PERO 0 SO OI BO i NES. Oo monbrs SNaURONE Y Introduction : It is discovered by “Sir Humpery Davy” in 1801. Defination of welding : Welding is a process in which two edges of similar or dissimilar metals are fused together with are without pressure the corresponding fitter metal of the some or different alloy metal to make singular joint. Application of Welding : Ship Building Railway construction Bridge construction Machine tool equipments Structural work Air craft construction Military or air equipment Manufacture of Boiler Pressure vessels & tanks Petrol, Diesel & Water pipe line Advantages of Welding : A good weld is strong on the Base metal. It is a permanent tight joint. It can be done quickly. Welding equipment not very costly. Portable welding equipments easily available. Large number of metal can be joint or Welder. Disadvantage of Welding : Welding gives out harmful radiation & spatters. Welding results in residual in stresses and distort. Edge preparation of the job is required before welding. Classification of Welding processes : S.M.A.W. : Shielded Metal arc welding C.A.W. : Carbon arc welding G.M.A.W. : Gas Metal arc welding G.T.AW. : Gas tungston arc welding M.M.A.W.: Manual metal arc welding S.A.W. : Submerged arc welding . PAW. : Plasma arc welding F.C.A.W. : Flux cored arc weldinga Qaonre _ S.A.W. : Stud arc welding. : | CLG, : Tungston innert gas welding. . MLG. : Metal innert gas welding. . MAG. : Metal added gas welding. . O.A.G.We: Oxy-Acetylene gas welding. S.W.G. ; Standard wire gauge. A.W.S: : American welding society. A.S.M.E. : American society for mechanical engineers. LWS. : Indian welding society. LB.R. : Indian boiler regulation. BLS. : Bureau of Indian standard. Gas Welding : Oxy-Acetylene gas welding (OAGW) Temp. - 3300°C Oxy-Liquefied Petroleum gas welding (OLPGW) Temp. - 2700°C Oxy-Hydrogen gas welding (OHAW) Temp. - 1600°C. Oxy-Propane gas welding (OPGW) Temp. - 1200°C Arc welding accessories/Equipments : Electrode holder: A device used for mechanically holding the electrode & conducting current. It is made of copper/ Alloy for better electrical conductivity. Welding cables : This are used to carry the welding current from the welding machine to work & back. It is made of cop- per flexible wire. Hand screen Helmet : This are used to protect the eye & face of welder from the spatter, spark & radiation during welding hand screen is designed to hold in hand, helmet is designed to were in head. Chipping hammer : It is used to removed to the slag from the weld bead. It is made of medium carbon steel. Wire Brush : It is used for any cleaning the working surface of the jobs after welding. Safety clothes : Apron : It is used to protect the front body of welder. Hand glove : It is used for wearing in hand. Safety shoes : Protected the feet of welder from metal spatters. Cap : It is used to protected head & the welder. Hand sleeves : It is used: to protect the arms of the welders.1 A.C. welding transformer - s SMAW — Shielded Metal Are Weldin ELECTRODE BLECTRODE | ELECTRODE LEADBe B) ii) c) POSM®NAUAwWDYH ARC WELDING MACHINES % Types of Welding Machines : A) AC Transformer : This type of AC welding machine which converts AC main supply in AC welding supply. Or its take power directly from the mains & transfer it to the voltage current required for welding. There are two types of AC transformer. Oil cooled transformer. ii) Air cooled transformer. Oil cooled transformers main voltage.: min.30amp & max. 240amp. Air cooled transformers main voltage: min. 25amp & max. 300amp DC Generator : this type of welding machine which convert AC main into DC welding supply. There are two types of DC Generator : i) Motor set - which works on electrical supply. Diesel set - which works on diesel. It has min. 25 voltage & max. 240 voltage and min. 0 Amp & max. 600 amp. i ii) AC/DC Rectifier : welding rectifier set is used to convert AC welding supply into DC welding supply. “ Safety precautions + Always welding in a dry area. Ventilation properly. Avoid breathing welding fumes Wear protecting clothing. Do not work with wet gloves or wet shoes. Avoid looking to arc with necked eyes. Use properly insulated holder. Protect your eyes while chipping the slag. Earth welding machine correctly & check cable connections. Avoid excessive welding current. Follow proper welding procedures.% SLENTER punew RRR aE. BR re MPSA See eS e ese} 2 TRY sguaceDifferent between AC Transformer & DC Generator. DC Generator Capital cost is more. Maintanance cost is high. Polarity is available. Bare & flux coated electrodes can be used. Ferrous & non ferrous metal can be welded. ( Al.,copper,silver) AC Transformer Capital cost is less. Maintanance cost is less. No polarity available. Only flux coated electrode can be used. Only ferrous meatal can be welded. (m.s, s-s) POnn Beye a a Care & Maintenance + Transformer & Generator body must be properly earthed. Machine always keep in dry floor. ly on its minimum capacity. Do not run the machine continuous! Do not change the current when welding is going on. Switch off the main supply of the machine while cleaning. Transformer must be change after recommended period. Aas oye _¢ ‘Common Tools + 1. Steel rule/Scale : It is used for measuring length & marking out as metric marking from 0 mm to 300 mmon one side & other side is British unit marking is 0 inch to 12 inch. 2. Center Punch : It is used to1 mark point on the work piece for further operation like, _ Drilling, Filing, Cutting & Chipping or it is used for marking dots on 1 jobs. | 3. Try square/right angle : It is used for check the squarness (in 90") of the job. _ Satiber: It is used for marking outline on metals. used for marking out cles & half circle on metals. is used for straightening of the metals press & aus h. ing and chipping out metals, s Us ed for holding job of work pieces. for Holding hot work pieces & holding pieces etal is done with the help of le It is used for removing metal from the outer surface & to make the metal pieces surfaces square. 7g. £' CLAMP eESEEE ‘TAPARI( : TAPARIA 4 | . Wa TNT ae nkI, STRAIGHT POLARITY. ELECTRODE HOLDER a (EARTH CABLE 2. REVERSE POLARITY + ELECTRODE HOLOER LL RK ARTH CABLE } Pee* Polarity + Polarity indicates direction of current flow. Direct current al- ways flow form the positive (+) pole to the negative (-) pole. Types of polarity 1. Straight polarity : In straight polarity the electrode holder is connected to the negative(-) & the earth cable is connected to the positive(+) pole of the power source or machine. Straight polarity used for (A) welding the thick section of the to obtain more fusion & penetration. (B) Welding with bare & coated electrode. "2. Reverse polarity : In Reverse polarity electrode holder is con-. nected to the positive(+) pole and earth cable is connected to the negative(-) pole of the power source or machine. Reverse polarity used for (A) Welding of non-ferrous metal (ss, Brass, Copper etc). (B) Welding of cast iron (C.1.). (C) Sheet metal. (D) Welding with heavy coated electrode. % Types of Joints ¢ 1. Butt joint 2. Tee joint 3. Lap joint 4. Corner joint 5. Edge joint 1. Butt joint : If the joint between to edges is known butt joint. Types of butt joint : i. Square butt joint (Plate thickness 1 mm to 6 mm) Single “V” butt joint (Plate thickness 6 mm to 20 mm) Double “V” butt joint (Plate thickness 15 mm to 45 mm) Single bevel butt joint (Plate thickness 20 mm to 35 mm) Double bevel butt joint (Plate thickness 20 mm to 55 mm) Single “J” butt joint (Plate thickness 25 mm to 60 mm) Double “J” butt joint (Plate thickness 35 mm to 75 mm) Single “U” butt joint (Plate thickness 35 mm to 75 mm) ix. Double “U” butt joint (Plate thickness 50 mm & above) 2. Tee joint : It is the joint between surface and edge is known as Tee joint. Type of Tee joints : : i, Square edge Tee joint (Plate thickness 4 mm to 25 mm) i Single “V” Tee joint (Plate thickness 25 mm to 70 mm) ene Double “V” Tee joint (Plate thickness 35 mm & above)' oa 25 toBrem. ROOT lqaeas Sigmon QuaRe BUTT J é “SINGLE ( oe DOINT 2. SINGLE “Y' BUTT JOINT. Fe Leas Roar ence | |5 61 BUTT ONIN, re | | oor enees hover, aes ROOT GAP D5 GLE “U* BUTT JOINT 9. DOVELE "U' BUTT JOINT ¥ (Nd: f e i Ea Se En Kon bree ONT 1 SQUARE EDGE TEE yoInT i SEE CEeeeeeeee Seer {SINGLE -y" TEE oT iLAP. JOINT- \SINGLE _FULLET LAP JOINT | ¢ _3 r ANER JOINTJ:SHORT ARC LENGTH f fe zim C00 Flax mateotal Pion niti LEC TRODE s YB Hs | 2. MIDIUM ARC LENGTH G15, ELECTRODE 3. LONG ARC LENGTH i3. Lap joint : It is the joint between two surfaces. It’s called lap joint. Types of Lap joints : i. Single fillet Lap joint . ii. Double fillet Lap joint.+ 4. Corner joint : It is the joint between two edge/corner it is called corner joint. Types of corner joints : Open corner joint. Close corner joint. Half edge corner joint. @ ; Causes Remedies [ 1. Arc length is too long. 1. Use good quality job/ metal, 2. Rusty job/unclean job. 2. Use proper welding cur-| L3 Welding current is too low. rent. “ Incomplete penetration : if the penetration is not come from the back side of root gap then it called incomplete penetration. Causes Remedies 1. Inproper joints. 1. Make. perfect joint. 2. Too large root face. 2. Make correct root face. 3. Root gap too small. 3. Use proper root gap. 4. Less arc current. 4. Perfect welding current. 5. Faster arc travel speed. 5. Proper travel speed. 6. Too large electrode diameter.| 6. Use suitable electrodes. Cracks : A hairline separation exhibits in the root or middle run of the weld metal. Causes Remedies Fast cooling. Use too high current. Over heating of the job due to continuous welding. 1. Job keep in open space for| slow coooling. 2. Use proper current. 3. Don’t weld continuously. 2 ’ Slag inclusion : intrapped in a weld metal. Slag or other non metallic foreign material Causes Remedies Too high or low current. Too large electrode diam- eter. Wrong arc length. In sufficient chipping and cleaning. = 1. Use proper current. 2. Select correct electrode. 3. Use proper arc length. 4. Clean properly. —2. OVER LAPING OVER LAPING* Effect of Long arc length : = Unstable arc. Poor fusion and penetration. More spaters. Oxidation of filler metal Poor control on melting metal Wastage of electrode metal *% WELDING DEFECTS “+ External Defects 2. Internal Defects External defects : The defects which accures on the surface of plate are welding metal and are visible are called external defects. Example : a) Spatters b) Crack c) Porosity d) Undercut E) Overlap Internal defects : The defects which are not visibly directly but they are visible after graphic test are called internal de- fects. Example : a) Slag inclusion b) Crack Undercut : A groove gets'formed in the parent metal along the si of weld bead. That known undercut. Causes Remedies 1. Too high current. 1. Use proper current. 2. Welding speed is too fast. 2. Use correct welding speed. 3. Wrong electrode manipula-| 3. Use proper electrode ma-| tion. nipulation. 4. Long arc length. 4. Use correct arc length. 5. Too large electrode diameter.| 5. Use proper electrodes. % Excessive reinforcement : Metal deposited more than 3mm above the surface of the job or base metal. It is called exessive reinforcement. Causes Remedies 1. Too less current. 1. Use proper current. 2. Wrong welding techniques. | 2. Use correct welding tech-| niques.4. INCOMPLITE .PENETRATION + _INCOMPLITE PENETRATION 5. CRACKS 6. SLAG INCLUSION firma th a | 7, SPATTERS“ -Spatters ; Small metal particles which are through out of the are during welding around the weld. Causes Remedies . Welding current is too high 1. Use proper current . 1 2. Long arc length. 2. Medium or correct ar¢ length. 3. In proper flux ingredients. | 3. Make sure the flux ingredi-| ents is perfect. 4. Dump electrodes. 4. Use good quality electrode. * Over laping : An over lap occurs when the molten metal from -.. > the electrode flows over the parent metal surfaces and re- mains their without gating properly fused. Causes Remedies 1. Lower arc current. 1. Use perfect current. 2. Slow arc travel speed. 2. Proper are travel speed. 3. Long arc. 3. Medium arc length. 4. In correct electrode diam-| 4. Always use suitable diam-| eter. eter electrodes. ..% “Distortion : Causes Remedies 1. In proper bead sequence. 1. Use proper bead sequence, 2. In proper set up. 2. Make proper set up 3. Excessive welding size. 3. Make welding in correct size| “ Lack of fusion : Causes Remedies _] I. In proper travel speed. 1. Use correct trave speed. 2. Welding current is too low. 2. Proper current. 3. Wrong electrode angel. 3. Make sure the electrode angel is correct. 4. Wrong electrode diameter. | 4. Use suitable electrodes.“ Magnetic Arc blow : Remedies Unbalanced magnetic field . Use ulternating current. during the welding. . Reduce welding curren Excessive magnetisum in and length. parts or fixture. . Change the location of the] connection on the work. ~ Effect of defects Weakness of the strength of the weld. Consumes more electrodes. Poor weld appearance. Waste of material. Thickness of base metal is reduced. GiB @ Nie__OXY-Acy GAS WELDING TRO.* [OXY-ACETYLENE GAS CUTTING] ~ > Gas Cutting : The process involves preheating the plate or Pipe to its igrition temperature with a mixture of fuel gases and then using oxygen as a cutting gas. As the basis for cut- ting is only the chemical reaction between oxygen and iron. Gas cutting equipment : Oxygen gas cylinder. (Oxygen press, 2500 Sq./ inch) Acetylene gas cylinder. (Acetylene press 500 pound Sq. /inch) Acetylene pressure regulator. Acetylene pressure regulator. Oxigen gas hose (Blue/Beak) Acetylene gas hose (Red) Cutting torch. Nozzle. Gas lighter... . 10. Trolly for the transportation. 11. Spindle key. 12. Spanner. 13. Pressure adjuster. 14. Hand gloves & goggle. 15. Acetyline gas is very danger gas. PHN AMALYH YS 1. Oxygen pressure regulator : This is use to pressure and ac- cording to the require welding pressure and control the flow of oxygen of the constant rate to the blow pipe. The thread connection are right hand | thread. Acetyline pressure regulator : This is used to reduce acetyline der gas pressure and according to the require welding cylin: 3 w of acetyline at the constant rate pressure and control the flo to the blow pipe. The thread connection are Jeft hand i thread. . Type of regulator 1. Single stage regulator. 2, Double stage regulator. . =SINGLE STAGE REGULATOR PRESSURE GAUGE INLET >RENE Se \ . Single stage regulator : When a spindle of the cylinder open slowly the high pressure gas from the cylinder caters in to the valve then gas infers the body of regulator which in control by the need valve. The pressure insulates that regulator tiset which pushes the diaphrom and the valve to which if is at- tached. Parts : Diaphrom Mechanism rod. Gauge (store working) Adjustor. Double stage Regulator : When the spindle of the cylinder open slowly the high pressure gas from cylinder cutis the first valve the gas then into the body regulator which is control by needle valve the pressure inside the regulator dither which push the diaphoom valve to which if is attached. Gas welding : In gas welding the faces to be joined are heated locally with gas flame and when the edges turn into liquid and joined the process is knows as fusion welding. Sometimes additional metal is added to the joint by melting a metallic rod called filler wire. Brazing : In brazing the filler material is dispersed over the closely fitted surfaces by the capillary attraction only. The filler material is generally composed of copper and zinc with flux powder. Soldering and brazing are joining process, where parts are joined without melting the base metals. Soldering filler metals melt below 840° F. Brazing filler metals melt above 840° F. Soldering is commonly used for electrical connection or me- chanical joints. Brazing is used only for mechanical joints. .2. ROOT FACE 4 RooTeaP | a NZ}. : Lm —o| presse | ROOT FACE ae 3B. Root | | Root _ | t 4, PENE TRATION 6. ROOT RUN Es |S \ PENETRATION LROOT RUN.~ Cutting Data Metal thickness Nozzle size Oxygen Preesure (in) Inch. mm. |[LBS/SQ. 1/32 1/8-1/4| 3-6 15 - 20 3/64 1/4-3/4] 6-19 | 20-30 1/16 3/4-4 | 19-100 | 30-60 5/64 4-6 | 100- 150] 60 - 65 3/32 6-8 | 150-200] 65-70 7/64 8-10 | 200 - 250] 70-75 1/8 10 - 12 | 250 - 300] 75 - 80 Note : Acetylene Pressure for all thickness 2to5LBS/O OR 0.14 to 0.35 KGS/SQ. CM. “% WELDER DEFINATION * . Root gap : It is the distance between parts to be jointed. Root face : The surface formed by squaring of the root edge of the fusion face to avoid burning sharp edge at the root. Root : The parts to be jointed that a nearest together. Penetration : The depth of fusion zone in the parent metal. Parent metal : The material or the part to be joined. , Root ran : The material or the part to be joined. Run : The metal deposited during one pass. Ne SS PikWELDING POSITIONS F FILLET WELDS FLAT POSITION HORIZONTAL VERTICAL POSITION GVERHEAD POSITION of POSITION aF 2F Nanas of Wels 7x Axis of Weld “axis of Weld ‘Anis of Weld Hevizontal Horizontal Vertical Honzontal GROOVE WELDS FLAT POSITION HORIZONTAL VERTICAL POSITION | OVERHEAD POSITION 1G 43 Plates and Axis Plates and Axis Plates vertical ana Piates Horizontal of Pipe Horizontal of Pipe Vertical Axis of Pipe Vertical TEST POSITION HORIZONTAL FIXED TEST POSITION HORIZONTAL 2G 5G 6 ” . 7 ' oF Rolled by | Axis of Pipe Vertica! While Welding* _ Position : _1. Flat: 1G, Flat position Butt joint 1F Tee Lap. Horizontal : 2G, Horizontal position Butt joint 2F - Tee. Vertical : 3G, Vertical position Butt joint 3F - Tee. Overhead : 4G, Over head position Butt joint, 4F - Tee. Pipe welding position : 1G - Root position 2. 2G - Fixed pipe fixed position horizontally. La 5G - Pipe 180° fixed. 4. 6G - 45° pipe fixed osition. te pip’ Pp roy (alolst f_QUTT FOU JOINT Te her 2 2. LAP JonT FLUX:COATING +i) G- GROOVE F- FILLET RODE 6 /BARE WIRE a S TEE Jointenre ba GEO E & * | ELECTRODE | Type of flux coating electrode : Cellulose electrode. Code no - E6010, E601 1,E7010, E7011. Low hydrogen electrode. Code no - E701/8, E7016. Rutile type electrode (Titania). Code no - E6012, E6013, E7013, E8013. ron powder electrode. Code no - E6027, E6024. Selection of electrode : According to the type of welding joint. According to the type of welding position. Properties of base or job metal. According to the welding current (AC/DC). Production offering. * Current conditions + iT a re | Metal thickness] Size of electrode | Length of electrodd Curren? — . Range | (m.m) (m.m) | SWG | (m.m) | Inch. | (AMP) 1.6 2.00 14 300 12 30-60 1.6 2.50 12 350 14 60-85 3.2 3.15 10 350 14 85-120 3.2 3.15 10- 450 18 85-1204 10 4.00 8 350+ 14 120-1757 10 4.00 8 450 18 120-175 12 5.00 6 450 18 160-240 30 6.00 4 450 18 {230-300 © - 6013 dia 3.15 mm - Length - 350 mm E - 7018 dia 2.5 mm - Length - 350 mm E - 7018 dia 3.15 mm - Length - 450 mm G - Groove : Butt joint Yo F - Fillet ; Lap joint 2. Tee joint 5. Comer Joint. -