Q1. Explain the classification of welding process.

A) Classification of welding processes based on whether base material is melting or not

Fusion Welding: When heat is applied externally, subsequent melting of base material takes place, which
upon cooling produces a sound joint. This type of welding process where faying surfaces of base material melt
down is known as Fusion welding. It may or may not take external filler material, and thus it can be further
classified into three categories—Autogenous, Homogeneous and Heterogeneous welding. All types of arc
welding and gas welding processes come under fusion welding category.

Solid-State Welding: When pressure is applied externally, instead of applying heat, then it is termed as solid-
state welding. However, in this process heat may produce internally that can elevate the temperature of base
materials. Here usually filler materials are not applied (autogenous welding). Resistance and Diffusion based
welding processes usually come under this category.

B) Classification of welding processes based on need and type of filler material

Autogenous Welding—In all fusion welding processes, external filler material may not necessary. If welding is done
without any external filler material, then it is termed as Autogenous welding. So here base material itself melts down
and produces intended weld bead. Solid state welding processes are mostly autogenous.

Homogeneous Welding—If external filler material is applied during fusion welding and the metallurgical composition
of filler material is same with that of base material, then that welding is termed as Homogeneous welding.

Heterogeneous Welding—If external filler material is applied during fusion welding but metallurgical compositions of
filler material and base materials are substantially different, then that welding process is termed as Heterogeneous
welding. Proper care must be taken before conducting heterogeneous welding to check whether filler material is
compatible with base materials or not. If they are not compatible, then result will be a defective welding.

C) Comprehensive classification of welding processes

Arc Welding

Manual Metal Arc Welding (MMAW)

Gas Metal Arc Welding (GMAW)

Tungsten Inert Gas (TIG) welding

Submerged Arc Welding (SAW)

Flux Cored Arc Welding (FCAW)

Electro Slag Welding (ESW)

Atomic Hydrogen Welding (AHW)

Stud Arc Welding (SW)

Gas Welding

Air-Acetylene Welding (AAW)

Oxy-Acetylene Welding (OAW)

Oxy-Hydrogen Welding (OHW)

Pressure Gas Welding (PGW)

Resistance Welding

Resistance Spot Welding (RSW)

Resistance Seam Welding (RSEW)

Percussion Welding (PEW)

Flash Welding (FW)

 Upset Welding (UW)

Solid-State Welding

Cold Welding (CW)

Roll Welding (ROW)

Diffusion Welding (DFW)

Forge Welding (FOW)

Friction Welding (FRW)

Explosion Welding (EXW)

Ultrasonic Welding (USW)

Thermo-Chemical Welding

Thermit Welding (TW)

Intense Energy Welding

Plasma Arc Welding (PAW)

Electron Beam Welding (EBW)

Laser Beam Welding (LBW)

D) Classification of welding processes based on utilization of automated system

Manual Welding: Here entire welding operation is performed by human operator (welder). So, quality of welded joint
depends on experience and capability of welder. It lacks consistency and is subject to human error. It is also time
consuming, but flexible. Manual Metal Arc Welding (MMAW) is commonly performed by human workers.

Semi-Automated Welding: Here automation is applied to perform some task and rest is done manually. So, it takes
advantages of both automation and manual operations. For example, Tungsten Inert Gas (TIG) welding can employ a
feeder vehicle to hold the torch and move it at a constant speed, while filler material can be fed manually.

Automated Welding: Fully automated by means of Computer Numerical Control (CNC) systems and robotics. It is less
flexible but highly productive. Human operators are also required to monitor the entire system and take suitable
decisions in emergency situations. Laser and electron beam welding processes utilize fully automated set-up. Fully
automated welding is commonly employed in automobile industries.

Q2. Explain construction & working principle of metal inert gas welding process.
MIG stands for metal inert gas welding or sometimes it is known as Gas Metal Arc welding. This welding is same as TiG
welding except a non-consumable electrode replaced by consumable electrode wire. This process is automated or
semi-automated arc welding process in which inert gases are used as shielding gas and a consumable wire electrode is
used. Due to its high speed, easy operation and easily automated qualities. It is mostly used in sheet metal industries
or in automobile industries.

Power Source: a DC power supply is used with reverse polarity (electrode wire is connected positive terminal and work
piece to negative terminal). The power source consists a power supply, a transformer, a rectifier which change
AC into DC and some electronic controls which control the current supply according to weld requirement.
Wire Feeder System: wire is continuously supplied by wire feed mechanism or system. It controls the speed of the
wire and also pushes the wire form welding torch to welding area.

Welding Torch: there is a mechanism which hold the wire and supply it continuously with the help of wire feed. The
front end of the torch is fitted with a nozzle. The nozzle is used to supply inert gases. These gases form a shielding area
around the weld zone and protect it from oxidization. The welding torch is air cooled or water cooled according to the
requirement. For high current supplied, the torch is water cooled and for low supply it is air cooled.

Shielding Gases: The primary function of shielding gases is to protect weld area from other reactive gases like oxygen
gases etc. which can affect the strength of welding joint. These shielding gases are also form plasma which helps in
welding. The choice of gas is depending on the welding material. Mostly argon, helium and other inert are used as
shielding gases.

Regulators: they are used to regulate the flow of inert gases from the cylinder. The inert gases are filled into cylinder
at high pressure.

Principle:

It works on basic principle of heat generation due to electric arc. This heat is further used to melt consumable
electrode and base plates metal which solidify together and makes a strong joint. The shielded gases are also
supplied through nozzle which protect the weld zone from other reactive gases. This gives good surface finish
and a stronger joint.

Working:

Its working can be summarized as follow.

• First, a high voltage current is change into DC current supply with high current at low voltage. This current
pass though welding electrode.
• A consumable wire is used as electrode. The electrode is connected to the negative terminal and work piece
from positive terminal.
• A fine intense arc will generate between electrode and work piece due to power supply. This arc used to
produce heat which melts the electrode and the base metal. Mostly electrode is made by the base metal for
making uniform joint.
• This arc is well shielded by shielding gases. These gases protect the weld form other reactive gases which can
damage the strength of welding joint.
• This electrode travels continuously on welding area for making proper weld joint. The angle of the direction
of travel should be kept between 10-15 degree. For fillet joints the angle should be 45 degree.

Q3. Explain working principle of oxy-acetylene welding with neat sketch.

OXY-ACETYLENE WELDING is the common method of gas welding. The oxy-acetylene welding process combines
oxygen and acetylene gas to provide a high temperature flame for welding. The chemical reaction between acetylene
and oxygen is exothermic in nature. Oxy-acetylene flame may also be used for all types of brazing. Oxy-acetylene
welding is a manual process.

WORKING PRINCIPLE

Gas welding is a fusion welding process in which welding is done by heating workpiece with flames obtained from oxy-
fuel gases. In these process, a mixture in proper proportion of such as acetylene, liquefied petroleum, methyl
acetylene propadene, natural gas and hydrogen with oxygen are burnt to get flame. The best flame i.e. 3500 deg. C
comes out by mixing of Acetylene and Oxygen. This flame can be used to melt metal and flame is directed by welding
torch. A filler metal is sometimes added, which is available as rod or wire with or without flux.

OXY-ACETYLENE WELDING EQUIPMENT

1. Oxygen gas cylinder

2. Acetylene gas cylinder
3. Oxygen pressure regulator
4. Acetylene pressure regulator
5. Oxygen gas hose (blue)
6. Acetylene gas hose (red)
7. Welding torch
8. Filler rods
9. Protective clothing for welders (apron, gloves,goggles)
10. Trolleys for cylinder transportation
MATERIALS SUITABLE FOR OXY-ACETYLENE WELDING

• Plain carbon steel and low –alloy steel.

• Cast iron (best results)
• Stainless steel
• Aluminum and magnesium
• Copper and copper alloys
• Mild steel
• Lead

TYPES OF FLAMES USED IN OAW

1). CARBURIZING FLAME: This flame contain excess of acetylene. It is suitable for application of requiring low heat.
Carburizing flame is used in welding of monel metal, nickel, high-carbon steel and many of non-ferrous. Steel is not
welded by using this flame.

2). NEUTRAL FLAME: If acetylene and oxygen are present in equal proportions(1:1),then neutral flame is produced. For
most welding operations, neutral flame is used, since it has least chemical effect on heated metal.

3). OXIDIZING FLAME: If flame has high oxygen content (ratio of oxygen & acetylene is 1.5:1), then oxidizing flame is
produced. Such flame are used in welding of copper and copper alloys (brass and bronze). This flame is harmful for
steel because it oxidizes the steel.

Q4. Explain construction & features of Electron Beam welding.

Electron Beam Welding Machine consists of following parts:

High Voltage Power Supply:

The Power supply is categorised into two ways one as low, and the other is high voltage.
Low voltage range of the thin welding is between 5 to 30 kV.
High voltage range for thick welding is between 70 to 150 kV.

Electron Gun:
In electron gun, the free electrons are generated by means of thermo-emission from a hot metal strap
or wire. The main purpose of the electron gun is to convert free electrons into an electron beam by
the help of cathode grid, anode, magnetic lens, and deflection coil.

Cathode Grid:
By this part, the free electrons are generated. However the voltage of generated free electrons is
very much low eV. To accelerate this free electrons, they are passes through high electric field
which is produced by Anode and emitter (Cathode).

Anode:
The anode is used to accelerate the electrons which are generated by the cathode grid.

Optical Viewing System:

Optical viewing system helps us to determine and set up the point of action where the electron
beam is impacted on the workpiece.

Magnetic lenses:
Magnetic lenses allow only the converging electrons to pass. It absorbs the low energy of divergent electrons
and It provides a high intense electron beam.

Deflecting Coil:
• The deflection coil is a type of magnetic lens and It is used in cathode ray tubes.
• It helps to scan the electron beam all over the screen.

Vacuum chamber:
• In the vacuum chamber, there is no presence of air. The welding in this machine takes place in a vacuum.
• The pressure presets here is below the atmospheric or at atmospheric pressure.
• It is also known as the Braun tube or chamber.

Workpiece:
• The workpiece is attached to the fixtures.
• The workpiece can be similar or dissimilar metals.

Workpiece Holding Device:

• The workpiece holding device is also called as Fixtures. It is used to hold the workpiece rigidly.
• The fixtures are made up of steel castings, stainless steel, cast iron, high tensile steel, and so on.

Features of Electron Beam Welding are:

• EBW is suitable for a variety of difficult applications, such as welding structures on which the reverse side
of the butt is inaccessible; gravity welding of thin metal; and welding in various spatial positions.
• There is no requirement for filler material in electron welding.
• There is very little distortion.
• The welding defects appear also very less.
• Electron welding also welds the hard material.
• The weld metal has a fine crystalline structure. high surface finish obtained.
• This provides a low level of overall heating of the structures
• It also provides a high metal joining rate.
• It has a narrow heat effective zone (HAZ) and welding.
• This process also helps to join uniform and diffusion metals.
• The welding process is continuous and tight.
• It has the ability to vacuumed the inner volume simultaneously, which is suitable for sealing instrument.
• The workpiece has high strength properties and maintains up to 95% of the strength of the base
materials.
• This beam welding process is very precise.
• The welding process is fully automated.
• Geometric shapes and dimensions are highly stable.
• It eliminates oxide and tungsten inclusion and removes impurities.
• It can be used to weld some joints that cannot be made by other welding processes.
• Compared with arc welding processes, EBW improves joint strength 15% to 25%.
• EBW process forms extremely narrow and deep joints having the ratio of weld thickness to weld width
between 5:1 to 25:1.
Q5. Explain Metalizing and cladding process with its features.

Metallization is a general term that refers to the application of a metal coating to another metallic or non-
metallic surface. Depending on the desired result, the coating can consist of metals such as zinc, gold,
aluminum or silver.
Features of the Metallizing Process: -
The metallization process can protect the workpiece from damaging external forces (corrosion, wear,
weathering, etc.), improve the appearance of the object (giving it a shiny look, for example), or enhance the
finished product’s functionality.
• Enhanced corrosion protection - Metallization can create a protective coating that inhibits the
development of red and/or white rust, increasing the product’s lifespan by as much as 20 years or
more.
• Increased durability — Most metallized coatings are known for their ability to adhere to the surface of
the underlying workpiece or substrate. They are less likely to peel, blister, crack or flake than other
types of finishes, which increases the substrate’s durability.
• Providing electrical conductivity - a plastic surface will enable it to transfer an electric current, which
is a vital manufacturing step in the electronics industry.
• Greater weather resistance — The steel on outdoor structures is vulnerable to the impact of snow, rain,
wind and sun over time. Metallization provides a protective coating that creates a barrier between the
underlying structure and the elements, which can lengthen the structure’s lifespan and preserve its
appearance.
• Reduced maintenance costs — Painted surfaces will need repainting periodically to preserve the finish.
A metallized surface will not require repainting or upkeep, resulting in lower maintenance costs.
Cladding is the bonding together of dissimilar metals. It is different from fusion welding or gluing as a
method to fasten the metals together. Cladding is often achieved by extruding two metals through a die as well
as pressing or rolling sheets together under high pressure.

• Roll bonding
In roll bonding, two or more layers of different metals are thoroughly cleaned and passed through a pair of
rollers under sufficient pressure to bond the layers. The pressure is high enough to deform the metals and
reduce the combined thickness of the clad material. Example: bonding of the sheets can be controlled by
painting a pattern on one sheet and the un-bonded portion can be inflated if the sheet is heated and the coating
vaporizes.

• Explosive welding
In explosive welding, the pressure to bond the two layers is provided by detonation of a sheet of chemical
explosive. No heat-affected zone is produced in the bond between metals. The explosion propagates across the
sheet, which tends to expel impurities and oxides from between the sheets.

• Laser cladding
Laser cladding is a method of depositing material by which a powdered or wire feedstock material is melted
and consolidated by use of a laser in order to coat part of a substrate or fabricate a near-net shape part. It is
often used to improve mechanical properties or increase corrosion resistance, repair worn out parts and
fabricate metal matrix composites.

Features of the cladding process

• Best technique for coating any shape => increase life-time of wearing parts.
• Particular dispositions for repairing parts.
• Most suited technique for graded material application.
• Well adapted for near-net-shape manufacturing.
• Low dilution between track and substrate.
• Low deformation of the substrate and small heat affected zone (HAZ).
• High cooling rate is equal to or, greater than fine microstructure.
• A lot of material flexibility.
• Built part is free of crack and porosity.
• Compact technology.
Q6. Explain working principle and process parameter of Laser beam welding.

Laser Beam Welding is a fusion welding process in which two metal pieces are joined together by the use of
laser. The laser beams are focused to the cavity between the two metal pieces to be joined. The laser beams
have enough energy and when it strikes the metal pieces produce heat that melts the material from the two metal
pieces and fills the cavity.

Working Principle

It works on the principle that when electrons of an atom get excited by absorbing some energy. And then after
some time when it returns back to its ground state, it emits a photon of light. The concentration of this emitted
photon increased by stimulated emission of radiation and we get a high energy concentrated laser beam. Light
amplification by stimulated emission of radiation is called laser.

process parameter of Laser beam welding

• Power Density: It is the one of the most critical parameters in laser processing. With a higher
power density, the surface layer can be heated to the boiling point in the microsecond time
range, resulting in a large amount of Vaporization. Thus, high power density is advantageous
for material removal processing such as punching, cutting and engraving. For lower power
densities, the surface temperature reaches to the boiling point and takes several milliseconds.
Before the surface is vaporized, the bottom layer reaches the melting point and it is easy to
form a good fusion weld.
• LBM processes to a great extent depend on the work-piece properties, laser intensity and
interaction time.
• For every material there is a threshold intensity that needs to be achieve for evaporation to
occur.
• All conventional LBM processes are located slightly above melting line that enables melting
and then evaporation.
• Process employing ultrashort pulsed lasers are situated well above melting line, therefore it is
more likely to evaporate material minimising the stage of melting.
• Laser Pulse Waveform: It are an important issue in laser welding, especially in sheet welding.
With a high intensity laser beam is incident on the surface of material, the metal surface will
be reflected by 60 to 98% of the laser energy and the reflectivity will vary with the surface
temperature. During a laser pulse action, the metal reflectivity changes greatly.
• Laser Pulse Width: Pulse Width is one of the important parameters of pulse laser welding. It is
different from material removal and material melting and also a key parameter that determines
the cost and volume of processing equipment.
• Welding speed: the speed of the welding speed will affect the heat input per unit time. If
welding speed is too slow, the heat input is too large, causing the workpiece to burn through. If
welding speed is too fast, the heat input amount is too small, causing the workpiece cannot be
welded well.
Q7. Discuss various types of weld defects.

Q8. Explain the Metallurgical consideration in welding process.

Q9. Explain the construction & welding principles of TIG welding.
Q10. Explain working principle of electric arc welding with neat sketch.
Q11. Explain construction & working principle of underwater welding with its application.
Q12. Explain the construction & features of soldering & brazing process.
Q13. Explain working principle of Plasma arc welding with its application.
Q14. Define welding arc? Explain the mechanism of arc initiation and its maintenance.
Q15. Write short notes on any two of the following
(a) Micro & Macro structure in welding
(b) Weld Design
(c) Spray welding
(d) Welding Machine and Equipment