INTRODUCTION TO

WELDING
 WELDING
a fabrication process whereby two
or more parts are fused together
by means of heat, pressure or both
forming a join as the parts cool.
Welding is usually used on metals
and thermoplastics but can also be
used on wood.
 WELDING
Welding is a method of repairing or
creating metal structures by joining
the pieces of metals or plastic through
various fusion processes. Generally,
heat is used to weld the materials.
Welding equipments can utilize open
flames, electric arc or laser light.
 HISTORY OF WELDING
There is no one person we can credit
with the invention of welding Middle
Ages.
 Blacksmiths of the Middle Ages welded
various types of iron tools by
hammering. The welding methods
remained more or less unchanged until
the dawn of the 19th century.
 HISTORY OF WELDING
August De Meritens
1881 welding was invented.
who used arc heat to join lead plates together.
Nikolai Slavynov figured out how to use metal
electrodes for welding.
 C.L. Coffin, an American engineer, discovered
an arc welding process using a coated metal
electrode that became the precursor of
shielded metal arc welding.
 HISTORY OF WELDING
Strohmenger
1900 was first introduced Coated metal electrode. A
coating of lime helped the arc to be much more
stable.
A number of other welding processes were developed
during this period. Some of them included seam
welding, spot welding, flash butt welding, and
projection welding. Stick electrodes became a
popular welding tool around this time as well.
 WELDING PROCESSES
 What is “welding”?
- is a process in which two or more pieces of
metal are joined together by the application of heat,
pressure or a combination of both.
 Forge Welding
- It is the welding process where the pieces of the
joint are heated in a forge, or furnace, and are
fused together with pressure produced by
hammer.
BASIC WELDING PROCESS

SMAW – Shielded metal Arc Welding

FCAW – Flux Cored Arc Welding
GMAW – Gas Metal Arc Welding
GTAW – Gas Tungsten Arc Welding
SAW – Submerge Arc Welding
Shielded Metal Arc Welding (SMAW
1
1. AC OR DC POWER
SOURCE AND
2 CONTROLS
3
2. ELECTRODE HOLDER
4
6
3. ELECTRODE
54. ARC
5. WORK
7 6. WORKPIECE LEAD
7. ELECTRODE LEAD
 SMAW
PROTECTIVE GAS FROM
ELECTRODE COATING ELECTRODE CORE
WIRE

ELECTRODE
MOLTEN WELD METAL COATING

ARC
SLAG

METAL DROPLETS

SOLIDIFIED WELD
METAL

BASE METAL

DIRECTION OF TRAVEL
 ADVANTAGES:

- equipment is relatively simple and inexpensive.

- newer solid-state power sources are so small
and light weight that they can be carried to the job.

 DISADVANTAGES:

- relatively slow production

- a layer of solidified slag must be removed.
- low hydrogen-electrodes require special
storage.
 Gas Metal Arc Welding (GMAW)
1. .WORK LEAD
Shielding Gas
2. .WATER TO GUN Regulator
3. .WATER FROM GUN
4. .GUN SWITCH CIRCUIT
5. .SHIELDING GAS TO GUN
6. .CABLE ASSEMBLY Electrode Supply

7. .SHIELDING GAS FROM CYLINDER

7
8. .WELDING CONTACTOR CONTROL Electrode Feed Unit

9. .POWER CABLE
10. .PRIMARY INPUT POWER Shielding Gas Supply

4
Welding Gun 8
5
Power Source
6
2 9

3
1
10
Workpiece Water Circulator
(optional)
 GMAW
SHIELDING GAS

NOZZLE

MOLTEN WELD
METAL
ELECTRODE
SOLIDIFIED WELD
METAL ARC

BASE
METAL

DIRECTION OF TRAVEL
ADVANTAGES:

- can be used successfully in situations where the presence of

hydrogen could cause problems.

- well suited for automatic and robotic welding or high production

- Since there are little or no cleaning required following welding,

overall operator productivity is greatly improved

- This efficiency is further increased because the continuous

spool of wire does not required changing as often as the
individual electrodes used in SMAW

- is clean process, because there is no flux present.

DISADVANTAGE:

Since SMAW uses shielding gas alone to protect

the puddle from the atmosphere excessive
contamination of the base metal may cause
porosity. Drafts or wind may disperse shielding
gases, which makes GMAW unsuitable for field
welding. The equipment used is more complex
than that used for SMAW, increasing the
possibility of mechanical problems that can lead
to quality problems. s. The used of short-circuiting
transfer can lead to lack of fusion discontinuitie
Flux Cored Arc Welding (FCAW)
Shielding Gas Regulator

Wire Feeder

Electrode
Supply

Power Source
Welding Gun
Shielding Gas Supply

Workpiece
 FCAW

NOZZLE (OPTIONAL)
GAS (OPTIONAL)

MOLTEN METAL

MOLTEN SLAG
FLUX CORED
ELEECTRODE

SILIDIFIED WELD METAL ARC

LAG

DIRECTION OF TRAVEL
ADVANTAGES

Due to increased deposition rates and a high tolerance for

contamination, FCAW has replaced SMAW and GMAW in
many applications. FCAW can be used in both shop and field
applications, and provides high productivity in the terms of
the amount of weld metal that can be deposited in a given
period of time, particularly for the hand-held process. FCAW
can be used in all positions.

DISADVANTAGES

Because a flux is present during welding, a layer of solidified

slag must be removed. The flux also generates a significant
amount of smoke, which reduces the welder’s visibility and
makes the weld puddle more difficult to observe.
 Gas Tungsten Arc Welding (GTAW)

Shielding
gas with
flow meter
regulator
GTAW Torch

Filler rod

Tungsten electrode

Base metal

Power supply
Ground cable
 GTAW/TIG
 
SHIELDING GAS NOZZLE

TUNGSTEN ELECTRODES

SHIELDING GAS

MOLTEN WELD ARC

METAL

FILLER ROD

SOLIDIFIED WELD
METAL

BASE
METAL

DIRECTION OF TRAVEL
ADVANTAGES
- The GTAW process is capable of welding virtually all
metals, even extremely thin materials.
- high-quality welds with excellent visual appearance can
be produced.
- the process is quite clean and there is no slag to remove
after welding.

DISADVANTAGES

- The skill level necessary to produce high-quality welds is

acquired only after much experience in manipulating the
electrode and feeding the filler wire.
- Because the process has a low tolerance for
contamination, the base and filler metals must be extremely
clean prior to welding.
- among the slowest of the available welding processes.
 Submerge Arc Welding ( SAW )

FLUX
HOPPER
CONTROL POWER
SYSTEM SOURCE

TORCH

FLUX

WORKPIECE
 SAW
FLUX RECOVERY

FROM FLUX HOPPER

CONTACT TUBE

MOLTEN FLUX
SLAG
CONSUMABLE ELECTRODE

GRANULAR FLUX
BLANKET

BASE METAL

SOLIDIFIED WELD MOLTEN WELD METAL ARC PATH

METAL

DIRECTION OF TRAVEL
ADVANTAGES
- SAW can be performed on numerous metals.
- It can typically deposit more metal than any of the more common
processes.
- It has operator appeal– because of the lack of an arc, the operator
has no need for a filter lens and other heavy protective clothing.
- Another benefit is that there is less smoke generated than with
the other processes.
- SAW has very deep penetrating capabilities.

DISADVANTAGES
- Cleaning the work surfaces and aligning the machine travel with
the joint are particularly important in submerged arc welding.
Improper alignment will result in offset beads with incomplete joint
penetration.
- In a highly restrained joint, joint misalignment may also cause
cracks.