Content

Classification of fabrication(joining) process Different types of welding

Gas welding
Principle, equipment Different type of flames

Arc welding
Manual metal arc welding/Shielded metal arc welding Inert gas arc welding (GTAW or TIG process, GMAW or MIG) Submerged arc welding Plasma arc welding

Resistance welding
Spot Seam Projection

Some other welding processes

Fabrication Processes
Some products cannot be manufactured as a single piece. The desired shape and size of such products can be obtained by joining two parts of same or different materials. These parts are manufactured individually and are joined together to obtain the desired product.
For example, aircraft and ship bodies, welded machine frames, furniture, computers, bridges and the transmission or electric towers etc., are all fabricated by joining several different parts.
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Classification of joining processes: Temporary Joint Permanent Joint A temporary joint can be easily dismantled separating the original parts without any damage to them In case it is a permanent joint, an attempt to separate the parts already joined will result in the damage of the parts. In a permanent joint, the joint is made such that it has properties similar to the base metal of the two parts. These parts cannot be separated into their original shape, size and surface finish
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Based on the process used for making the joint, the joining processes can be further classified as: Mechanical Fasteners bolts-nuts, rivets, screws Adhesive bonding Welding, Brazing, Soldering The choice of a particular joining process depends on several factors such as application, nature of loads or stresses, joint design, materials involved and size and shape of the components

WELDING
Welding is one of the most extensively used fabrication method. The joint strength obtained in welding is being equal to or some times more than that of the parent metal. It is not only used for making structures, but also for repair work such as the joining of broken castings. Welding is a process of metallurgical joining of two pieces of metals by the application of heat with or without the application of pressure and addition of filler metal. The joint formed is a permanent joint. It is extensively used in the fabrication work in which metal plates, steel sections, castings of ferrous metals are joined together. It is also used for repairing broken, worn-out or defective metal parts.
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Modern methods of welding may be classified under two broad headings. Plastic or pressure welding process Fusion or non-pressure welding process In plastic or pressure welding process the pieces of metal to be joined are heated to a plastic state and then forced together by external pressure. This procedure is used in forge welding, resistance welding, spot welding in which pressure is required. In the fusion or non-pressure welding, the material at the joint is heated to a molten state and allowed to solidify. This includes gas welding, arc welding
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STEPS OF WELDING PROCEDURE 1. Surface Cleaning: Surfaces of the parts to be welded need to be thoroughly cleaned to remove dust, dirt, oil, grease etc. 2. Edge Preparation: Preparing a contour at the edges of the pieces to be joined. It may involve beveling or grooving. This is done in order to get the fusion or penetration through the entire thickness of the member. 3. Clamping: Pieces to be welded are clamped suitably so that there are no undesirable movements during welding.
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4. Initial Weld: Initial tack welds are done at the opposite corners of the joint to secure the pieces together. Any cracks at this stage must be removed as they cause residual stresses. 5. Intermediate and Final Welding: The weld joint is formed through various weaving movements (weld beads). During this process, filler metal and a suitable flux are used. After the intermediate run of welding, final run is taken. 6. Removal of Excess Material: Extra material on the weld surface can be removed using tongs and chipping hammer. The weld is allowed to cool and then cleaned.
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Classification of welding processes:

(i). Arc welding Carbon arc Metal arc Metal inert gas Tungsten inert gas Plasma arc Submerged arc Electro-slag (ii). Gas Welding
Oxy-acetylene Air-acetylene Oxy-hydrogen (iv).Thermit Welding (v).Solid State Welding

Friction Ultrasonic Diffusion Explosive

(vi).Advanced Welding process Electron-beam Laser (vii).Related Process Oxy-acetylene cutting Arc cutting Hard facing Brazing Soldering

(iii). Resistance Welding Butt Spot Seam Projection Percussion

GAS WELDING Gas welding is a fusion welding process. The flame produced by the combustion of gases is employed to melt the metal. The molten metal is allowed to flow together thus forming a solid continuous joint upon cooling. By burning pure oxygen in combination with other gases, in special torches, a flame up to 33000C can be attained. In oxy-fuel gas welding (OFW) the heat is obtained from the combustion of a fuel gas such as acetylene in combination with oxygen.

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Oxy-acetylene Gas Welding Equipment

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Oxy-acetylene Gas Welding Equipment

1. 2. 3. 4. 5. Welding torch & tip An acetylene cylinder:15.5 bar, red or maroon An oxygen cylinder: 125 bar, blue or black Pressure regulator: control flow/pressure of gases Pressure gauge: shows cylinder pressure and gas working or delivery pressure 6. Rubber hoses: black/green hose for oxygen & red/orange hose for acetylene 7. Safety devices: Goggle with coloured glasses, hand gloves, helmet, apron, sleeves, shoes etc.

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The oxy-acetylene flame is used to pre heat the parts to be welded around the joint and also to melt the filler metal. A jet of oxy acetylene flame issuing from the nozzle of a burner is played on the junction of the two pieces to be welded. At the same time a filler rod is held in the zone of jet and its melt is deposited on the fused junction. A weld is obtained after the molten metal solidifies. The coating on the filler rod acts as a flux to keep the joint clean.

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GAS WELDING FLAMES (OXY-ACETYLENE FLAMES)

Neutral Flame

1. Neutral Flame: (Gas ratio is 1) A certain amount of oxygen is required for complete combustion of fuel gases. When the oxygen supply varies, the flame appearance obtained would also vary. In neutral flame all the acetylene present is completely burned and thus all the available heat in the fuel gas is released. This is the most desirable flame to be used in oxy-acetylene welding. Due to neutral flame no chemical change and no oxidation in molten metal. This is desired for most welding operations. Used for welding steel, stainless steel, cast iron, Cu etc.

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2. Carburizing or Reducing Flame: ( Gas ratio 0.95 to 1)

Excess of acetylene is present, Low temp flame. The excess unburnt carbon is absorbed in ferrous metals, making the weld hard and brittle. An intermediate flame feather exists - reddish in colour. The length of the flame feather is an indication of the excess acetylene present. Carbonizing flame is used for welding high carbon steels and cast iron, alloy steel. Since this flame provides a strong reducing atmosphere in the welding zone, it is useful for those materials which are readily oxidize like oxygen free copper alloys.

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3. Oxidizing Flame: (Gas ratio 1.15 to 1.5) Excess of oxygen is present, similar to the neutral flame Inner white cone is some what small, giving rise to higher tip temperatures. Excess of oxygen causes the metal to burn/oxidize quickly. Desirable for welding only brass because a thin layer of slag forms over the molten metal. Widely used for oxyacetylene cutting and not suitable for welding since the weld metal will be oxidised.

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Advantages of Oxy-acetylene Gas Welding 1.The equipment is inexpensive, simple and is easily portable. 2.Useful for welding light metals such as automobile bodies and repair works. 3.A large variety of material can be welded. 4.Welds can be produced at reasonable cost. 5.Compared to electric arc welding this provides greater flexibility with respect to heat impact and cooling rates.

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Disadvantages of Oxy-acetylene Gas Welding

1. It is much slower than electric arc welding and does not concentrate the heat close to the weld. Thus, the heat treated area is larger, which causes more distortion. 2. If electric arc welding is available gas welding is seldom used for work over 3.2mm thick. 3. The process is not satisfactory for heavy sections 4. Highly skilled operators are required to produce a good weld. 5. Equipment should be handled carefully as in certain circumstances acetylene is explosive.

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Applications of Oxy-acetylene Gas Welding:

For joining of thin materials. For joining materials in whose case excessively high temperature or rapid heating and cooling of the job would produce unwanted changes in the metal. For welding both ferrous and non-ferrous metals. In automotive &aircraft industries, project site works, workshops etc.

Other Gas Welding

Oxygen-Hydrogen Welding The oxygen-hydrogen torch can reach temperatures much higher than the oxy-acetylene torch. More expensive than oxy-acetylene welding and involves the flammability risk with hydrogen. Plasma Welding Hydrogen plasma burns even hotter than hydrogen gas, permitting the welding of extremely high-melting-point metals. Very clean procedure that results in very little slag or foreign matter in the weld.

Gas Cutting
Iron and steel get oxidised when it is heated to a temperature between 800 to 10000 0C When a high pressure oxygen jet with a pressure of the order of 300 KPa is directed against a heated steel plate, the oxygen jet burns the metal and blows it away causing the cut
This process is used for cutting steel plates of various thicknesses (up to 2 m) mainly because the equipment required is simple and can be carried anywhere without handling the heavy steel plates. The torch tip has a provision for preheating the plate as well as providing the oxygen jet. Thus the tip has a central hole for oxygen jet with surrounding holes for preheating flames