8 Welding Technology and Design

A weld puddle is established first by the gas torch. Then the torch is moved
forward in different shapes, such as circular path, zig-zag path, oscillating path
etc., ensuring in each case that sufficient time is given to obtain maximum
penetration.
Gas welding is more suitable for thin plates and sheets as its flame is not as
piercing as that of arc welding. Welding time is also comparatively longer in gas
welding and heat affected zone (HAZ) and distortion are larger than in arc welding.
The gases which are generally expensive are to be properly stored.
Oxy-acetylene flame can also be used for cutting operations, known as flame
cutting. When iron is heated to a temperature of about 750-870°C, it reacts rapidly
with oxygen to form iron oxide whose melting point is lower than that of steel.
The heat generated will be sufficient to melt iron oxides and also some free iron.
The cutting torch has a central orifice of oxygen jet surrounded by several orifices
of oxygen-acetylene mixture to produce the required heating. Thus oxygen supply
is ensured for the formation of iron oxides during the cutting operation.
1.2.2 Fusion arc welding

1.2.2.1 Shielded metal arc welding (SMAW) and submerged arc welding (SAW)
Shielded metal arc welding
Shielded metal arc welding (SMAW) is a manual process of welding and is a
common and versatile method used for joining shapes that cannot be easily set up
for automatic welding methods. In this method a solid electrode with an extruded
backed-on-coating material is used. A typical SMAW method is shown in Fig.1.6.
The arc is struck by short circuiting the electrode with the work piece. Welding
current is chosen according to the electrode diameter, type of electrode, and the
kind of welding job. The arc voltage is determined as function of the arc length. In
MMA it will be very difficult to keep a uniform arc length. When welding with

Fig. 1.6 Shielded metal arc welding

(Courtesy : Welding Hand Book AWS, USA, 1966)