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Edge Joint
Corner Joint
Welding processes
Fusion welding
Welding in the liquid state with no pressure
and union is by molten metal bridging
e.g: SMAW, GTAW,SAW,FCAW, MMAW ….
Solid phase welding
Carried out below the melting point without
filler additions. The pressure often used and
union is often by plastic flow.
e.g: Forge welding & Friction welding
WELD TYPES
BW- Butt-weld
SW-Socket weld
SOB-Set-on branch
RFD-Reinforced pad
1. Root gap
2. Root face
3. Bevel surface
4. Bevel angle
5. Included angle
6. Seam width
7. Thickness of the plate
Fillet Joint
1. Throat thickness
2. Leg length
3. Joint root
4. Joint edge
5. Joint surface
6. Fusion depth
7. Seam width
Butt weld & SW - Socket weld
.
Butt weld fittings
Socket weld fittings
.
WELDING POSITIONS
1F
2F
3F 1F 1G
4F
5F
1G 2F 2G
2G
3G
4G
3F
5G 3G
6G
4F 4G
.
.
1-G
2-G 6-G
6-G 5-G
WELDER QUALIFICATION
Qualified In
Tested on Test Details Plate & Pipe over Pipe 2x7/8” Fillet on
Plate 24”OD Groove to 24” OD pipe / plate
Groove
1G 1G 1G 1F
Test Position – 2G 1G,2G 1G,2G 1F,2F
Groove 3G 1G,3G 1G 1F,2F,3F
(ASME Sec.IX
4G 1G,4G 1G 1F,2F,4F
QW-461.9)
3G&4G 1G,3G,4G 1G ALL
2 G, 3 G & 4 G ALL 1G,2G ALL
1F - - 1F
Test Position – 2F - - 2F
Fillet 3F - - 3F
(ASME Sec.IX
4F - - 4F
QW-461.9)
3F&4F - - 3F&4F
Allied processes
Thermal cutting
Oxy-fuel gas, plasma, laser cutting
Gouging
Surfacing
Peak
temperatures
- Cathode
18000 K zone
Anode
zone Electric discharge between 2
electrodes through a gas
+
Fusion welding
This process involves the partial melting of the two members
welded in the join region. The thermal energy required for this
fusion is usually supplied by chemical or electrical means.
Work piece
Features of electrode coating
Shielding - decomposes to form gaseous shield for
molten metal.
Deoxidation - fluxing action removes oxygen and
other atmospheric gases.
Alloying - provides additional alloying elements
for weld deposit.
Ionizing - improves electrical characteristics to
increase arc stability.
Insulating - solidified slag provides insulating
blanket to slow down weld metal cooling rate.
Electrode classification as per
AWS
E XX XX - X
Electrode
Minimum Tensile Strength in thousands psi
Positions in which electrode can be used
Composition of the coating (determines operating
characteristics and recommended electrical current)
Minimum content of alloying elements for low
alloy steels only.
POWER SOURCES
Shielded metal arc welding
process Fig : Schematic illustration of the shielded
metal-arc welding process ( also known as
stick welding, because the electrode is in
the shape of a stick).
Inert
Torch gas
Tungsten lead (-)
electrode
Torch Power
Collet
source
Ceramic Gas lens
shroud (optional)
Arc
Filler
Weld metal
Work
Weld pool lead (+)
Process features
Stable arc at low power (80A at 11V)
Independently added filler
Ideal for root runs in pipe or thin sheet
Low productivity 0.5kg/h manual
Clean process, no slag
Low oxygen and nitrogen weld metal
Excellent profile even for single sided welds
Gas Metal-Arc Welding
and
THEIR CAUSES
AND PREVENTION
Definition of Discontinuity
In welding the main objective is to obtain sound, defect-
free welded joints.
Normal welds may contain imperfections
which cause some variation in the normal average
properties of the weld metal. These are called as
discontinues.
Definition of Defects
Whenever such discontinuities exceeds the limit
specified by engineering design, those are called as
defects.
Defects are caused by the following
reasons :