MDP252

ARC welding
Name ID
Seif Khaled Seif Elmolook Mohamed 21P0143
Ibrahim
Omar Alaa Eldin Mohamed 18P9390

May Fadl Helil 18P8064

Table of Contents
1. INTRODUCTION ............................................................................................................... 2
2. Types of welding. ............................................................................................................ 3
1) Fusion Welding: ......................................................................................................................... 3
2) Solid-state Welding: in ............................................................................................................... 3
3. Fusion welding: ............................................................................................................... 3
4. Types of fusion Welding processes: ................................................................................. 4
5. Arc Welding: ................................................................................................................... 5
6. The Different Electrodes Used in Arc Welding .................................................................. 6
7. Difference between TIG and MIG welding. .................................................................... 12
8. Conclusion:.................................................................................................................... 13
 1. INTRODUCTION

Welding is a process in which materials of the same fundamental type or

class are brought together and caused to join (and become one) through
the formation of primary chemical bonds under the combined action of
heat and pressure . The definition found in IS0 standard is “Welding is
an operation in which continuity is obtained between parts for assembly,
by various means”. Hence, the welding is the fusion of two or more
pieces of metal together by using the heat produced from an electric arc
welding machine. Arc welding dates back to the late 1800’s, when a
man was welding with a bare metal rod on iron, the sparks from the
welding caught a stack of newspapers on fire near him and while
welding, he noticed that his welds started looking a lot better. The
reason for this was the smoke took the oxygen out of its welding
environment and decreased porosity. The arc is struck between the
electrode and the metal. It then heats the metal to a melting point. The
electrode is then removed, breaking the arc between the electrode and
the metal. This allows the molten metal to “freeze” or solidify. The arc is
like a flame of intense heat that is generated as the electrical current
passes through a highly resistant air gap.
 2. Types of welding.

Welding processes divide into two major categories:

1) Fusion Welding: in which coalescence is accomplished by melting
the two parts to be joined, in some cases adding filler metal to the joint
2) Solid-state Welding: in which heat and/or pressure are used to
achieve coalescence, but no melting of the base metals occurs and no
filler metal is added.

3. Fusion welding:

Fusion welding processes are all those welding processes where

faying surfaces of parent part as well as filler material melt down
during welding for weld bead formation. So heat is always associated
with these processes. External application of pressure is not required
for these processes, except for resistance welding group where
substantial contact pressure needs to be maintained during welding
for sound joining. Filler material may or may not be applied.
 4. Types of fusion Welding processes:

• Arc welding processes

o Shielded Metal Arc Welding (SMAW)
o Gas Metal Arc Welding (GMAW)
o Tungsten Inert Gas (TIG) welding
o Submerged Arc Welding (SAW)
o Flux Cored Arc Welding (FCAW)
o Electro-Slag Welding (ESW)
o Electro-Gas Welding (EGW)
o Arc Stud Welding (SW)
o Carbon Arc Welding (CAW)
o Atomic Hydrogen Welding (AHW)
• Gas welding processes
o Air-Acetylene Welding (AAW)
o Oxy-Acetylene Welding (OAW)
o Oxy-Hydrogen Welding (OHW)
o Pressure Gas Welding (PGW)
• Resistance welding processes (many consider this as solid-state
welding)
o Resistance Spot Welding (RSW)
o Resistance Seam Welding (RSEW)
o Projection Welding (PW)
o Percussion Welding (PEW)
o Flash Welding (FW)
o Upset Welding (UW)
• Intense energy welding processes
o Plasma Arc Welding (PAW)
o Electron Beam Welding (EBW)
o Laser Beam Welding (LBW)

Advantages and Disadvantages of fusion welding processes:

Advantages

o Filler material can be applied easily. So a large lacuna can be

filled.
 o No need to apply external pressure, so primary shape of the
components does not matter (a suitable shape is required to
uniformly apply pressure).
o Joint design and edge preparation are not crucial as these
parameters affect only achievable penetration.
o More than two components can easily be welded at a step.

Disadvantages

o The process is associated with distortion and residual stress

generation as it involves melting and solidification.
o Palpable heat affected zone (HAZ) exists in the welded
components. HAZ is always considered as the weak portion
in welded assembly.
o Mechanical properties of parent materials are also severely
affected by intense heating.
o Joining dissimilar metals by fusion welding is challenging
task, especially if the metals have substantially different
melting point and coefficient of thermal expansion.

5. Arc Welding:

Arc welding is a type of welding process using an electric arc to create

heat to melt and join metals. A power supply creates an electric arc
between a consumable or non-consumable electrode and the base
material using either direct (DC) or alternating (AC) currents. The base
metal is melted, a filler material is typically added to the joint to form a
pool of molten material (the weld pool) that cools to form a joint. The
welding region is sometimes protectedby some type of inert or semi-
inert gas, known as a shielding gas, and filler material is sometimes used
as well. The arc length should be 2mm to 3mm, and beyond 4mm the
power supply cuts off.

6. The Different Electrodes Used in Arc Welding

The type of electrode used for an arc welding process is selected to

match the details of the specific method. Arc welding electrodes can be
grouped into two broad categories: non-consumable and consumable

i. Non-Consumable Electrode Methods

A non-consumable electrode does not meltdown on the weld pool. It
remains intact throughout the welding. The non-consumable electrode
does not supply filler. Thus, filler material is required to supply
separately.

1) TIG (Tungsten Inert Gas):

(TIG) welding is a process that produces an electric arc maintained
between a non consumable tungsten electrode and the part to be welded.
The heat-affected zone, the molten metal and the tungsten electrode are
all shielded from atmospheric contamination by a blanket of inert gas
fed through the GTAW torch. Inert gas (usually Argon) is inactive or
deficient in active chemicalproperties.

Fig – Tungsten Inert Gas Welding

The shielding gas serves to blanket the weld and exclude the active
properties in the surrounding air. Inert gases such as Argon and Helium
do not chemically react or combine with other gases. They pose no odor
and are transparent,
Permitting the welder maximum visibility of the arc. In some instances
Hydrogen gas may be added to enhance travel speeds. The GTAW
process can produce temperatures of up to 35,000° F (19,426° C). The
torch contributes heat only to the work-piece. If filler metal is required
to make the weld, it may be added manually in the same manner as it is
added in the oxyacetylene welding process. GTAW is used to weld
stainless steel, nickel alloys such as Monel and in conel, titanium,
aluminum, magnesium, copper, brass, bronze and gold. GTAW can also
weld dissimilar metals to one another such as copper to brass and
stainless to mild steel.

2) PAW (Plasma Welding)

Plasma welding is a method that strikes a plasma arc between the
electrode and base material and uses it for welding. It is classified as a
non-consumable electrode type and, as with TIG welding, it uses a
tungsten rod for the electrode. The difference is that it uses a nozzle to
cover the electrode and a plasma gas to prevent the arc from spreading.
The resulting high heat concentration enables high-speed welding with a
narrow bead and less distortion. Due to its highly directional arc, plasma
welding is suitable for fillet welds and can eliminate spatter. Its low
electrode consumption allows high-quality welding for a long time.
Although the welding machines are expensive compared to TIG welding
machines, the running costs are low. This is one of the best methods for
automatic welding.

The pilot gas (inert gas)

passes through the torch and
is ionized by the pilot arc
heat (plasma conversion).
The ionized pilot gas forms a
plasma jet, spouts from the
nozzle hole and acts as the
conductor for the arc current.
This narrows down the arc to
give it high energy density
and spout from the insert tip
hole. The spread of the arc is
limited to about one-fourth
that of TIG welding,
resulting in an arc with
higher current density.
Fig – Plasma Welding
ii. Consumable Electrode Methods

Electrodes are used in electric arc welding processes. the electrode is

used to produce the electric arc between the electrode and the metals to
be welded together, generating the heat with which to melt the base
metals. Consumable electrodes become part of the weld. The electrode
serves as the filler metal and melts along with the metals to be welded
together. the consumable electrode is the filler metal welding rod and
contains a flux that is used to produce a barrier to protect the weld from
any contamination.

1) SMAW (Shielded metal arc welding):

SMAW is the most common form of welding. An arc welding machine

supplies electric current to an electrode wire. The electric current travels
through the air gap between the end of the electrode wire and the base
metal. As the electric current flows through this air gap, an electric arc is
formed. The electric arc produces heat that heats the base metal to its
melting temperature. The heat from the base metal produces a shielding
gas that protects the base metal, arc, electrode, and weld from the
atmosphere during
the welding process.
As the flux covering
on the electrode wire
melts, a shielding gas
is created. When the
flux cools, it
solidifies and forms a
protective slag over
the weld bead. As the
electrode wire melts,
it becomes the filler
metal to the weld.
Fig -Shielded metal arc
2) GMAW (Gas Metal Arc Welding):

Gas Metal Arc Welding (GMAW) is a welding process which joins

metals by heating the metals to their melting point with an electric arc.
The arc is between a continuous, consumable electrode wire and the
metal being welded. The arc is shielded from contaminants in the
atmosphere by a shielding gas.

Fig.- Gas Metal Arc Welding

3) Electrogas arc welding (EGW)

Electrogas arc welding (EGW) is used for welding vertical butt joints of
products such as ship shell plates, bridges, storage tanks, and pressure
vessels. This page introduces the features of electrogas arc welding
(EGW), including the shielding gas, welding wire, and welding machine
structure.

Fig.- Electrogas arc welding

Applications of Arc Welding:

1. Maintenance and Repair: Arc welding is a versatile method

of performing repairs to metallic components. Not only can it
be used for repairing cracks or attaching patches, but it can
also be used for building up new material where there has
been excessive wear.
2. Ship Building: Arc welding is the fundamental construction
method used to join plate metal together with a watertight
seal.
3. Industrial Piping: Arc welding is used in workshops and in
the field to fabricate industrial piping runs of various
materials.
4. Vehicle Assembly: Large automated automobile assembly
plants use arc welding (typically MIG welding) to join the
various parts of the vehicle frame and other components
together.

Advantages:

• Versatility: Arc welding can be used to weld a wide range of

materials, including carbon steel, stainless steel, aluminum,
and alloys.
• Portability: Some arc welding techniques, such as SMAW,
are portable and can be used in remote locations or outdoor
environments.
• Cost-effectiveness: Arc welding equipment is relatively
affordable and widely available, making it accessible to
small-scale fabricators and hobbyists.
 Disadvantages:

• Skill requirement: Achieving high-quality welds with arc

welding techniques requires skill and experience.
• Limited automation: While some arc welding processes can
be automated, such as robotic welding in manufacturing,
others require manual operation, leading to lower
productivity in certain applications.
• Potential defects: Arc welding can introduce defects such as
porosity, slag inclusions, and lack of fusion if not performed
correctly or under improper conditions.

7. Difference between TIG and MIG welding.

TIG Welding MIG Welding

Advantages • No flux • No flux is used so no need to
• Speed welding clean.
• Used in both ferrous and non- • Produce very high-quality weld
ferrous welding • Weld zone is visible
• High-quality welding • No possibility of cracks.
• No weld cleaning is necessary • There is no frequent change of
electrode, so it is more
efficient.
• Easily automated.

Disadvantages • High cost • Weld surface must be clean

• Slow process and free from oil, grease, and
• A separated filler rod is paint.
required • On site welding is a difficult
one.
• Difficult to weld in small
corners
• Equipment is costly
• Less portable one
Applications • Welding of sheet metal and
thinner sections
• Precision welding in aircraft,
chemical and instrumental
industries.
• Used for most types of sheet
metal welding
• Fabrication of pressure vessels
and steel structures
• Automotive industry and home
improvement industry

8. Conclusion:
Arc welding is a versatile and widely used welding process with
applications across various industries. By understanding the principles,
techniques, applications, advantages, and challenges of arc welding,
manufacturers and welders can optimize their processes to achieve high-
quality welds efficiently and cost-effectively. Continued advancements
in welding technology and equipment are expected to further enhance
the capabilities and versatility of arc welding in the future.