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20 Welding Revised
20 Welding Revised
• Riveting
• Welding
– Pressure Welding
– Fusion Welding
Welding
• In engineering, any process in which two
or more pieces of metal are joined
together by the application of heat,
pressure, or a combination of both. Most
of the processes may be grouped into two
main categories: pressure welding, in
which the weld is achieved by pressure;
and heat or fusion welding, in which the
weld is achieved by heat.
PRESSURE WELDING
• Cold pressure welding, carried out at ambient
temperature, relies upon the use of high
compressive pressures (1400-2800N/mm2 for
aluminium and at least double that value for
copper). This provides interfacial deformations of
60% to 80% that break the oxide layers to expose
fresh, uncontaminated metal that makes contact. In
this state, inter atomic forces take over to produce
the weld.
FUSION WELDING
• Any Welding Process in which the weld is
made between metals in a state of fusion
without hammering or applied pressure.
• The pieces to be joined are heated to the
melting point at the joint, a filler metal is
added, the weld pool is stirred and the
weld is allowed to form on cooling.
WELDING METHODS USED IN
P.P.ERECTION AND
MAINTENANCE
• GAS WELDING
• MANUAL METAL ARC WELDING
• TIG WELDING
GAS WELDING
• In this fusion welding
process the base metal
or metals being joined
are brought to the state
of fusion with a high
temperature flame
produced by burning a
combustible gas.
GAS WELDING
• HEAT SOURCE
• A combustible gas Acetylene is
mixed with equal volume of
Oxygen to produce a flame
with a temperature of about
32000 C
• C2H2 + O2 -- 2CO +H2
• CO +H2 + O2 -- CO2 + H2O
GAS WELDING
• Atmospheric Contamination
– Oxidation of molten metal by atmospheric
Oxygen
• Prevention
C2H2 + O2 -- 2CO +H2
CO +H2 + O2 -- CO2 + H2O
– Fluxes
GAS WELDING
• Filler Wires and Rods
• Metal Transfer
GAS WELDING EQUIPMENTS
• Gas Cylinders
• Pressure Regulators
• Hoses and connectors
• Welding Torch
• Nozzles
GAS WELDING TECHNIQUES
• Rightward Technique
GAS WELDING TECHNIQUES
• Leftward Technique
MANUAL METAL ARC
WELDING
• The most versatile welding process
• An electrical arc produced between an
electrode and the work piece provides the
heat source.
• Electrode provides filler material and
consumable
MANUAL METAL ARC
WELDING
• ARC
– The arc produced consists of large current
discharge sustained through thermally
ionised column termed as plasma.
MANUAL METAL ARC
WELDING
• Metal Transfer
MANUAL METAL ARC
WELDING
• Atmospheric Contamination
Electrodes
• Core Wire
– Conduct Electricity to the
arc
– Supply filler material to the
weld
• Coating
– Stabilize arc
– Produce Gas shield
– Flux and clean away the
impurities
– Form protective slag
– Add alloying constituents
ARC WELDING MACHINES
• Function
To provide electrical energy for convenient
starting, maintaining and controlling the arc.
• Open Circuit Voltage
Voltage between the secondary terminals of a
welding machine when no current is flowing
in the circuit.
High O.C.V. is required to ionise the air gap
at the time of initiating the arc.
ARC WELDING MACHINES
• Requirements
– No load voltage should be high enough to
strike the arc but not so high to endanger the
welder.
– Should be capable of giving the required
welding current
– Provision for continuous adjustment of
welding current
– Should be light in weight, small in size and
low cost.
ARC WELDING MACHINES
• Transformers - A.C.Output
• Generators - D.C.Output
• Rectifiers - D.C.Output
ARC WELDING MACHINES
• Transformers
Less initial cost
No moving parts
Air or Oil cooling
Step Down
Not suitable for
nonferrous metals
Current Regulation
Moving Core
Tapped Type
ARC WELDING MACHINES
• Generators
Drooping
Characteristics
ARC WELDING MACHINES
• Rectifiers
COMPARISON OF WELDING
MACHINES
• D.C.MACHINES • A.C.MACHINES
– More cost – Less cost
– No risk of shock – Risk of shock
– Polarity can be – Polarity can not be
selected selected
– Easy arc maintenance – Arc maintenance
– Less spattering difficult
– More spattering
– More voltage drop
across cables – Less voltage drop
– All types of electrodes – Special electrodes with
can be used arc stability only can
be used
ARC WELDING ACCESSORIES
• Electrode holder
– Light in weight
– Firm contact between
holder and electrode
– Sound mechanical
joint between holder
and welding cable
– Adequate rating for
welding current
– Good insulation
– Flexibility
• Screw head type
• Jaw head type
ARC WELDING ACCESSORIES
• Cables
– Welding cable
– Welding return cable
• Requirements
– Flexible
– Wear resistant
insulated covering
ARC WELDING ACCESSORIES
• Cable Joints & Earth
clamps
• Tools
– Wire Brush
– Chipping Hammer
• Protective Gear
– Eye protection
– Gloves
– Cap & Apron
TUNGSTEN INERT GAS WELDING
• Heat Source
– Electric arc maintained between the tip of
non consumable electrode and work piece.
• Electrode
– Pure Tungsten
– Alloyed Tungsten
• Thoriated Tungsten
• Zirconiated Tungsten
TUNGSTEN INERT GAS WELDING
Advantages of alloyed
Tungsten electrodes
– Better arc initiation
and re ignition
– Arc stability at low
current values
– Carry high current
without tip erosion
– Longer life
TUNGSTEN INERT GAS WELDING
Methods of Heating
– Local methods
• Gas flame
• Radiant gas heaters
• Induction coils
• Exo thermic heating
• Elctric resistance heating
PRE HEATING REQUIREMENTS FOR WELDING
MATERIAL MIN.TEMP.FOR TIG ROOT HYD.CON. WELD METAL NON HYD.CON. WELD
RUN METAL
CLASSIFICA CARBON STEEL ROOT RUN MATL. MIN. MATL. MIN.
TION 127mm & 127mm & THICKNESS PREHEAT THICKNESS PREHEAT
12.5mm 12.5mm mm TEMP. mm TEMP.
thick thick C C
CARBON 5 20mm : 5 30 5 20 5
STEEL 20mm : 100 30 100 20 100
0.25C
CARBON 50 100 ALL 150 ALL 200
STEEL
0.25C
0.4C
C-Mo 5 100 12.5 20 38 150
12.5 100
1Cr 1/2 Mo 5 100 12.5 100 12.5 150
12.5 150 12.5 200
20.0 200
11/4Cr 1/4 Mo 5 100 12.5 100 12.5 150
12.5 150 12.5 200
20.0 200
21/4Cr1Mo 50 100 12.5 150 12.5 200
12.5 200
POST HEATING
REQUIREMENTS
• FOR Cr,Mo,V STEEL
– Rate of Heating 2000C/Hr
– Max. Temp. 710 -7300C
– Soaking Period 2 - 2.5 m/mm
– Rate of Cooling 2.5 - 30C /m up to 3000C
WELD DEFECTS - CRACKS
Discontinuity produced either by tearing of metal while in plastic condition or by fracture while in cold condition
CAUSE
– High localised stresses arising from shrinkage of weld metal and the resistance to the movement of parts
REMEDY
– Pre and post heat treatment
WELD DEFECTS - CAVITIES OR
POROCITY
Group of small cavities caused by gas entrapped in weld
metal
CAUSE
– Condition of electrode
– moisture content of coating
– too low welding current
– presence of high sulfur in parent metal or in core wire
WELD DEFECTS - SOLID INCLUSION
Solid foreign substances entrapped in the weld metal
CAUSES
– Electrode coating
– dirty surfaces
– incorrect joint design
– use of too large electrode
– inadequate removal of slag between the deposition of successive runs
– too high speed
– too long arc
WELD DEFECTS - LACK OF FUSION
AND PENETRATION
CAUSES
– Too low welding current
– Wrong polarity connection
– Bad incorporation of tack welds
WELD DEFECTS - IMPERFECT SHAPE
Burning away of the side walls of the joint recess or reduction in base metal thickness at the line
where the last bead is fused to the surface
CAUSES
– design of the joint
– damp electrode
– excessive weld current
– improper welding technique