WELDING

Introduction
Welding is a process in which two materials are
permanently join together through bond of
same material.
Welding can be basically classified in to two.
Fusion welding Pressure welding
Heat the metal and apply
Melt the edges of the metal pressure on them. No need filler
components and bond together material.
with filler material.
Ex: Forged welding, Resistance
Ex: Arc, Gas ,MIG .TIG welding, Friction welding.
 ELECTRIC ARC WELDING
Manual Metal Arc Welding

• In arc welding, heat for welding is supplied by low

voltage and high amperage electric arc. The arc is
produced by jumping the current between the air gap
of electrode and the work piece. The temperature of
heat produced by the electric arc is about 35000c to
40000c. Using this heat , weld metal and filler metal
melt and bond together.
 Welding Equipment
• Welding transformer - to supply electric power
• Welding electrode – to supply filler material
• Electrode holder - to hold the electrode
• Electric cable - to carry the electrical power to
the welding system
• Earth clamp - to protect the worker by taking the
worker away from the circuit.
• Welding table – to hold the work
Manual Metal Arc Welding Unit
 Welding transformer
• The purpose of a transformer is to provide a
single function of changing the high
voltage/low amperage main supply to low
voltage/ high amperage welding supply.
 Three types of welding suppliers
• Direct current (DC) Motor generators
• Alternative Current(AC) Transformers
• AC transformers with DC rectifiers

1. DC Motor generators
In a DC generator , driving a generator motor
using electrical power, gasoline or diesel power
generates electrical power.
Better suited for thin metals, portable units available,
without main supply of electricity can be used.
2. AC Transformer

AC transformer is a power supply equipment which supplies AC

power from main supply by changing the voltage and current of
the main supply.(low voltage and high currant)
lower initial cost, low operational maintenance.

3. DC Transformer/ Rectifier

AC supply from main supply is transfer to DC supply and also

controls the voltage and current output. DC transformer/
rectifier supplies straight polarity power as well as reverse
polarity power.
compact equipment , high efficiency.
 Welding electrode
Electrode supplies filler metal to the joint. They are
supplied in a range of sizes from diameter 2mm to
6mm. Electrodes are coated with flux.
The arc is produced by bringing the consumable
electrode into contact with the work piece and
withdrawing it a slight distance to establish correct arc
length, which should be approximately the diameter of
core wire.
The size of the electrode refers to the diameter of core
wire. According to the core diameter the amperage will
be changed
There are different standard of electrodes.

• British standard – in this standard electrode is numbered as

follows. These are given the strength of the metal,
elongation, impact strength of the metal, covered flux,
electrode efficiency, welding position, current/voltage to be
used, hydrogen control.

• American standard
In this standard, electrode is numbered as follows, to identify
the strength of metal, position to be used, and flux type. E
identified the electric arc welding.
E 60 12
 ELECTRODE SIZE
• Electrodes are usually produced in lengths of 250,
300, 350 and 450mm. About 20mm of core wire
length is kept as bare at one end for inserting into the
electrode holder to give the power supply. The size of
the electrode is measured and designated mainly by
the diameter of the core wire. Core diameter in mm is
given below. In the bracket shows the standard wire
gauge in British system.
• 1.6mm(16) 2mm(14) 2.5mm(12) 3.2mm(10)
4mm (8) 5mm(6) 6mm(4)
From American welding society
Electrode Diameter Amp Range

6010 and 6011 3/32 50-70

1/8 100-130
5/32 140-170

6012 1/8 100-130

5/32 165-200

6013 3/32 60-75

1/8 100-135
5/32 140-180

7018 3/32 70-110

1/8 120-160
5/32 150-200

7024 1/8 140-180

5/32 180-240
 Types of joints
• Butt joint

• Lap joint
• Corner joint

• Edge joint

• T- joint
 PIPE WELD POSITIONS
In pipe welding many of the skills and practices are
similar to other welding procedures. Most used method
is Butt welding. There are four main standard positions
in pipe welding.
• 1G position
Pipe horizontal rolled weld Flat (±150 )
Rotate pipe and deposit weld at or near the top
• 2G position
• Pipe vertical weld flat (±150 )
• Pipe shall not be rotated during welding
• 5G position
• Pipe horizontal fixed (±150 )
• Pipe shall be rotated during welding

• 6G position
• Pipe inclined fixed (450±50 )
• Pipe shall not be rotated
during welding
 Welding defects
1. Dimensional discrepancies
• Warpage (distortion)
• Incorrect joint preparation
• Mismatching
• Incorrect welding size and profile
 Welding defects
2. Structural discontinuity
• porosity
• Slag inclusion
• Incomplete fusion
• Different form of cracks
 Causes for welding defects
• Porosity - impurities, excess moisture in
electrodes covering improper arc length,
excessive current and too high welding speed
• Slag inclusions- incomplete de- slagging of
previous pass, wide electrode weaving, too large
size electrode,
• Incomplete fusion – excessive travel speed,
excessive electrode size, insufficient current or
poor joint,
• Under cuts- excessive welding current , arc length