Workshop Welding Shop

Welding shop
BASICS OF MANUFACTURING
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Topics
 Study of tools & operations of Gas welding &
Arc welding

 Simple butt and Lap welded joints.

 Oxy-acetylene flame cutting.
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Welding definition
 Itis process of joining two
similar or dissimilar metals
with the application of heat
and with or without the
application of pressure.
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 Welding is a process of joining two or more
similar or dissimilar metals by melting them
locally at the place of intended joint. Filler
material may be added and a pool of molten
metal is made.
 This pool of metal becomes a strong joint after
solidification. Sometimes help of pressure
along with heating is taken to produce a weld.
 Flux is added to remove impurities and protect
the weld from oxidation.
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Types of welding processes
 Pressure welding- resistance
welding
 Non pressure welding- arc
welding, gas welding
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Arc welding
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 In this method, metal pieces to be welded are
heated locally to the melting temperature by
creating an electric arc and then allowed to
solidify to form welded joint. Additional metal
for filling the weld is provided by core wire of
electrode (As in metal arc welding) or by filler
rod (As in case of carbon arc welding).
 For creating an arc low voltage high
amperage AC or DC current is used.
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 Filler material is used to supply extra molten
metal to fill the gap between joints. Filler
material has similar composition and lower
melting point then the base material.
 Flux is some time used to remove the oxides
formed during welding process by combining

with the impurities and forming slag, which
floats on the molten metal. Molten slag
covers the weld and protects it from
oxidation.
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POLARITY IN DC ARC WELDING
The potential difference should be such that
the heat generated at positive terminal is 2/3
and at negative terminal is 1/3. The
temperature of the arc is 3700oC to 4000oC. In
DC welding two types of polarities are used.
In DC welding two types of polarities are used.
Straight Polarity: welding electrode is kept
negative and work piece is kept positive.
Reverse Polarity: In this work piece is negative
and electrode is positive.
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Arc welding
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Arc welding accessories
 Power supply- A.C. OR D.C SUPPLY
 ELECTRODE HOLDER
 ELECTRODE- BARE ELECTRODE AND COATED
ELECTRODE
 PROTECTIVE SHIELD
 GLOVES
 WELDING CLOTHES
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 Various equipment used in Electric arc welding:
Following equipment are needed in Electric arc welding
 High current Low Voltage AC or DC Source :
 In DC arc welding current is generated by a DC
generator. The generator can be driven by means of an

electric motor of by means of a petrol or Diesel engine.
They can be portable or standing type. The voltage
required is 60-80V for striking the arc and 15-25volts
for maintaining the arc.
 In AC arc welding a step down transformer is used
which transforms AC supply from 440 Volts AC to 80-

100 Volts AC.
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ARC WELDING EQUIPMENT and
accessories
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ARC WELDING EQUIPMENT and
accessories used in arc welding
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Electrode holder- to hold the
electrode in arc welding
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Arc welding helmet and goggles to protect
eyes and skin from ultraviolet and infrared
rays emitted by welding arc
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Welding helmet, goggles, Welding
gloves, wire brush, chipping hammer
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ARC WELDING
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Advantages of Electric Arc welding
 Suitable for variety of application and positions

 High metal deposition rate
 Less training required for welders and less
supervision needed.
 Equipment are easy to use and are less costly
 Equipment are portable and can be used in
confined places
 Auxiliary gas shield is not required
 Suitable for most commonly used metals and
alloys
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Disadvantages of electric arc welding
 Incorrect welding may result into low weld

toughness
 Lack of fusion of metal if weld parameters are
incorrect
 Slag is to be removed after every pass in
multipass welding
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Arc welding application
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Arc welding application
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GAS WELDING
In this process heat for melting is supplied
by combustion of a fuel gas with oxygen. The
fuel gas can be acetylene, hydrogen, propane
or butane.
The molten metal from the edges of metal
flows and solidifies together in the weld and
a continuous joint is obtained. A filler metal
may be added when the metal is flowing to
fill the cavity.
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GAS WELDING EQUIPMENT and its
accessories
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Gar welding accessories( as shown in
figure)
 Gas cylinders- oxygen( black colour) and
acetylene ( red colour)gas cylinders
 Hose pipes
 Pressure regulators
 Welding torch or blow pipe with needles
valves
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Oxy acetylene gas welding
 Oxy Acetylene Welding : This is used for
welding almost all metals because it produces
comparatively higher temperatures and also
an inert gas envelope consisting of CO2 and
H2O is formed around the weld, which
prevents liquid metal from oxidation. The
temperatures obtained are of the order of
3200oC -3500oC.
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FIGURE – GAS WELDING
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Equipment used in Oxyacetylene welding & cutting
Pressure Regulators: Oxygen and acetylene cylinders

are fitted with pressure regulators to reduce
pressure of gases as per the requirement.
Blow pipes or Torches: Torch for high pressure and
low pressure system differ in design. The low
pressure torch has an inbuilt ejector which draws
acetylene from the low pressure generator and
mixes with the Oxygen. In high pressure torch
there is only a mixing provision for the two gases.
The torch is fitted with regulating valves for
oxygen and acetylene.
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Gas welding equipment
Other equipment: Other equipment needed for gas
welding are
 Keys for cylinders and valves
 Hoses for Oxygen and Acetylene
 Spanners for connecting hoses
 Safety equipment like goggles, Screens, Lather
hand glows and lather apron

 Chipping hammer
 goggles
 Wire brush, Spark lighter etc.
 Trolley to carry oxygen cylinders
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GAS WELDING
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Gas welding flames
 Oxidising Flame : Oxidizing flame is obtained when the quantity of
oxygen is more than that required for perfect combustion. The
inner cone is pointed and very short in this case. Such flame is not
required except for welding brass. Maximum temperature of about
3400oC - 3500oC at the tip of inner cone is obtained.
Neutral Flame : When quantity of oxygen is so adjusted that it is
just sufficient for complete combustion a neural flame is obtained.
The length of the inner cone becomes more. Most of the metals
are welded using this flame. Maximum temperature of about
3200oC - 3300oC at the tip of inner cone is obtained.
Carburising Flame
 When the quantity of oxygen is less than required for complete
combustion we get carburizing flame. This 2800oC - 3150oC at the
tip of inner cone is obtained. type of flame is used for welding
lead.
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GAS WELDING FLAMES
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Types of Weld Joints
 Mainly two types of weld joints are made by

gas welding :-
◦ Butt Welds i.e. welding two pieces of metal
without any overlap.
◦ Fillet Welds i.e. joining two pieces perpendicular
to each other or with an over lap.
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Butt joint and fillet joint
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Some coommon welding joints
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Common welding positions
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Gas welding application
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Resistance welding
 Resistance welding processes are pressure
welding processes in which heavy current
is passed for short time through the area
of interface of metals to be joined. The
basic governing equation
 H = I 2 R T, H- total heat generated
 These processes differ from other welding
processes in the respect that no fluxes are

used, and filler metal rarely used.
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 All resistance welding operations are
automatic and, therefore, all process
variables are preset and maintained
constant.
 Heat is generated in localized area which
is enough to heat the metal to sufficient

temperature, so that the parts can be
joined with the application of pressure.
Pressure is applied through the electrodes.
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Working principle of resistance
welding
The heat generated during resistance welding is
given by following expression:
H = I 2 R T
 Where, H is heat generated
 I is current in amperes
 R is resistance of area being welded
 T is time for the flow of current.
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Figure – resistance welding
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Types of resistance
welding
Spot welding
Seam welding
Butt welding
Projection welding
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Spot welding
 In resistance spot welding, two or
more sheets of metal are held
between electrodes through which
welding current is supplied for a
definite time and also force is exerted
on work pieces
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Figure – spot welding
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Figure – spot welding machine
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Application of spot welding
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Spot welding use
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Spot welding in automobile using
robot welding
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Advantages of Resistance welding
 Very little skill is required to operate the

resistance welding machine
 Process is suitable for high production rate
 HAZ (Heat affected Zone) is very small.
 No filler metal is required
 Possible to weld two dissimilar metals or
sheets of different thickness

 Semi-automatic equipment are available
 No consumable other than electricity is
required.
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SOLDERING AND BRAZING
 Soldering is a process in which two or more metal
items are joined together by melting and flowing a
filler metal into the joint. Filler metal has relatively
low melting point. Bond is through wetting action.
Resulting joints are not as strong as the base
metal but they have adequate strength.
 It is often confused with welding but the
difference between them is, in soldering the work
piece is not melted, they are joined using a filler
metal, but in welding work piece is joined by
melting.
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 This method is used for joining metals
particularly when they are in the form of
sheets or wires, by using another metal or
alloy which has fairly low melting point
compared to the base metal to be joined. The
metal or alloy used for this purpose is known
as solder. There are two types of solders soft
solder and hard solder.
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FIGURE- SOLDERING PROCESS
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SOLDRING IRON AND SOLDER
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SOLDERING APPLICATION
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BRAZING
 It is a process of joining metals with the help
of hard solder. Brass is generally the main
constituent of this solder.
 Brazing solder is commonly known as spelter
which is an alloy of copper, zinc and tin.

 Hard solder provides much stronger joint as
compared to soft soldering.

 However in this case the metal piece to be
joined is heated to slightly above the melting

point of the filler metal.
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BRAZING PROCESS
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APPLICATION OF BRAZING
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DIFFERENCE BETWEEN SOLDERING,
WELDING AND BRAZING
WELDING soldering BRAZING
Welding joints are Brazing are weaker
strongest joints used Soldering joints are than welding joints
to bear the load. weakest joints out of but stronger than
Strength of the three. Not meant to soldering joints.
welded portion of bear the load. Use to This can be used to
joint is usually more make electrical bear the load up to
than the strength of contacts generally. some extent.
base metal.
Temperature Temperature Temperature may go
required is 3800 requirement is up to to 600 degree
degree Centigrade in 450 degree Centigrade in
Welding joints. Centigrade in Brazing joints.
Soldering joints.
Work piece to be Heating of the work Work pieces are
joined need to be pieces
heated till their required is not heated but below
their melting point.
melting point.
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WELDING SOLDERING BRAZING
Mechanical properties No change in May change in
of base metal may mechanical properties mechanical properties
change at the joint due after joining. of joint but it is almost
to heating and cooling. negligible.
Heat cost is involved Cost involved and skill Cost involved and sill
and high skill level is requirements are very required are in
required. low. between others two.
Heat treatment is
generally required to No heat treatment is No heat treatment is
eliminate undesirable required. required after brazing.
effects of welding.
No preheating of Preheating of
workpiece is required workpieces before May change in
before welding as it is soldering is good for mechanical properties
carried out at high making good quality of joint but it is almost
temperature. joint. negligible.
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WELDING DEFECTS
1. Heat affected zone(HAZ)
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CRACKS
 Cracks may be of micro or macro size and may
appear in the weld metal or base metal or base
metal and weld metal boundary.
 Different categories of cracks are longitudinal
cracks, transverse cracks or radiating/star
cracks and cracks in the weld crater.
 Cracks occur when localized stresses exceed
the ultimate tensile strength of material. These
stresses are developed due to shrinkage during
solidification of weld metal.
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Fig.- cracks
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Porosity
 Porosity results when the gases are entrapped in the
solidifying weld metal.
 These gases are generated from the flux or coating
constituents of the electrode or shielding gases used during
welding or from absorbed moisture in the coating. Rust,
dust, oil and grease present on the surface of work pieces
or on electrodes are also source of gases during welding.
 Porosity may be easily prevented if work pieces are properly
cleaned from rust, dust, oil and grease.
 Futher, porosity can also be controlled if excessively high
welding currents, faster welding speeds and long arc
lengths are avoided flux and coated electrodes are properly
baked.
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Fig.- Porosity
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Slag inclusions
 Slag inclusions may be in the form of slag or any other
nonmetallic material entrapped in the weld metal as these may
not able to float on the surface of the solidifying weld metal.
 During arc welding flux either in the form of granules or
coating after melting, reacts with the molten weld metal
removing oxides and other impurities in the form of slag and
it floats on the surface of weld metal due to its low density.
 However, if the molten weld metal has high viscosity or too
low temperature or cools rapidly then the slag may not be
released from the weld pool and may cause inclusion.
 Slag inclusion can be prevented if proper groove is selected,
all the slag from the previously deposited bead is removed,
too high or too low welding currents and long arcs are
avoided.
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Fig.- slag inclusions
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Lack of fusion
 Lack of fusion is the failure to fuse together
either the base metal and weld metal or
subsequent beads in multipass welding
because of failure to raise the temperature of
base metal or previously deposited weld layer
to melting point during welding.
 Lack of fusion can be avoided by properly
cleaning of surfaces to be welded, selecting

proper current, proper welding technique and
correct size of electrode.
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Fig.- Incomplete fusion
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Excessive penetration or lack of
penetration
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Imperfect shapes
 Imperfect shape means the variation from the desired
shape and size of the weld bead.
 During undercutting a notch is formed either on one
side of the weld bead or both sides in which stresses
tend to concentrate and it can result in the early failure
of the joint.
 Main reasons for undercutting are the excessive welding
currents, long arc lengths and fast travel speeds.
 Underfilling may be due to low currents, fast travel
speeds and small size of electrodes. Overlap may occur
due to low currents, longer arc lengths and slower
welding speeds.
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Imperfect shapes
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Fig.- imperfect shapes
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Carbon arc welding
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Carbon arc welding
 Carbon Arc Welding (CAW) is a welding
process, in which heat is generated by an
electric arc struck between an carbon
electrode and the work piece. The arc heats
and melts the work pieces edges, forming a
joint. If required, filler rod may be used in
Carbon Arc Welding. End of the rod is held in
the arc zone. The molten rod material is
supplied to the weld pool.
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TIG( tungsten inert gas arc welding)
or GTAW
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MIG or GMAW welding
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MIG( metal inert gas welding) or
GMAW welding
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MIG or GMAW welding
 Gas metal arc welding (GMAW), sometimes referred
to by its subtypes metal inert
gas (MIG) welding or metal active gas (MAG) welding,
is a welding process in which an electric arc forms
between a consumable wire electrode and the
workpiece metal(s), which heats the workpiece
metal(s), causing them to melt, and join.
 Pure inert gases such as argon and helium are only
used for nonferrous welding;

 argon and carbon dioxide are frequently mixed in a
75%/25% to 90%/10% mixture for ferrous welding
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 MIG welding is one of the more simple welding methods of
metal welding as it does not require a high level of skill to
achieve results.
 The process is semi-automatic because an electrode wire and
gas are automatically fed through the gun at a user defined
speed or pressure when the operator pulls down the trigger,
the electronic arc can also be user defined and carried out
automatically on operation.
 MIG is a quick and easy form of welding; it is used often by
robotics in automated production lines.
 MIG however does not offer the best penetration when
welding therefore is not the best choice for use on thick plates
where a strong weld is required.
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Workshop Welding Shop

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Welding shop

welding, gas welding

amperage AC or DC current is used.

formed during welding process by combining

generator. The generator can be driven by means of an

which transforms AC supply from 440 Volts AC to 80-

 Suitable for variety of application and positions

 Incorrect welding may result into low weld

Pressure Regulators: Oxygen and acetylene cylinders

hand glows and lather apron

 Mainly two types of weld joints are made by

processes in the respect that no fluxes are

is enough to heat the metal to sufficient

 Very little skill is required to operate the

sheets of different thickness

which is an alloy of copper, zinc and tin.

compared to soft soldering.

joined is heated to slightly above the melting

cleaning of surfaces to be welded, selecting

used for nonferrous welding;

75%/25% to 90%/10% mixture for ferrous welding

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