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227

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4
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Welding fundamentals

E1F
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Welding typesE2.1

EFFusion welding E1
KEFPressure welding E2

EF E3

K
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EF E1

EF E2

EF E3

E F E4

EF E5

EF E6

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227

EF

Weld jointsE4.1

W
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KKE1.1F

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WEdge preparationE5.1

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KWE2.1F

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WWelding positionsE7.1

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KKK

KKBackhandForehand
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KKE5.1F

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Basic weld symbolsE9.1

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WE6.1F

WE7.1FEF

WE7.1F

-8-

227

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W8.1F

WE8.1F

W9.1F

WE9.1F

W10.1

WE10.1F

-9-

227

EF

WK

E11.1F

WE11.1F

- 10 -

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WSafety rulesE10.1
E1.10.1
Safety precautions in electric Arc - welding

J 1

KHot part

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K{ {
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- 11 -

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J 3

K{
Kcover plate fliter plate

K
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K
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E2.10.1

Safety precautions in Oxy Acetylene welding

K E1

K E2

KEF E3

K10 E4
K E5

K E6
K E7
K E8

K E9

K(reducing valve) E10

- 12 -

227

EF

KE11
K

K E12

KE13

KE14

KE15

E16
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K10E17

KE18
KE19

E20
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KE21

KE22

KE23
W

KE24

KECO2FE25

KE26

K E27

- 13 -

227

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KE28
K

E29

K
K

K E30

KE31

KE32

KE33

KE34
KE35

K E36

KE37

K E38
KE39

KE40

W
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E1

E3

E2

KEFKEF
KEF

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KE5K

E4

KE7KE6

WE9KE8

- 14 -

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K5E10

KE11

K6E12
6E13

- 15 -

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-1-

227

EF

_______________________

- 16 -

227

EF

W
K J

K J
K J
K J

K4

K4

- 17 -

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Thermal weldingE2

WK

FJ

EFJ

FJ

EFJ
KEFJ
EFJ
EFJ

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Electric arc weldingE1.2

EF

WWE1.1.2

1881

1895K
1905K

KKK

- 18 -

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WE2.1.2K
EBase metalF KKKEF

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K
J

K -

E32F KK

F -

KKE
E1.2FKK

KK

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- 19 -

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WE3.1.2
W

E
K

KE

KE
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E
K

Dip or short circuiting transferE

FK

KE2.2FKE

WE2.2F

- 20 -

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Spray transferE

KKK

KE3.2F

WE3.2F
Pulsed transfer E

K
K

KE4.2F

WE4.2F

- 21 -

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EF

WTypes of Arc welding EE4.1.2K

KBare electrodeJ

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Shielded arc welding E

Submerged arc welding E

WEF EF E

K Tungesten Inert gas arc welding TIG

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arc welding

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MIG
KWE5.2F

- 22 -

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EF

WAdvantages of arc welding E5.1.2

4000 KK -

K -

KJ

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KDirect current

KAlternating current

K690 W -

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E6.2FK
K

WE6.2F

- 23 -

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WE1.6.1.2

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250 150

315 200

350 220

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Types ofPolarityE2.6.1.2

Indirect polarity

Direct polarity

EFJ

EFJ

J
J

- 24 -

227

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W
KE1
KE2

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E5

KE6

E7

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KEF

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WE11
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- 25 -

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EF

227
EF

___________________________

___________________________

- 26 -

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EF

W
K J

K J

K J
K J

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K12

- 27 -

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E2.2
E1.2.2
1914

FK

H2O2FK

N2

E
E7.2FK

Shielded Arc welding submerged Arc welding

KJ 19301914
KWE7.2F

- 28 -

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E2.2.2
KE8.2F

WE8.2F
WE3.2.2
W

J
J

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- 29 -

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EF

KAcid coverings
K

KCellulosic coverings

KK

KRutile coverings
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25 to 30 ml/100g

Basic coverings

E4.2.2
W

J
K

KJ

KJ

KJ

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DINK

156BS639K155148[1]
K161

EAWSFAmerican welding society

E 6010K

- 30 -

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EF

KE

E420 N.mm-2F6000060

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1J

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- 31 -

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W
KE1

KE2
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- 32 -

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EF

227

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MIG
______________________

- 33 -

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KEMIG)0

W
K J
K J
K J

K J
K J

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K4

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- 34 -

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E3.2
Metal Inert gas arc welding (MIG)

KK19501920
MIGW

TIG

E2400F

E1.3.2
KMIGE9.2F
EF

KK

KK

K
KK

MIG - Metal inert gas arc weldingWE9.2F

- 35 -

227

EF

MIG - EquipmentE2.3.2

KE10.2F

WE10.2F

K
K

KEF

- 36 -

227

EF

E11.2F
KK

KWE11.2F

KK

KE12.2FK

- 37 -

227

EF

KWE12.2F

W
K

W
K

- 38 -

227

EF

Inert gasesE3.3.2

KJ

WJ

KG

KG
WJ

K K5

- 39 -

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W
WE1

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WMIGE6

EFEF

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- 40 -

227
EF

TIG
_________________________________

- 41 -

227

EF

ETIGF

KJ
K J
K J

K J
K J

K J

K2

K4

- 42 -

227

EF

Tungesten inert gas arc welding E4.2

E1.4.2
E13.2F
KE3400F

WE13.2F

EFTIGJ

KE200F

KEHigh frequencyFJ

- 43 -

227

EF

TIGE2.4.2

MIG

E14.2FK

KTIG

TIGWE14.2F

- 44 -

227

EF

TIGE3.4.2

W
E

KE15.2F

TIGWE15.2F

KE16.2FK

TIGWE16.2F

- 45 -

227

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TIGE

K
KE17.2FK

TIGWE17.2F

E4.4.2

4.51.5

K2J 1

J -

J
J

- 46 -

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EF

E5.4.2
KK

- 47 -

227
EF

- 48 -

227

EF

WE1
EF
EF

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WE2

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WTIGE4

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EF
KEF

WTIGE6

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EF

- 49 -

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EF

227

EF

WTIGE7

KEF
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EF
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WTIGE8
KEF

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EF

WTIGE9
KEF

A300EF

EF

EF

WTIGE10
EF

EF

- 50 -

227
EF

TIG
_________________________________

- 51 -

227

EF

ETIGF

KJ
K J
K J

K J
K J

K J

K2

K4

- 52 -

227

EF

Tungesten inert gas arc welding E4.2

E1.4.2
E13.2F
KE3400F

WE13.2F

EFTIGJ

KE200F

KEHigh frequencyFJ

- 53 -

227

EF

TIGE2.4.2

MIG

E14.2FK

KTIG

TIGWE14.2F

- 54 -

227

EF

TIGE3.4.2

W
E

KE15.2F

TIGWE15.2F

KE16.2FK

TIGWE16.2F

- 55 -

227

EF

TIGE

KE17.2FK

TIGWE17.2F

E4.4.2

4.51.5

K2J 1

J -

- 56 -

227

EF

E5.4.2
KK

- 57 -

227
EF

- 58 -

227

EF

WE1
EF
EF

EF

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WE2

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WE3
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WTIGE4

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WTIG E5

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EF

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WTIGE6

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EF

EF

EF

WTIGE7

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- 59 -

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227

EF

EF

EF

WTIGE8
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WTIGE9
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A300EF

EF

EF

WTIGE10
EF

EF

- 60 -

EF

227

EF

J
K J

K J

K J

K3

K8

- 61 -

227

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Gas weldingE3

E1.2
KK

KEFillerFEWeld poolF
KEBeadF
K

EFE1.3F

EFE1.3F

E1.3
W

2526 C3H8

2538

CH4

2650

H2

2900

KC3H4

3087

C2H2

2927

C2H4

Acetylene (C2H2 , 92.3 % C , 7.7 % H)

1815KK

1892
KL35K

- 62 -

227
EF

1774K20,9

K218J K
K860

Gas welding equipmentE3.3

E2.3F
K

E2.3F

KK

- 63 -

227

EF

WCylindersE1.3.3

39010KK

8713021KE3

L75150K
5410030

L5315K

EFK

K
EatuF2L1.5600

WE3.3F

- 64 -

227

EF

WPressure gaugeE2.3.3

KE4.3F

WE4.3F

WRegulatorE3.3.3

KK
WSafety valveE4.3.3

K
K160K

WTorchEFE5.3.3

KKK

KKEFKE300.2FEBase metalF
E5.3F

- 65 -

227

EF

EFWE5.3F
WHosesE6.3.3

KK

K5K

KE6.3FK

WE6.3F

- 66 -

227

EF

WFlame typesE4.3

KK

250030001000

K1800
KE7.3FK

WE7.3F

- 67 -

227

EF

WK

KCarburizing flame

WE8.3F

KOxidizing flame

WE9.3F

K Neutral flame

WE10.3F

- 68 -

227

EF

E1

KE2
E3

KE4

WE5

EF

EF

EF

EF

WE6

KE

KE2

KE3

KE4

- 69 -

EF

227
EF

_________________________

- 70 -

227

EF

K J
KK J
KK J

K3

K4

- 71 -

227

EF

Resistance weldingE1.4

65000100254
K

WE1.1.4
Direct F

Ecurrent

K
K

KE1.4F

WE1.4F

KE2.4F

KK

- 72 -

227

EF

WE2.4F
WE2.1.4

WE6.4FE3.4F
KEFSeam weldingJ

WE3.4F

- 73 -

227

EF

Projection resistsnce weldingJ

E4.4F

WE4.4F

KE 65000FFlash weldingJ

KK

E5.4FK

WE5.4F

- 74 -

227

EF

WE3.1.4
J

J
E0.004 inFJ

KJ
Thermit weldingE3.4
E1.3.4

E1FK

K
E2F

KE3F

E6.4FK

KWE6.4F

- 75 -

227

EF

WE2.2.4
KJ
KJ
J

J
WSoldering and brazingE3.4

KK{
E1.3.4

EF
0.07 K

KE8.4F

WE8.4F

- 76 -

227

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E9.4F

KWE9.4F

E750F
Filler rodE2.3.4

E1FK

220J 1834.50.595
236J 183

60 J J 40

214J 183 49.5

KWE1F

0.550

KK
- 77 -

227

EF

E2FK

870760

0.85

50

50

870860

0.85

45

54

40

50

J J

79

900J 860
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10

714

KWE2F

WE3.3.4

K J

- 78 -

227

EF

KE1

E2
KE3
K E4
K E5

K E6
K E7

E8

- 79 -

227

EF

_____________________

_____________________

- 80 -

227

EF

K1

- 81 -

227

EF

Advanced welding processesE4.4

Electron beam weldingE1.4.4
WE1.1.4.4

EF

EF

K15000L224000K

KQ = 0.212 . E (V). I (A)

K900

KE10.4F

WE10.4F

- 82 -

227
EF

WE2.1.4.4
-

K -

KEVacuumFJ
E12000<FJ
KJ

- 83 -

227

EF

Arc plasma weldingE2.4.4

WE1.2.4.4
K
KEF

K11000

KKKK2J 1

KE11.4F

WE11.4F
WE2.2.4.4
K -

K -

150K153 0.1 J K

- 84 -

227

EF

Laser beam weldingE3.4.4

WE1.3.4.4
K

E050
K
4000
KE12.4FK

WE12.4F

- 85 -

227

EF

E1

E2

E3

E4
E5

E6

- 86 -

EF

48

227

EF

KK J

K2

KK

- 87 -

227

EF

E5
E1.5
F
Non ferrous

FerrousKE

Cast iron

Grey CI

Steel

White CIJ

Ductile CIJ

Carbon steel

Alloyed steel

J
J

E2.5

0.02 0,22J

KJ

- 88 -

227

EF

0.22 0,4J

KJ

WW

0.45 0,8J

KJ

KJ

W
NiCr MnTiMoWV

- 89 -

227

EF

2.5 FE2.5FW

5510FE10
W -

W -

Stress reliefingEF
E2,5

4.62J

KJ

- 90 -

227

EF

KE7030F

EFJ

KK
W -

K600500

50
K347

KKJ
E4.5

K2050
KJ

K5

WJ

WE1

2850G
K814

25G
K5G
KG

K260250E2
- 91 -

227
EF

K350300E3

5015J

K35

10014MIGJ

K140.5TIG

75002J

K0.1231000
E5.5

E5.5FCuJ

0.2J

K0.3

201070J

K500400J

EZnFEHFEFJ

K K907

- 92 -

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EF

E1

E3

E2

E4

E6

E5

E7

E9

E8

- 93 -

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227

EF

W
K J
J

K J
K J

K4

K4

KK

- 94 -

227

EF

WWelding defectsE6

K
K

WE1.6
K K K -

K -

K -

K -

500 -

KK -

WE1.6F

- 95 -

227

EF

WE2.6

KE
E

E
E1.2.6

EAgingF__W
KFatigueW

KW

AlZrTi
KK

WJ

5 30 ml/ KW
100g
KW
EHazFKF

[H] HF
+ (F) ---- (HF)

- 96 -

227

EF

Fe3O4W
K

W
[FeO] + (SiO2) ----- (SiO2.FeO)
{K
WE2.2.6

SJ

0.01%

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------- (Ca3P2O8)F3CaOE[P2O5] +

- 97 -

227

EF

E3.2.6

FE1FE0F

E2.6FE62

WE2.6F

KEF

256J 2

- 98 -

227

EF

E130001000 -

E900723F

E750500F K

KE500100F -

WE

WCarbon equivalent
C.e. = C% + Mn%/6 + (Cr% + Mo% + V%) / 5 + (Ni% +Cu%)/15
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400 VPNZ0.5%Z

K300 VPN

EF
E200J 75F

K300 ml / 100g

- 99 -

227
EF

DistortionE

KK

KK

W
-

K
K

K5040

KE4.2.6
W

K -

K K -

K -

- 100 -

227

EF

E3.6
E1.3.6

KJ

KJ
KJ
KJ

W BS 5500
K63

K2

K1<K151>

E2.3.6
KWE

WE

WE
K

- 101 -

227

EF

F WE

EKKKKKKKK

WE
WE

E3.3.6

J J
J

- 102 -

227

EF

Weldments inspection methodsE4.6

Destructive testing methodsE1.4.6

BS2633 K

KASME 9
E

KE3.6FK

KWE3.6F

- 103 -

227
EF

E
EFE4.6FEF

WE4.6F
E

E5.6FKEF

WE5.6F
- 104 -

227

EF

Non destructive testing methods

E2.4.6

FE RayX FEUltra SonicF

KEDye penterantFEMagnet Field

K

Visual inspection E1.2.4.6

E6.6FK

WE6.6F

- 105 -

227

EF

Dye penetrantE2.2.4.6

KKK

KKEF

KE7.6F

WE7.6F

- 106 -

227

EF

WUltrasonic wavesE2.2.4.6

KE8.6FK

WE8.6F

- 107 -

227

EF

WX Ray testE3.2.4.6

KX

K
E9.6FKK

WE9.6F

Magnetic field testE4.2.4.6

KK
KKE10.6FKKE53

WE10.6F
- 108 -

227

EF

Pressure testE5.2.4.6

KK
E11.6FKK
K

WE11.6F

- 109 -

227

EF

WE1

EF

EF

EF

EF

WE2

EF

EF

EF

EF

WE3

EF

EF

EF

EF

WE4

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EF

EF

EF

EF

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EF

EF

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EF

WE6

EF

EF

WE7

EF EF EF

- 110 -

227

EF

EF

EF

WE8

EF EF EF

WE9

EFEF EF

WE10

EFEF EF

- 111 -

EF

227

EF

Glossary

acceptance
accessories
accurate
achieve
adjusting
allowance
alloyed steel
alloying elements
American welding society
angular distortion
approval
approve
approximation
Arc
arc length
arc voltage
asymmetrical
atmosphere
average
Backfire
Backhand
basic covering
Bead
behaviour
Bending test
Brazing
Butt joint
Capacity
capping run
Carburizing flame
cellulosic coverings
characteristics
check
client
Corner joint

227
EF

cold pressure welding

composition
concentration
constituents
contamination
contraction
Cracks
crater
cross section
current supply
Cylinder
De-oxidation
depth
Destructive testing
Direct polarity
Dye penetrant
Edge joint
edge preparation
Electric arc
Electric resistance
Electrode
electrode efficiency
essential parameters
expansion
final run
Filler
Filling runs
fixed
Flame
flame cone
Flame core
Flame cutting
Flash welding
flashing back
Flat
flow of current
Forehand
formula

227
EF

fracture

Friction welding

Fusion welding

gap

Gas igniter

generator

Hardness test

heat distribution

heat input

heat source

high frequency

Horizontal

Hose

Hose clips

hot pressure welding

Impact test

improvement

indirect polarity

induction heating

Inert gas

Influence

Inlet

Inspection

Inversely

inverter

keyholing

killed steel

lap joint

leakage

light fabrications

limitations

Load

longitudinal expansion

Magnetic field

Metal inert gas Arc welding MIG
mild steel

Mixing chamber

Neutral flame

227
EF

Non - destructive testing

Nozzle
Occur
Orifice
Outlet
Outlet
Overhead
Oxidizing flame
parent metal
passage of electricity
Phase
Pin holes
Porosity
power source
preheating
Pressure gauge
pressure vessels
pridect
procedure
protection
Protective cap
purpose
rapidly developing
Rays
rectifier
regulator
requirements
residual stresses
response
root run
rutile coverings
Salg inclusions
sample
seam welding
shematic diagram
Shielded Arc welding
shrinkage
Slag

) )

) )

227
EF

Slot
Soldering
Spanner
Splash of metal
Spot welding
straightening
stress concentration
Submerged Arc welding
supplying
symmetrical
T- Joint
Tensile test
termination
thermal conductivity
Thermit welding
thershold
tool steel
Torch
transverse shrinkage
Tungesten Arc welding TIG
Ultra Sonic
Ultrasonic testing
Underbead cracks
Undercut
vacuum chamber
Valve
ventilation
Vertical
Visual inspection
Weld pool
Weld quality
Weldability
Welding
welding defects
welding positions
Welding technique
Working pressure

-
( )

T





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( )

227

EF

W
1978 E1
K
KK E2
K1982
Welding principles and applications, Larry Jeffus, 4th edition, Delmar E3
publisherUSA, 1999.
Welding Engineering,R.L. Agrawal, Khanna publisher, Delhi, 1985. E4

1987K E5
Practical welding, S. Gibson, Mcmillan press, London, 1994 E6

Principles of welding , L. M. Gourd, thitd edition, Edward Arnold, 1995, E7

London

2006 E8
rd

Work shop Technology, part 3, W.A.J. Chapman, 3 Edition, Arnold, 1986 E9

227

EF

W

31
3

W
E1.1
E2.1

E3.1

E5.1

E7.1

11

11

12
15

E4.1

E6.1

E8.1

E9.1

E10.1

E1.10.1

E2.10.1

W
3

E2

E1.2

E2.1.2

E4.1.2

E1.1.2

E3.1.2

E5.1.2

E6.1.2

10

227

EF

E1.6.1.2

E2.1.6.2

13

E2.2

14

E2.2.2

15

E4.2.2

13
14

15

17

20

E1.2.2

E3.2.2

E5.2.2

E3.2

20

MIGE1.3.2

24

E3.3.2

21
25

28

28
29

E2.3.2

TIGE4.2
E1.4.2

TIGE2.4.2

29

TIGE3.4.2

32

TIGE5.4.2

31

34

E4.4.2

227

EF

E3

E1.3

E3.3

E2.3.3

E4.3.3

E6.3.3

3
5

10

E2.3
E1.3.3

E3.3.3
E5.3.3

E4.3

W
3
3

W
E1.4

E1.1.4

E2.1.4

E3.1.4

6
6

E2.4

E1.2.4
E2.2.4

7
7

E1.3.4

E3.3.4

10

E3.4

E2.3.4

227
EF

W
13

E4.4

13

E1.4.4

14

E2.1.4.4

15

E1.2.4.4

13

15

E1.1.4.4

E2.4.4

15

E2.2.4.4

16

E1.3.4.4

16

17

E3.4.4

W
EK5

E2.5

E4.5

E1.5

E3.5

E5.5

W
EK6

E2.6

E1.6

E1.2.6

E2.2.6

E3.2.6

227
EF

E4.2.6

E3.6

E2.3.6K

9
10

11

11

E1.3.6

E3.3.6

E4.6

E1.4.6

13

E2.4.6

14

E2.2.4.6

13

15
16
16
17
18

E1.2.4.6

E3.4.62

E4.2.4.6

E5.2.4.6
E6.2.4.6