ADVANCES IN

WELDING TECHNIQUES

IN TODAY’S

HEAVY ENGINEERING INDUSTRY

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Welding is an operation for
• joining two or more materials.
• with or without,
– application of heat or pressure or both.
– addition of filler.

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 TYPES OF WELDING

• FUSION WELDING

• ELECTRIC RESISTANCE WELDING

• SOLID-STATE WELDING ………...

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 FUSION WELDING
• Melting of base material and/or filler.
• Heat source
– Flame
– Electric arc
– High energy beam
– Electric resistance, high frequency current
– Friction
– Chemical energy
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FUSION WELDING PROCESSES
• Shielded Metal Arc Welding SMAW
• Gas Tungsten Arc Welding GTAW
• Gas Metal Arc Welding GMAW
• Flux Cored Arc Welding FCAW
• Submerged Arc Welding SAW
• Electro-Slag Strip Cladding ESSC
• Plasma Arc Welding PAW
• Electron Beam Welding EBW
• Laser Beam Welding LBW
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SOME APPLICATIONS IN HED
Thick Walled High Pressure Reactors

Shell Courses
Dished End

Skirt
Support Ring
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SOME APPLICATIONS IN HED
Thick Walled High Pressure Reactors
Dished End Petal Seams
Nozzle Support Ring

Long seam/circ. Seam Overlay on Shell & Dished End

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FABRICATION CRITICALITIES
• High deposition rates required for increased Productivity
Requires mechanization & automation

• Problems due to,

- heavy thickness
- weldability
Requires Preheating and Postheating during welding
Stress Relieving after welding
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Mechanization

• Welding on profile (nozzle welding)

• Use of seam tracker

• Step overlay technique

• Flexible automation

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 Auto Pre-heat/Post-heat Control

INFRA-RED
SENSOR
PROCESSOR

PID
CONTROLLER
TEMP.
RECORDER
INFRA-RED SENSOR

GAS
HEADERS

GAS
HEADERS-
ON /OFF

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 Pre-heating/Post-heating

Low flame
Infra-red Sensor-Circseam
0°C

600°C Actual Temperature Plot

High flame 54
STRESS RELIEVING / POST WELD HEAT TREATMENT

Quenching Facility
Bogie-Hearth Furnace
14 x 9 x 9 m
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THANK YOU
02 Sept. 2000
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