Fundamentals of

Welding Process
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Fundamentals of welding process

• Welding is a materials joining process in which two or more

parts are coalesced at their contacting surfaces by a suitable
application of heat and/or pressure.
• Many welding process are accomplished by heat alone, with
no pressure applied; others by a combination of heat and
pressure; and still others by pressure alone, with no external
heat supplied.
• In some welding process a filler material is added to facilitate
coalescene
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Types of welding process

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Arc welding
• Arc welding (AW) is a fusion-welding process in which coalescene of
the metals is achieved by the heat of an electric arc between an
electrode and the work.
• An electric arc is a discharge of electric current a cross a gap in a
circuit. It is sustained by the presence of a thermally ionized column
of gas (called a plasma) through which current flows.
• To initiate the arc in an AW process, the electrode is brought into
contact with the work and then quickly separated from it by a short
distance.
• The electric energy from the arc thus formed produces temperatures
of 5500C
• In most arc welding processes, filler metal is added during the
operation to increase the volume and strength of the weld joint.
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Power density
• Power density can be computed as the power entering
the surface divided by the corresponding surface area:

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Power density

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Resistance welding
• Resistance welding is a group of fusion-welding
processes that uses a combination of heat and pressure
to accomplish coalescence, the heat being generated by
electrical resistance to current flow at the junction to be
welded.
• By comparison to arc welding, resistance welding uses no
shielding gases, flux, or filler metal, and the electrodes
that conduct electrical power to the process are non-
consumable. Resistance welding is classified as fusion
welding because the applied heat almost always causes
melting of the faying surfaces. However, there are
exceptions. Some welding operations based on resistance
heating use temperatures below the melting points of the
base ©2010
metals, so fusion does not occur.
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Resistance welding
• The principal components in resistance welding are
shown in figure below

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e