Welding – materials joining process of materials by heating them to suitable temperatures with or without application of pressure or

by application of pressure.

- Process of joining together two pieces of metal so that bonding takes place at their original boundary surface.
- Used for making permanent joints.
- Use for manufacture of automobile bodies, aircrafts etc.

Types of welding

1. Plastic/pressure welding – the piece of metal to be joined are heated to a plastic state and forced together by external
pressures. (Resistance welding)
2. Fusion/non-pressure welding – the material of the joint is heated to a molten state. (Gas Welding, Arc Welding)

GROOVE WELD

Groove weld is defined in the American Welding Society (AWS)

- “A weld in a weld groove on a work piece surface, between work piece edges, between work piece surfaces, or between
workpiece edges and surfaces.
- “A channel in the surface of a workpiece or an opening between two joint members providing space to contain weld metal.”

TYPES OF WELDING JOINTS

1. Butt Joint

- universally accepted method for attaching a pipe to itself. It is also used for valves, flanges, fittings, and other equipment.
- is also known as a square grove weld. It’s the easiest and probably the most common weld there is.

2. Lap Joint

- Lap welding joints are used most often to joint two pieces with differing thicknesses together.
- Lap Joint is formed when 2 pieces are placed in an over lapping pattern on top of each other.

3. Tee Joint

- Joints are formed when two members intersect at a 90°angle which makes the edges come together in the center of a plate or
component.

4. Corner Joint

- one of the most popular welds in the sheet metal industry the Corner welding joint
- It is used on the outer edge of the piece. This weld is a type of joint that comes together at right angles between two metal
parts to form an L.
- common in the construction of boxes, box frames and similar fabrications.

5. Edge Joint

- It often applied to sheet metal parts that have flanging edges or are placed at a location where a weld must be made to attach
to adjacent pieces.
- filler metal - is added to melt or fuse the edge completely and to reinforce the plate.

6. Fillet Joint

- It is just another terminology for corner, lap, and tee joints.

- the most common type of welding joint and accounts for nearly 75% of joints made with arc welding.
- mostly used in piping systems to join pipe to socket joints.
TYPES OF WELDING:

1. ELECTRIC ARC WELDING

- The arc welding is a fusion welding process in which the heat required to fuse the metal is obtained from an electric arc
between the base metal and an electrode.
- Electric arc is produced when two conductors have a contact together and then separated by a small gap of 2 to 4 mm, such
that the current continues to flow, through the air. The temperature produced by the electric arc is about 4000°C to 6000°C.

2. OXYGEN-GAS WELDING
- Oxyacetylene gas welding is commonly used to permanently join mild steel.
- A mixture of oxygen and acetylene, burns as an intense/focused flame, at approximately 3,500 degrees centigrade.
- Oxyacetylene can also be used for brazing, bronze welding, forging / shaping metal and cutting.

3. FORGE WELDING
- A solid state welding process in which both the plates are heated quite below its melting temperature.

4. ELECTRICAL RESISTANCE WELDING

- The welding heat is obtained at the location of the desired weld by the electrical resistance through the metal pieces to a
relatively short duration, low voltage, high ampere electric current.

Types:

a. Spot Welding
- It is used for welding lap joints, joining components made from plate material having 0.025 to 1.25 mm in thickness. The
plate to be joined together are places between the two electrode tips of copper or copper alloy.

b. Roll Spot and Seam Welding

- When the spot welds on two over lapping pieces of metal are spaced, the process of welding is known as roll spot welding. If
the spot welds are sufficiently made close, then the process is called seam welding. This process is best for metal thickness
ranging from 0.0.25 to 3 mm.

c. Projection Welding
- It is similar to spot welding except that one of the metal pieces to be welded has projections on its surface at the points,
Where the welds are to be made. In other words it is a multi spot welding process.

d. Butt Welding
- The butt welding is of two type :
Upset butt welding
Flash butt welding

- The upset butt welding- is especially adopted to rods, pipes and many other components of uniform sections.
- The flash butt welding - is extensively used in the manufacture of steel containers and in the welding of mild steel shanks
to high speed drills and reamers.

Reference line —is the anchor to which all the other welding symbols are tied. The instructions for making the weld are strung along
the reference line.

WITH FLAG —weld is to be made in the field during erection of the structure.

WITHOUT A FLAG, weld will be made in shop.

An open circle at the arrow/reference line junction is present if the weld is to go all around the joint, as in the example below.
Fillet Weld

- Used to make lap joints, corner joints and T joints.

- As its symbol suggests, the fillet weld is roughly triangular in cross-section, although its shape is not always a right triangle
or an isosceles triangle.

Groove Welds

- groove weld is commonly used to make edge-to-edge joints, although it is also often used in corner joints, T joints, and joints
between curved and flat pieces. determining the quality of the weld.)

Square Groove Welds

groove is created by either a tight fit or a slight separation of the edges. The amount of separation, if any, is given on the weld symbol

V-Groove Welds

- The edges of both pieces are chamfered, either singly or doubly, to create the groove. The angle of the V is given on the weld
symbol, as is the separation at the root (if any).

Bevel Groove Welds

- The edge of one of the pieces is chamfered and the other is left square. discussed in the V-groove section.

U-Groove Welds

- The edges of both pieces are given a concave treatment. Depth of edge treatment, effective throat and separation at the root
are described using the methods discussed in the V-groove section.

J-Groove Welds

- The edge of one of the pieces is given a concave treatment and the other is left square. It is to the U-groove weld what the
bevel groove weld is to the V-groove weld.

Flare V Groove Welds

- Commonly used to join two rounded or curved parts. The intended depth of the weld itself is given to the left of the symbol,
with the weld depth shown in parentheses

Flare Bevel Groove Welds

- As with the flare-V, the depth of the groove formed by the two curved surfaces and the intended depth of the weld itself are
given to the left of the symbol, with the weld depth shown in parentheses.