Unit 4 (Welding Process)

Q1). Explain Submerged arc welding. Its definition, principle,

working advantages and disadvantages.
Ans. Submerged Arc Welding (SAW):

Definition: Submerged Arc Welding (SAW) is a welding process in which the arc is
generated between a continuously fed electrode, usually a solid or cored wire, and
the workpiece. The arc is submerged beneath a layer of granular flux, which shields
the weld zone from atmospheric contamination. The heat generated by the arc melts
both the electrode and the workpiece, creating a weld pool that solidifies into a
strong, high-quality joint.
Principle: The principle of Submerged Arc Welding (SAW) revolves around creating a
fusion weld by generating an electric arc between a continuously fed electrode and
the workpiece, all while being submerged under a layer of granular flux that creates a
protective atmosphere to shield the weld from atmospheric contamination

Working:

The working of Submerged Arc Welding (SAW) involves a systematic process to

create a high-quality fusion weld. Here's a step-by-step explanation of how SAW
works:

1. Electrode Feed:
 A continuous wire electrode is fed through a welding gun or torch. This
electrode is usually made of a solid or cored wire.
2. Flux Application:
 Before welding, a layer of granular flux is deposited over the area to be
welded. The flux covers the welding arc and the weld pool during the
process.
3. Arc Initiation:
 The electric arc is initiated between the tip of the continuously fed
electrode and the surface of the workpiece. This arc generates intense
heat.
4. Heat Generation and Melting:
 The heat generated by the electric arc is significant enough to melt
both the continuously fed electrode and the surface of the workpiece.
This results in the formation of a molten weld pool.
5. Flux Activation:
 As the arc penetrates the granular flux layer, the flux becomes
activated. The flux serves several purposes, including creating a
protective atmosphere to shield the weld from atmospheric
contamination, regulating the weld pool, and contributing alloying
elements to the weld metal.
6. Weld Pool Formation:
 The molten metal from the continuously fed electrode and the
workpiece combines in the weld pool. The controlled environment
provided by the flux ensures a clean and strong weld.
7. Solidification:
 As the molten metal cools, it solidifies to form a fused weld joint
beneath the layer of flux.
Applications:

1. Shipbuilding:
 Used for welding ship structures.
2. Pressure Vessels:
 Applied in the welding of large vessels.
3. Pipeline Construction:
 Commonly used for welding pipelines.
4. Heavy Machinery:
 Utilized in the fabrication of heavy equipment.
5. Railroad Construction:
 Used in welding railroad tracks and structures.
6. Steel Structures:
 Applied in the construction of bridges and industrial buildings.
7. Automotive Industry:
 Used for specific applications in vehicle manufacturing.

Advantages:

1. High Productivity: SAW is a high-deposition rate process, making it suitable

for welding thick sections in a single pass.
2. Deep Penetration: The process provides deep weld penetration, resulting in
strong and reliable welds.
3. Reduced Fume Emission: The flux layer produces a protective cover,
minimizing fume emissions and improving workplace safety.
4. Minimal Spatter: SAW typically produces minimal spatter, reducing the need
for post-weld cleanup.
5. Suitable for Long Welds: Well-suited for long, straight welds, such as those
found in the fabrication of pipes and vessels.

Disadvantages:

1. Limited to Flat Position: SAW is generally limited to flat or horizontal

welding positions, which may restrict its application in certain situations.
2. Equipment Complexity: The equipment for submerged arc welding can be
relatively complex and less portable compared to some other welding
processes.
3. Initial Setup Cost: The initial setup cost, including the welding machine and
flux handling equipment, can be relatively high.
4. Limited to Certain Materials: While suitable for a range of materials, SAW is
most commonly used for low-alloy steels and some stainless steels.
 Submerged arc welding is widely employed in applications such as shipbuilding,
heavy equipment manufacturing, and the fabrication of large structures due to its
efficiency and ability to produce high-quality welds.

Q2). Explain Resistance welding. Its definition, principle, working advantages

and disadvantages.

Ans. Resistance Welding:

Definition: Resistance welding is a group of welding processes that use the heat
generated by the resistance of the workpieces to electric current to produce a weld.
In this method, the workpieces are clamped together, and an electric current is
passed through them, causing localized heating and subsequent melting of the
materials at the welding interface.

Principle:

1. Workpiece Clamping:
 The workpieces to be welded are securely clamped together under
pressure.
2. Electric Current Application:
 An electric current is passed through the workpieces. The resistance to
the current flow generates heat at the contact points between the
workpieces.
3. Localized Heating:
 The heat generated is concentrated at the welding interface, causing
the metals to melt and form a weld pool.
4. Weld Formation:
 When the current is stopped, the molten metal solidifies, creating a
fused joint.

Working:

 Resistance welding includes various methods such as spot welding, seam

welding, and projection welding.
 The choice of method depends on factors like the type of joint, the material
being welded, and the production requirements.
Advantages:

1. High Speed and Productivity:

 Resistance welding is a rapid process, making it suitable for high-
volume production.
2. No Filler Material Required:
 Typically, no additional filler material is needed, reducing material
costs.
3. Localized Heat:
 Heat is applied precisely to the welding area, minimizing the heat-
affected zone and preserving material properties.
4. Good for Automation:
 Well-suited for automation and can be easily integrated into
production lines.
5. Consistent Weld Quality:
 Produces consistent and high-quality welds when performed under
controlled conditions.

Disadvantages:

1. Limited to Certain Materials:

 More suitable for welding certain types of metals and alloys, such as
carbon steels and stainless steels.
2. Thickness Limitations:
 Thickness of the materials being welded may be limited compared to
other welding methods.
3. Equipment Complexity:
 The equipment can be relatively complex and may require regular
maintenance.
4. Joint Accessibility:
 Limited flexibility in joint configurations and accessibility.
5. Initial Setup Cost:
 The initial investment in resistance welding equipment can be relatively
high.

Resistance welding is widely used in automotive, aerospace, and manufacturing

industries for its speed, efficiency, and ability to produce consistent welds. Proper
process control is crucial to ensuring weld quality, and the method is particularly
advantageous in mass production scenarios.
Q3). Explain Spot welding. Its definition, principle, working advantages and
disadvantages.

Ans. Spot Welding:

Definition: Spot welding is a type of resistance welding process where two or more
metal sheets are joined at specific points, or "spots," by applying heat and pressure.
This is achieved by passing an electric current through the sheets and using the
resulting resistance-generated heat to melt and fuse the metal at the contact points.

Principle: The principle of spot welding is rooted in the basic concept of electrical
resistance. The process relies on the generation of heat caused by the resistance
encountered when electric current flows through the interface of the metal sheets to be
joined.

Working: The working of spot welding involves a series of steps that utilize electrical
resistance to create localized heat, leading to the fusion of metal sheets at specific
points. Here's a detailed explanation of how spot welding works:

1. Workpiece Preparation:
 Two or more metal sheets are overlapped or placed in contact with
each other. The sheets to be joined should have clean and flat surfaces.
2. Electrode Application:
 Copper alloy electrodes are brought into contact with the metal sheets
at the desired welding spots. The electrodes serve as the conductive
medium through which the electric current flows.
3. Clamping:
 The metal sheets are clamped together under pressure. This clamping
ensures good contact between the electrodes and the workpieces,
facilitating efficient current flow.
 4. Electric Current Application:
 An electric current is passed through the electrodes and the metal
sheets. The resistance to the current flow at the contact points
generates heat.
5. Localized Heating:
 The heat generated is concentrated at the specific welding spots. This
localized heating causes the metal at the contact points to reach its
melting temperature.
6. Melting and Fusion:
 The molten metal from both sheets fuses together as it solidifies. This
process creates a metallurgical bond, forming a spot weld.

7. Cooling:
 After the current is stopped, the molten metal cools and solidifies
rapidly due to the clamping pressure. This ensures a quick and strong
bond.
8. Spot Formation:
 The solidified metal at the welding spots forms discrete points of
fusion, creating spot welds that securely join the metal sheets.

Applications:

1. Automotive Industry
 Vehicle body assembly
2. Sheet Metal Fabrication
 Appliances (e.g., refrigerators, washing machines)
3. Electronics and Electrical Industries
 Battery manufacturing
 Electronics device assembly
4. Aerospace Industry
 Aircraft components

Advantages:

1. High Speed and Productivity:

 Spot welding is a fast process, making it suitable for high-volume
production.
2. No Filler Material Required:
 Typically, no additional filler material is needed, reducing material
costs.
3. Localized Heat:
  Heat is applied precisely to the welding spots, minimizing the heat-
affected zone and preserving material properties.
4. Consistent Weld Quality:
 Provides consistent and reliable welds when performed under
controlled conditions.

Disadvantages:

1. Limited Joint Configurations:

 Spot welding is best suited for joining overlapping sheets, and it may
not be as versatile as other welding methods for complex joint
configurations.
2. Thickness Limitations:
 Best suited for thin to medium thickness materials; may not be suitable
for very thick sections.
3. Equipment Complexity:
 The equipment can be relatively complex and may require regular
maintenance.
4. Electrode Wear:
 The electrodes are subject to wear over time, requiring periodic
replacement.
5. Limited Joint Accessibility:
 Limited flexibility in joint configurations and accessibility.

Spot welding remains a widely used process due to its efficiency and speed,
particularly in industries where mass production of sheet metal assemblies is
common. Proper maintenance and process control are essential to ensure the quality
and consistency of spot-welded joints.
Q4.) Explain Seam welding. Its definition, principle, working advantages and
disadvantages.

Seam Welding:

Definition: Seam welding is a type of resistance welding process that produces a

continuous, leak-tight weld along the entire length of a joint. It is commonly used for
joining cylindrical or curved components by creating a series of overlapping spot
welds.
Principle: Seam welding operates on the principle of resistance welding, utilizing the
heat generated by the electrical resistance between the workpieces and electrodes.
As electric current flows through the electrodes and the overlapping metal sheets,
the resulting resistance produces localized heat. The continuous movement of wheel-
shaped electrodes along the joint melts and fuses the metal, creating a seamless
weld. This continuous welding process ensures a leak-tight and durable joint along
the entire length of the seam.

Working: The working of seam welding involves a continuous and automated

process for creating a leak-tight weld along the length of a joint. Here's a concise
explanation of how it works:

1. Workpiece Preparation:
 Two or more metal sheets are overlapped or placed edge to edge,
forming a joint.
2. Electrode Application:
 Wheel-shaped electrodes are applied along the length of the joint.
3. Electric Current Application:
 An electric current is passed through the electrodes and the
workpieces, generating continuous heat along the joint.
4. Continuous Welding:
 The electrodes move continuously along the joint, causing the metal to
melt and fuse. This process creates a seamless and leak-tight weld.

The continuous movement of the electrodes ensures a uniform and consistent weld,
making seam welding particularly suitable for applications where a continuous,
durable, and leak-resistant joint is essential.
Applications:
1. Automotive Industry:
 Used in the fabrication of vehicle fuel tanks, exhaust systems, and other
cylindrical components.
2. Metal Containers:
 Applied in the production of cylindrical metal containers, such as drums
and cans.
3. Pressure Vessels:
 Used in the manufacturing of cylindrical pressure vessels.
4. Pipes and Tubes:
 Seam welding is commonly employed in the production of pipes and
tubes.
5. Aerospace Industry:
 Used for joining cylindrical components in aircraft manufacturing.
Advantages:

1. Continuous Weld:
 Produces a leak-tight, continuous weld along the entire length of the
joint.
2. High Productivity:
 Seam welding is a rapid and efficient process, suitable for high-volume
production.
3. Automation:
 The process can be easily automated, increasing productivity.
4. No Filler Material Required:
 Typically, no additional filler material is needed.

Disadvantages:

1. Limited Joint Configurations:

 Seam welding is most effective for linear or circumferential joints and
may not be suitable for certain complex geometries.
2. Thickness Limitations:
 May have limitations for very thick materials compared to other
welding methods.
3. Equipment Complexity:
 The equipment can be relatively complex and may require regular
maintenance.
4. Electrode Wear:
 Similar to spot welding, the electrodes are subject to wear over time,
requiring periodic replacement.

Seam welding is a versatile process for joining cylindrical or curved components,

offering the advantages of continuous and leak-tight welding. Proper maintenance
and process control are essential for ensuring the quality of seam-welded joints.
Q5.) Explain Gas welding. Its definition, principle, working advantages and
disadvantages.

Gas Welding:

Definition: Gas welding is a welding process that uses the heat produced by a flame
obtained by burning a mixture of fuel gas and oxygen. It is a versatile process
suitable for various metals.

Principle:

1. Combustion Reaction:
 The fuel gas (e.g., acetylene) combines with oxygen in a controlled ratio
to create a high-temperature flame.
2. Heat Generation:
 The flame's heat is used to melt the edges of the metal pieces to be
joined.

Working:

 The fuel gas and oxygen are mixed in the correct proportions and ignited to
create a flame.
 The flame is directed onto the workpieces, causing them to melt.
 A filler rod may be added to the molten pool to facilitate the joining of the
metal.

Applications:

1. Metal Fabrication:
 Used in general metal fabrication for joining and cutting.
2. Repair Work:
 Suitable for on-site repair and maintenance tasks.
3. Artistic Welding:
 Applied in artistic welding for its precise control over heat.

Advantages:

1. Versatility:
 Can be used for welding, cutting, brazing, and heating.
2. Portability:
 Equipment is relatively portable, allowing for on-site applications.

Disadvantages:
 1. Limited Thickness:
 May not be suitable for welding thick sections.
2. Skill Requirement:
 Requires skill to control the flame and achieve quality welds.

Q6.) Explain oxy-Acetylene welding. Its definition, principle, working

advantages and disadvantages.

Ans. Oxy-Acetylene Welding:

Definition: Oxy-acetylene welding is a welding process that utilizes a flame

produced by the combustion of acetylene gas mixed with oxygen. This
versatile process is commonly used for joining metals and cutting, offering
a high-temperature flame for efficient heat generation.
Principle: Oxy-acetylene welding operates on the principle of controlled
combustion of acetylene gas mixed with oxygen. The precise combination
of these gases in the welding torch produces a high-temperature flame.
This intense flame is directed onto the workpieces, causing localized
melting. The addition of a filler rod facilitates the joining of molten metal,
forming a strong weld. The process is versatile, used for welding and
cutting various metals.

Working: The working of oxy-acetylene welding involves several steps:

1. Gas Mixture Preparation:

 Acetylene gas and oxygen are carefully mixed in the welding torch in
the correct ratios.
2. Ignition:
 The mixed gases are ignited at the torch tip, creating a high-
temperature flame.
3. Flame Adjustment:
 The flame is adjusted according to the specific welding or cutting
requirements. A neutral flame is often used for welding.
4. Heat Application:
 The intense flame is directed onto the metal surfaces to be joined,
causing them to reach their melting points.
5. Metal Fusion:
 The molten metal edges fuse together as the flame is moved along the
joint, creating a strong metallurgical bond.
6. Filler Rod Addition (Optional):
 A filler rod may be added to the molten pool to enhance the weld's
strength and ensure proper fusion.
7. Cooling:
 The welded joint is allowed to cool and solidify, forming a durable
weld.

The process offers flexibility in welding various metals and is adaptable for cutting
applications. Skill full control of the flame and proper technique are crucial for
achieving high-quality oxy-acetylene welds.

Applications:

1. Metal Joining:
 Used for welding ferrous and non-ferrous metals, including
Aluminium and stainless steel.
 2. Cutting:
 Suitable for metal cutting by directing the flame onto the metal
to create a localized oxidation reaction.

Advantages:

1. Versatility:
 Suitable for various welding and cutting applications.
2. Portability:
 Portable equipment allows for on-site use.
3. High Temperature:
 Produces a high-temperature flame, making it effective for
melting and joining metals.

Disadvantages:

1. Skill Requirement:
 Requires skill for precise control of flame and achieving quality
welds.
2. Limited Thickness:
 May not be suitable for welding very thick sections.
3. Safety Concerns:
 Acetylene is a highly flammable gas, requiring careful handling
and storage.
4. Gas Supply Dependency:
 Availability of acetylene and oxygen cylinders is necessary for
the process.

Oxy-acetylene welding is widely used in metal fabrication, repair work, and

other applications where a portable and versatile welding process is
needed. Proper safety precautions and skillfull operation are essential for
successful oxy-acetylene welding.