WELDING

Definition :
A localized Joining of material with or without the use of
filler and also with or without the application of pressure.

or
Bringing two perfectly smooth & clean material surfaces to
an intimate contact, which is an atomic distance, indeed,
between the two, is known as welding.

Welding Joint Terminology

Types of Common Welded Joints

Single Vee Butt Joint
Fillet Joint
Spot Welded Joint
Plug Welded Joint
Edge Joint

Types of Common Welded Joints

Butt Joint
Fillet Joint
Lap Joint
Open Corner Joint
Closed Corner Joint

Types of Fillet Welds

Mitre Fillet
Convex Fillet
Concave Fillet

Leg Hieght
Face

Leg length
Reinforcement
Designed throat
Actual Throat

Weld Positions
Weld Slope
Weld Rotation
Flat Position
Horizontal Vertical Position
Horizontal Position
Over Head Position
Vertical Up Position
Vertical Down Position
Inclined Position

G - Positions on Plate
1G
2G
3G
4G

G - Positions on Pipe
1G
2G
5G
6G

F - Positions on Plate

1F
2F
3F
4F

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F - Positions on Pipe
1F
2F
2FR
4F
5F

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Welding Processes
Following are the common Welding Processes Used in the Industries

1.
2.
3.
4.
5.
6.
7.

Oxy- Gas Welding

Manual Metal Arc ( M.M.A ) Welding
Metal Inert Gas ( MIG), Metal Active Gas ( MAG ) Welding
Tungsten Inert Gas ( TIG) Welding
Plasma Arc Welding( PAW )
Submerged Arc Welding ( SAW )
Electroslag Welding

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OXY-GAS WELDING

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OXY-GAS WELDING
It is a fusion welding process
Uses a fuel gas and oxygen to provide a flame hot enough to
melt the materials to be joined.
Suitable for almost all thicknesses and types of ferrous and
most non-ferrous metals.
All positions welding is possible
Relatively cheep method
Reasonable ease of operation

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OXY-GAS WELDING
This Method is suitable for
Welding of most metals including carbon steels,
stainless steels, cast iron, bronze, copper, aluminum etc.
Metals less than 5 mm thickness
The main disadvantages are
Slow speed of travel
High heat input

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OXY-GAS WELDING
Process Technique
A flame temperature of 31000 C is produced
This high temperature flame is used to bring a small area of
parent metal
to melting
point. into the molten pool
Separate
fillertip
wire
is then dipped
The filler is melted off and mixes with the base metal
to produce the weld

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OXY-GAS WELDING
There are three distinct flame used in this method
The neutral flame
Equal quantities of oxygen and acetylene
Distinct inner white cone with a rounded tip
Suitable for all carbon steel, cast irons, low alloy steels and
aluminum
The carburizing (carbonizing) flame
Slight excess of acetylene.
Feather around the inner white cone.
Used for welding of high carbon steels and for hard surfacing.
The oxidizing flame
Has an excess of oxygen
Inner white cone is shorter and sharper than the neutral cone.
This flame is suitable for brass, bronze, zinc applications,
Used for bronze welding and brazing
1
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Three Distinct Flame

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Manual Metal Arc Welding

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Manual Metal Arc Welding

Most Versatile Welding Process
Suitable for almost all types of metals and all positions
Its operation is comparatively easy
It is a fusion welding
The heat being provided by electric arc
The arc has an average temperature of around 6,000 degree
C
M.M.A welding is carried out using either a.c. or d.c.
In case of d.c. current + ve or ve polarity may be used
A high open circuit voltage (o.c.v.) required is 65-90 volts
Lower welding voltage required is 20-40 volts
Reasonable range of current must be available; 30-350 amps
1
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Effect of Amperage too low

Poor penetration or fusion,
unstable arc,
irregular bead shape,
slag inclusion,
porosity,
electrode freezes to the weld,
possible stray arc strikes.
Effect of Amperage too high
Excessive penetration,
burn through,
porosity,
spatter,
deep craters,
undercut,
electrode overheats,
high deposition (positional welding difficult).
1

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Effect of Voltage too low

Poor penetration,
Electrode freezes to work
Possible stray arcs
Fusion defects
Slag inclusions
Unstable arc
Irregular bead shape.
Effect of Voltage too high
Porosity
Spatter
Irregular bead
Slag inclusion
Very fluid weld pool
positional welding difficult.
1

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Travel speed too slow

Excessive deposition
Cold laps
Slag inclusions
Irregular bead shape.
Travel speed too Fast
Narrow thin bead
Slag inclusion
Fast cooling
Undercut
Poor fusion and Penetration

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An electrode connected to the d.c.+ve pole will have two thirds of

the available energy.The remaining one third of the energy in the
parent material
It will result in:
wide and shallow weld pool
Broad HAZ
Slow Rate of Cooling
Hydrogen Intrapment
An electrode connected to the d.c. ve pole has One third of the
energy develops at the electrode and two thirds of the energy in the
parent material.
This will result in
Weld pool which is narrow, deep and fast freezing
limited h.a.z.
May lead to hydrogen entrapment and a brittle metallurgical
structure
1
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In A.C. The polarity is reversing 100 times per second (50 c.p.s.).
Effect of equalizing the heat distribution
Heat at the electrode and half in the parent material.

Types of Consumables used in MMA

Rutile: Titanium Dioxide, Clay , Sodium silicate
Cellulosic: Cellulose( wood pulp), Titanium Dioxide, Sodium silicate
Basic: Lime stone ( Calcium carbonate ), Titanium Dioxide, Sodium
silicate

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The m.I.g./m.a.g. welding process

uses a bare wire consumable
electrode .
The wire, typically 0.8-1.6 mm
diameter, is continuously fed from
a coil through a specially designed
welding gun.

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Eliminate the possibility of atmospheric contamination by

introducing a shielding gas.
Argon is an efficient shielding gas, being inert, it doesnot
chemically react with the weld metal.
When an inert gas is used for shielding the welding process is
know as metal inert-gas (m.i.g.) welding.
Deoxidizers must exist in the wire.
This process is widely referred to as CO2 welding is also called
metal active-gas (m.a.g.) welding.
Metal transfer modes
Spray or free flight transfer,
Dip transfer (semi-short circuiting arc),
Globular transfer, Pulsed transfer.
1

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Spray or free flight transfer

The weld metal transfers across the arc in the form of a fine
spray.
High deposition rates and deep penetration welds.
Suited to thick materials,
The flat or horizontal welding positions.
Dip transfer (semi-short circuiting arc)
Amperage and low arc volts are required.
Used on thinner sections for all positional
welding,
Vertical down welding

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For m.I.g./m.a.g. welding is usually electrode d.c. +ve of a flat

Characteristic.
Advantages
minimal wastage of consumable electrode,
no frequent changing of consumable electrode,
little or no interpass cleaning required (no slag produced)
heavier weld beads are produced, faster welding process,
low hydrogen process preheat may not be required.
Disadvantages
increased risk or porosity due
to displacement of the gas shield, more maintenance of plant
involved, high risk of lack or fusion.

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