Welding-3

Andó Mátyás – Szőlősi József

Eötvös Loránd Tudományegyetem

Savaria Műszaki Intézet
9700 Szombathely, Károlyi Gáspár tér 4.
 TUNGSTEN INERT GAS (GTAW OR TIG) WELDING

2020/2021 first semester Andó Mátyás - Szőlősi József – ELTE-IK-SMI 2

ISO 4063 – 14, tungsten inert gas arc welding (TIG welding)
• Hungarian called AWI welding (Argon shielded Tungsten electrode Arc
welding)
• Belongs to TIG welding group (Tungsten Inert Gas)
• Tungsten is metal with an extremely high
melting point (above 3400 ° C)
a non-consumable electrode
• High quality, excellent welding seams
• If a welding filler material (solid wire / rod)
is also used, ISO 4063 - 141, usually manual feed
• Less productive
• Expensive process
• It also produces excellent seams in case of stainless steel materials and
aluminum welding
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 Process of TIG welding
• TIG Welding Polarity Options:
• Electrode negative (DC-): 70% of heat in the workpiece, narrow, deep welding seam
(not often used for aluminum because it does not break up oxide surface layers)
• Electrode Positive (DC+): 70% of heat in the electrode, tungsten overheating, suitable
for breaking up the oxide and nitride layers because Argon ions bombard the top
layer and the outgoing electrons also loosen it; wide, shallow seam (used to form the
ball at the end of the tungsten)
• Alternating current (AC): 50% -50% heat load between eletrode and workpiece,
suitable for welding aluminum, first oxide layer breaks, deeper fusion in the next
phase
• Determination and adjustment of gas mixture (the risk of oxidation of
metals with high affinity for oxygen, eg aluminum, magnesium, titanium
can be reduced by a few percent hydrogen gas) and volume flow
• Select of filler material - if necessary
• Adjust welding voltage and current
• Welding (the machine flows the gas at the push of a button - gas afterflow
can be set)
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 Laser beam welding

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 ISO 4063 – 52, laser welding
• Focuses on a very small (1-2 mm) spot on the
workpiece with high energy density
• Highly dependent on the absorption coefficient of the
workpiece surface (light absorption capacity)
• Heat is transferred to the inside of the workpiece due
to heat conduction
• Welding is often done under a microscope
• Excellent welding seam without deformation and
discoloration
• Welding joints are typically without welding
consumables
• Repair of molds, injection molding and cutting tools -
typically with welding consumables
• Steel, aluminum, but also special materials such as
titanium

2020/2021 first semester Andó Mátyás - Szőlősi József – ELTE-IK-SMI 6

 Process variants of laser beam welding
• ISO 4063-521: solid state laser welding (with high power solid state
lasers eg Nd-YAG laser - Neodymium-doped Yttrium Aluminum
Garnet)
• ISO 4063-522: gas laser, laser beam welding (eg CO2 laser)
• ISO 4063-523: diode laser,
laser welding
• A new kind of laser beam welding
(now in its heyday): laser hybrid
welding, where laser beam and wire
electrode arc welding are combined.
It typically spreads in the
automotive industry.
2020/2021 first semester Andó Mátyás - Szőlősi József – ELTE-IK-SMI 7
 Process of laser welding

• Technology selection
(thermal conductive-conduction mode
or deep welded-keyhole mode)
• Choice of welding material -
if necessary
• Setting the correct welding parameters
• Welding

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 Hybrid welding process: laser + MIG / MAG

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 Spot welding

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 ISO 4063 – 2, Resistance welding group
• Welding thin sheets or welding steel wire for steel mesh
• The heat comes from the resistance created by the current of
workpiece, and pressure is applied (electrodes)
• Resistance spot welding (21) and Resistance seam welding (22)

2020/2021 first semester Andó Mátyás - Szőlősi József – ELTE-IK-SMI 11

 Process of reisistance spot welding
• Select the welding current
• Select the geometry of the electrode
• Adjust the compression force and the post-pressure time
• Adjust welding current and voltage
• Positioning of parts
• Closing electrodes
• Welding
• Opening electrodes after a definied time
• Place plates in a new position or the piece is ready

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 Butt welding

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 ISO 4063 – 24, flash welding
• Used to weld the front surfaces of wires, pipes, rods,
even on large surfaces
• Process without filler material
• Heat is generated due to the resistance of the
workpiece (under the effect of flowing current)
• The two workpieces are clamped separately, the current
is connected to the workpiece through the clamping
and the compressive force is also created through this.
• There is usually a fixed and a moving side
• Small hand-held machines exist, but automatic
machines are preferred
• Up to steels of different compositions, light and non-
ferrous metals

2020/2021 first semester Andó Mátyás - Szőlősi József – ELTE-IK-SMI 14

 Flash welding process
• Setting the parameters (current, times, pressure…)
• Clamps workpieces and turns on power
• It touches pieces - at the very beginning the metal evaporates at the
points of contact - it causes splashing and sparking
• If preheating is required, the pieces are pulled apart - then pushed
back together(frequency). Then the surfaces getting more clean
• An increasing surface is in contact,
the front surface completely melts
• Combines with dynamic push
• Power turns off
• Workpiece cools, clamp opens
2020/2021 first semester Andó Mátyás - Szőlősi József – ELTE-IK-SMI 15
 Flash welding diagrams
• Flash welding without • Flash welding with preheating
preheating(242) (241)
• u-upsetting

upsetting
preheating

upsetting
upsetting
If
f

t preheating tf upsetting

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 Friction welding

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 ISO 4063 – 42, Friction welding
• Without filler material
• The equipment has high rigidity and centers the workpieces correctly
• The circle cross-section is optimal, but not a condition for this process
• Process:
• One piece is rotated
• The two pieces are compressed (normal force) while maintaining the
conditions of movement (one standing, the other rotating - relative
displacement) - for 1-150 seconds.
• The surfaces melt, and the required heat is provided by the frictional force
created between the two pieces
• The relative movement ceases and the compressive force is increased,
resulting the welding to take place (compacted)

2020/2021 first semester Andó Mátyás - Szőlősi József – ELTE-IK-SMI 18

 Ultrasonic welding

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 ISO 4063 – 41, Ultrasonic welding
• Cohesion bonding is created due to pressure and friction due
ultrasonic vibrations
• The sonotrode is displaced by the ultrasound relative to the
anvil, up to 20,000 times per second
• Due to micro-displacements and pressure, the oxide layers
decompose and a locally plastic deformation occurs. At this
point, a high temperature is created for a moment, but the
amount of heat is minimal.
• Globally heat generation is small and deformation is minimal
• For metals, it is typically used in fine mechanics
• Cheap and good quality welding
• Several types of materials can be
connected to each other
(used for metals, plastics)

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 Where are we now?

Post weld
ISO 4063
heat
Preparation Welding
treatment,
procedure
machining

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 Follow-up processes after welding

• Heat treatment: primary goal is to reduce internal stresses; high

temperature tempering, softening, or normalization. Warping can
also occur during heat treatment.
• Straightening: to eliminate warps - plastic deformation
• Cold straightening can be done by static force (presses, clamps) or by
dynamic force (hammering), then heat treatment causes warping
again
• During hot straightening, it is suddenly heated and cooled at given
points – effectuate opposite deformation

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 Follow-up straightening
Cold process Hot process

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 Weldability - practical point of view
• It is always necessary to consider the phase transition of a given
workpiece and filler material when it is melted and solidified.
• The achievable mechanical properties (eg strength, fatigue…) must be
examined.
• Aluminum alloys can be welded under shielding gas in case of rapid
heating; in the case of zinc and copper alloys, they are typically not
weldable
• Copper alloys can also be welded with shielding gas and rapid heating
• Stainless steel and nickel alloys can be welded by specialised methods
• Titanium and tantalum alloys can be welded with shielding gas with
suitable technology
2020/2021 first semester Andó Mátyás - Szőlősi József – ELTE-IK-SMI 24
 Weldability of steels
• All steels can be
welded under
proper conditions
• Case hardening
steels (below
0.2% C content)
are easy to weld
• As the carbon
content is higher,
it is difficult to
weld

2020/2021 first semester Andó Mátyás - Szőlősi József – ELTE-IK-SMI 25

 Schaeffler diagram of weldability of high-alloy
steels
• A – Austenit
• M – Martensite
• F – Ferrite
• –X– gain size increases
above 1150°C
• ---- danger of sigma phase
precipitation 500-900°C
• –●– high risk of hot
cracking above 1250°C
• –○– high risk of cold
cracking around 400°C
2020/2021 first semester Andó Mátyás - Szőlősi József – ELTE-IK-SMI 26
 Dissimilar steel welding
• Welding steels of different material compositions
• Apply an outer layer of a different composition to a given steel, e.g. due to
corrosion resistance, abrasion resistance…
• In addition to the composition, differences in different properties can also
be a problem (thermal expansion, tendency to harden…)
• What will be the composition of the mixed welding joint when two
materials are welded together?
• The chromium and nickel equivalents of the two materials (A1, A2) must be
determined
• Connect with a straight line - assuming 50-50% mixing, half of the straight
line will have a mixed state (K)
• In the case of welding material (H point), at the part corresponding to the
melting ratio of the straight lines H and K, the material composition of the
seam will be (V)

2020/2021 first semester Andó Mátyás - Szőlősi József – ELTE-IK-SMI 27

 Schaeffler-diagram – vegyes kötés
• By changing the raw materials
as little as possible, the position
of the K point can be changed
• The filler material can be
changed relatively freely, it can
be achieved by mixing with the
right proportion to get the V
point to the point where the

Equivalent nickel
risk from point of welding is
minimal
• It should not be forgotten that
this still makes the raw
materials behave differently,
e.g. thermal expansion - there
is always a risk of cracking
Equivalent chrome
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 Filler materials

• Different verisons:
• Electrodes
• TIG sticks
• Solid wire electrodes
• Powdered wire electrodes
• Wire / powder combinations
• Autogenous sticks
• Different material qualities
• Different sizes

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 Select a specific filler material from a catalog
• Welding technology determines the design
• The base material determines the
composition. With a good setting, up to two
steels with different material compositions
can be welded in good quality
• Both the welding position and the type of
seam also affect the type and size
• Depending on the parameters, you can select
from hundreds of welding fillers, so it is
worth starting with a specialist catalog.
• Good quality strong weld can only be
achieved with the proper selected material
for the base material, seam and welding
technology

2020/2021 first semester Andó Mátyás - Szőlősi József – ELTE-IK-SMI 30

 Repetition: Material properties
Mechanical properties:
• Strength: is the resistance of materials to forces to break their
cohesiveness. Steel components are required to withstand the greatest
possible load per unit cross-section without permanent deformation or
tearing.
strength characteristic variants: hardness, tensile strength, yield
strength, conventional yield strength
• Toughness: structural force in a material that does not break, tear easily,
but rather bends, stretches slightly. If the material is tougher, it takes more
energy to tear or break it.
Metrics: impact work, elongation, contraction

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 Repetition: stresses

• Static stress time

• Alternating stress
time

• Pulsating (cyclic) tension

time

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 Welding quality assurance_3
Emlékeztető: Hegesztés-1 EA

• ISO 9001
• MSZ EN ISO 3834-2
• MSZ EN ISO 15085
• Welding plant certifications, welder certifications, welding
supervision, regulations, instructions…

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 Welding tests
• We perform a pre-production(FAI)
and periodic review
• Geometry checks– fit, shape: Visual Does the welded structure
inspection pass the welding tests?
• Destructive tests (Mechanical tests,
tensile test, bending test, hardness Is it suitable for the use?
test, Charpy test)
• Non-destructive tests (X-ray,
ultrasound, magnet particle
inspection, liquid penetration
inspection)
• Fatigue tests (low cycle, high cycle)

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 Welding tests - visual inspection
• Geometry checks
– fit, shape:
Visual inspection

MSZ EN 13018: 2016

Non-destructive testing. Visual testing. General principles
MSZ EN ISO 17637:2017
Non-destructive testing of welds. Visual testing of fusion-welded
joints
MSZ EN ISO 5817: 2014 Important:
Welding. Fusion-welded joints in steel, nickel, titanium and their investigation
alloys (beam welding excluded). Quality levels for imperfections circumstances, process,
means, documentation
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 Welding tests - destructive

• Destructive tests (Mechanical tests,

tensile test, bending test, hardness
test, Charpy test)

Filler material
Heat aff. zone

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 Welding tests – Non-destructive tests
• Non-destructive tests (X-ray,
ultrasound, magnet particle
inspection, liquid penetration
inspection)

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 Welding tests - fatigue
• Fatigue tests (low cycle, high cycle)

Low-cycle (Coffin-Manson type) fatigue (Nt <103… 104), during which the load is above
the yield point (Ϭmax ≥ Rp0.2), resp. deformation is elastic-plastic and failure is the extent
of cracks that occur inside the material. This can occur e.g. pressure vessels and pipelines
in the chemical or energy industries, which are sometimes stopped and then restarted, are
so-called at stress collector locations (cross-sectional changes, welding nodes, ...).
High cycle number (Wöhler's) fatigue (Nt >> 103… 104), during which the load is less than
the yield point (Ϭmax <Rp0.2), resp. the deformation is usually elastic and the fracture is
caused by crack propagation due to surface deformations, defects, local stress collector
(which can cause a small plastic deformation) design details. This is typical e.g. most
rotating machine parts (shaft, bearing, wheel, ...) or rope track for fatigue wire ropes.

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 Welding tests - fatigue

• Fatigue tests (low cycle, high cycle)

Low cycle (Coffin-Manson)
fatigue

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 Welding tests - fatigue
• Fatigue tests (low cycle, high cycle)
High cycle number (Wöhler)

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 Welded structures - design aspects

• Design of welded structures, a few things, aspects:

Structures must be designed during the design phase to withstand the
various types of stresses and impacts over their lifetime.

The most important failure states of the structures:

• load capacity; plastic fracture,
• stability; dent, buckling,
• fatigue,
• deformation limit state,
• brittle fracture limit state
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 Welded structures - design aspects
• Design of welded structures, a few things, aspects:

1. Use as few seams as possible, only the required dimensions, sizes; due the
residual welding stresses are reduced too.
2. The number of on-site joints of the brackets and the on-site welded
connections of the bars should be kept to a minimum. The field support
joints of the brackets must be made with a tensioned screw connection.
3. The tack weld seams connecting the elements of the brackets and rods
must be symmetrical to the center of gravity of the bracket and the rod,
otherwise warping must be taken into account.
4. The seams must be made in an easily accessible way, preferably in a
horizontal position, so in this case machine welding can be used.
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 Welded structures - design aspects
• Design of welded structures, a few things, aspects:

5. Non-inspectable, non-repairable seams should be avoided.

6. Simple solutions should be sought on static load supports.
7. Fatigue-sensitive supports require curved rounded, machined structural
solutions.
8. In the case of fatigue-sensitive structures, sudden cross-section changes
and incisions should be avoided. Efforts should be made to conduct the lines
of force continuously without breaking.
9. In the case of power-transmitting joints, butt seams shall be preferred
against corner seams.

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 Welded structures - design aspects
Technological and economic considerations must be
taken into account in selecting the appropriate
material quality and strength group.

The use of steel belonging to a higher strength

group may reduce the weight of the structure, but it
may not increase the proportion of e.g. stiffness,
resistance to compressive, fatigue stress, and
weldability problems can occur.
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 Video links
• Flame welding: https://www.youtube.com/watch?v=NAA2wFZYGYo
• Electric arc welding: https://www.youtube.com/watch?v=FXN6qiDsClw
• TIG welding: https://www.youtube.com/watch?v=TidFih7Dpus
• Arc welding: https://www.youtube.com/watch?v=U1GTgDQFE4A
• Laser welding: https://www.youtube.com/watch?v=K3mFAyq3UAk
• https://www.youtube.com/watch?v=LT-mfiNmWYM
• Spot welding: https://www.youtube.com/watch?v=AwL1CAg43PU
• https://www.youtube.com/watch?v=5VEGcu9mOtE
• Stud welding: https://www.youtube.com/watch?v=Ljz6twH-Pc4
• Butt welding: https://www.youtube.com/watch?v=ye58wasNIGo
• https://www.youtube.com/watch?v=Gq6yB-YujMs
• Friction welding: https://www.youtube.com/watch?v=-aEuAK8bsQg
• Ultrasonic welding: https://www.youtube.com/watch?v=yLGiY6Ehofo
• https://www.theweldings.com/resistance-welding/

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