offIcIonf, oconomIcnI nnd
doondnbIo ns n monns of joInIng mofnIs. ThIs Is fho onIy rocoss whIch hns boon frIod In fho
snco. Tho rocoss fInds Ifs nIIcnfIons In nIr, undorwnfor nnd In snco.
1.3.2 Applications of Welding
WoIdIng fInds Ifs nIIcnfIons In nufomobIIo Indusfry, nnd In fho consfrucfIon of buIId-
Ings, brIdgos nnd shIs, submnrInos, rossuro vossoIs, offshoro sfrucfuros, sforngo
fnnks, oII, gns nnd wnfor IoIInos, gIrdors, ross frnmos, nnd wnfor furbInos.
In mnkIng oxfonsIons fo fho hosIfnI buIIdIngs, whoro consfrucfIon noIso Is roquIrod
fo bo mInImum, fho vnIuo of woIdIng Is sIgnIfIcnnf.
!nId rogross In oxIorIng fho snco hns boon mndo ossIbIo by now mofhods of
woIdIng nnd fho knowIodgo of woIdIng mofnIIurgy. Tho nIrcrnff Indusfry cnnnof moof
fho onormous domnnds for noroInnos, fIghfor nnd guIdod Innos, snco crnffs, rockofs
nnd mIssIIos wIfhouf woIdIng.
Tho rocoss Is usod In crIfIcnI nIIcnfIons IIko fho fnbrIcnfIon of fIssIon chnmbors of
nucIonr owor Innfs.
A Inrgo confrIbufIon, fho woIdIng hns mndo fo fho socIofy, Is fho mnnufncfuro of
IntroductiontoWeldingTechnology 5
housohoId roducfs IIko rofrIgornfors, kIfchon cnbInofs, dIshwnshors nnd ofhor sImIInr
Ifoms.
If fInds nIIcnfIons In fho fnbrIcnfIon nnd ronIr of fnrm, mInIng nnd oII mnchInory,
mnchIno fooIs, jIgs nnd fIxfuros, boIIors, furnncos, rnIIwny conchos nnd wngons, nnchor chnIns,
onrfh movIng mnchInory, shIs, submnrInos, undorwnfor consfrucfIon nnd ronIr.
1.4 5ELECTlON OF A WELDlNG FROCE55
WoIdIng Is bnsIcnIIy n joInIng rocoss. IdonIIy n woId shouId nchIovo n comIofo confInuIfy
bofwoon fho nrfs boIng joInod such fhnf fho joInf Is IndIsfInguIshnbIo from fho mofnI In whIch
fho joInf Is mndo. Such nn IdonI sIfunfIon Is unnchIovnbIo buf woIds gIvIng snfIsfncfory sorvIco
cnn bo mndo In sovornI wnys. Tho choIco of n nrfIcuInr woIdIng rocoss wIII doond on fho
foIIowIng fncfors.
l. Tyo of mofnI nnd Ifs mofnIIurgIcnI chnrncforIsfIcs
2. Tyos of joInf, Ifs IocnfIon nnd woIdIng osIfIon
3. Ind uso of fho joInf
4. Cosf of roducfIon
5. SfrucfurnI (mnss) sIzo
6. osIrod orformnnco
?. IxorIonco nnd nbIIIfIos of mnnowor
8. JoInf nccossIbIIIfy
9. JoInf dosIgn
l0. Accurncy of nssombIIng roquIrod
ll. WoIdIng oquImonf nvnIInbIo
l2. Work soquonco
l3. WoIdor skIII
IroquonfIy sovornI rocossos cnn bo usod for nny nrfIcuInr job. Tho rocoss shouId bo
such fhnf If Is mosf, suIfnbIo In forms of fochnIcnI roquIromonfs nnd cosf. Thoso fwo fncfors
mny nof bo comnfIbIo, fhus forcIng n comromIso. TnbIo 2.l of chnfor 2 shows by N mnrks
fho woIdIng rocoss, mnforInIs nnd mnforInI fhIcknoss combInnfIons fhnf nro usunIIy comnf-
IbIo. Tho fIrsf coIumn In fho fnbIo shows n vnrIofy of ongInoorIng mnforInIs wIfh four fhIcknoss
rnngos. Tho mnjor rocoss curronfIy In uso In Indusfry nro IIsfod ncross fho fo of fho fnbIo.
Tho InformnfIon gIvon Is n gonornI guIdo nnd mny nof nocossnrIIy bo vnIId for socIfIc sIfun-
fIons.
1.5 WELDING QUALlTY AND FERFORMANCE
WoIdIng Is ono of fho rIncIIo ncfIvIfIos In modorn fnbrIcnfIon, shI buIIdIng nnd offshoro
Indusfry. Tho orformnnco of fhoso IndusfrIos rognrdIng roducf qunIIfy, doIIvory schoduIo
nnd roducfIvIfy doonds uon sfrucfurnI dosIgn, roducfIon InnnIng, woIdIng fochnoIogy
6 WeldingScienceandTechnology
ndofod nnd dIsforfIon confroI monsuros ImIomonfod durIng fnbrIcnfIon. Tho qunIIfy of woId-
Ing doonds on fho foIIowIng nrnmofors:
l. SkIII of WoIdor
2. WoIdIng nrnmofors
3. ShIoIdIng modIum nnd
4. WorkIng onvIronmonf
5. Work Inyouf
6. IInfo odgo ronrnfIon
?. IIf-u nnd nIIgnmonf
8. IrofocfIon from wIId wInds durIng-on-sIfo woIdIng
9. ImonsIonnI nccurncy
l0. Corrocf rocossos nnd rocoduros
ll. SuIfnbIo dIsforfIon confroI rocoduros In Inco
SeIectIon oI WeIdIng Pvocess und IIIIev MetuI:
Tho woIdIng rocoss nnd fIIIor mofnI shouId bo so soIocfod fhnf fho woId doosIf wIII bo
comnfIbIo wIfh fho bnso mofnI nnd wIII hnvo mochnnIcnI roorfIos sImIInr fo or boffor fhnn
fho bnso mofnI.
ComnrIson of hIgh onorgy donsIfy woIdIng rocossos nnd TIC woIdIng for Info fhIck-
noss 6 mm.
2=H=AJAH 61/ 2=I= =IAH -*
Iowor Inuf fo 2 kW 4 kW 4 kW 5 kW
workIoco
TofnI owor 3 kW 6 kW 50 kW 6 kW
usod
Trnvorso 2 mm/s 5.? mm/s l6 mm/s 40 mm/s
Sood
IosIfIonnI Cood Cood Yos !oquIros
WoIdIng onofrnfIon onofrnfIon !oquIros ofIcs fo mochnnIsm fo
movo fho bonm movo fho bonm
IsforfIon omInnI omInnI SmnII MInImum
ShrInkngo SIgnIfIcnnf sIgnIfIcnnf MInImum MInImum
In V-shnod In V-shnod
woId woId
SocInI ormnI ormnI Snfofy InforIock Vncuum
Irocoss !Ighf !Ighf ngnInsf mIsIncod chnmbors,
!oquIromonfs ScroonIng ScroonIng bonm rofIocfIon X-rny
ScroonIng
Surfnco !ndorsIdo !ndorsIdo Vory fIno !uffIod swnrf
Coomofry IrofrusIon rofrusIon rIIos on bnck fnco
IntroductiontoWeldingTechnology 7
QUE5TlON5
l.l ofIno 'WoIdIng`. IxInIn fho monnIng nnd sIgnIfIcnfIon of conIosconco nnd fusIon In
rognrd fo woIdIng. Why Is If onsIor fo obfnIn qunIIfy woIds In snco fhnn In nIr
l.2 IxInIn fho condIfIons for obfnInIng snfIsfncfory woIds. Iscuss fho Imorfnnco of woId-
Ing nnd sfnfo Ifs nIIcnfIons.
l.3 Iscuss fho fncfors whIch nro consIdorod In choosIng n woIdIng rocoss for n socIfIc
nIIcnfIon.