3) Types of Welding Methods and Their Uses.

Welding is the manufacturing process of joining two or more similar or dissimilar metals by the application of heat,
with or without application of pressure and addition of filler material.
Welding is a fabrication process that joins materials by using high heat to melt the parts together and allowing
them to cool causing fusion. Today in each and every field welding is essential. There is no such metal left out
which cannot be welded.

Classification of Fusion welding processes :-

While joining by fusion welding processes, filler material can be applied during welding, if required. Due to the
application of external heat, this filler material melts down and deposits on weld bead to supply excess material
required for filling the root gap for obtaining a sound weld. It is to be noted that application of filler material is not
necessary, it is usually applied when sufficient root gap exists or edge preparation is conducted. According to the
application and nature of filler material, fusion welding processes can be grouped into three categories as follows.
A) Autogeneous welding B) Homogeneous welding C) Heterogeneous welding.

A) Autogeneous welding :- Autogenous welding is one way of performing fusion welding without the application of
external filler material.
Tungsten Inert Gas (TIG) and oxy-fuel welding processes can be performed in autogenous mode/way. Various
advanced welding processes, such as Plasma Arc Welding (PAW), Laser Beam Welding (LBW), Electron Beam
Welding (EBW), etc. are mostly autogenous.

B) Homogeneous welding :- Homogeneous welding is one way of performing fusion welding with the application
of external filler material whose metallurgical composition is almost same with that of the base metals. Thus in
homogeneous welding, filler material having composition same with that of the base metal is applied.
Manual Metal Arc Welding (MMAW), Gas Metal Arc Welding (GMAW), Flux Cored Arc Welding (FCAW), etc.
always use consumable filler material and thus can be performed in homogeneous mode.

C) Heterogeneous welding :-Heterogeneous welding is one way of performing fusion welding with the application
of external filler whose metallurgical composition is substantially different from that of the base metals. So if filler
material is applied during joining and the metallurgical composition of filler is different from that of the base metal
then it is termed as heterogeneous welding.
Brazing and soldering are common examples of heterogeneous joining. Manual Metal Arc Welding (MMAW), Gas
Metal Arc Welding (GMAW), Flux Cored Arc Welding (FCAW), etc. can also be performed in heterogeneous mode.

Differences between homogeneous and heterogeneous welding.

Homogeneous welding Heterogeneous welding

1 In this method, metallurgical composition of filler
material is identical with that of the parent
materials.
2 Similar metals can be joined by this process.
3 Melting point of filler is same with that of the
base plates.
4 Physical, chemical and mechanical properties of
weld bead are roughly same with that of base
metals.
5 Joints are susceptible to corrosion. Corrosion
resistance of the joint cannot be improved by
homogeneous welding.
6 Rate of expansion or contraction is
approximately same for molten filler and base
metals. So chance of crack formation is also
less.
In this method, metallurgical composition of filler
material is substantially different from that of the
parent materials.
Dissimilar metals can be joined by this process.
Melting points of two can be substantially different
and this factor should be carefully considered prior
to welding.
Properties of weld bead can be improved to
desired level by suitably selecting compatible filler.
Corrosion resistance of the joint can be enhanced
by heterogeneous welding. This is advantageous
for marine applications.
Unequal rate of contraction between molten filler
and base metals during solidification can lead to
residual stress generation and crack formation,
which are highly undesirable.

Udayachal High School

Mechanical Technology
Std 9 th Welding
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Types of welding:-
1) Fusion welding :- The material at the joint is heated to a molten state and allowed to solidify then it is known
as fusion welding. Fusion welding also known as Non Pressure welding.
For example :- Arc Welding, Gas Welding, MIG welding, Submerged Arc welding, Brazing.
Arc welding methods are as given below :-
a) Manual metalic arc welding b) Carbon arc welding c) Submerged Arc welding d) Metal inert gas welding.

2) Non Fusion welding :- The piece of metal to be joint is heated to a plastic state and then forced together by
applying external pressure then it is known as non fusion welding. Non Fusion welding is also known as pressure
welding. For example :- Forge welding, Resistance welding, Stud welding.

In industries, metals are joined by using following main methods: -

A) Mechanical method B) Thermal method

A) Mechanical method - In this method, two plates are joined together by using mechanical energy, not heat
energy. There are three types :- i) Riveting ii) Nut bolting method iii) Seaming / Hook folding method.

i) Riveting :- It is this method, two metal plates are kept one over the other, then clamped together and drilling is
done. Then same diameter rivets are inserted into drilled hole. By using Ball pein hammer, the shank of the rivet
is spread and forms the shape of the rivet. It is mainly used in manufacturing of railway coaches and thin sheets
of water tank.

ii) Nut bolting method :- In this method, two metal plates are kept one over the other, then clamped together and
drilling is done. Then same diameter bolts are inserted into drilled hole. Then metal plates are joined together by
using nut and bolt which is tightened with the help of spanner. This method is used for making structure of tower
for boiler, loose parts of engine and railway coaches etc.

Udayachal High School

Mechanical Technology
Std 9 th Welding
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iii) Seaming / Hook folding method :- In this method, plates with less thickness are joined together. The edge of
the plate is bent and then it is joined together by hammering operation. This is known as Seaming Joint. This
method is used for manufacturing of steel cupboards, lockers, water buckets, etc.

Advantages of Mechanical methods :-

1) Joint can be separated very easily.
2) No heating is done, so metals are not expanded or contracted.
3) We can join metals together of various properties.
4) The properties of metal can not change.

Disadvantages of Mechanical methods :-

1) It takes more time for joining.
2) For assembling the parts more labour is required.
3) This method is costly.
4) It provides less strength and appearance.
5) This is a temporary joint.

B) Thermal method :- In this method, the work pieces are joined together by using heat. There are four types.
i) Forging ii) Soldering iii) Brazing iv) Welding.
i) Forging :- In this method, metal plates are heated to a plastic state and then external pressure is exerted
manually or with power hammers, presses or special forging machines and then joined together. This is known as
forging. Metal is heated by using blacksmith furnace or by using oxy acetylene gas.
ii) Soldering :- Soldering is a process in which two or more parts are joined together by melting and putting a filler
metal in to the joint. The filler metal having a lower melting point than the adjoining metal.
Solder is the combination of lead and tin used in equal proportion. Small electronics and electrical components are
mounted on printed circuit board (PCB) by using soldering.
iii) Brazing :- Brazing is a metal joining process in which two or more metal items are joined together by melting
and flowing a filler metal into the joint. The filler metal having a lower melting point than the adjoining metal. Brazing
differs from welding in that it does not involve melting the work pieces. For this operation, brass filler rod is used
which is made from copper and zinc.
iv) Welding :- Welding is the manufacturing process of joining two or more similar or dissimilar metals by the
application of heat, with or without application of pressure and addition of filler material.
In arc welding method, electrical energy is converted in to heat energy and by using electrode, welding is done.
In gas welding method, oxygen and acetylene gases are burnt together and flame is generated. Then by using
that flame heat is generated and welding is done with the help of filler rod.

Exercise :-
1) State the classification of fusion welding.
2) What is an autogenous welding?
3) What is homogeneous welding?
4) What is heterogeneous welding?
5) Differentiate between homogeneous welding & heterogeneous welding.
6) Write a note on fusion welding.
7) Write a note on non fusion welding.
8) Write down different method used for metal joining.
9) Write down various types of metal joining processes by using mechanical method.
10) Write down various types of metal joining processes by using thermal method.
11) State the advantages of mechanical joint.
12) State the disadvantages of mechanical joint.
13) Define the following.
a) Forging b) Soldering c) Brazing d) welding.
Udayachal High School
Mechanical Technology
Std 9 th Welding
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