Metal works

Welding- a fabrication or sculptural process that joins material, usually metals to become
one.

Golden Death Mask of tut-ench-amun

Welding was used in the construction of the Iron Pillar in delhi India, erected about 1600
years ago and weighing 5.4 metric tons.

98% Iron
1% Vajra - sanghata- in iron pillar

Until the end of the 19th century, the only welding process was forge welding, which
blacksmiths had used for centuries to join iron and steel by heating and hammering them.

History of welding

The discovery of the production of an arc between two carbon electrodes using a battery is
credited to chemist Sir Humphry Davy in 1800.

Welding, was transformed during the 19th century. In 1802, Russian scientist
Vasily Vladimirovich Petrov, created the stable electric arc, which enabled metal workers to
melt metals.

From this many other forms, including current forms, have been born including:

1. Carbon arc welding

2. Alternating current welding
3. Resistance welding
4. Oxyfuel welding

3 welding process

● Welding arc
● Filler metal
● Shielding

World l and ll caused a major surge in the use of welding processes with various military
powers attempting to determine which of the several new welding processes would be best.

What is similar to welding?

Soldering and brazing which involve melting a lower melting-point material between the work
pieces to form a bond between them, without melting the work pieces.

Types
1. Plastic welding or pressure welding
Ex. resistance welding

2. Fusion welding or Non pressure welding

Ex. Gas welding, arc welding

Arc welding
● Uses an electric arc to coalesce metals
 ● Arc welding is the most common method of welding metals
● Electricity travels from electrode to base metal to ground
● A welding generator (D. C) or Transformer (A.C)
● Electrodes holder
● Electrode
● Protective shield
● Gloves
● Wire brush
● Chipping hammer
● Goggles

MIG- Metal Inert Gas

TIG- Tungsten Inert Gas
Tungsten electrode acts as a cathodes

Metalworking- is the process of forming and shaping metals to create useful tools, object,
equipment parts.

Materials used for metalworking include ferrous and non-ferrous metals such as steel,
aluminium, gold, silver, bronze, iron.

Metalworking has been a way for civilizations to communicate status, religious belief, and
symbolism.

Metal ores have been extracted from the earth for thousands of years, placing great
importance on metalworkers as the source of extricating metals.

Metalworking techniques- create everything from small decorative objects to large scale
structures.

Cutting- removes material from metal using milling, routing, turning, and CNC (computer
numerical control)

Joining- is the process of combining several pieces of metal with heat through welding and
soldering. Methods welding, soldering, brazing

Forming- is the process of re-shaping and fabricating metal objects without adding or
removing any material. This process is possible through a combination of heat and pressure.
Both forging and bending are essential methods for forming metal.

The english wheel is a tool that allows metalworkers to easily form and shape cold material,
such aluminium or steel.

Metal Casting- is the process that can be traced back to around 4000 BCE, and still used for
making sculptures, tools, and jewelry.

Methods
Lost wax casting- involves carving or shaping your piece in wax, creating a plaster mould
around it.
Sand casting- uses sand as the mold material, such as clay and is gated.

Milling- is the process of removing precise amounts of material from a great piece.
Mill and lathe are the cornerstones of any machine and can produce pieces with great
precision.
Turning- is a machining process in which a cutting tool moves linearly while the workpiece
rotates, strategically removing material from the piece.

Grinding- uses an abrasive process to remove material from the workpiece, typilly in the
finishing stages of metalworking.

Drilling- creates holes in metal using drill press, handheld drill.

Soldering- is another method for joining metals by melting a filler metal on top of the metals
being joined to make a reliable electrical bridge. First type of welding

Riveting- are permanent mechanical fasteners that can create kinetic joints.

Reshaping and manipulating the shape of metal can be done when the material is hot or
cold.

Forging- is one of the oldest metalworking processes used to form and shape metal.

Roll Forming- is a process that involves the continous bending of a long strip.

Rolling- is a metal process in which metal stock is passed through a rolling mill to reduce the
thickness or to make the thickness uniform.

● Hot rolling- is typically used to produce sheet metal and larger workpiece.
● Cold rolling- works well for smaller objects.

Welding Metals: Types and Properties

There are several considerations when selecting a metal for welding. this includes:
● Melting Point
● Ductility- how the metal reacts to bending, stretching.
● Electrical conductivity- effects what the metal can be used for
● Strength- what is the breaking point of a metal.

Types of Welding Metalss

1. Steel
● It is an alloy that contains iron and 2% of other materials.
● It is also versitile and can be used with any welding process.
2. Stainless Steel
● This achived by adding 10% to 30% chromium to other elements such as
iron.
● There is also a nickel alloy available.
● Stainless is welded using arc welding (TIG, MIG, or Stick)

3. Aluminum
● Isn’t as corrosive as other metals
● It is lighter than stainless steel
● In welding, pure aluminum and alloys are used.
 ● GTAW welding (TIG), GMAW (MIG) aluminum is the preferred arc welding
method as it produces the best result.

4. Copper
● Is popular due to its electrical conductivity, heat conductivity, corrosion
resistance, appearance and wear resistance.
● 99.3% minimum copper content.
● Process used in welding include, welding, brazing, and soldering.
● Copper is welded using Gas Tungsten Arc Welding (TIG) and GMAW
● Copper is preheated, however, copper alloy do not need to be preheated due
to high levels of thermal conductivity.

5. Cast Iron
● In terms of welding metals, low carbon steel is easier to weld than cast iron.
● Cast iron has higher carbon and silicon content, and is not as ductile.
● Cast iron is welded with oxy acetylene welding.

6. Nickel Alloy
● Nickel Alloy 141
● Nickel Alloy 61
● Nickel-Copper Alloy 190
● Nickel-Copper Alloy 60

7. Magnesium
● Magnesium alloys are lightweight (⅔ of aluminum)
● It absorbs vibration and easy to cast
● It has a melting temperature similar to aluminum and is welded in a similar
way.
● The metal is welded with TIG welding

Welding Safety Equipment & Protective Clothing

Types of Welds & Joints

The most popular weld is the fillet weld, named after its cross-sectional shape.

Types of Joints
● Butt joint
● Corner joint
● Edge joint
● Lap joint
● Tee joint

Types of welds

Fillet welds- joins two surfaces at an approximate right angle to each other.
● Full fillet weld- is a weld where the size of the weld is the same as the thickness of
the thinner object joined together.
 ● Staggered intermittent fillet weld- refers to two lines of intermittent welding on a a
joint. ex. tee joint
● Chain Intermittent fillet weld- refers to two lines of intermittent fillet welds in a lap joint
or T where the welds in one line are approximately opposite those in other line.

Terms associated with fillet welds

Boxing- which refers to the continuous of a fillet weld around a corner of a member.
Convexity- refers to the maximum perpendicular distance from the face of a convex
fillet weld to a line joining the weld toes.

Groove weld
● Second most popular type of weld.
● The groove weld refers to beads that are deposited in a groove between two
members to be joined.
Basic groove welds
1. Square groove weld 5. Flare v groove weld
2. Single v groove weld 6. Flare bevel groove weld
3. single bevel groove weld
4. single u groove weld

Surfacing weld- composed of one or more strings or weave beads deposited on a unbroken
surface.

Plug weld- are circular welds made through one member of lap or tee joint joining that
member to the other.

Slot weld- made in elongated hole in one member of a lap or tee joint exposed through the
hole. This hole may be open at one end may be partially or completely filled with metal.

Flash weld- is referred to as a resistance welding process where fusion is produced over the
entire abutting surface.

Seam weld- made by arc seam or resistance seam welding where the welding process is not
specified.

Spot weld- made by arc spot or resistance spot welding.

Upset weld- is a resistance welding process where fusion occurs progressively along a joint
of over the entire abutting surface. Heat comes from the resistance to the flow of electric
current.

4 Main types of welding processes

1. MIG Welding (GMAW)

● the shielding gas comes from a pressurized bottle of inert gas
● the shielding gas for MIG is usually carbon dioxide
● speed is an issue or you're a beginner or you need to keep the heat down,
MIG welding is the best process.
 2. TIG Welding (GTAW)
● It is difficult to process to master.
● It takes more knowledge, dexterity, time and experience.
● But it pays off with better , more beautiful and stronger weld.
● the main way TIG differ from other processes is its electrodes. The electrodes
in the torch is a short tungsten rod, sharpened to a point.
● used in places where strong and clean welds are needed.
● some structures made by TIG welding is aircraft frames, electric devices, high
-end electronics cabinetry.

3. Stick Welding (SMAW)

● came first, and its the simplest concept
● it has the oldest, simplest, and most proven technology.
● has a power source and big cables leads with an electrode holder
● It works well on steel, cast iron, aluminum, stainless, and hard surfacing on
farm equipment.
The diameter of the welding rod varies according to the thickness of the metal. Welding rods
are covered with a thick coating of a material called flux .

4. Flux Cored Arc Welding (FCAW)

● Also known as gasless MIG welding
● Highly versatile process for low cost, easy learning, and strong results.
FCAW-S- The S means self shielded and its the common flux core technique because its
inexpensive, simple and effective in a breeeze.
FCAW-G- also known as dual shielded wire weldingthe G means external shielding gas use
in addition to the standard flux core wire.

Inverter vs. Transformer

The main difference is that an inverter welding machine is significantly more efficient and
lighter. But transformer welding machines are reliable in the long run and better suited to
harsher conditions.

Transformer Welding- don’t use advanced technology to reduce the core size.

History of transformer
● The first transformer based welders appeared in the early 1900s
● until the 1920s and 1930s that transformer welders saw actual adoption

How does a transformer work?

Transformer welders use a step down transformer. This simple technology takes high
voltage, low amperage current and reverses it into low voltage , high amperage current.

The transformer core encompasses three parts:

1. Primary coil- connected to the main input voltage from the power supply
2. Secondary coil- connected to the welding leads
3. Core- magnetic field produced in the primary coil and secondary coil.
Inverter welding- use modern technology to improve efficiency and reduce the machines
weight drastically.

How does an Inverter welder work?

Inverter welders works by increasing the power input frequency fromm 5550Hz to 20, 000-
100,000Hz.

Generator for welding