Welding Design

History

- Early Egyptians about 5500 BC

- Making copper pipes from sheets overlapping and hammering

- Type of welding – forge welding

- Welding technology developed around 1877

- After world war I, electrodes and gas were used

Arc Welding

Welding is the process of joining materials by heating them to suitable temperature

What is arc welding?

- Welding process that uses electrical energy in the form of an electric arc to generate
the heat necessary for the welding.
Basic Welding Processes

1. Shielded Metal Arc Welding (SMAW)

2. Submerged Arc Welding (SAW)

3. Gas Metal Arc Welding (GMAW)

4. Flux Cored Arc Welding (FCAW)

5. Electro Gas Welding (EGW)

6. Electro Slag Welding (ESW)

7. Stud Welding
Shielded Metal Arc Welding (SMAW)

- simplest, oldest, most versatile method

- Also called manual stick electrode process

- Metal is transferred from the electrode to the base material

- Electrode wire becomes filler material

- Coating becomes partly into shielding gas, partly into slag

and some part is absorbed by the welded material

- Coating is clay-like mixture of silicate binders and powdered

materials such as fluorides, carbonates, oxides, metal alloy and
cellulose.

- Coating prevents from forming nitrides and oxides that will

cause embrittlement.
Shielded Metal Arc Welding (SMAW)
Submerged Arc Welding (SAW)

- Arc is not visible, covered by a blanket of granular fusible material

- The granular flux allows the weld to be made without spatter, sparks,
or smoke and protects the weld pool against the atmosphere, serves to
clean the weld metal and modifies the chemical composition of the weld
metal

- High quality, good ductility, high impact strength, high density, good
corrosion resistance

- Mechanical properties of the weld are as good as the base material

- Signed as FXXX-EXXX
Weldability of structural steel

Weldability is a measure of the ease of producing a crack-free and sound

Structural joint
Types of Joints

a) Butt joint

b) Lap joint

c) Tee joint

d) Corner joint

e) Edge joint
Types of Welds

a) Groove weld

b) Fillet weld

c) Slot weld

d) Plug weld
Types of Groove Welds
Types of Fillet Welds
Slot and Plug Welds in combination with Fillet Weld
Weld Positions
Basic Weld Symbols
Weld Symbol Meaning
Basic Weld Symbols
Example
Possible Weld Defects
Minimum weld size
Minimum weld size
Strength of Fillet Welds