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Job Knowledge 1
Process terminology
The European standard, BS EN ISO 4063:2010 Welding and allied processes - Nomenclature of processes and reference numbers, assigns a
unique number to the main welding processes. These are grouped as follows:
Arc welding
Resistance welding
Gas welding
Forge welding
Other welding processes
Brazing, soldering and braze welding
Each process is identified within the group by a numerical index or reference number. For example, the MIG welding process has a reference
number of 131 which is derived as follows:
1 - Arc welding
3 - Gas-shielded metal arc welding
1 - Metal arc inert gas welding
The reference numbers are used as a convenient way of identifying the welding process in documentation such as welding procedures (BS EN ISO
15614 series) and welder qualification (BS EN 287 and BS EN 9606 series) records.
Process options
Factors which must be taken into account when choosing a suitable welding or joining process are:
material type
product form: plate or tubular
capital cost
Although consideration of these factors will identify the most suitable welding process, the choice within a company may be restricted by the cost
of implementing a new process, availability of plant or current workforce skill. Welding and joining processes available to the welding engineer
can be separated into the following generic types:
Fusion
arc
gas
power beam
resistance
Thermomechanical
friction
flash
explosive
Mechanical
fasteners
Solid state
adhesive
soldering
brazing
The suitability of the processes for welding and joining materials, joint types and components are shown in Table 1.
Table 1. Suitability of the processes for welding and joining materials, joint types and components
In selecting a suitable process, consideration must also be given to the type of application, for example, the portability of equipment, whether it
can be used on site, whether it is manual or mechanised, and the overall cost of the welding plant.
When welding using a fusion process, the edges of a component are melted together to form weld metal.
Table 2. Heat source, mode of shielding, thickness range and metal deposition rates for various fusion processes
Parent
Deposition
Process Heat source Shield metal
rate kg/hr
thickness mm
Arc
MMA Arc Gas/flux 1-100 1-4
MIG Arc Gas 0.5-100 1-8
TIG Arc Gas 0.1-100 1-4
SAW Arc Flux 5-250 5-20
ES/EG Resistance/arc Flux/gas 5-250 5-20
Stud Arc - 4-20 -
Gas
Oxyfuel Flame Gas 0.6-10 1-2
Power beam
Laser Radiation Gas 0.2-25 -
EB Electrons Vacuum 0.2-250 -
Resistance
Spot/Seam Resistance - 0.2-10 -
Thermit
Thermit Chemical Gas 10-100 -
Table 2 shows heat source, mode of shielding, thickness range and metal deposition rates for a range of fusion processes. Although fusion
welding is one of the simplest joining techniques, problems likely to occur include porosity in the weld metal, and cracking in either the weld or
heat affected zone (HAZ). Porosity is avoided by ensuring adequate shielding of the weld pool and, for materials such as aluminium, the addition
of filler wire.
Consideration of the joint design and the chemistry of the weld metal will prevent weld metal cracking. HAZ cracking which might be caused by
hydrogen, is avoided by using low hydrogen consumables and controlling the heat input and the rate of cooling of the parent metal.