Chapter 1a:

Welding, Allied Processes and Some Terminologies

Organized by:
Yupiter HP Manurung
Mohd Shahriman Adenan
Muhd Faiz Mat
Introduction to Welding
Fabrication
• Selected – light, simple, cheap
• Application – steel structures,
bridge construction, ship
industries, pressure vessel,
pipeline. Repair e.g. Cast and
Worn Products. Hard Facing.
• Employment requires
synchronization of welding
characteristics with product
function and the environment.
 What is welding?
• A joining process that is intended to
make the material at the joint or joint
surfaces as homogenous as possible
with the base material.

Homogenous in terms of material, chemical

composition, metallurgical, mechanical or physical
characteristics
 So, what is welding?

Welding is more of a process of creating a

continuity of material homogeneity at the
joint with the base material.
When can welding happen?

Welding can happen when the faces of the

material to be joined either in solid phase or in
liquid phase
How can welding happen in solid phase?

It can happen when the material at the surfaces to

be joint is in plastic condition (still in solid phase)
How is welding being classified?

The simple way to classify welding is by its process

phases.
What are the process phases in welding?

There are 2 kinds of process phases in welding:

1. Solid phase welding process
2. Liquid phase welding process
What is solid phase welding process?

Solid phase welding process is a process of

joining material without melting it either by
heating, or by pressure, or by using both.

This is by bringing the material at the joint into plastic condition

suitable for welding to occur.(In this condition the material is still
in a solid state)
What is liquid phase welding process?

Liquid phase welding process is a process of joining material by

melting it.

This is by bringing the material at the joint into liquid state

What are the examples of welding that under the
category of solid phase?

Examples are:

Ultrasonic welding
Friction welding
Friction stir welding
Explosive welding
Cold or hot roll bonding
Blacksmith & forged welding
Diffusion bonding
What are the examples welding processes under
the category of liquid phase?
Examples are:
GAS WELDING
SMAW (MMAW)
GMAW (MIG)
GTAW (TIG)
FCAW
SAW
Spot welding
Plasma welding
Laser welding
Electron beam welding
Thermit welding
Electroslag welding
Shielded Metal Arc Welding (SMAW)
Gas Tungsten Arc Welding (GTAW) - TIG
Gas Metal Arc Welding (GMAW) - MIG
Flux Core Arc Welding (FCAW)
Submerged Arc Welding (SAW)
Is Soldering Welding?

Because the material used for joining is not the same material (not homogenous) with
the base material.
It melts at lower temperature than the base metal
Its strength is lower than the base metal
The material used for joining is called solder (alloy of lead and tin)
Is Brazing Welding?

Because the material used for joining is not the same material (not homogenous) with
the base material.
It melts at lower temperature than the base metal
Its strength is lower than the base metal
The material used for joining is brass (alloy of copper and zinc)
Then, what is the difference between Soldering
and Brazing?

Material for soldering is solder while material for brazing is brass

The melting temperature of solder is much lower than that of
brass
Therefore, the strength of joint made by soldering is much lower
than that made by brazing
What is thermal cutting?
A process of removing material from the base metal by the help
of heat either by melting it or without melting it.

Examples
Oxy Acetylene Gas Cutting
Powder Cutting
Air Arc Cutting / gouging
Air Plasma Arc Cutting
Laser Cutting
Electron Beam Cutting
Why are welding technologies developed?

SMAW  GTAW  GMAW  SAW  FCAW

GTAW  PLASMA
SMAW has shortcoming

Need to change the electrode

Electrode wastage is high

Weld bead needs thorough cleaning – chipping, brushing, grinding, gouging

High possibility of slag inclusion

Low productivity
Why GTAW being developed?

Theoretically to solve problem in aluminum welding created by

SMAW and gas welding
The aluminum oxide formed acts as insulator which make welding
(and cutting) becomes difficult
Shielding by inert gas of argon and helium - gives better protection and
penetration
AC current is more suitable for welding aluminum because when the
arc reverses it will clean the oxide that is being formed
How about GMAW?

Continuous feeding of filler wire – productivity becomes

high

Virtually no cleaning required

Better protection of weld, weld pool and weld arc - by

inert/inactive gas (e.g. Argon) or Semi-inert/semi-active gas
(e.g. Carbon dioxide)
Why SAW developed?

Faster welding for thicker metal

Can use bigger diameter of wire, hence, using bigger current

Using both flux and continuous filler wire separately – taking

advantage of both of SMAW and GMAW

Fast speed welding

Productivity higher than GMAW

Why FCAW developed?

Using continuous tube type of small diameter of filler wire with flux
filled inside the tube > less bulky
Using both flux and continuous filler wire – taking advantage of both
of SMAW and GMAW
Fast speed welding
Productivity higher than GMAW
2 methods of welding can be done -either shielded or unshielded by
gas
Why PLASMA welding?

Plasma arc virtually hotter than normal arc even from tig
Weld is cleaner
Can weld thicker metal
Can do keyhole welding/fine quality of welding
Nowadays the plasma arc can be controlled to produce micro plasma (0.1 to 15A)
for welding very thin metal, or medium plasma (15 to 200A) or keyhole plasma
(over 100A)
Why new evolution of welding power
sources?
To solve problems in welding
To improve welding quality
To minimize welding skill
To ease welding
To minimize ‘human tension/stresses’ in welding
To minimize problems due to human factors
Welding becomes more comfortable and user friendly
Productivity increased
Weld quality increased
Welding power sources become smaller, lighter and more portable and comfortable to carry
Energy consumption becomes lower
Here are some other reasons that inverters save in
energy costs:
Greater transformer efficiencies are realized through the use of ferrite cores in the inverter's power transformer. This reduces the current losses
resulting in lower idle currents in the supply conductors

The inverter transformer coils are physically smaller than common transformers. A smaller coil translates to less wire wrapping around the core - less
wire means fewer losses and greater efficiency

The inverter's power electronic components have been carefully designed to reduce losses and extend operating life

Many inverters, such as Lincoln's Invertec V350 Pro, uses a copper conductor. Copper has higher thermal and electrical conductivity compared to aluminum,
which will minimize losses and maximize efficiency

Operating at higher frequencies than conventional welders, inverters require less output inductance for smooth operation. The energy needed for stick
welding or for globular transfer welding processes is stored in capacitors allowing for smaller output chokes

The compact design and relatively small physical size of an inverter welder means shorter leads and cables (or even direct connections) between power
components. Shorter current paths translate to lower resistances and better efficiencies

Because the inverter is designed to inherently have low losses, smaller cooling fans are required. This means less power is needed for moving cooling air
and, again, greater efficiency

The smaller size of the components inside the inverter machine translate into less heat to dissipate and again, greater efficiency
https://www.lincolnelectric.com/en-us/support/process-and-theory/pages/inverter-power-detail.aspx