DILLA UNIVERSITY

COLLEGE OF ENGINEERING AND TECHNOLOGY

SCHOOL OF MECHANICAL AND AUTOMOTIVE
ENGINEERING
Department Of Mechanical Engineering
Manufactureing Engineering (MEng3092)
Group Assignment

Name of students. Id.No.

1.Wana Bulti..............................................................RNS-1492/20
2.Abraham Girma......................................................RNS-9438/20

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1)Discuss briefly with neat sketch on the following arc welding
processes that uses consumable and non-consumable electrodes.
Arc welding is welding using the heat of an arc as a heat source. In arc welding, positive voltage is applied to the
electrode (welding rod/wire) and negative voltage is applied to the base material. This makes an arc occur from
the base material to the electrode.

1.1.Shielded metal arc welding (SMAW)

SMAW is considered as one of the least efficient welding process because the operator’s factor of chipping away
slag and changing of worn-out electrodes during the process.

Figure 1.1
Welding Process
  Electric arc started by striking work with electrode.
  Heat of arc melts electrode and surface of base metal.
  Tiny globules of molten metal form on tip of electrode and transferred by arc into molten pool on
work surface.
  After weld started, arc moved along work.
 The electrode used in his process is consumable (a rod
covered with flux).
  The flux burns to form the protective layer/cover for the weld.
  The current type used in this process can either be AC or DC depending on the design of the
weld.
  Because of the versatility and simplicity of this process, it is most generally and widely used across
the world, it is mostly used for repair and maintenance in the heavy steel industry.
1.2.Submerged arc welding (SAW)
Submerged Arc Welding (SAW) is a joining process that involves the formation of an electric arc between a
continuously fed electrode and the workpiece to be welded. A blanket of powdered flux surrounds and covers
the arc and, when molten, provides electrical conduction between the metal to be joined and the electrode. It
also generates a protective gas shield and a slag, all of which protects the weld zone.
Submerged arc welding is an arc welding process in which heat is generated by an arc which is produced
between bare consumable electrode wire and the work-piece.

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 Figure 1.2
Welding processes
Submerged Arc Welding (SAW) is a joining process that involves the formation of an electric arc between a
continuously fed electrode and the workp iece to be welded. A blanket of powdered flux surrounds and
covers the arc and, when molten, provides electrical conduction between the metal to be joined and the
electrode.

1.3.Metel inert gas welding (MIG, GMAW)

MIG welding is an arc welding process that joins two metals together using a consumable wire electrode.

Metal Inert Gas (MIG) welding is an arc welding process that uses a continuous solid wire
electrode heated and fed into the weld pool from a welding gun. The two base materials are melted together
forming a join.The gun feeds a shielding gas alongside the electrode helping.

Figure.C.
What is MIG Welding?
 It is also known as Gas Metal Arc Welding.
 In Gas Metal arc welding,
If gas used is inert gas like Helium, Argon, then it’s called Metal Inert Gas (MIG) Welding.
If gas used is reactive gas like CO2, O2, then it’s called Metal Active Gas (MAG) Welding.
 It is a high deposition rate welding process.
 The metal wire is fed from a spool.
 This is a semiautomatic welding process.
 MIG welding is a gas shielded metal arc welding process using the heat of an electric arc between a
continuously fed, consumable electrode wire and the material to be welded.

Figure.1.3
MIG Welding Process

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 Metal is transferred through a protected arc column of inert gas to the work.
 A wire of copper coated mild steel is fed continuously from a reel through a gun with melting rate up to 5
m/min.
 Current through wire ranges from 100 to 400 A depending upon the diameter of wire.
 The welding machine is a dc constant voltage machine.

1.4.Tungsten inert gas welding (TIG, GTAW)

Gas tungsten arc welding (GTAW) uses a nonconsumable tungsten electrode that must be shielded with an
inert gas. The arc is established between the tip of the electrode and works to melt the metal being welded.
Gas tungsten arc welding
Gas tungsten arc welding (GTAW) is employed for welding thin section tube and sheet (up to about 7 mm wall
thickness) and for root runs (and second pass) in thicker products. Such joints may be completed using
processes with higher deposition rates, like GMAW, SMAW, SAW, FCAW, etc. GTAW offers a high degree of
control and usually gives a good quality root profile with mechanical and corrosion properties approaching
the base materials.

Figure 1.4
What is the process of tungsten inert gas welding?
Tungsten Inert Gas (TIG) Welding | Linde Gas
Tungsten Inert Gas (TIG) welding uses the heat generated by an electric arc struck between a non-
consumable tungsten electrode and the workpiece to fuse metal in the joint area and produce a molten weld
pool.

1.5.Plasma arc welding (PAW)

Plasma arc welding (PAW) is an arc welding process similar to gas tungsten arc welding (GTAW). The electric
arc is formed between an electrode (which is usually but not always made of sintered tungsten) and the
workpiece. The key difference from GTAW is that in PAW, the electrode is positioned within the body of the
torch, so the plasma arc is separated from the shielding gas envelope. The plasma is then forced through a
fine-bore copper nozzle which constricts the arc and the plasma exits the orifice at high velocities
(approaching the speed of sound) and a temperature approaching 28,000 °C (50,000 °F) or higher.

Arc plasma is a temporary state of a gas. Plasma arc welding PAW is a fusion welding process that uses a non-
consumable electrode and an electric plasma arc to weld metals.

Figure 1.5
The processes of the plasma arc welding.

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Plasma arc welding (PAW) is an arc welding process very similar to TIG welding as the arc is formed between
a pointed tungsten electrode and the workpiece. However, by positioning the electrode within the body of the
torch, the plasma arc can be separated from the shielding gas envelope.
The plasma welding process was introduced to the welding industry as a method of bringing better control to
the arc welding process in lower current ranges. Today, plasma retains the original advantages it brought to
industry by providing an advanced level of control and accuracy to produce high quality welds in miniature
or precision applications and to provide long electrode life for high production requirements.

2)Explain briefly the following Radiant Energy Welding processes.

Radiant energy welding is a type of welding process that uses radiant energy in the form of electromagnetic
waves, such as infrared, ultraviolet, or visible light, to provide heat for welding.

2.1.Electron beam welding (EBW)

Electron beam welding (EBW) uses a high-velocity beam of electrons to melt and fuse metals together. The
electron beam can be focused to create a small weld area, which makes it ideal for welding delicate parts or
complex designs. is a fusion welding process in which a beam of high-velocity electrons is applied to two
materials to be joined.

THE PROCESSES OF EBW

Electron beam (EB) welding is a fusion welding process whereby electrons are generated by an electron gun
and accelerated to high speeds using electrical fields. This high speed stream of electrons is tightly focused
using magnetic fields and applied to the materials to be joined. The beam of electrons creates kinetic heat as it
impacts with the workpieces, causing them to melt and bond together.

Electron beam welding is performed in a vacuum environment as the presence of gas can cause the beam to
scatter. Due it being a vacuum process and because of the high voltages used, this welding method is heavily
automated and computer controlled. As a result, specialised fixtures and CNC tables are used to move the
workpieces inside the welding vacuum chamber.

2.2.LASER BEAM WELDING (LBW)

Laser beam welding (LBW) is a welding technique used to join pieces of metal or thermoplastics through the
use of a laser. The beam provides a concentrated heat source, allowing for narrow, deep welds and high
welding rates.

THE PROCESSES OF LBW

The process is frequently used in high volume and precision requiring applications using automation, as in
the automotive and aeronautics industries. It is based on keyhole or penetration mode welding.

These are the generic steps in the laser welding process:

Clean the parts to be welded and position them accurately. The contact line should be closed and gap-free to
improve weld quality.
Use manual clamps or automated fixtures to hold parts in place and keep them stable during the welding
process.
Adjust the beam’s focal point onto the welding area. The optical gear in the welding torch usually provides for
easy adjustment of focus.
Adjust the beam power and test it on scrap material and trial parts. Before moving to the workpiece, make
sure it is putting out sufficient energy to melt the material but not enough to excessively heat parts.
Apply the beam at the start of the welding area. Once an appropriate melt pool has formed, it must be
traversed along the weld in a steady motion. Traditional welding techniques such as hot point rotation will
encourage good fusion and improve the weld quality.

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Cool the part naturally once the welding is complete. You can also quench it in water or use other cooling
methods.

3)Discuss on these most important types of resistance welding

processes.
Resistance welding, sometimes called electric resistance welding (ERW),is a process by which metals can be
joined together by applying pressure and conducting a strong electric current through the metal combination
to heat up the welding joint and melt the metals, forging them together.
There are many resistance welding processes with different uses, such as spot welding, seam welding, and
butt welding. Each one has a different specific welding application that makes it optimal for a particular
situation.

3.1. Resistance Spot Welding

Resistance spot welding has been used extensively in the automotive industry for the joining of steel and in
the aerospace industry for airframe components made from aluminium alloys. It is one of the oldest and
simplest forms of resistance welding, in which a weld nugget is produced by passing an electric current
between the two metal components whilst they are held together between electrodes, typically made from
copper-based alloys due to its superior conductive properties.

3.2. Resistance Butt Welding

Resistance butt welding is a process in which the two components of similar cross section can be joined
together in one operation that takes place simultaneously across the entirety of the affected object, rather
than just in small spots. The welding application of butt welding is often in wires and rods with small
diameter measurements, generally up to about 16mm diameter.

3.3. Resistance Seam Welding

Resistance seam welding is a variation of the standard spot welding form, however instead of spot one
nugget, a series of overlapping nuggets is produced. This is usually done by replacing the conventional spot
welding electrodes with wheels, which turn as the parts are fed between them. The process thus produces a
continuous welded seam rather than a single spot. Seam welding is often used in the production of thin sheet,
leak-tight containers such as fuel tanks, and is generally unsuitable for welding aluminium.