Welding and Surface Process

Overview
Final
Arc welding
Resistance welding
Oxyfuel gas welding
Friction Stir welding
418
Assoc.Prof.Dr.‐Ing. Patiphan Juijerm Iron and Steel Institute of Thailand (ISIT)
Department of Materials Engineering, Kasetsart University 1st‐2nd Fl., Bureau of Industrial Sectors Development Building,
Bangkok 10110, Thailand
Welding
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.
Welding process involves localized coalescence

or joining together of two metallic parts at
their faying surfaces. The faying surfaces are
the part surfaces in contact or close proximity
that are to be joined. Welding is usually
performed on parts made of the same metal,
but some welding operations can be used to
join dissimilar metals.
419
Welding
Advantages Disadvantages
• Welding provides a permanent joint. • Most welding operations are
The welded parts become a single performed manually and are
entity. expensive in terms of labor cost.
• The welded joint can be stronger than • Most welding processes are inherently
the parent materials (filler metal and dangerous because they involve the
welding process are required). use of high energy.
• Welding process is usually the most • Since welding accomplishes a
economical way to join components permanent bond, it does not allow for
and fabrication costs and time. convenient disassembly.
• Welding is not restricted to the factory • The welded joint can suffer from
environment. It can be accomplished certain quality defects that are
‘‘in the field.’’ difficult to detect.
420
Welding
Applications
• Construction ‐ buildings and bridges
• Piping, pressure vessels, boilers, and storage tanks
• Shipbuilding
• Aircraft and aerospace
• Automotive
• Railroad
421
Welding
Fusion zone consists of a mixture of filler metal and base metal that have
completely melted.
Heat‐affected zone (HAZ): The metal in this zone has experienced temperatures
that are below its melting point, yet high enough to cause microstructural changes
in the solid metal.
principal zones typical grain structure
422
Welding
completely melted.
in the solid metal.
Recrystallization
(Fine grains)
Grain growth
Low hardness (Coarse grains)
Recrystallization typical grain structure

High hardness (Fine grains)
423
Welding
completely melted.
in the solid metal.
424
Welding
completely melted.
in the solid metal.
Problems
• Crack
• Distortion
• Residual stress
• Brittle martensite
Preheating and post weld heat treatment

should be a one of methods to decrease
problems.
425
Welding
Welding processes
Fusion welding Solid state welding
• Arc welding (AW) • Diffusion welding (DFW)

• Resistance welding (RW) • Friction welding (FRW)
• Oxyfuel gas welding (OFW) • Ultrasonic welding (USW)
• Others
Some 50 different types of welding processes have been catalogued by the

American Welding Society (AWS).
426
Welding
Welding processes
Fusion‐welding processes use heat to

Fusion welding melt the base metals. In many fusion
welding operations, a filler metal is
• Arc welding (AW) added to the molten pool to facilitate
the process and provide bulk and
• Resistance welding (RW) strength to the welded joint. A fusion‐
• Oxyfuel gas welding (OFW) welding operation in which no filler
• Others metal is added is referred to as an
autogenous weld.
Some 50 different types of welding processes have been catalogued by the

American Welding Society (AWS).
427
Welding – Arc welding
Welding processes
Fusion welding Arc welding (AW): Arc welding refers to

a group of welding processes in which
heating of the metals is accomplished
• Arc welding (AW) by an electric arc.
• Resistance welding (RW)
• Oxyfuel gas welding (OFW)
• Others
428
Welding – Arc welding
Welding processes
Consumable electrodes provide the source of the

Fusion welding
filler metal in AW. They are available in rods and
wire. In both rod and wire forms, electrode is
• Arc welding (AW) consumed by arc and added to weld joint as filler
• Resistance welding (RW) metal.
‐ Shielded Metal Arc Welding (SMAW)
‐ Gas Metal Arc Welding (GMAW) Non‐consumable electrodes are made of tungsten
• Others which resists melting. Gradually depleted during
(Metal Inert Gas welding, MIG)
welding (vaporization is principal mechanism).
‐ Tungsten Inert‐Gas Arc Welding (TIG) Any filler metal must be supplied by a separate
wire fed into weld pool.
429
Welding – Arc welding, SMAW
Welding processes
SMAW is an AW process that uses a consumable

Fusion welding
consisting of a filler metal rod coated with chemicals
that provide flux and shielding (sometimes called
• Arc welding (AW) "stick welding“).
SMAW is usually performed manually on common
‐ Gas Metal Arc Welding (GMAW) applications. Base metals include steels, stainless
• Others
(Metal lnert Gas welding, MIG)
steels, cast irons, and certain nonferrous alloys. It is
‐ Tungsten Inert‐Gas Arc Welding (TIG) not used or seldom used for aluminum and its
alloys, copper alloys, and titanium.
430
Welding – Arc welding, SMAW
Welding processes
Fusion welding Advantages Disadvantages
• Arc welding (AW) •

High quality welds are • Consumes bigger electric
made rapidly at a low current
• Resistance welding
(RW) cost. • Dirty work finish
• Oxyfuel gas welding (OFW)• Can be used easily even • Prone to slag inclusions
‐ Gas Metal Arc Welding (GMAW) to thick and wide work • Consumable electrode
• Others
(Metal lnert Gas welding, MIG) piece to be joined. stick
• Can be used from thinner • Electrode length varies
‐ Tungsten Inert‐Gas Arc Welding (TIG) to thicker materials. during the operation
431
Welding – Arc welding, GMAW
Welding processes
GMAW is an AW process in which the electrode is

Fusion welding a consumable bare metal wire, and shielding is
accomplished by flooding the arc with a gas.
• Arc welding (AW)
• Wire is fed continuously and
‐ Shielded Metal Arc Welding (SMAW) auto‐matically.
• Shielding gases, Ar and He
‐ Gas Metal Arc Welding (GMAW)
• Others for aluminum welding, and
(Metal Inert Gas welding, MIG) CO2 for steel welding (named
MIG).
‐ Tungsten Inert‐Gas Arc Welding (TIG)
• No slag on weld bead.
432
Welding – Arc welding, GMAW
Welding processes
• Arc welding (AW) • Produced high quality and • Cannot weld in vertical or
much faster. overhead positions (high
‐ Shielded Metal Arc Welding (SMAW) heat input + fluidity).
• No flux is used (no slag).
‐ Gas Metal Arc Welding (GMAW) • Equipment is complex
• Others
(Metal Inert Gas welding, MIG) • Minor weld spatter, and it (more maintenance).
is easily removed.
‐ Tungsten Inert‐Gas Arc Welding (TIG) • Wind affects on shielding
gas flow (on field).
433
Welding – Arc welding, TIG
Welding processes
TIG is an AW process that uses a non‐consumable

Fusion welding tungsten electrode and an inert gas (Ar, He) for
arc shielding. It commonly uses for aluminum and
stainless steel.
• Arc welding (AW)
• Others
(Metal Inert Gas welding, MIG)
434
Welding – Arc welding, TIG
Welding processes
• Arc welding (AW) • High quality welds for • Slower than consumable
suitable applications electrode AW processes.
• No spatter because no • Higher cost than consum‐
filler metal through arc. able electrode AW.
• Others
(Metal Inert Gas welding, MIG) • Little or no post‐weld
cleaning because no flux
435
Welding – Resistance welding
Welding processes
Resistance welding (RW): Resistance welding

Fusion welding achieves coalescence using heat from
electrical resistance to the flow of a current
• Arc welding (AW) passing between the faying surfaces of two
• Resistance welding (RW) parts held together under pressure
• Others
436
Welding – Oxyfuel gas welding
Welding processes
OFW is operations that burn various fuels

Fusion welding mixed with oxygen to perform welding. OFW is
performed by a high temperature flame from
• Arc welding (AW) combustion of acetylene and oxygen.
• Others
437
Welding – Friction welding
Welding processes
Solid state welding
• Diffusion welding (DFW)

• Friction welding (FRW)
• Ultrasonic welding (USW)
Friction welding (FRW): Coalescence

is achieved by the heat of friction
between two surfaces.
438
Welding – Friction welding
Welding processes
Solid state welding
• Diffusion welding (DFW)

• Friction welding (FRW)
• Ultrasonic welding (USW)
Friction Stir Welding
439
Welding Quality
To obtain a weld joint that is strong and absent of defects, some issues
have to consider:
• Residual stresses and distortion
• Welding defects
• Inspection and testing methods
440
Welding Quality
have to consider:
• Welding defects
441
Residual stresses and distortion
Rapid heating and cooling in localized regions during fusion welding
result in thermal expansion and contraction that cause residual stresses,
and stresses cause distortion.
Shrinkage
Butt welding
Distortion
Residual stress Warping
442
Welding Quality
have to consider:
• Welding discontinuity
443
Welding discontinuity
The significance of a weld discontinuity should be viewed in the context
of the fitness‐for‐purpose of the welded construction. Fitness‐for‐
purpose is a concept of weld evaluation that seeks a balance between
quality, reliability and economy of welding procedure.
o Design related: Undesirable changes in cross section
o Welding process Related: Undercut, Porosity etc.
o Metallurgical: Cracks
444
445
446
Welding process Related
Undercutting is a defect that appears as a groove in the parent metal
directly along the edges of the weld. It is most common in lap fillet welds,
but can also be encountered in fillet and butt joints.
Causes:
• Improper welding parameters;

particularly the travel speed
and arc voltage.
• Excessive welding currents
447
Incomplete fusion is usually caused by the use of too low a welding current and
can be eliminated by simply increasing the amperage. Other causes can be the
use of too slow a travel speed and an incorrect torch angle. Both will allow the
molten weld metal to roll in front of the arc, acting as a cushion to prevent
penetration. The arc must be kept on the leading edge of the weld puddle.
448
Porosity is gas pores found in the solidified weld bead. These pores may vary in
size and are generally distributed in a random manner. However, it is possible that
porosity can only be found at the weld center. Pores can occur either under or on
the weld surface. The most common causes of porosity are atmosphere
contamination, excessively oxidized work piece surfaces, inadequate deoxidizing
alloys in the wire and the presence of foreign matter.
Causes:
• Inadequate shielding gas flow.

• Excessive shielding gas flow.
This can cause aspiration of air
into the gas stream.
• Severely clogged gas nozzle or
damaged gas supply system
(leaking hoses, fittings, etc.)
• An excessive wind in the
welding area. 449
450
Metallurgical
Crack can occur due just to thermal shrinkage or due to a combination of strain
accompanying phase change and thermal shrinkage. It is serious defect because it
is a discontinuity in the metal that significantly reduces strength.
451
Metallurgical
Hot cracking occur immediately after welds are

completed and sometimes while the welds are
being made. These defects, which are often
caused by sulphur and phosphorus, are more
likely to occur in higher carbon steels.
452
Metallurgical
Cold cracking (Hydrogen induced

cracking) occurs at or near room
temperature and sometime may
occur hours or days after cooling.
Usually cracks start in base metal in
heat‐affected zone or may appear as
underbead cracks parallel to weld or
as toe cracks at edge of weld. Occurs
more often in steels than other
metals.
453
Welding Quality
have to consider:
• Welding discontinuity
454
Inspection and testing methods
A variety of inspection and testing methods are available to check the
quality of the welded joint. Standardized procedures have been
developed and specified over the years by engineering and trade
societies such as the American Welding Society (AWS).
Visual inspection is no doubt the most widely used welding inspection method.
An inspector visually examines the weldment for (1) conformance to dimensional
specifications on the part drawing, (2) warping, and (3) cracks, cavities,
incomplete fusion, and other visible defects.
Nondestructive test (NDT) includes various methods that do not damage the
specimen being inspected. Penetrant Inspection (PT), Magnetic Particle Testing
(MT), Ultrasonic Inspection (UT), Eddy Current Testing (ET) and Radiographic Test
( RT ) can be used.
Destructive testing methods in which the weld is destroyed either during the test
or to prepare the test specimen. They include mechanical and metallurgical tests. 455
Overview
Final
456
Surface processing
Surface cleaning: Industrial cleaning processes that remove oil and

• Chemical cleaning contaminants that result from previous processing
• Mechanical cleaning or the factory environment.
Surface treatment: Mechanical and physical operations that alter the

part surface in some way, such as improving its finish
• Carburizing
or impregnating it with atoms of a foreign material
• Nitriding
to change its chemistry and physical properties.
• Boronizing
• Shot peening
Surface coating: Processes that apply a layer of material to a surface.

• Electroplating
• Chrome plate
• Anodizing
• Galvanizing 457
Surface processing
Wear Corrosion
Fatigue
Surface treatment: Main objectives

• Carburizing
• Nitriding  Increase wear resistance
• Boronizing
• Shot peening  Increase fatigue resistance
Surface coating:  Increase corrosion resistance
• Electroplating
• Chrome plate  Appearance
• Anodizing
• Galvanizing 458

Welding and Surface Process

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Welding and Surface Process

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Overview

Friction Stir welding

Welding is a materials joining process in which two or more parts are

Welding process involves localized coalescence

principal zones typical grain structure

Recrystallization typical grain structure

Preheating and post weld heat treatment

Fusion welding Solid state welding

• Arc welding (AW) • Diffusion welding (DFW)

Some 50 different types of welding processes have been catalogued by the

Fusion‐welding processes use heat to

Some 50 different types of welding processes have been catalogued by the

Fusion welding Arc welding (AW): Arc welding refers to

Consumable electrodes provide the source of the

SMAW is an AW process that uses a consumable

Fusion welding Advantages Disadvantages

• Arc welding (AW) •

GMAW is an AW process in which the electrode is

Fusion welding Advantages Disadvantages

TIG is an AW process that uses a non‐consumable

‐ Tungsten Inert‐Gas Arc Welding (TIG)

Fusion welding Advantages Disadvantages

Resistance welding (RW): Resistance welding

OFW is operations that burn various fuels

Solid state welding

• Diffusion welding (DFW)

Friction welding (FRW): Coalescence

Solid state welding

• Diffusion welding (DFW)

Friction Stir Welding

• Residual stresses and distortion

• Inspection and testing methods

• Residual stresses and distortion

• Inspection and testing methods

Residual stress Warping

• Residual stresses and distortion

• Inspection and testing methods

o Design related: Undesirable changes in cross section

o Welding process Related: Undercut, Porosity etc.

o Design related: Undesirable changes in cross section

o Welding process Related: Undercut, Porosity etc.

o Design related: Undesirable changes in cross section

o Welding process Related: Undercut, Porosity etc.

• Improper welding parameters;

• Excessive welding currents

• Inadequate shielding gas flow.

o Design related: Undesirable changes in cross section

o Welding process Related: Undercut, Porosity etc.

Hot cracking occur immediately after welds are

Cold cracking (Hydrogen induced

• Residual stresses and distortion

• Inspection and testing methods

Surface cleaning: Industrial cleaning processes that remove oil and

Surface treatment: Mechanical and physical operations that alter the

Surface coating: Processes that apply a layer of material to a surface.

Surface treatment: Main objectives

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