Welding Lecture 1 Welding Introduction

1-Welding Definition
Welding is a material joining process in which two or more parts are joined together at their contacting surfaces by a suitable application of heat and/or pressure. In some welding process a filler material is added to facilitate coalescence. Welding is most commonly associated with metallic parts but for plastics also it is used.
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Welding
Advantage: 1. Provides permanent joint. 2. The welded joint can be stronger than the parent materials . 3. The welding joint most economical method to join in terms of material usage and fabrication costs. Limitations: 1. Expensive in the terms of Labor costs (performed manually). 2. Dangerous because they involve the use of high energy. 3. Can suffer from certain quality defects that are difficult to detect.
2-Welding History
Thermit Welding (1903) Cellulosic Electrodes (1918) Arc Stud Welding (1918) Seam Welding of Tubes (1922) Mechanical Flash Welder for Joining Rails (1924) Extruded Coating for MMAW Electrodes (1926) Submerged Arc Welding (1935) Air Arc Gouging (1939)
Welding history
Inert Gas Tungsten Arc (TIG) Welding (1941) Iron Powder Electrodes with High Recovery (1944) Inert Gas Metal Arc (MIG) Welding (1948) Electro Slag Welding (1951) Flux Cored Wire with CO 2 Shielding (1954) Electron Beam Welding (1954) Constricted Arc (Plasma) for Cutting (1955) Friction Welding (1956) Plasma Arc Welding (1957) Electro Gas Welding (1957)
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Welding history
Short Circuit Transfer for Low Current, Low Voltage Welding with CO 2 Shielding (1957) Vacuum Diffusion Welding (1959) Explosive Welding (1960) Laser Beam Welding (1961) High Power CO 2 Laser Beam Welding (1964) All welded Liberty ' ships failure in 1942, gave a big jolt to application of welding. However, it had drawn attention to fracture problem in welded structures
3-Welding Applications
General Applications Welding is vastly being used for construction of transport tankers for transporting oil, water, milk and fabrication of welded tubes and pipes, chains, LPG cylinders and other items. Steel furniture, gates, doors and door frames, body and other parts of white goods items such as refrigerators, washing machines, microwave ovens and many other items of general applications are fabricated by welding. Pressure Vessels One of the first major use of welding was in the fabrication of pressure vessels. Welding made considerable increases in the operating temperatures and pressures possible as compared to riveted pressure vessels.
Welding Applications
Building Structures Aircraft and Spacecraft Railways Micro-Joining Electrical Industry: Nuclear Installations Defense Industry Electrical Industry: Nuclear Installations Defense Industry Micro-Joining
4-Type of welding joints
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Type of welding joints
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5-Types of Welds
A :inside single fillet corner joint B :out side single fillet corner joint C: Double fillet lap joint D: Double fillet tee joint
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Dashed lines show the original part edges

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Types of groove welds
A: Square groove weld one side B: Single bevel groove weld C: Single V groove weld
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Types of groove welds
D: Single U groove weld E: Single J groove weld F: Double V groove weld

Dashed lines show the original part edges
Types of Welds
A: Plug weld B: Slot weld
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Types of Welds
A: Spot weld B: Seam weld
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Types of Welds
A : Flange weld B: Surface welding
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Joint Configuration
Butt Weld
1= Groove Face 2= Root Opening 3= Groove Angle 4= Root Face 5=Plate thickness 6=Bevel Angle 3 6 4 5
1
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Joint Configuration
Parts of a butt weld
Toe of Weld both side
Weld Face
Face or Weld Reinforcement
Weld Root
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Joint Configuration
Parts of a butt weld
Weld Metal
Cap
Groove Faces
Base Metal
Heat Affected Zone (HAZ)
Root
6-Welding Classification (Types)

Types of Welding Processes I-Liquid state welding processes (Fusion). II-Solid state welding processes. III-Solid / Liquid state bonding processes.
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I-Liquid state welding processes (Fusion)

Use heat to melt the base metals. A filler metal is added. A fusion welding with no filler is referred to as autogenous weld. There are two inherent problems with fusion welding: Effect of localized heating and rapid cooling on the microstructure and properties of the parent metals. Effect of residual stresses developed in the parent metals due to restrained expansion or contraction. This effect the impact of fatigue life of weldment
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Liquid state welding processes (Fusion)
Examples
1. 2. 3. 4. Arc Welding (AW). Resistance welding (RW) . Oxyfuel Welding (OFW) . Other Processes:
(Electron beam welding and Laser beam welding.)
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1-Arc Welding (AW)

Heating of the metals with electric arc
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2-Resistance welding (RW)

Using heat from electric resistance to the flow of a current passing between the faying surface of two parts held together under pressure.
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3-Oxyfuel Welding (OFW)

Heating with a mixture oxygen and acetylene (oxyfuel gas).
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II-Solid state welding processes.

In solid state welding the surfaces to be joined are brought into close proximity by: 1. Heating the surfaces without causing melting and applying normal pressure. 2. Providing relative motion between the two surfaces and applying light normal pressure. 3. Applying high pressure without heating. In these processes the materials remain in solid state and welding is achieved through the application of heat and pressure, or high pressure only (No melting, No fillers ).
Solid state welding processes Examples

1. Friction welding (FW). 2. Diffusion welding (DFW). 3. Ultrasonic welding (USW ).
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1-Friction welding (FRW)

Coalescence is achieved by the heat of friction between two surfaces.
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2-Diffusion welding (DFW)

Two surfaces are held together under pressure at an at an elevated temperature and the parts coalesce by solid state fusion.
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Diffusion welding (DFW) is a solid state welding process by which two metals (which may be dissimilar) can be bonded together. Diffusion involves the migration of atoms across the joint, due to concentration gradients. The two materials are pressed together at an elevated temperature usually between 50 and 70% of the melting point. The pressure is used to relieve the void that may occur due to the different surface topographies.
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3-Ultrasonic welding (USW )

Moderate pressure is applied between the two parts with ultrasonic oscillating motion
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Ultrasonic welding
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III-Solid / Liquid state bonding processes

In these processes, the braze metal, solder, or an adhesive is applied to the joint in liquid state while the materials to be joined remains in a solid state, that is, they do not melt.
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7-Features of a fusion welded joint

Fusion zone Weld interface Heat affected zone (HAZ) Unaffected base metal (BM
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Regions of a Fusion Weld

Fusion zone (FZ) Weld interface Heat affected zone (HAZ) Unaffected base metal (BM)
FZ
HAZ
BM
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8-Welding Symbols
Examples: Single V Butt Weld
75 deg. groove angle
1/8
75 deg
75 deg
1/8
1/8 root opening
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WELDING SYMBOL
Staggered intermittent fillet weld
3
(3/8)
3-10 3-10
(3/8)
10 3/8
Fillet weld side view
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WELDING SYMBOL
Single V Groove
Double V Groove
Single Bevel Groove
Double Bevel Groove 3/29/2013 Prof.Dr.Adel M. abdelmaboud 42

Welding Lecture 1 Welding Introduction

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1-Welding Definition

4-Type of welding joints

Type of welding joints

Dashed lines show the original part edges

Types of groove welds

Types of groove welds

D: Single U groove weld E: Single J groove weld F: Double V groove weld

A: Plug weld B: Slot weld

A: Spot weld B: Seam weld

A : Flange weld B: Surface welding

Toe of Weld both side

Face or Weld Reinforcement

Heat Affected Zone (HAZ)

6-Welding Classification (Types)

I-Liquid state welding processes (Fusion)

Liquid state welding processes (Fusion)

(Electron beam welding and Laser beam welding.)

1-Arc Welding (AW)

2-Resistance welding (RW)

3-Oxyfuel Welding (OFW)

II-Solid state welding processes.

Solid state welding processes Examples

1-Friction welding (FRW)

2-Diffusion welding (DFW)

3-Ultrasonic welding (USW )

III-Solid / Liquid state bonding processes

7-Features of a fusion welded joint

Regions of a Fusion Weld

1/8 root opening

Fillet weld side view

Single Bevel Groove

Double Bevel Groove 3/29/2013 Prof.Dr.Adel M. abdelmaboud 42

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