Hello!

I am Abhishek Punyani
I am here to give a presentation on welding
process.

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INTRODUCTION
TO
WELDING
PROCESSES
 1.
Basics of Welding
Let’s start with the first set of slides
 Welding process is easy

Last
First Second Remove
Adjust
Select current and
slag and
electrode pressure check the
weld

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 Basics of Welding
DEFINATION  In addition to melting the base metal,
 Welding is a filler material is typically added
a fabrication or sculptural process to the joint to form a pool of molten
that joins materials, material (the weld pool) that cools to
usually metals or thermoplastics, by form a joint
using high heat to melt the parts
together and allowing them to cool
causing fusion.

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 Many different energy sources can be
used for welding, including a
gas flame (chemical), an electric
arc (electrical), a laser, an electron
beam, friction, and ultrasound.
 While often an industrial process,
welding may be performed in many
different environments, including in
open air, under water, and in outer
space.

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Big concept

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Types of Welding processes

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Important types of welding

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 Components in Welding
 Suitable Electrrde
 Filler Material
 Electric supply
 Grounding material
 Wire Brush

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 Electrodes
 A welder needs an electrode to generate an electric current to do arc
welding. In welding, an electric current is conducted through an electrode
which is used to join the parent metals.
 When you keep electrode tip near the parent metal electric current
jumps from the electrode tip to the parent metal.
 These electrodes can be positively charged anode or they can be
negatively charged cathode.
 The standards for electrodes are fixed by American Welding Society

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American Welding Society(AWS)
standards

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American Welding Society(AWS)
standards

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 Types of welding electrode

Electrode

Consumeable non comsumeable

Bare Coated Tungsten Carbon or Graphite

electrode electrode electrode electrode

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Selection of
electrodes
Stick welding is a skill that takes
much practice to master, and
selecting the correct electrode for
the job can be equally challenging.
Stick electrodes are available in a
wide range of types, each of which
provides different mechanical
properties and operates with a
specific type of welding power
source. Factors you should consider
when selecting a stick electrode
include base metal type, joint fit-up
and welding positions.

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 Basic guidelines to select electrodes
Assess Your Base Metal Welding Current
The first step in Some electrodes can be
choosing an electrode is used with only AC or DC
to determine your base power sources while other
electrodes are compatible
metal composition. Your
with both. To determine the
goal is to match (or correct current type for a
closely match) the particular electrode, refer
electrode composition to the fourth digit of the
to the base metal type, AWS classification, which
which will help ensure a represents the type of
strong weld. coating and type of
compatible welding current
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Tensile Strength
To prevent cracking or
other weld discontinuities,
match the minimum tensile
strength of the electrode
to the tensile strength of
the base metal. For ex in
case of E6063 the minimum
tensile strength id 60,000
Psi
Welding current

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Types of welded joints

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Big concept

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 Why are electrodes shielded
(importance of flux)
 During welding, the flux material decomposes and produces fumes. These
fumes shield the molten weld pool from the atmosphere.
 In the absence of those fumes, molten weld pool will directly come in the
contact of atmosphere and may react with the oxygen present in the
environment and thus oxidation will take place, which is very dangerous
and may lead to failure
 Density of flux material is less than the weld material hence the flux
comes upwards and floats on the weld pool and hence protect the weld
pool.
 During solidification, flux material also solidifies and forms a thin layer
on the surface of weld called as slag.

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 Why are electrodes shielded
(importance of flux)

 This thin layer of slag helps in slow cooling of weld material.

 In the absence of this thin layer of slag, rapid cooling of molten weld
pool will take place which is very dangerous because rapid cooling
results in microstructural changes of weld metal

 Flux also helps in initiation of arc. Especially when welding is done in

AC (Alternating Current), polarity keeps on changing at a constant
rate.

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How should a perfect welded joint look
(slag is removed)

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 Safety and precautions
 Prevent Electric Shocks
 Protect Eyes, Skin & Ears
 Protect Against Fumes and Gases
 Protect Against Fire or Explosion
 Protect Against Flying Sparks and Hot Metal
 Protect Against exploding Cylinders
 Protect Against Injury

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 Safety equipment required
 Welding Helmets
 Other Eye and Face Protection
 Safety Glasses
 Gloves
 Body Protection
 Respirators
 Boots

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Underwater welders can earn
$100,000.00 to well over
$200.000.00 a year.
Whoa! That’s a big number, isn’t it?

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 More than 50% of all man made products
require welding. From the cars, planes and
trains that we travel about in, to the
buildings that we live and work in

The First Industrial Robot Was Made to

Weld

100%
Fun isn’t it!
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TIG Welding being performed on chromoly pipes

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Electrode arc welding
being done with proper
gear and safety
equipment

Place your screenshot here

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 Made By

Name :- Abhishek punyani

Roll number:- 1719240007
Year :- 3rd sec D
Branch :- Mechanical engineering
Submitted to:- Dr. Ambuj Saxena

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Thanks!
Any questions?

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