Welding

A fabrication or sculptural process that joins materials, usually

metals or thermoplastics, by using high heat to melt the parts
together and allowing them to cool causing fusion.
Fusion Welding

processes that uses heat to join or fuse two or more materials

by heating them to melting point. There are two types of fusion
Homogenous
Homogeneous

one way of performing fusion welding with the application of

external filler material whose metallurgical composition is
almost same with that of the base metals.
Gas Welding

metal joining process in which the ends of pieces to be joined

are heated at their interface by producing coalescence with one
or more gas flames (such as oxygen and acetylene), with or
without the use of a filler metal.
Electro Slag Welding

a welding process, in which the heat is generated by an electric

current passing between the consumable electrode (filler
metal) and the work piece through a molten slag covering the
weld surface. Prior to welding the gap between the two work
pieces is filled with a welding flux.
Energy Beam Welding

is a fusion welding process in which a beam of high-velocity

electrons is applied to two materials to be joined. The work
pieces melt and flow together as the kinetic energy of the
electrons is transformed into heat upon impact. EBW is often
performed under vacuum conditions to prevent dissipation of
the electron beam.
Electric Arc Welding

a fusion welding process in which the heat required to fuse the

metal is obtained from an electric arc between the base metal
and an electrode.
Types of Electric Arc Welding
MIG Welding

an arc welding process in which a continuous solid wire

electrode is fed through a welding gun and into the weld pool,
joining the two base materials together. A shielding gas is also
sent through the welding gun and protects the weld pool from
contamination.
TIG Welding

stands for tungsten inert gas and is technically called gas

tungsten arc welding (GTAW). The process uses a non-
consumable tungsten electrode that delivers the current to the
welding arc.
Stick Welding

a form of welding that uses electricity to melt a metal filler

rod/electrode/stick (electrode is the proper term) that melts
both the metal joint and electrode all at once to fuse two
pieces of metal together and fill the joint with filler metal at the
same time.
Heterogeneous Welding

one way of performing fusion welding with the application of

external filler whose metallurgical composition is substantially
different from that of the base metals
Heterogeneous
Brazing

the use of a bronze or brass filler rod coated with flux to join
steel work pieces.
Pressure Welding
Pressure Welding

carried out by several welding methods which have in common

the fact that the surfaces of the joint are pressed or worked
together
Friction Welding

a solid-state welding process that generates heat through

mechanical friction between workpieces in relative motion to
one another, with the addition of a lateral force called "upset"
to plastically displace and fuse the materials.
Soldering

the process of joining two or more electronic parts together by

melting solder around the connection. Solder is a metal alloy
and when it cools it creates a strong electrical bond between
the parts.
 Now let's look into the
arc welding categories,
click on the photo to get
more details

Shielded Metal Arc Welding

Video

https://www.youtube.com/watch?v=
elmDvqdeMKI

Gas Tungsten Arc Welding Gas Metal Arc Welding

Video Video

https://www.youtube.com/watch? https://www.youtube.com/w
v=uO5pVLOAmD4 atch?v=twUAa5LWUvk
In this topic, we will look into the common weld defects that
may occur during a welding operation.

Weld Crack

This is the most unwanted defect of all the other welding defects. Welding
cracks can be present at the surface, inside of the weld material or at the heat
affected zones.

Causes Of Weld Crack:

1. Poor ductility of the given base metal.
2. The presence of residual stress can cause a crack on the weld metal.
3. The rigidity of the joint which makes it difficult to expand or contract the
metals.
4. If there is high content on sulfur and carbon then also the cracks may
appear.
5. Using hydrogen as a shielding gas while welding ferrous materials.

Remedies for Weld crack:

6. Using appropriate materials may decrease the chances of crack.
7. Preheating the weld and reducing the cooling speed joint helps in reducing
crack.
8. Reduce the gap between the weld joints by using reasonable weld joints.
9. While welding releases the clamping force slowly which increases fill to
capacity of welding material.
Undercraft

When the base of metal melts away from the weld zone, then a
groove is formed in the shape of a notch, then this type of
defect is known as Undercut. It reduces the fatigue strength of
the joint.

Causes of Undercut:

1. If the arc voltage is very high then this defect may occur.
2. If we use the wrong electrode or if the angle of the
electrode is wrong, then also the defect may form.
3. Using a large electrode is also not advisable.
4. High electrode speed is also one of the reasons for this
defect.

Remedies for Undercut:

5. Reduce the arc length or lower the arc voltage.

6. Keep the electrode angle from 30 to 45 degree with the
standing leg.
7. The diameter of the electrode should be small.
8. Reduce the travel speed of the electrode.
Spatter

When some metal drops are expelled from the weld and
remain stuck to the surface, then this defect is known as
Spatter.

Causes Of Spatter:
1. High Welding current can cause this defect.
2. The longer the arc the more chances of getting this defect.
3. Incorrect polarity
4. Improper gas shielded may also cause this defect.

Remedies for Spatter:

5. Reducing the arc length and welding current
6. Using the right polarity and according to the conditions of
the welding.
7. Increasing the plate angle and using proper gas shielding.
Porosity

Porosity in the condition in which the gas or small bubbles gets

trapped in the welded zone.

Causes of Porosity:
1. It occurs when the electrode is not coated properly.
2. Using a longer arc may also increase its chances.
3. Increased welding currents.
4. Rust or oil on the welding surface.

Remedies for porosity:

5. Proper selection of the electrode.
6. Decreasing the welding current.
7. Using smaller arc and slowing the process to allow the
gases to escape.
8. Remove rust or oil from the surface and use a proper
technique.
Overlap

When the weld face extends beyond the weld toe, then this
defect occurs. In this condition the weld metal rolls and forms
an angle less than 90 degrees.

Causes of Overlap:
1. Improper welding technique.
2. By using large electrodes this defect may occur.
3. High welding current

Remedies for Overlap:

4. Using a proper technique for welding.
5. Use small electrode.
6. Less welding current.
Crater

It occurs when the crater is not filled before the arc is broken,
which causes the outer edges to cool faster than the crater. This
causes a stress and then crack is formed.

Causes of the crater:

1. Incorrect torch angle.
2. Use of large electrode:
3. Improper welding technique

Remedies for crater:

4. Using a proper torch angle may reduce the stress on the
metal.
5. Using a small electrode may also decrease the crater.
6. Use a proper technique.
There are five different types of welded joints for bringing two
parts together for joining.
Five types of welded joints are butt joint, corner joint, lap joint,
tee-joint and edge joint.

Click on the tabs to know the more about the joints

Butt Joint

In Butt welded type, the parts lie in the same plane and are
joined at their edges.

Corner Joint

The parts in a corner joint form a right angle and are joined at
the center of the angle.
 Lap Joint

Lap joint consists of two overlapping parts.

Tee Joint

In a Tee-joint, one joint is the right angle to the other joint in

the approximate shape of the letter “T”.

Edge Joint

The parts in edge joint are parallel with at least one of their
edges in common and the joint is made at the common edge(s).
In this topic we will discuss the Weld Types being carried out on
board ships
Bead Weld

Bead Weld is a weld deposit produced by a single pass with one

of the welding processes. A weld bead may be either narrow
or wide, depending on the amount of transverse oscillation

Surface Weld

Surfacing Weld welding process used to apply a hard, wear-

resistant layer of metal to surfaces or edges of worn out parts.
Fillet Weld

Fillet weld is triangular in shape and this weld is used to join

two surfaces that are at approximately right angles to each
other in a lap, tee, or comer joint

Plug and Slot Weld

Plug and Slot welds are welds made through holes or slots in
one member of a lap joint. These welds are used to join that
member to the surface of another member that has been
exposed through the hole