UNDERSTANDING

WELDING
Types of Joints

• Butt
• Tee
• Corner
• Lap
Butt Joint

• Members to be joined are in

same plane
Tee Joint

• Members to be joined form a tee

Corner Joint

• Members to be joined form a

corner
Lap Joint

• Members to be joined overlap

each other
Types of Joining
Processes

• Fastening
• Adhesive
• Soldering
• Brazing
• Fusion Welding
Fastening

• Joined members can be

separated easily

• Joint is not permanent

• The material property of the

joining members is not affected
Adhesive

• Joined members can be separated, but not

easily

• Joint is not permanent

• The joint strength may be lower than that

of the members joined

• The material property of the joining

members is not affected
Soldering

• Joined members can be separated, but not easily

• Joint is not permanent

• The joint strength may be lower than that of the members

joined

• The joining members are heated but they do not melt

• The material property of the joining members is not

affected

• The filler metal melts at temperature less than 420C

Fusion Welding

• Joined members cannot be separated except by cutting,

grinding , chiseling

• Joint is permanent

• The joint strength can be same as that of the members joined

• The joining members are heated and the joining faces are melted

• The material property of the joining members is affected and a

heat affected zone forms in the joining member

• The filler metal melts along with the faces of the joining member
and forms weld metal
Criteria for Fusion
Welding

• Heat for fusion shall be provided

• Base metal and filler metal shall melt

• Molten metal shall be shielded from

Oxygen & Nitrogen of air

• Fused weld metal shall be free from defects

• Fused metal & HAZ shall have properties as good as base

metal
Fusion Arc Welding
Processes

• SMAW – Shielded Metal Arc Welding

• GTAW - Gas Tungsten Arc Welding
• GMAW – Gas Metal Arc Welding
• FCAW - Flux-cored Arc Welding
• SAW- Submerged Arc Welding
Thermal Cycle during
arc welding
• There is very fast heating

• There is very fast cooling from

melting point to 500C

• The cooling rate depends upon the

heat – input in the arc

• The cooling rate also depends on the

thickness of the joining members
SMAW

• Heat is provided by arc between stick electrode and joining member

• Shielding of the molten metal done by the flux which melts and produces
shielding gases and slag

• Welding is manual

• The welding operation is not continuous

• The rate of deposition is low

• The depth of fusion is less

• Welding can be done in all positions

• Welding power source is of constant current type

GTAW

• Heat is provided by arc between non-consumable tungsten electrode and

joining member

• Shielding of the molten metal done by the inert shielding gas

• Welding is manual / machine / Automatic

• The welding operation in manual mode is not continuous

• The rate of deposition is low

• The depth of fusion is less

• Welding can be done in all positions

• Welding power source is of constant current type

GMAW

• Heat is provided by arc between filler wire electrode and joining member

• Shielding of the molten metal done by the gas which is provided thru the
nozzle on the welding gun

• Welding can be semi-auto, machine or auto

• The welding operation can be continuous in machine or auto mode since

wire is fed by machine

• The rate of deposition is more than SMAW

• The depth of fusion is more than SMAW

• Welding can be done in all positions

• Welding power source is of constant voltage type

FCAW – Gas Shielded

• Heat is provided by arc between flux cored filler wire electrode and joining member

• Shielding of the molten metal done by the gas which is provided thru the nozzle on the
welding gun

• Welding can be semi-auto, machine or auto

• The welding operation can be continuous in machine or auto mode since wire is fed by
machine

• The rate of deposition is more than SMAW / GTAW

• The depth of fusion is more than SMAW / GTAW

• Welding can be done in all positions

• Welding power source is of constant voltage type

SAW

• Heat is provided by arc between filler wire electrode and joining member

• Shielding of the molten metal done by the flux which is provided thru the
flux delivery chute on the welding head

• Welding can be machine or auto

• The welding operation is continuous

• The rate of deposition is more than SMAW and GMAW

• The depth of fusion is more than SMAW and GMAW

• Welding can be done only in Flat and Horizontal positions

• Welding power source is of constant voltage type or constant current

with feed back to wire feeder
Welding Variables for
SMAW
• Power
• Electrode Type
• Electrode Polarity
• Electrode diameter
• Current
• Arc length
• Forehand or Back-hand technique
• Welding weave
• Welding Speed
• Run Out Length
• Heat Input
Welding Variables for
GTAW
• Power
• Tungsten Electrode Type
• Electrode Polarity
• Electrode diameter
• Filler Wire type
• Filler wire dia
• Shielding Gas & Gas Flow
• Purging Gas & Gas Flow
• Gas Nozzle Type, shape & Dia
• Current Type and level
• Arc length
• Welding weave
• Filler wire Feed
• Welding Speed
• Heat Input
Welding Variables for
GMAW
• Gas Type
• Gas Pressure
• Gas Flow
• Shielding cup diameter
• Power
• Polarity
• Wire Type
• Wire Diameter
• Arc Voltage
• Current / Wire Feed
• Forehand or Back-hand technique
• Welding Weave / Oscillation
• Welding Speed
• Heat Input
Welding Variables for
FCAW
• Gas Type
• Gas Pressure
• Gas Flow
• Shielding cup diameter
• Power
• Polarity
• Wire Type
• Wire Diameter
• Arc Voltage
• Current / Wire Feed
• Forehand or Back-hand technique
• Welding Weave / Oscillation
• Welding Speed
• Heat Input
Welding Variables for
SAW
• Power
• Polarity
• No. of electrodes
• Diameter of electrodes
• Type of electrodes
• Inclination and Spacing of electrodes
• Alignment of electrodes
• Flux Type
• Electrode Stick-out
• Flux Burden
• Arc Voltage
• Current / Wire Feed Rate for each electrode
• Welding Speed
• Re-circulation of Flux
Effect of Variables on
various process outputs
• Depth of Penetration
• Deposition Rate
• Fusion Profile
• Weld Bead Width
• Weld Bead Re-inforcement
• Weld Finish
Depth of Penetration

Increased by

• Higher Current
• Higher current density
• Back ward inclination of
electrode
• DC electrode positive
Deposition Rate

Increased by

• Higher Current
• Higher current density
Fusion / Bead Profile

Is affected by

• Shielding gas
• Type of flux
• Position of electrodes
• Backward or forward inclination
of electrode
Bead Width

Is affected by

• Welding Voltage
• Welding Speed
• Weaving width
Bead Re-inforcement

Is affected by

• Welding Voltage
• Welding Speed
• Weaving width
• Positioning of electrodes