WELDING PROCESSES

Presented by
Parveen Kumar{05110}
 INTRODUCTION
As we all know that whatever the product that is
impossible to manufacture as a single piece.
Welding is a process which is used to join the two
parts to get a desired product.
Welding is a joining process. The types of welding
processes are:-
cont……….
 Diversity of welding processes
welding

Solid state welding Fusion welding Soldering and brazing

Resistance welding Soldering

Cold welding Brazing
Friction welding
Diffusion welding Electrical energy Chemical energy

Flash welding Oxyacetylene welding

Ultrasonic welding
Explosion welding
Consumable electrode
Gas metal arc welding
Shielded metal arc welding
Submerged arc welding
Flux cored arc welding
Oxyfuel gas welding
Non consumable Other processes
electrode
Laser beam welding
Gas tungsten arc welding Thermit welding
Atomic hydrogen welding Electron beam welding
Plasma arc welding

Electrogas welding
Electroslag welding
 FUSION WELDING
 It is defined as the melting of two material
parts by attaching together by means of heat
Heat may be supplied by chemical or
electrical means.
 In this filler metal may or may not be use .
cont…….
 FUSION WELDING COMPRISES:-
Oxyfuel gas welding
Arc welding processes
1. Consumable electrode
2. Nonconsumable electrode
 Thermit welding
 Electron beam welding
 Laser beam welding

cont……………
 1. OXYFUEL GAS WELDING
Oxyfuel gas welding is the welding process that
use a fuel gas combined with oxygen to produce a
flame.
This frame is the source of the heat that is used
to melt the metal at the point of joint.
The most common gas welding process which is
oxyacetylene welding and is used for automotive
bodies, and various other repair works.
cont……..
 In this process, heat is generated in two steps:-
1. Primary combustion process:-
In this process, acetylene reacts with O2 and give
CO and H2 and it produces 1:3 of the total heat
generated in the flame.
2. Secondary combustion process:-
It consist of further burning of H2 and CO with O2
and this reaction produces about 2:3 of the
total heat.
The temp. developed in the flame is about 3300C.
cont………
 Types of flame:-
1. When there is no excess oxygen, then it is known as neutral
flame.
2. If the oxygen is notin large amount, then it is known as
oxidizing flame.
• This is harmful for steel, because it oxidizes the steel.
• It is used only for Cu and Cu alloys because in those cases,
a thin protective layer of slag forms over the molten metal.
3. If the ratio of O2 is deficient, then the flame becomes
reducing flame.
The temp. of reducing flame is lower, so it is suitable for
applications requiring low temp. such as brazing, soldering
etc.
cont……….
OXYACETYLENE FLAMES USED IN WELDING
OXYACETYLENE TORCH AND SETUP
 FILLER METALS
• Filler metals are used to supply additional material
to the weld zone during welding.
•They are available as rod or wire made of metals
compatible with those to be welded.
• These consumable filler rods may be coated with
flux .
• The function of the flux is to retard oxidation of the
surface of the parts being welded by generating a
gaseous shield around the weld zone.
cont………
 ARC WELDING
• Arc welding processes use a welding
power supply to create and maintain
an electric arc between an
electrode and the base material to
melt metals at the welding point.
• They can use either direct (DC) or
alternating (AC) current, and
consumable or non-consumable
electrodes.
• The welding region is sometimes
protected by some type of inert or
semi-inert gas, known as a shielding
gas, and filler material is
sometimes used as well.
 Types of arc welding:-
1.Shielded metal arc welding:-
Shielded metal arc welding is one of the oldest,
simplest and most versatile welding process.
The electric arc is generated by touching the tip of a
coated electrode against the work piece and then
withdrawing it quickly to a distance sufficient to
maintain the arc.
The electrode arc in the shape of thin, long stick, so
this process is also known as stick welding.
Cont……….
 A bare section at the end of the electrode is
clamped to one terminal of the power source ,
while the other terminal is connected to the work
piece being welded.
 The current usually ranges from 50A to
300A,power requirements are generally less then
10KW.
The current may be dc or ac . For sheet metal
welding dc is preferred because of the steady arc
it produces .
Cont……
The polarity of the dc current is important and its
selections is depend upon the metal to be welded ,
types of electrode and the depth of the heated
zone.
In straight polarity , the work piece is positive and
electrode is negative.
It is preferred for sheet metals , because it
produces shallow penetration , and for joints with
very wide gaps.
In reverse polarity , the electrode is positive and
deeper weld penetration is possible
Cont……
SHIELDED METAL ARC WELDING
SMAW SYSTEM SETUP
• Advantages - The process is very versatile, requiring
little operator training and inexpensive equipment.
• Disadvantages – 1. the process is generally limited to
welding ferrous materials, though speciality electrodes
have made possible the welding of cast iron, nickel,
aluminium, copper, and other metals.

APPLICATIONS -- SMAW is often used to weld carbon

steel, low and high alloy steel, stainless steel, cast iron,
and ductile iron.
> While less popular for nonferrous materials, it can be
used on nickel and copper and their alloys and, in rare
cases, on aluminum.
> The thickness of the material being welded is bounded
on the low end primarily by the skill of the welder, but
rarely does it drop below 0.05 in (1.5 mm). No upper
bound exists: with proper joint preparation materials of
virtually greater thickness can be joined.
 SUBMERGED ARC WELDING
In this process, the weld arc is shielded by a granular flux,
consisting of lime, silica, MnO2, CaF2,and other compounds.
The thick layer of the flux completely covers the molten
metal.
The flux also acts as a thermal insulator, promoting deep
penetration of heat into the work piece.
The consumable electrode is a coil of bare round wire
{1.5-10}mm dia.
Electrical current ranges from 300-2000a and the voltage
is up to 400v.
Cont………
 GAS METAL ARC WELDING
This process is also known as MIG welding.
In this process, the weld area is shielded by an inert
atmosphere of Ar, He, CO2 or various other gas
mixtures.
The consumable bare wire is fed automatically
through a nozzle into the weld arc.
Deoxidizers are usually present in the metal itself, in
order to prevent oxidation of the molten weld puddle.
In this process, metal can be transferred by three
methods :-
Cont……..
 In spray transfer , small droplets of molten metal
from the electrode are transferred to the weld area
at a rate of several hundred droplets per seconds.
The transfer is spatter free and very stable.
High dc current and voltages and large
diameter electrodes are used , with argon rich
gas mixture used as a shielding gas.
In globular transfer , carbon dioxide gas are
used , and globules propelled by the forces of
electric arc transfer the metal , with considerable
spatter.
Cont………..
In short circuiting , the metal is transferred in
individual droplets , more than 50 per second.
As electrode tip touches the molten metal
and short circuit.
Low current voltages are utilized , with
carbon dioxide rich gases and with electrodes
made of small diameter wires.
The power required is about 2 kw.
Cont………
MIG OPERATION
GMAW torch nozzle cutaway image. (1) Torch handle, (2) Molded phenolic dielectric
(shown in white) and threaded metal nut insert (yellow), (3) Shielding gas nozzle,
(4) Contact tip, (5) Nozzle output face

GMAW WIRE FEED UNIT

GMAW SYSTEM SETUP
ADVANTAGES – 1. Can be applied to non-ferrous metals
2. automated/semi-automated process with good
speed
DISADVANTAGES – 1. Porosity due to gas entrapment
when the gas is not pure 2. Cannot be used outdoors
or under water due loss of shielding gas in such
conditions

APPLICATIONS - GMAW is commonly used in industries

such as the automobile industry, where it is
preferred for its versatility and speed. A related
process, flux cored arc welding, often does not utilize
a shielding gas, instead employing a hollow electrode
wire that is filled with flux on the inside.
 FLUX CORED ARC WELDING
This process is similar to gas metal arc welding ,
with the exception that the electrode is tubular in
shape and is filled with flux.
Cored electrode produce a more stable arc , improve
weld contour , and produce better mechanical
properties of the weld metal.
Self shielded cored electrodes are also available.
These electrodes don’t requires external gas
shielding , because they contain emissive fluxes that
shield the weld area against the surrounding.
Cont………
 ELECTROGAS WELDING
This process is used primarily for welding the edges
of sections vertically in one pass , with the piece
placed edge to edge .
It is known as machine welding process because it
require special equipment .
The weld metal is deposited into a weld cavity
between the two pieces to be joined.
The space is enclosed by the two water cooled
copper dams to prevent the molten slag from running
off.
Cont………
Single or multiple electrodes are fed through a
conduit , and a continuous arc is maintained
using flux cored electrodes .
The current ranges from 400-750 amp.
Power requirement is about 20 kw.
Shielding is done by the means of an inert gas
such as argon and it depends upon the type of
material being welded.
Cont…………..
 ELECTROSLAG WELDING
The application of this process are similar to
electrogas welding .
The main difference is that the arc is started between
the tip and the bottom of the part to be welded.
Flux is added and then melted by the heat of arc.
After the molten slag reaches the tip of electrode ,
the arc is extinguished .
Heat is then produced by the continuously by the
electrical resistance of the molten slag.
Cont…………….
 ARC WELDING PROCESSES NON
CONSUMABLE ELETRODES
In these processes generally tungsten electrode is
used.
As one pole of the arc , it generates the heat
required for welding .
A shielding gas is supplied from an external sources
to protect the welding zone from atmospheric effects.
These are the following processes which come under
this category.
Cont…………..
 GAS TUNGSTEN ARC WELDING
It is also called TIG welding .
The filler metal is provided from the filler
wire , because the tungsten electrode is not
consumed in this operation.
A constant and stable arc gap is maintained
at a constant current level.
In tig welding filler metal may or may not be
used e.g in the welding of close fit joint.
Cont…………..
The power supply may be ac or dc type
depending upon the metal to be welded.
Ac is used for al , mg , because the cleaning
action of ac remove oxides and improves weld
quality.
Power requirement ranges from 8-20 kw.
There is one major disadvantage of this
process is that the contamination of tungsten
electrode is taking place by the molten metal.
Cont……..
GTAW SYSTEM SETUP
GTAW WELD AREA
• ADVANATAGES – 1. most preferred method for non
ferrous metals 2. best quality welds are produced
• DISADVANTAGES – 1. complex technique requires
skilled labour 2. costly (requires shielding gas and
filler material)

APPLICATIONS - 1. The aerospace industry is one of

the primary users of gas tungsten arc welding , it is
used extensively in the manufacture of space
vehicles, and is also frequently employed to weld
small-diameter, thin-wall tubing.
2. In maintenance and repair work, the process is
commonly used to repair tools and dies, especially
components made of aluminum and magnesium.
3. The welds it produces are highly resistant to
corrosion and cracking over long time periods, GTAW
is the welding procedure of choice for critical welding
operations like sealing spent nuclear fuel canisters
before burial.
 PLASMA ARC WELDING
In this process a concentrated plasma arc is
produced and is aimed to the weld area .
The arc is stable and reaches temp. as high as
33000 c.
A plasma is a ionized hot gas , combination of
equal number of electrons and ions.
The plasma is initiated between the tungsten
electrodes and the orifice by a low current pilot
arc.
Cont………..
Operating current is usually below 100A, but they can
be higher for special applications.
 There are 2 methods of plasma arc welding:---
1. In the transferred arc method the workpiece being
welded is part of the circuit current.
 The arc transfers from the electrode to the
workpiece.
2. In the non transferred method the arc occurs between
the electrode and the nozzle.
 Heat is carried to the workpiece by the plasma gas.
 This thermal transfer mechanism is similar to that for
oxyfuel flame.
Cont………………
 THERMIT WELDING
This process involves exothermic reaction between metal
oxides and metallic reducing agents.
The heat of the reaction is the utilized in welding.
The most common mixture of material used in welding
steel and cast iron is finally divided particles of iron oxides,
Fe, Al.
This non explosive mixture produces a temperature of
3200 C in less a minute.
This welding process involves the alignment of the parts to
be joined, but with a gap between them usually filled with
wax.
Cont…………….
If the parts are thick, the mold cavity may be
preheated to improve welding and to dry the mold.
Drying of the mold is very important otherwise
superheated steam trapped in the mold can cause
explosions.
The superheated product of the reaction are allow
to flow into the gap, melting the edge of the parts
being joined.
This welding suitable for welding and repairing
castings and thick steel structural sections.
Cont………..
 ELECTRON-BEAM WELDING
In this process the heat is generated by high velocity
narrow beam electrons.
The kinetic energy of the electrons is converted into
heat as they strike workpiece.
The process requires special equipments to focus the
beam on the workpiece in the vacuum.
The higher the vacuum, more the beam penetrates and
greater depth to width ratio.
This process is used for workpiece whose thickness
ranges from foil to plate.
No shielding gas, flux or filler metal is required.
Cont…………….
 LASER BEAM WELDING
This welding process utilizes high power laser beam
as the source of heat to produce fusion weld’
In this beam can be focused on very small area
which is being welded.
It has high energy density, so it has high penetrating
capability.
This process is suitable for welding deep and narrow
joints.
In this, the depth to width ratio is ranging from 4:10.
Cont…………..
Its application is in automotive industry for
welding of transmission components.
The power level is up to 100 kw.
Laser beam welding process produces
welds of good quality, with minimum
shrinkage and distortion.
Cont………..
References:--
 Manufacturing engg. And tech.
by Kalpakjian
thanks