UNIT-3 & 4

SOLID STATE WELDING

• It is a welding process, in which two work pieces are joined under a

pressure providing an intimate contact between them and at a temp.
essentially below the melting point of the parent material.

•Bonding is a result of diffusion of the interface atoms.

Friction Stir Welding (FSW)

Friction stir welding (FSW) is a solid-state joining process that

uses a non-consumable tool to join two facing workpiece without
melting the workpiece material. Heat is generated by friction
between the rotating tool and the workpiece material, which leads
to a softened region near the FSW tool.
Friction Stir Welding
The FSW is the process in which a tool is used which does not gets
consumed in joining the workpiece so it is called a non-consumable
tool.  A non-consumable rotating tool with a pin and a shoulder is
inserted into the adjacent edges of sheets or plates to be joined
and moved along the line of joint till the end. It is considered to be
the most significant development in the metal joining process and
is a “green” technology due to its energy efficiency, environment
friendliness, etc.
 Working Process of Friction Stir Welding
1.(FSW)
Firstly clamp the workpiece in a heavy-duty setup, so that it does not move or
shake at the time of welding.
2. Workpiece should be abutting i.e. both parts should be kept side to side at a
particular distance from each other.
3. Now insert a blunt or probe tool till the whole pin gets inserted in the abutting
edges.
4. Now the shoulder gets in touch with the abutting edges.
5. The tool starts rotating within contact with the job.
6. Due to contact of the workpiece, friction is applied and as a result of it, heat
is generated.
7. This heat makes the metal plastically melt.
8. When the metal gets plasticized the high downward forces or pressure makes
 Important Welding Parameters

 1. Tool Design:
Tool design is a very important factor in improving the quality of the workpiece. To achieve a good finish
in job the tool material should be sufficiently strong, tough and hard-wearing at the welding
temperature. The tool should conduct less heat to decrease heat losses and minimizes the damage to the
machine’s parts caused by the heat produced. The tool should be highly resistive to oxidation so that
there are no traces of rust.
 2. Tool Speeds:
As we know the friction stir welding process is a slower welding process, this is because the cylindrical
tool turns on the joint to generate heat, and then moving along the length of the joint transmitting that
heat. The probe tool with the cylindrical part rotates within the range of 200 to 2000 rotations per
minute (rpm). The traverse rate of the tool along the joint line is between 10 to 500 millimeter per
minute (mm/min).
 3. Tool Tilt:
Tool tilt is also an important aspect to get a good quality of weld. It welds the joint in a slightly lean position
or tilt position which is about 2 to 4 degrees. The forces applied downwards can affect the joint, so to
prevent this condition a tilt is given.
 4. Plunge Depth:
The plunge depth is the total depth till which the shoulder of the tool gets inserted into the metal sheet
while the pin penetrates further than the shoulder.  It is very important factor to determine the quality of
job as the plunge depth needs to be correctly set because it ensures the necessary downward pressure is
achieved and also ensure that the tool fully penetrates the weld because if the tool is not inserted to
correct depth machine may deflect from its position. And on giving excessive plunge depth the job may
have pin rubbing marks on it.
 Other welding parameters include spindle power, torque, Z force, as well
as the distance between the FSW weld and the side of the plate.
 Process parameter
 The welding was carried out by using the selected variations of parameters as shown in Table1 which is
obtained by Taguchi’s orthogonal array method for minimizing the number of experiments.

Welding Run Rotational Welding speed Tool diameter Depth of

No. speed (rpm) (mm/min) (mm) plunging (mm)
1 450 80 8 0.2
2 450 160 12 0.2
3 450 250 16 0.2
4 560 160 8 0.2
5 560 250 12 0.2
6 560 80 16 0.2
7 710 250 8 0.2
8 710 80 12 0.2
9 710 160 16 0.2
 Advantages:
1. Mechanical properties of the metal are not degraded after the welding process.
2. There is no production of fumes and unwanted metal spatter of molten state.
3. In the FSW process safety level is up to the mark and no risk of getting hurt.
4. No consumable, no filler metal and no shielding gas is required in this process.
5. It can be used in any position i.e.in horizontal, vertical etc.
6. It can be applied to various types of joints like lap joints, butt joints, T joints, and fillet joints.
7. There is no requirement to clean the metal surface.
 Disadvantages:
1. The hole which is made by the blunt probe tool is left unfilled at the time of exit.
2. Heavy-duty clamping setup is required to hold the workpiece or job during the welding process.
3. Large downward forces are required to get the probe tool get inserted inside the metal.
4. Many times this welding process is slower than many other processes.
5. Friction stir welding cannot make weld joints in which there is requirement of metal deposition.
6. The initial cost of the FSW machine is too high.
7. It is less flexible than manual and arc welding processes
 Application
 Shipbuilding and marine industries: The process is suitable for the following applications:- Panels for
decks, sides, bulkheads and floors, aluminium extrusions, helicopter landing platforms, marine and
transport structures, refrigeration plant
 Aerospace industries: The friction stir welding process can therefore be considered for: for welding in Al
alloy fuel tanks for space vehicles, manufacturing of wings, external throw away tanks for military aircraft
military and scientific rockets etc.
 Railway industries: Applications in high speed trains, building of container bodies, railway tankers, etc.
 Land transportation: Applications in automotive engine chassis, body frames, wheel rims, truck bodies,
etc.
ULTRASONIC WELDING

Ultrasonic welding is a welding technique whereby high-

frequency ultrasonic acoustic vibrations are locally applied
to work pieces being held together under pressure to create
a solid state weld. It is commonly used for plastics and
metals, and especially for joining dissimilar materials.
Parts

 TRANSDUCER

Produces high frequency ultrasonic vibrations.

 CONVERTOR

Converts the electrical signal into a mechanical vibration

 BOOSTER

Modifies the amplitude of vibrations

 SONOTRODE

Applies the mechanical vibrations to the parts to be welded

Explosion Welding
Common Explosives used
Diffusion Welding
 Diffusion Welding

Diffusion Welding is a Solid State Welding process, in which pressure

applied to two work pieces with carefully cleaned surfaces and at an
elevated temperature below the melting point of the metals. Bonding
of the materials is a result of mutual diffusion of their interface
atoms.
Advantages:
 The joint have same mechanical and physical properties as parent material.
 Thisprocess produces clean joint which is free from interface discontinuity
and porosity.
 Both similar and dissimilar material can be joint by diffusion bonding
process.
 Itprovides good dimension tolerance. So it is used to make precision
components.
 Low running cost.
 It is simple in working.
 It does not use filler material, flux etc. which are used in arc welding
process.
 It can weld complex shapes.
 Disadvantages:
 High initial or setup cost.
 Itis time consuming process. It takes more time compare to other
welding process.
 Surface preparations of welding plates are more critical and
difficult.
 Size of the weld is limited according to equipment available.
 This process is not suitable for mass production.
 Highlydepend on welding parameters like surface finish, welding
material, temperature, pressure etc.
Application:

 It is mostly used to weld refectory materials used in

aerospace and nuclear industries.
 Diffusion bonding is used to weld titanium, zirconium and its
alloy.
 It can weld nickel alloy.
 It is used to weld dissimilar metals like Cu to Ti, Cu to Al etc.
Underwater Welding
Underwater Welding

 To repair the cracks in ships ,bridge and

submarine.
 For quick process in under water welding.
 To construction of pipe line in under sea.
 To weld any cracks in oil pipe line.
 Requirement of underwater welding

 Power supply requirements 400 Amp or larger. DC generators,

motor generators and rectifiers are acceptable power supplies.
 Power converters.
 Welding Generator, Pre-Setup.
 Diesel Driven Welding Generator Amperage and Voltage
settings.
 Gas Manifolds.
Advantage and Disadvantage

 Advantage  Disadvantage
 Minimal amount of  Repaid quenching of the weld
equipment is needed. metal by surrounding water.
 Operating speed is high.  Decreases impact strength
 No seal chamber is and losses.
required.  Hydrogen embattlement
causes cracks.
 Poor visibility in water.
 Electric shock will occurred.
 Applications of wet welding

 It is key technology for repairing marine structure .

 Welding is directly performed under water is directly exposed to
the wet environment.
 Increased freedom movement makes more effective, efficient
and economical.
 Supply is connected to the welder / driver via cables or hoses.
Advantage and disadvantage of dry welding

 Advantage  Disadvantage

 More safety then wet  Higher cost of process,

training, etc.
welding.
 Large quantity of costly and
 Good Quality weld.
complex equipment.
 Surface monitoring.  More deep, more energy
requirement.
 It should be weld only
reachable place.
Microwave hybrid joining

 The unique characteristics of microwave radiations like

volumetric heating, less power utilization, eco-friendly with
environment, highly quality products etc. are attracting numbers
of researches in this field. These techniques in not fully
developed as compared to other joining techniques but results of
this technique are relatively better in terms of hardness, HAZ
and tensile strength. Many materials which are extensively used
in industries like aluminium, stainless steel, cast iron, etc. have
been joined by microwave joining process.
 Microwave Joining
 In microwave joining process domestic and industrial microwaves
are used for bulk material joining. These domestic and industrial
microwaves works on stranded frequency 2.45GHz. Refractory brick
with cavity is used to hold the work piece.
 Epoxyresin blumer and bisphenol-A are used to hold the interface
powder.
 Charcoal powder are used as a susceptor which suscepts the
microwave radiations and concentrate them at the interface of the
joint. Graphite sheet is used as a separator to separate the
interface powder.
Adhesive weld bonding
Adhesive weld bonding

 A material that is applied to the surfaces of articles to join

them permanently by an adhesive bonding process.
 An adhesive is a substance capable of forming bonds to each of
the two part when the final object consists of two sections that
are bonded together.
 A feature of adhesives is the relatively small quantities that are
required compared to the weight of the final objects.
Functions of Adhesive
• To join parts together.
Transmitting stresses from one member to another in a manner that
distributes the stresses much more uniformly than can be achieved
with mechanical fasteners.

Adhesive bonding often provides structures that are mechanically

equivalent to or stronger than conventional assemblies at lower cost
and weight.
 Exposed surfaces are not defaced and contours are not disturbed, as
happens with mechanical fastening systems.
 Lighter weight materials can often be used with adhesive bonding than
with conventional fastening
 Because the uniform stress distribution in the joint permits full
utilization of the strength and rigidity of the adherends.
Non-conventional welding (hybrid welding)
 Hybrid welding


The aim of nonconventional welding is increasing of joining
process efficiency.
 Hybrid welding processes combines two welding processes to
improve or increasing of joining process efficiency. The first
hybrid welding process was the plasma – MIG welding which
represents a combination between plasma welding and
shielded gas welding with fusible electrode (MIG welding).
At present over 20 hybrids welding processes are known, the
most important as the following:

- Laser arc hybrid welding which combines the laser
welding with a TIG or MIG shielded gas electric arc
welding process;
- MIG welding combined with submerged arc welding.
- Resistance spot welding combined with brazing.
- Laser activated friction stir welding
- A-TIG welding (chemically activated TIG welding).
- Ultrasonically activated TIG welding.
Advantages of Hybrid Welding
The new process combines the advantages of the two welding
processes, namely productivity by energy concentration,
high welding speed, deep penetration and reduced heat
influence on the material and as an effect the reduced level
of deformation by welding, specific characteristics of laser
welding, with the toughness application by using a filler
material.
So, the hybrid welding is applicable mostly for the series
production welding of thicker materials considering greater
tolerances to prepare components for the welding operation.
Magnetic impelled arc butt welding
Magnetic impelled arc butt welding
 Magnetically impelled arc butt (MIAB) welding is a solid state welding
process involving rotation of arc around the tube to aid the uniform
heating of faying surfaces.
 Magnetically impelled arc butt (MIAB) welding is a pressure
welding process used for joining of pipes and tubes with an 
external magnetic field affecting arc rotation along the tube
circumference. In this work, MIAB welding of low alloy steel (T11)
tubes were carried out to study the microstructural changes
occurring in thermo-mechanically affected zone (TMAZ).
How MIAB welding works?
 Welding arc rotate in the gap between tubes due to the presence of external magnetic
field generated with permanent or electromagnets.
 The maximum Linear Speed of the arc movement is 870 km/hour.
 The spinning arc in combination with thermal conductivity of the welded metal creates
very uniform heating at the joint.
 On completion of welding, the welded parts are rapidly brought under pressure

MIAB welding is a forge welding process that relies on an electric arc to generate
necessary heating to melt the surfaces being welded.
Applications of MIAB welding

 Butt welding of thin-walled tubes

 Butt and T-butt welding of automobile parts
 Butt welding of thick-walled tubes
 Butt welding of solid parts
 Tube to plate welding
 Tube to flange welding
 “This machine tool based process is attractive to the mass production
industries because of the short cycle times and reproducible quality.”
Automotive applications

 Vehicle drive shafts.

 Rear axle assembly.
 Wheel bearing housing.
 Pipe and tube assemblies.
 Shock absorber assemblies.
 Nuts welded to plates.
 Brake pipes
 Comparison to other welding processes

MIAB has replaced automated TIG, MIG, Resistance and Flash Butt Welding.

Why MIAB scores over other welding process?

 Less internal flash.

 Shorter weld times.
 Less metal loss.
 Reduced machine maintenance.
 Uniform welding.
 Low power consumption
 No rotation of components
 No consumables needed. e.g.. Filler material.
UNIT-4
Tungsten inert gas welding
 Tungsten Inert Gas (TIG) welding, also known as Gas Tungsten Arc

Welding (GTAW) is an arc welding process that produces the weld with

a non-consumable tungsten electrode. The pulsed high frequency gas

tungsten-arc welding process (PHFGTAW) is an innovation on the more

conventional GTAW process, wherein a direct current straight polarity (dcsp)

arc is pulsed between two discrete levels of welding current in the

frequency range of 60 to 25,000 Hertz (Hz).

 Working
 Arc is struck between the non-consumable tungsten electrode and the work piece to fuse metals
 Arc is covered by a layer of shielding gas which acts as the flux and keeps the nitrogen and
oxygen in the air from coming in contact with the molten puddle.
 When the puddle is formed on the base metal, the torch is moved along the joint until the
workpiece is fused together
 A filler rod may or may not be used
 If a filler rod is used, it should be the same composition as the base metal.
 The filler rod is fed manually into the leading edge of the puddle.
 The torch may be moved in a semicircular motion to vary the width of the bead.
 FEATURES OF TIG WELDING
 Temperature may be in the range of 10000k.
 Automatic and manual techniques can be used.
 TIG may be done in all positions.
 Metal thickness upto 5mm.
 Weld speed from 8mm/s to 50mm/s.
 With superior arc and weld puddle control, clean welds are produced.
 No sparks or spatter because only the necessary amount of filler metal is added to the
welding pool.
 No smoke and fumes unless.
 No flux required as argon gas protects the weld pool from contamination.
 DCSP VS AC IN TIG
 DCSP  AC
• Higher penetration • Medium penetration
• Deeper weld puddle • Medium depth
• 62.5% of heat at work enables thick • 50% of heat at both electrode & work piece
sheets weld enables thin sheets weld
• To weld metals like copper, stainless • Preferred for aluminium & magnesium
steel, etc. which do not need cleaning
of oxide
 TIG SHIELDING GASES
ARGON VS HELIUM

Argon
 Heavier in weight
 Good arc starting
 Less base metal distortion
 Good cleaning action
 Good arc stability
 Focused arc cone
 Lower arc voltages
 For thin sheets
Helium
 Faster travel speeds
 Increased penetration
 Difficult arc starting
 Less cleaning action
 Flared arc cone
 Higher arc voltages
 Higher cost than argon
 For thick sheets
 ADVANTAGES & DISADVANTAGES

Advantages
 Welds more metals & metal alloys
 High quality and precision
 Pin point control
 Aesthetic weld beads
 No sparks or spatter
 No flux or slag
 No smoke or fumes
Disadvantages
 Lower filler metal deposition rates
 Good hand-eye coordination a
required skill
 Brighter UV rays than other processes
 Slower travel speed than other processes
 Equipment costs tend to be higher
Gas Metal Arc Welding (GMAW)

 GMAW is defined as arc welding using a continuously fed consumable electrode and
a shielding gas.
 GMAW is also known as Metal Inert Gas (MIG) or metal active gas (MAG) welding.
 Produces high-quality welds.
 Yields high productivity.
Operation
 GTAW is considered the most difficult among welding processes, because the welder must
maintain a short arc length, great care and skill are required to prevent contact between the
electrode and the workpiece. Both hands are used one to feed the filler metal and the other to
move the welding torch.
 To strike the welding arc, a high frequency generator provides a spark which allows the arc
to be initiated while the electrode and the workpiece are separated, typically about 1.5–3 mm
apart.
 An alternate way to initiate the arc is the "scratch start". Scratching the electrode against
the work with the power on also serve to strike an arc. However, scratching can cause
contamination of the weld and electrode. Some GTAW equipment is capable of a mode called
lift arc.
 When a spark is present, the equipment immediately increases power and converting the
spark to a full arc.
 The welder moves the torch in a small circle to create a welding pool, the size of which
depends on the size of the electrode and the amount of current
Materials

 Gas tungsten arc welding is most commonly used to weld stainless steel and

nonferrous materials, such as aluminum and magnesium, but it can be applied to nearly

all metals, with notable exceptions being lead and zinc.

Equipment's
 To perform gas metal arc welding, the basic necessary equipment is:
 a welding gun
 a wire feed unit
 a welding power supply
 an electrode wire
 a shielding gas supply.
GMAW Circuit diagram

(1)Welding torch
(2)Workpiece
(3)Power source
(4)Wire feed unit
(5)Electrode source
(6)Shielding gas supply
Wire Feed Unit

• It supplies the electrode to the work, driving it through the conduit and on to the
contact tip.

• Most models provide the wire at a constant feed rate, but more advanced machines
can vary the feed rate in response to the arc length and voltage.

• Some wire feeders can reach feed rates as high as 30.5 m/min (1200 in/min), but feed
rates for semiautomatic GMAW typically range from 2 to 10 m/min (75–400 in/min).
 Power Supply
• A constant voltage power supply.

• As a result, any change in arc length (which is directly related to voltage) results in a large change in
heat input and current.

• sometimes a constant current power source is used in combination with an arc voltage-controlled wire
feed unit.

• In rare circumstances, a constant current power source and a constant wire feed rate unit might be
coupled.

• Alternating current is rarely used with GMAW; instead, direct current is employed and the electrode is
generally positively charged
Shielding Gas

• Purpose of shielding gas is the protect the weld area from the contaminants in the
atmosphere.

• Gas can be Inert, Reactive, or Mixtures of both.

• Gas flow rate is between 25-35 CFH.

• Argon, Helium, and Carbon Dioxide are the main three gases used in GMAW
 Tool Style

 The top electrode holder is a semiautomatic air-cooled holder.

 Compressed air circulates through it to maintain moderate temperatures.

 It is used with lower current levels for welding lap or butt joints.

 The second most common type of electrode holder is semiautomatic water-cooled,

where the only difference is that water takes the place of air.

 It uses higher current levels for welding T or corner joints.

 The third typical holder type is a water cooled automatic electrode holder—which is
typically used with automated equipment.
 Electrode
• Electrode selection greatly influences the mechanical properties of the weld and is a key factor of weld quality.
• Electrodes contain deoxidizing metals such as silicon, manganese, titanium and aluminum in small percentages
to help prevent oxygen porosity.

• Some contain denitriding metals such as titanium and zirconium to avoid nitrogen porosity.

• Depending on the process variation and base material being welded the diameters of the electrodes used
typically range from 0.7 to 2.4 mm (0.028–0.095 in) but can be as large as 4 mm (0.16 in).

• 1.14 mm (0.045 in) - short-circuiting metal transfer process.

• 0.9 mm (0.035 in) - spray-transfer process mode

 Short Circuit (Short Arc)
• Operates at low voltages and welding current.

• Small fast-freezing weld puddle obtained.

• Useful in joining thin materials in any position, as well as thick materials in vertical and
overhead positions.

• The weld process parameters (volts, amps and wire feed rate)- between 100 to 200 amperes
at 17 to 22 volts.

• Metal transfer occurs when an electrical short circuit is established.

• It can only be used on ferrous metals.

 Pulsed-Spray
• A variation of the spray transfer mode.
• Uses a pulsing current to melt the filler wire and allow one small molten droplet to fall with
each pulse.
• The pulse provides a stable arc and no spatter, since no short-circuiting takes place.
• The smaller weld pool gives the variation greater versatility, making it possible to weld in all
positions.
• Maximum speed (85 mm/s or 200 in/min).
• Required shielding gas - primarily argon with a low carbon dioxide concentration.
• Requires a special power source capable of providing current pulses with a frequency between
30 and 400 pulses per second.
• It requires lower heat input and can be used to weld thin workpieces, as well as nonferrous
materials.
 Advantages

• High deposition efficiency when used in certain transfer modes.

• The process can be used on thin materials with relative ease if properly set.
• Low Hydrogen weld deposit with all electrodes.
• High production factor since no slag is required to be removed and uses a continuous
electrode.
• With the parameters properly set for the application, anyone can weld after a very short
amount of practice.
• One given electrode size can be used on various thicknesses of materials productively.
 Disadvantages
• Requires a Wire Feeder which is difficult to move and can sometimes be a
maintenance/repair burden.

• Needs Shielding Gas so welding in windy conditions can be difficult.

• No slag system so out of position welds are sometimes more difficult.

• Increased chance of lack of fusion if parameters and welding technique is not controlled.

• The gun is difficult to get into tight places.

• Is not suitable for windy conditions and underwater welding.

Applications
 While the aerospace industry is one of the primary users of gas tungsten arc welding, the
process is used in a number of other areas. Many industries use GTAW for welding thin
workpieces, especially nonferrous metals. It is used e in the manufacture of space vehicles,
and is also employed to weld thin-wall tubing such as those used in the bicycle industry. In
addition, GTAW is often used to make root or first pass welds.
 It is used to repair tools and dies and for maintenance purposes.
 No other welding process permits the welding of so many alloys in so many product
configurations.
 Filler metal alloys, such as elemental aluminum and chromium, can be lost through the
electric arc from volatilization. This loss does not occur with the GTAW process. Because
the resulting welds have the same chemical integrity as the original base metal.
 Hot Wire TIG
 In hot wire welding, filler wire is resistance heated until close to the melting
point and added to the weld puddle behind the tungsten.
 This prevents the wire from chilling the weld pool and allows the filler metal to
flow out across the weld puddle resulting in a smooth, attractive weld bead.
 Since nearly all of the full energy of the welding arc is available for penetration
or to generate the weld pool and fusion, a two to three times faster travel
speed is realized.
 More wire can be deposited and fill rates are increased with the added benefit
of weld quality as good as or in some cases better than with cold wire GTAW
Wire entry
 The location of wire entry into the weld pool is critical.
 For hot wire GTA welding, wire entry is normally at the rear of the puddle with the
wire deposited in the depression behind the arc at the rise of the weld pool.
 This permits faster travel speed than with cold wire GTAW where wire entry is
at the leading edge of the puddle.
 Hot wire travel speeds of 203-228 mm/min are typical compared to about 101
mm/min for cold wire GTAW.
Advantages Disadvantages
 It is an automated process with high  Higher welding skills are
levels of productivity required (for manual welding).
 Able to make high quality welds on  It is very expensive compared to
nearly all weldable metals and alloys. other arc welding processes.
 No need to remove slag.
 No spatter.
 No need to change electrodes.
 Higher deposition rate
 High welding speed.
 Welding is possible in all positions.
 Applications
 This process is used in joint welding and overlay welding(ex: Pipeline
Construction)
 Ship Building
 Off shore engineering power station construction.
 It is also used to make root-run in important element structures.
Cold Metal transfer welding
 Fronius of Austria in 2004, after many years of research and development have
unveiled new arc welding based on modified MIG welding process called cold
metal transfer welding. CMT is a type of MIG welding process, but novelty is
that droplet transfer occurs by new mechanical droplet cutting method.

 In CMT; droplet transfer process, when electrode wire tip brought in contact
with the molten pool, a high short circuit current flows and this control of
short circuit is performed dropping the welding current and retracting the wire
which stimulate the detachment of droplet

 CMT hot process ensues, involving the arc being re-ignited, the wire being fed
forward once more, and the set welding current reflowing.
Objectives of CMT

 To examine the importance of cold metal transfer process and its

contribution towards welding industries.

 To examine the various control parameter in CMT process for no-spatter

welding and improved weld bead aesthetics.

 To examine the microstructure and other weld characteristics of CMT.

The CMT process is a novel welding technology that can be
employed to handle welding tasks formerly viewed as tremendously
difficult or impossible. This welding process is highly recommended
for robot applications and any automatic applications. For any
common purpose base metals and wires can be handled, also new
product development are possible.
 Narrow-gap GTAW Techniques

Hot-wire Method. In this most popular narrow-gap GTAW technique,

electric currents passing through filler wires increase the deposition rate. The
amount of electric current that can be used is limited because of the arc blow
that results. A switching method has been developed to flow arc and wire
current alternately to solve this problem.

In another hot-wire method, the welding wire is inserted from behind the
weld pool and a small direct current flows through the wire. This causes the
GTAW arc to incline in the weld advancing direction
Double-shield System. This method is used to supply center and shield
gas. The center gas cools the arc column to converge the arc, increasing
the electric current density. A typical application uses mixed gas of 50
percent helium and 50 percent argon as the center gas and argon gas
outside the mixed gas. This successfully increases the depth of
penetration. Combining this approach with a hot-wire method or a twin-
wire method, in which a wire is inserted from behind, also increases the
deposition rate.
Oscillation Method. In this method, a tungsten electrode is mounted at a slant
on the torch shaft while the shaft is twisted to increase penetration into the
groove walls. Arc oscillation prevents formation of voids that normally are
generated by a high-current arc.
Combining the oscillation method with the hot-wire method can result in high-
speed, high-deposition welding. The actual realized deposition rate typically is
60 grams per minute in flat position and 35 grams per minute in vertical-up
position.
Other Techniques. GTAW also can be used with the maximum peak
current of 500 amps at high-frequency pulses of 5 to 15 kilohertz to
help improve the arc's concentration on the center of the groove.
Another technique is the two-electrode method, in which a torch with
two electrodes generates two arcs simultaneously. The pulses are
overlapped on each electrode to produce large currents without
concentration of arc force. The maximum deposition rate is 30 grams
per minute
 MIG Welding

MIG welding is a gas shielded metal arc welding process using the heat of an electric arc
between a continuously fed, consumable electrode wire and the material to be welded. Metal is
transferred through a protected arc column of inert gas to the work.

 A wire of copper coated mild steel is fed continuously from a reel through a gun with a melting
rate up to 5m/min.
 Current through the wire ranges from 100 to 400 A depending upon the diameter of the wire.

 CO2 is principally used apart from argon or argon-helium mixture as shielding gas.

 The welding machine is a dc constant voltage machine.

Tools and equipment used in MIG
welding
 1. Power source: MIG
welding uses a dc constant
voltage transformer.

 2. Wire feeder: A wire

feeder is required to feed the
electrode wire continuously
and smoothly to the welding
gun.
3. Conduit and hoses: Conduit facilitates feeding of wire to the torch and hoses supply the
shielding gas

4. Welding gun: it transfers the welding current to the wire and provides the gas for shielding
the arc and weld pool.
5. Gas cylinders: They are used to store shielding gases like CO2, argon, etc.

6. Safety equipment: They all the tools for safety and precaution purpose like helmet,
goggles, apron, gloves and boots .
 Advantages and Disadvantages of MIG
Disadvantages
Advantages
The arc is less stable.
No flux required.
Fast welding and deposition rates. Generates more spatter.

Increased corrosion resistance. Limited to short –circuit mode of metal

Easily automated welding. transfer.

Suitable for all metals including Relatively high heat and light generation.
aluminum and stainless steel.
Equipment is quite complex.
Least expensive and highly economic.
Not suitable for base metal contamination.
Application of MIG welding

1. The most common application of MIG welding is automotive repair.

2. Special welding equipment can be used to weld pipes.

3.It can even be used to reinforce the surface of a worn out railroad track.

4.Because of its high economy and utility it is widely used in various

industries.
 Joint preparation
 Joint preparation Refers to the way pieces of metal are put together or
aligned with each other.
 The five (5) basic weld joint designs are:
 Butt Joint
 Lap Joint
 Corner Joint
 Tee Joint
 Edge Joint
Five basic weld joints that may be found in a weldment

 Butt Joint
 Lap Joint
 Corner Joint
 Tee Joint
 Edge Joint
Open Corner Closed Corner

Two ways of fitting up an outside corner joint.

Some considerations in selecting a type of joint to use on
a fabrication

 Accessibility for welding

 Strength requirements
 Cyclic or static loading
 Material thickness
 Welding process to be used
 Material type
 Code Requirements
 Cost
 two edge preparations used with butt joints.

Single vee Groove

Bevel Groove Vee Groove
Single
bevel

Double Vee Groove

Double bevel
Single J groove J Groove

Single U Groove
Double J groove U Groove
Square Groove
Single square

Double square Double U Groove

ASSIGNMENT (AWT)
Pulse & Synergic-MIG
Narrow-groove welding techniques
Twist arc GMAW technique
Multi-cathode GTAW

ASSIGNMENT (SQCR)
Dodge-Roming type system for acceptance sampling by attributes
Acceptance sampling plans under risk
Acceptance sampling by variables
Thank you