WELDING

WELDING TYPES,
DEFINITIONS,
USE & LIMITATIONS
Joining - definition

 Welding – A joining process of two materials,

metals/non-metals, that coalesced by the
application of pressure and/or temperature
through melting & re-solidification of the base
metals and filler metal.
 Welding – Local coalescence of two similar or
dissimilar metallic parts at their faying surfaces.
 Sometime a filler material is needed to facilitate
coalescence in Arc/Fusion welding process.
Advantage - Disadvantage

 Advantage:
 Most efficient way to join metals
 Lowest-cost / most economical joining method
 Affords lighter weight through better utilization of
materials
 Joins all commercial metals
 Provides design flexibility
 Welding is portable

 Disadvantage:
 Manual Labor
 high energy and dangerous
 does not allow disassemble and defects
Classification of welding processes
Welding
Soldering and brazing

Solid state welding Fusion welding

Resistance welding Soldering
Cold welding Brazing
Friction welding
Diffusion welding Electrical energy Chemical energy
Flash welding Oxyacetylene welding
Ultrasonic welding Oxyfuel gas welding
Explosion welding
Non
Consumable consumable Other processes
electrode electrode
Gas metal arc welding Gas tungsten arc welding Laser beam welding
Shielded metal arc welding Atomic hydrogen welding Thermit welding
Submerged arc welding
Plasma arc welding Electron beam welding
Flux cored arc welding
Electrogas welding
Electroslag welding
Basic Welding Joints
Welding Positions

Four standard
positions of welding
based on the
direction of gravity
Welding positions - plates
Welding positions - plates
Welding position – Pipe Welds
Welding position – Pipe Welds
Specifying
weld
locations

Symbols applied to
reference line
Joining - Categories
 Two Categories
 Fusion welding –
melting with or without filler
Arc, Gas and High Energy Beam

 Solid-state welding –
Heat and pressure, but no melting &
no filler
 AC or DC
power

5.1 Arc Welding (AW)

source

 A fusion welding where the coalescence of the metals

(base metals as well as filler) is achieved by the heat from
electric arc.
 Productivity: Arc time
 Technical issues
 Electrodes – consumable and non-consumable

electrodes
 Arc Shielding – To shield the arc from the surrounding

gas. Helium and argon are typically used. Flux does a

similar function.
 Power source – dc for all metals or ac for typically

steels
 Heat loss due to convection, conduction and radiation
 Shielded Metal Arc Welding (SMAW)

 A consumable electrode – a filler

metal rod coated with chemicals for
flux and shielding (230-460mm long
and 2.5-9.4mm in diameter)
 The filler metal must be comparable
with base metals.
 Current: 30-300A and Voltage: 15-
45V
 Cheaper and portable than oxy-fuel
welding
 Less efficient and variation in
current due to the change in length
of consumable electrodes during
the process.
 Shielded Metal Arc Welding

Process Capabilities:
Versatile process
 Indoor & Outdoor welding
Multi-position welding
Equipment is simple & portable
Universal process for repair welding
LIMITATIONS OF SMAW PROCESS

Limitations:

> Productivity is less

> Fixed length of electrode
> Deslaging Less metal deposition
> Cannot be used for heavy fabrication welding
> Requires more number of welders
> Control of distortion is difficult
> Continuous & automatic Welding is not possible
> More strain to the welders
CLASSIFICATION OF ELECTRODES (AWS 5.1)

E6010
Electrode

60 Psi
Welding
70 position Coating and
current conditions
80
90
100
110
120
AC Arc welding
power sources

For MMAW
OCV: 65 to 90V
Amps: 400A
Gas Tungsten Arc Welding (GTAW)
 AW with non-consumable Electrodes

Gas Tungsten Arc Welding (GTAW)

 Tungsten (Wolfram) Inert Gas (TIG)

Welding
 With or without a filler metal
 Tungsten melts at 3410°C
 Shielding gas: argon, helium or a mixture
 All metals (commonly Al and Stainless
steels) in a wide range of thickness
 Slow and costly but high quality weld for
thin sections
 AW with non-consumable Electrodes

Principle - TIG process

In TIG welding an arc is formed between a

nonconsumable tungsten electrode and the metal being
welded. Gas is fed through the torch to shield the
electrode and molten weldpool. If filler wire is used, it is
added to the weld pool separately.
 AW with non-consumable Electrodes
TIG welding
 Limitations
 Requires greater
welder dexterity than
MIG or stick welding
 Lower deposition
rates
 more costly for
welding thick
sections
Benefits
 Superior quality welds
 Welds can be made
with or
without filler metal
 Precise control of
welding
variables (heat)
 Free of spatter
 Low distortion
 TIG Welding Advantages

• Well-known and understood process

• Readily available, low cost consummable parts
• Excellent gas shielding for cleaner parts
• Electrode can be extended for improved weld joint
access
• Soft TIG arc can offer benefits for specific
applications
• TIG arc shape has advantages for specification
parts/weld joints
Torch for TIG
welding
Thank you