6.2 THE WELD JOINTS tal cduas 6.2.1 Type of Welded Joints ‘There are five basic types of joints (a) butt LM tas, (b) corner 4S y thay, (c) lap 451i thes, (d) lee idm US le Aho, and (e) edge 4ila aLey, The joints shown in Figure 6.1 B Ue | Zi ~ il | i / f / @ 0 @ @ @ Figure 6.1 Five basic types of joints: (a) butt, (b) corner, (c) lap, (d) tee, and (e) edge. 6.2.2 Types of Weld ‘There are two main types of weld shown in figure 6.6 a. But or groove welds: usually require that the edges of the parts be shaped into a groove to facilitate weld penetration. b, Fillet weld: is used to fill in the edges of plates created by comer, lap, and tee joints, as in Figure 29.3. Weld face Fusion zone oy =I I-Root opening (a) Butt weld (b) Fillet weld Figure 6.2 Types of weld 2015/2016 Chapter 6 Page 3 of 22 Dr. Samir M. Yousef Khalilé 6.2.3 Edge preparations ,lat gad ta jga For welding the edges of joining surfaces of metals are prepared first. Different edge preparations may be used for welding butt joints according to metal thickness, which are given in Figure 63 Gael oer Straight Single -V a Double -V { ? } ) Single bevel See Double - J Double bevel Figure 6.3 Butt welding joints edge preparations for thin and thiek plates 6.2.4 Welding Positions = g23) 644, there are four types of welding positions, which are given as: flat or As shown in Figure down hand position, horizontal position, vertical position and, overhead position as) ss E23 (Ge Flat Horizontal Vertical Over head Figure 6.4 Kinds of welding positions mir M. Yousef Khalil 2015/2016 Chapter 6 Page 4 of 22f 6.3 TYPES OF WELDING PROCESSES Some 50 different types of welding operations have been cataloged by the American Welding Society (AWS) 4: «4! glalll 4bis, Welding processes can be divided into three major groups: (1) fusion welding, (2) resistance welding and (2) solid-state welding. 6.3.1 Fusion Welding Processes jp! plat ote Fusion-welding processes use heat to melt the base metals. In many fusion welding operations, @ filler metal is added to the molten pool to facilitate the process and provide bulk and strength to the welded joint. It divided into: Shielded metal are welding Submerged are welding Gas metal are welding Gas tungsten are welding Plasma are welding Electroslag welding Laser beam welding Electron beam welding Oxy-fuel gas welding 6.3.1.1 Shielded metal are welding (SMAW) 2015/2016 Chapter 6 Page § of 22 Dr, Samir M. Yousef Khi (st 24 i lal) le ay Sy nl fl gel pal An electric are, between a flux covered metal electrode Sli Ghd Jisull 45 581Y1 and the base metal, is used to generate heat. Heat from the electric arc (temperature 5500 C*) melts both the end of the electrode and the base metal to be joined. The filler metal (electrode) used in the rod must be compatible Gs with the metal to be ‘welded, the composition usually being very close !3> (2.8 to that of the base metal. The electric current may be either alternating (AC) or direct (DC). Currents typically used in SMAW range between 30 and 300 A at voltages from 15 to 45 V. ‘The electrode is a flux covered metal wire (electrode c¢ The flux has the following function: > Prevent the formation Ws of oxides and other unwanted contaminants@8ss, of to dissolve them and facilitate removal; it melts to form a slag, which covers the completed weld+A portion of the flux tums into a protective gas shield-iky which surrounds the are as the clectrode melts, o protect the weld from oxygen, nitrogen, and hydrogen of the air, Stabilize the arcs} Lill 1, and reduce spattering ji ci, * The heat generated depends on the current setting and length of are (the length of are has t0 be manually controlled by the operator), * This is a simple, portable, inexpensive operation. * Wide variety of metals, welding positions and electrodes are applicable. This process is discontinuous due to the limited length of the electrode. Figure 6.5 shows the shield metal welding equipments, Figure 6.6 weLoing MACHINE ELECTRODE ‘CABLE ELecTRODE WoRK: Figure 6.5 Shield metal are welding equi — Consumable electrode Direction of travel dabei /—Electrode coating (flux) Protective gas —. Slag from electrode coating Solidified weld metal Base metal Molten weld metal Figure 6.6 Shielded metal are welding (SMAW). 2015/2016 Chapter 6 Page 6 of 22 Dr. Samir M. Yousef Khalil6.3.1.6 Oxy etylene welding * Oxyacetylene welding (OAW) is a fusio ‘welding process performed by a high-temperature flame from combustion of acetylene and oxygen, principle of welding shown in Figure 6.13 Combustion of acetylene proceeds in two stages: |. Inner core sil 4513 sls of the flame. Coty + 02 = 2CO + Hy+ heat 2. Outer envelope sl sal G34 of the ame: CO + Hy +02 = CO» + 30 + heat The type of flame obtained depends on the ratio of oxygen to acetylene being bumt (Carburizing, Neutral, and Oxidizing flames), Figure 6.14 shows these flames. © Neutral flame dssie cit: equal quantity 3200 °C flame temperature, used for welding mild steel, cast iron, aluminum: and stainless steel. (Neutral flames are used in most welding applications). © Oxidizing flame 4554 «4: 3400 °C flame temperature, used for welding brass and bronze (copper alloy) © Carborizing flamegis.$ 4: 3100 °C flame temperature, used for welding, high carbon steel and nonferrous alloy. * Gas welding equipments are: oxygen gas cylinder, acetylene gas cylinder, pressure regulatorsbiws pli. oxygen and acetylene hoses pills, welding torch lal sy, Figure 6.15 shows the equipments. J Mixture of CoHy + Op Direction of travel La Welding torch tip Filler rod 4 iis Flame Y; ON Soliditied weld metal \ Molten weld metal Figure 6.13 The principle of the oxyfuel gas welding operation. Base m 2100 12800 Geer) (2500) Inner cone S040 to 3300°C (6500 to 6000) (@) Neutral flame Brightiuminous Be Innet cone envelope (¢) Carburizing (reducing) ams Figure 6.14 Three basie types of oxyacetylene flames used in oxyfuel gas welding and cutting operations 2015/2016 Chapter 6 Page 12 of 22 Dr. Samir M. Yousef KhalilPRESSURE REGULATORS ¢ GAS CONTROL VALVES iy L N\ WELDING OXYGEN ( Bere CYLINDER —~ WELDING FUEL GAS CYLINDER 1 Figure 6.15 Basic oxyfuel gas welding equipments Oxy acetylene cutting ‘The cutting process is illustrated in Figure 6.16, Basically, a mixture of oxygen and the fuel gas is used to preheat c#55 the metal to its ‘ignition’ temperature which, for steel, is 700°C - 900°C (bright red heat) but well below its melting point. A jet of pure oxygen is then directed into the preheated area, causing 44: exothermic chemical reaction 31 all 2 Ab J=li between the oxygen and the metal to form iron oxide or slag. The oxygen jet blows away 285 the slag enabling the jet to pierce “5 through the material and continue to cut through the material tube corrying the A cutting oxygen cutting lever 8 sued core yn maintcin the fuel os” distance 30° pre-heating flame stoge | + torch movement AY NK. NN geet 4 iron oxide Sw om oy Figure 6.17 Diagram of oxyacetylene eutting process stage 2 2015/2016 Chapter 6 Page 13 of 22 Dr. Samir M. Yousef Khalil