Exercise No. 5 Welding: Mtec 121: Workshop Theory and Practice 116

116 MTec 121: Workshop Theory and Practice
Exercise No. 5
Welding
Introduction
The demand of metal fabrication in our society is growing faster and
faster. One of the important processes of metal fabrication is welding which
binds two parts together at greater strength and durability. In this exercise, the
principle of welding, types of welding, welding positions, and welding tools and
equipment were discussed. The shielded metal arc welding was also
emphasize as one of the most commonly used and inexpensive type of
welding.
Learning Outcomes
1. Define welding operation;
2. Identify the different welding techniques;
3. Identify the different welding position; and
4. Identify the tools and equipment used in welding operation.
Materials
Exercise Manual, Ball pen, Bond paper
Discussion
What is Welding
Welding is a joining process that fuses two materials together by an

application of heat and/or pressure in order to bond the materials as one unit
after they were cooled. This process can be applied on metals, thermoplastics
and even wood. The parts that are joined together are called the parent
materials or base materials and the joint is known as the weldment.
There are some cases in which the welding operation requires the use
of a third metal to make the weldment even stronger, and it is termed as the
filler or consumable material. Such examples of this operation are arc
welding, oxy-acetylene welding, and etc.
Figure 5-1 below shows the nomenclature a complete metal welding
operation. The yellow zone indicates the weld metal which is the fusion of the
melted metal and the filler, and the area around it is known as the Heat
Affected Zone (HAZ) which is the portion of the joint that was heated to
crystallization temperature but not melted. The accumulation of the HAZ and
the weld face is known as the weld zone. The excess weld metal is one of
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the important factors of having a good weldment since an adequate amount

indicates a strong joint.
Several factors should be considered in order to achieve a nice
weldment for metals. These are the type and size of the filler metal, the
quantity of the power input (by heat, electricity, or pressure), the type and
thickness of the parent materials, and the welding speed/ travel speed.
A welding operation can also be used to cut metals especially sheet
metals.
Figure 5-1 the nomenclature of the weldment
Types of Welding operation
The classification of welding operation for metal fabrication varies

according to several bases. In this exercise, the basis of sorting this operations
or processes is the type of power source.
1. Gas Welding
It is a welding process that utilizes the combustion reaction of fuel gas
(such as acetylene) and oxygen to bond the two parent metals even without
the use of filler metals and a source of pressure. However, other gas welding
still needs some filler metals in order to provide additional strength on the
weldment. This is suitable for steel and also aluminum materials.
Examples of gas welding are Air Acetylene, Oxy-Acetylene, and Oxy-
Hydrogen Welding.
Figure 5-2a and 5-2b shows a simple diagram of a gas welding with the
tools and equipment and a person equipped with proper PPE doing gas welding
operation respectively.
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Figure 5-2 (a) A diagram of a gas welding, and (b) a person dress
with PPE doing gas welding
2. Arc Welding
It is a fusion-type welding operation that binds the base metals through
the use of an electrical source (an electrical arc) from an Ac or Dc power supply.
The electrical arc being generated melts the base metal together with the filler
metal within 6500 0F. Since this operation is expose to the atmosphere, it would
normally react with oxygen and nitrogen to form a rust, however, with the help
of a protective shielding gas or slag coming from the filler metal, this problem
will be minimized. Figure 5-3 shows a simple diagram of an arc welding.
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Figure 5-3 shows a diagram of an arc welding
Examples of arc welding includes the carbon arc welding (CAW) –

that utilizes a non-consumable carbon electrode as the filler metal, plasma arc
welding (PAW) – that is similar to Gas tungsten arc welding (GTAW) but only
the plasma arc is being separated from the shielding gas (Figure 5-4a), the
Tungsten Inert Gas Welding (TIG) – that uses non-consumable tungsten
electrode, produces high quality and clean weldments, and can be used for a
variety of metals such as aluminum, chromium, stainless steel and other alloys
(Figure 5-4b), and the Metal Inert Gas welding (MIG) – that utilizes a
continues feed of solid metal electrode and a supply of shielding gas such as
carbon dioxide or argon, that is good for welding both thin sheet of metals,
structural metals, and even stainless steel. (Figure 5-4c).
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Figure 5-4 shows diagrams for (a) plasma arc welding, (b) Tungsten
Inert Gas welding, and (c) Metal Inert Gas Welding
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Shielded Metal Arc Welding (SMAW)

The other example of arc welding is the Shielded Metal Arc Welding
(SMAW) or stick welding which is the most commonly used, inexpensive and
most accessible welding technique. It can be applied for a wide range of metal
fabrications in ship building, auto repair and etc. Additionally, SMAW will work
even on outside and harsh environments as long as the user is dressed in
proper attire. Figure 5-5 shows the diagram of the SMAW operation.
Figure 5-5 shows a diagram of the Shielded Metal Arc Welding
SMAW is generally comprise of several equipment. These are the

power supply (Figure 5-6a) that can be either AC or DC source (if DC,
additional equipment are needed such as a step-down transformer and a
rectifier), the electric cable (electrode lead cable and the workpiece lead
cable), the electrode holder (Figure 5-6b) that holds the electrode/filler metal,
and the consumable electrode (Figure 5-6c).
a b
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Figure 5-6 (a) SMAW Power supply, (b) Electrode

holder, and (c) SMAWs welding electrode
The consumable electrode being used for SMAW has its unique
designation based on the American Welding Society (AWS). The designation
is no less than a code comprising of a letter and followed by either 4 or 5 digit
numbers. The first letter denotes the type of welding electrode, the first two
digits of a 4-digit electrode or the first 3 digits of a 5-digit electrode is the tensile
strength of the resulting weldment, the second to the last digit indicates the
welding position, and the last two digits indicates the type of coating and
welding current setting. For example, an E6010 is an arc welding electrode
(E) that has a tensile strength of 60,000 pounds per square inch and it can be
applied for all positions (1). The number 2 for the last two digits indicates flat
and horizontal position, number 4 for flat, horizontal, vertical down, and
overhead positions. Table 5-1 indicates the designation of some arc welding
electrodes.
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Table 5-1 Different types of SMAW welding electrodes
In using a SMAW operation, consider some variables that needs to be

controlled in order to achieve a nice weldment. These are the current of the
power source, the travel angle – at flat or horizontal position, drag the angle
from 5-10 degrees and for vertical or overhead, push the electrode at 5-10
degrees, the arc length – ranges mostly from 1/16 to 3/32 inches or no more
than the size of the electrode, and the travel speed – select a speed enough
to generate a weld puddle (Figure 5-7a) that measures between 1.5 to 2 times
the electrode diameter.
To establish a nice weldment using SMAW, it is desired to follow the
correct arrangement of welding pass (Starts from root pass, hot pass, fill pass,
and lastly the cap pass) (Figure 5-7b) and maintain a consistent welding
stroke (Figure 5-7c).
If the SMAW operation is not executed properly, several defects would
occur. These are cracking of the weldment, shallow penetration, poor
fusion or connection, porosity, wandering arc, undercutting (Figure 5-7d) –
a depression on the base metal or at the joint due to excess weld puddle or
overstaying the arc, and welding spatters (Figure 5-7e)– small chucks of
metal sticking near the weldment.
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a b
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Figure 5-7 (a) weld puddle/weld pool, (b) arrangement of

weld pass, (c) weld strokes, (d) weld undercut, and (e)
weld spatters
Peening the weld reduces the stress level of the weldment and also
relieves the problems being discussed in the previous paragraph. This method
applies several hammer blows on the weldment while it is still hot.
3. Resistance welding
A welding process that joins two base metals by the use of pressure
and electrical current being passed on the joint area over a definite period of
time. It does not need any filler metal to aid bonding that is why it is relatively
less costly than the other techniques. The type of material being used as an
electrode is copper.
Examples of resistance welding are spot welding, seam welding,
projection welding, resistance butt welding, and flash butt welding. Figure
5-8 shows a resistance welding machine. This type of welding is suitable on
aerospace repair and fabrication.
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Figure 5-8 shows a resistance welding machine
4. Solid state welding

It is a welding operation that does not require any fusion process. It only
needs enough pressure between the two base metals to be joined, and then
generating small amount of heat below the base metal’s melting point that
would result to a sound joint (Figure 5-9). During its joining process, both base
metals should have a constant contact in order to establish the right amount of
pressure easily. This method is also termed as friction welding.
Examples of solid state welding are cold welding, diffusion welding,
forge welding, fabrication welding, hot pressure welding, and roll
welding.
Figure 5-9 an example of a solid state roll welding
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5. Thermo-chemical Welding
A welding process that utilizes the heat coming from the exothermal
reaction of a certain substance or chemical to bind the two base metals. The
substance is put between the joints and after it gives off energy exothermally,
it cools and became the weldment. A good example of this operation is Thermit
welding that utilizes the “Thermit” substance which comprise mostly of a
mixture of fine aluminum powder and iron oxide (Figure 5-10). This method is
mostly applied on railroads.
Figure 5-10 diagram of a Thermit welding operation
6. Radiant energy Welding

A welding process that heats up the two base metals to be joined
through the use of a high-energy focusing beam. This is a newly discovered
welding operation and is still developing until these days. Examples of this
technique are the electron beam welding that uses high energy electrons
(Figure 5-11a) and the Laser beam welding that uses the high intensity
Laser beam (Figure 5-11b).
a
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Figure 5-11 (a) electron beam welding, and (b) Laser beam welding
Welding joints and welding positions
There are several welding connections being utilized in the metal

fabrication industry. Each of this joints has its own configuration and roles
depending on the type of application they are up to. Figure 5-12a shows
some of these welding joints.
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Figure 5-12 welding joints
The welding operation also requires a lot of positions since in the

actual set-up of metal fabrication, a worker do not have an absolute freedom
to weld a certain part in horizontal position at all times. The worker should
always consider that there are some parts or assemblies that are fixed and
cannot be dismantled or repositioned anymore. Figure 5-12b shows some
welding positions for each welding joints. It should be noted that letter “G”
indicates a butt/groove, edge, and corner joints, and “F” indicates Tee, and
Lap joints.
Figure 5-13 welding positions
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Exercise No. 5 Welding: Mtec 121: Workshop Theory and Practice 116

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Exercise No. 5 Welding: Mtec 121: Workshop Theory and Practice 116

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116 MTec 121: Workshop Theory and Practice

Welding is a joining process that fuses two materials together by an

the important factors of having a good weldment since an adequate amount

Figure 5-1 the nomenclature of the weldment

Types of Welding operation

The classification of welding operation for metal fabrication varies

Figure 5-3 shows a diagram of an arc welding

Examples of arc welding includes the carbon arc welding (CAW) –

Shielded Metal Arc Welding (SMAW)

Figure 5-5 shows a diagram of the Shielded Metal Arc Welding

SMAW is generally comprise of several equipment. These are the

Figure 5-6 (a) SMAW Power supply, (b) Electrode

Table 5-1 Different types of SMAW welding electrodes

In using a SMAW operation, consider some variables that needs to be

Figure 5-7 (a) weld puddle/weld pool, (b) arrangement of

Figure 5-8 shows a resistance welding machine

4. Solid state welding

Figure 5-9 an example of a solid state roll welding

Figure 5-10 diagram of a Thermit welding operation

6. Radiant energy Welding

Welding joints and welding positions

There are several welding connections being utilized in the metal

Figure 5-12 welding joints

The welding operation also requires a lot of positions since in the

Figure 5-13 welding positions

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