Course Contents

 Metal Casting
 Foundry, sand casting, Die casting, permanent mold casting etc.
 Forming and Shaping of Plastic and Composite
 Compression/Transfer/Injection molding etc.
 Forming and shaping of metals
 Rolling, Forging, Extrusion, Forming, Drawing, etc.
 Metal Cutting
 Lathe, Milling, Shaper, Planner, Drilling, Tools, Grinding etc.
 Joining Processes and Equipments
 Temp/Perm joining, Welding, Soldering, Brazing, tec.
 Surface Treatment and Coating
2
 3

FUNDAMENTALS OF
WELDING
Chapter 30
 Joining and Assembly
4

 Joining
 welding, brazing, soldering, and adhesive bonding
 These processes form a permanent joint between parts
 Assembly
 mechanical methods (usually) of fastening parts together
 Some of these methods allow for easy disassembly, while others do not
 Welding
5

 Joining process in which two (or more) parts are coalesced at

their contacting surfaces by application of heat and/or pressure
 In some welding processes a filler material is added to
facilitate coalescence
 The assemblage of parts that are joined by welding are called
Weldment
 Advantages
6

 Provides a permanent joint

 Welded components become a single entity
 Welding joints can be stronger than joining material depending
upon the filler metal
 Usually the most economical way to join components in terms of
material usage and fabrication costs
 Mechanical fastening usually requires additional hardware components
(e.g., screws and nuts) and geometric alterations of the parts assembled
 Not restricted to a factory environment
 Welding can be accomplished "in the field"
 Limitations and Drawbacks
7

 Most welding operations are performed manually and are

expensive in terms of labor cost
 Most welding processes utilize high energy and are inherently
dangerous
 Welded joints do not allow for convenient disassembly
 Welded joints can have quality defects that are difficult to
detect
 Welding
8

 The part surfaces in contact or close proximity that are being

joined are called “Faying surfaces”
 Welding involves localized coalescence of two metallic parts
at their faying surfaces
 Welding is usually performed on parts made of the same
metal, but some welding operations can be used to join
dissimilar metals
 Types of Welding Processes
9

 Some 50 different types of welding processes have

been catalogued by the American Welding Society
(AWS)
 Welding processes can be divided into two major
categories:
 Fusion welding
 Solid state welding
 Fusion Welding
10

 Joining processes that melt the base metals

 In many fusion welding operations, a filler metal is
added to the molten pool to facilitate the process
and provide bulk and added strength to the welded
joint
 A fusion welding operation in which no filler metal is
added is called an “Autogenous Weld”
 Fusion Welding Processes
11

 Arc welding
 melting of the metals is accomplished by an electric arc
 Resistance welding
 melting is accomplished by heat from resistance to an
electrical current between faying surfaces held together
under pressure
 Oxyfuel gas welding
 melting is accomplished by an oxyfuel gas such as acetylene
 Solid State Welding
12

 Joining processes in which coalescence results from

application of pressure alone or a combination of heat
and pressure

 If heat is used, temperature is below melting point of

metals being welded
 No filler metal is added in solid state welding
 Some Solid State Welding Processes
13

 Diffusion welding
 coalescence is by solid state fusion between two surfaces
held together under pressure at elevated temperature
 Friction welding
 coalescence by heat of friction between two surfaces
 Ultrasonic welding
 coalescence by ultrasonic oscillating motion in a direction
parallel to contacting surfaces of two parts held together
under pressure
 Principal Applications of Welding
14

 Construction - buildings and bridges

 Piping, pressure vessels, boilers, and storage tanks
 Shipbuilding
 Aircraft and aerospace
 Automotive
 Railroad
 Welder and Fitter (Arc welding)
15

 Welder
 manually controls path or placement of welding gun
 Often assisted by second worker, called a fitter,
who arranges the parts prior to welding
 Welding fixtures
 Positioners
 The Safety Issues
16

 Self study!!!
 For info

 Because of hazards of manual welding, and to

increase productivity and improve quality, various
forms of mechanization and automation are used
 Machine welding
 Automatic welding

 Robotic welding
 The Weld Joint
17

 The junction of the edges or surfaces of parts that

have been joined by welding
 Two classifications related to weld joint:
 Types of joints
 Types of welds used to join the pieces that form the joints
 Five Types of Joints
18

 Butt joint
 Parts lie in same plane and are joined at their edges
 Corner joint
 Parts in a corner joint form a right angle and are joined
at the corner of the angle
 Lap joint
 Consists of two overlapping parts
 Tee joint
 One part is perpendicular to the other in the
approximate shape of the letter "T“
 Edge joint
 Parts in an edge joint are parallel with at least one of
their edges in common, and the joint is made at the
common edge(s)
 Types of Welds
19

 Each of the preceding joints can be made by welding

 Other joining processes can also be used for some of
the joint types
 There is a difference between joint type and the way
it is welded - the weld type
 Fillet Weld
 Groove Weld

 Plug/Slot Weld

 Flange Weld
 Fillet Weld
20

 Used to fill in the edges of plates created by corner, lap, and

tee joints
 Filler metal used to provide cross-section in approximate shape
of a right triangle
 Most common weld type in arc and oxyfuel welding
 Requires minimum edge preparation
 Can be single/double and continuous/intermittent

inside single fillet Outside single fillet double fillet lap double fillet tee
corner joint corner joint joint joint
 Groove Welds
21

 Usually requires part edges to be shaped into a

groove to facilitate weld penetration
 Edge preparation increases cost of parts fabrication
 The grooved shapes include square, bevel, V, U, and
J, in single or double sides
 Most closely associated with butt joints
Groove Welds

Square groove weld Single bevel groove Single V-groove weld

one side weld

Single U-groove weld Single J-groove weld Double V-groove weld

for thicker sections
 Plug/Slot weld
23

 Attaching flat plats

 Case???
Spot/seam weld
 A small fused section between surfaces of two
sheets or plates
 Used for lap joints
 Most closely associated with resistance welding
 Flange weld
25

 Weld on the edge of two or more parts

 Surfacing weld
26

 Not a joining process

 Deposit the filler material on base part (one or
more beads)
 Increase thickness or to provide protective coating
 27

WELDING METHODS AND

PROCEDURES
Chapter 31
Two Major Categories of Welding

 Fusion welding
 Examples: arc welding, resistance spot welding, oxyfuel gas
welding

 Solid state welding

 Examples: forge welding, diffusion welding, friction welding

28
Arc Welding (AW)
 A fusion welding process in which coalescence of the
metals is achieved by the heat from an electric arc
between an electrode and the work

29
Electric Arc
 An electric arc is the discharge of electric current across a gap
in a circuit
 To initiate the arc in AW, electrode is brought into contact with
work and then quickly separated from it by a short distance

30
Arc Welding (AW)
 Electric energy from the arc produces temperatures ~ 10,000
F (5500 C), hot enough to melt any metal
 Most AW processes add filler metal to increase volume and
strength of weld joint
 Same basic process also used in arc cutting

31
Arc Welding
 A pool of molten metal is formed near electrode tip
 As electrode is moved along joint, molten weld pool solidifies
in its wake

32
Manual Arc Welding and Arc Time

 Problems with manual welding:

 Weld joint quality
 Productivity

 Arc Time = (time arc is on) / (hours worked)

 Also called “arc-on time”
 Typical values:
 Manual welding arc time = 20%
 Machine welding improves arc time to ~ 50%

33
Arc shielding
 At high temperature, metals are v reactive to Oxy, Hyd, Nit, etc.
which can degrade the weld quality
 AS is accomplished by covering the electrode tip, arc and
molten metal pool with a blanket of gases, flux or both
 Common shielding is done by inert gases

34
Arc shielding (Flux)
 Flux is a substance used to prevent the formation of
oxides and unwanted contaminants
 Provides protective atm for welding
 Stabilize the arc

 Reduce spattering

 The flux melts and becomes liquid slag during

welding (removed with brushing or chipping)

35
Arc shielding (Flux)
 The method of flux application include
 pouring granular flux onto the welding operation
 using a stick electrode coated with flux material in which the
coating melts during welding to cover the operation
 using tubular electrodes in which flux is contained in the core
and released as the electrode is consumed

36
Electrodes
 Consumable Electrodes
 Provide the source of filler metal
 Available in rods (9-18 in, 3/8 in dia) and wires

 Must be changed periodically

 Wire: Continuous

 Non-consumable Electrodes
 Material That resist melting (Usually Tungsten)
 Filler metal is supplied separately

37
AW Processes (Consumable Electrodes)

 Shielded Metal Arc Welding

 Gas Metal Arc Welding
 Flux-Cored Arc Welding
 Electrogas Welding
 Submerged Arc Welding

38
Shielded Metal Arc Welding (SMAW)

 Uses a consumable electrode consisting of a filler metal rod

coated with chemicals that provide flux and shielding
 Sometimes called "stick welding"
 Power supply, connecting cables, and electrode holder are not
so expensive

39
Welding Stick in SMAW

 Composition of filler metal usually close to base metal

 Welding stick is clamped in electrode holder
connected to power source
 Heat of welding process melts the coating and
provides protective atm and slug
 30-300A and 15-45V

40
SMAW Applications

 Used for steels, stainless steels, cast irons, and certain

nonferrous alloys
 Not used or rarely used for aluminum and its alloys,
copper alloys, and titanium
 Preferred over Gas welding for thicker sections
(above 5mm)

41
Gas Metal Arc Welding (GMAW)

 Uses a consumable bare metal wire as electrode and

shielding accomplished by flooding arc with a gas
 Wire is fed continuously and automatically from a spool
through the welding gun

42
Gas Metal Arc Welding (GMAW)

 Wire size depends upon

 Thickness of part and deposition rate
 Shielding gases include inert gases such as argon
and helium for aluminum welding, and active gases
such as CO2 for steel welding
 Bare electrode wire plus shielding gases eliminate
slag covering on weld bead

43
GMAW Advantages over SMAW

 Better arc time because of continuous wire electrode

 Sticks must be periodically changed in SMAW
 Better use of electrode filler metal than SMAW
 The end of the stick cannot be used in SMAW
 Higher deposition rates
 Eliminates problem of slag removal
 Can be readily automated

44
Flux-Cored Arc Welding (FCAW)

 Adaptation of shielded metal arc welding, to overcome

limitations of stick electrodes
 Electrode is a continuous consumable tubing (in coils) that
contains flux and other ingredients (e.g., deoxidizers and
alloying elements) in its core

45
FCAW: Types

 Self-shielded FCAW
 Core also includes compounds that produce shielding
gases along with flux
 Gas-shielded FCAW
 Uses externally applied shielding gases
 Hybrid of SMAW and GMAW
 Shielded gases
 Carbon dioxide for mild steel and Carbon-argon mixture
for stainless steel

46
Electrogas Welding (EGW)

 Uses a continuous consumable electrode

 flux-cored wire or bare wire
 with externally supplied shielding gases, and molding
shoes to contain molten metal
 Vertical butt joints

47
Electrogas Welding (EGW)

 When flux-cored electrode wire is used and no external gases

are supplied, then special case of self-shielded FCAW
 When a bare electrode wire used with shielding gases from
external source, then special case of GMAW

48
 Submerged Arc Welding (SAW)

 Uses a continuous, consumable bare wire electrode, with arc

shielding provided by a cover of granular flux
 Electrode wire is fed automatically from a coil
 Flux introduced into joint slightly ahead of arc by gravity from
a hopper,
 completely submerging operation, preventing sparks, spatter, and
radiation

Slow cooling,
better quality
49
SAW Applications

 Steel fabrication of structural shapes (e.g., I-beams)

 Seams for large diameter pipes, tanks, and pressure vessels
 Welded components for heavy machinery
 Most steels (except hi C steel)
 Not good for nonferrous metals

50
AW Processes
(Nonconsumable Electrodes)

 Gas Tungsten Arc Welding

 Plasma Arc Welding
 Carbon Arc Welding
 Stud Welding

51
Gas Tungsten Arc Welding (GTAW)

 Uses a nonconsumable tungsten electrode and an inert gas

for arc shielding
 Melting point of tungsten = 3410 oC (6170 oF)
 Also called TIG welding (Tungsten Inert Gas welding)

52
Gas Tungsten Arc Welding (GTAW)

 Used with or without a filler metal

 When used, filler metal is added to weld pool from separate rod or
wire
 Applications:
 Can weld dissimilar metals
 aluminum and stainless steel are most common

53
Advantages and Disadvantages of GTAW

 Advantages:
 High quality welds for suitable applications
 No spatter because no filler metal through arc

 Little or no post-weld cleaning because no flux

 Disadvantages:
 Generally slower and more costly than consumable
electrode AW processes

54
Plasma Arc Welding (PAW)

 Special form of GTAW in which a constricted

plasma arc is directed at weld area

55
Plasma Arc Welding (PAW)

 Tungsten electrode is contained in a nozzle

 that focuses a high velocity stream of inert gas (argon) into
arc region
 to form a high velocity, intensely hot plasma arc stream

 Temperatures in PAW reach 28,000 oC (50,000 oF),

due to constriction of arc, producing a plasma jet of
small diameter and very high energy density

56
PAW Advantages and Disadvantages

 Advantages:
 Good arc stability
 Better penetration control than other AW
 High travel speeds
 Excellent weld quality
 Can be used to weld almost any metals

 Disadvantages:
 High equipment cost
 Larger torch size than other AW - tends to restrict
access in some joint configurations
57
Other processes

 Carbon arc welding

 Nonconsumable carbon electrode is used
 Not used now a days

 Stud welding
 Join studs or similar components with the base metal

58
Resistance Welding (RW)

 A group of fusion welding processes that use a combination

of heat and pressure to accomplish coalescence
 Heat generated by electrical resistance to current flow at
junction to be welded

59
Resistance Spot Welding
 Parts: usually sheet metal)
 Two opposing electrodes
 Means of applying pressure to squeeze parts
between electrodes
 Power supply: a controlled current is applied for a
specified time duration

60
Advantages and Drawbacks of RW

 Advantages:
 No filler metal is required
 High production rates are possible

 Lends itself to mechanization and automation

 Operator skill level is lower than for arc welding

 Good repeatability and reliability

 Disadvantages:
 High initial equipment cost
 Limited to lap joints

61
Resistance welding Types
 Resistance spot welding
 Resistance seam welding
 Resistance projection welding

62
Resistance Spot Welding (RSW)
 Resistance welding process in which fusion of faying surfaces
of a lap joint is achieved at one location by opposing
electrodes
 Used to join sheet metal parts using a series of spot welds
 Widely used in mass production of automobiles, appliances,
metal furniture, and other products made of sheet metal
 A typical car body has ~ 10,000 spot welds
 Annual production of automobiles throughout the world is measured in
tens of millions of units

63
Resistance Spot Welding (RSW)

 Sheets of 3mm or less

 Size and shape of weld is determined by electrode tip

 Rocker-Arm spot welder

 Press type spot welder
 Portable spot welder

64
65
Resistance Seam Welding (RSEW)

 Uses rotating wheel electrodes to produce a series of

overlapping spot welds along lap joint
 RSEW capable of producing air-tight joints
 Applications:
 Gasoline tanks
 Automobile mufflers

 Various other sheet metal containers

66
Resistance Seam Welding
 Conventional Resistance Seam Welding
 Roll spot Welding
 Continuous Resistance Seam

67
Resistance Projection Welding (RPW)

 A resistance welding process in which coalescence occurs at

one or more small contact points on parts
 Contact points determined by design of parts to be joined,
and may consist of projections, embossments, or localized
intersections of parts

68
Fastener welded on sheet metal cross-wire welding

69
Other Resistance Welding (self study)

 Flash Welding
 Upset Welding
 Percussion Welding
 High Frequency Resistance Welding

70