Vocational Training Report On

Welding Design
Name: Arka Dey
Roll No: 08102007024
3rd Year
Under The Guidance Of
Mr. S.K. Mahato
(Instructor, Basic Training Centre )
Mr. D. Chatterjee
(Instructor, Regional Welding Training Institute)

Kharagpur Railway Workshop

Kharagpur, West Midnapore
 SALIENT FEATURES
OF
KHARAGPUR WORKSHOP
 It is an ISO 9001:2000 certified organization established in
1898; now the second largest in Asia.
 Periodic overhauling and repair of electric and diesel engines
and locomotives are done here.
 In 0.61 million square meters workshop area 0.28 million
square meters is covered.
 Inside the workshop 94.5kms of rail track is laid and 11kms of
road is constructed.
 The workshop has a staggering 1458 number of highly
sophisticated machine operated by trained operators.
 It not only has the working unit but also training unit including
regional welding training institute.
 What is Welding
 Welding can be defined as a permanent satisfactory and most economical joining
process of two similar or dissimilar metal or alloy, with or without the application
of pressure and or with or without application of filler rod to form one
homogeneous mass under the influence of heat.
Advantages of Welding

 Welding portion becomes as strengthen as the original metal.

 Welding joint is cheaper than any other method of joining two
metallic.
 Two similar or dissimilar metal or alloy can be joined firmly.

Disadvantages of Welding

Welding results in residual stress and distortion of work piece.

Welded joints for any reasons need stress relief heat treatment.
Edge preparation of work piece is generally required before
welding them.
 Types of Welding
1. Arc welding 4. Thermit Welding
 Carbon arc,
 Metal arc, 5. Solid State Welding
 Metal inert gas,  Friction,
 Tungsten inert gas,  Ultrasonic,
 Plasma arc,  Diffusion,
 Submerged arc, 
 Electro-slag. Explosive.
2. Gas Welding 6. Newer Welding
 Oxy-acetylene,  Electron-beam,
 Air-acetylene,  Laser.
 Oxy-hydrogen.
3. Resistance Welding 7. Related Process
 Butt,  Oxy-acetylene cutting,
 Spot,  Arc cutting,
 Seam,  Hard facing,
 Projection, 
 Percussion. Brazing,
 Soldering.
Welding Defects
Welding defects can be classified into two groups:
A.External defects,
B.Internal defects.

External defects
These are the defects that are visible, external defects include
Spatter, Crack,
Overlap, Twisting,
Undercut, Sagging,
Inclusion, Crater,
Blow hole, Porosity,
Penetration, Lack of fusion.

Internal defects
These are the defects that are not visible, internal defects include
Porosity or worn hole , Lamellar tearing,
Slag inclusion, Lack of fusion,
Cold cracking Incomplete penetration.
 Welding Design
Welding design is one the most concerned part in welding process. The edge
preparation is one of the most important factor in design. The position in which
welding is done is another concerning matter in welding design:

Flat (Down Hand) position, Vertical position,

Horizontal position, Overhead position.

Type of the joint should be considered first for proper welding joint. Various kinds of
joints are:
 The Butt weld
The Butt Weld is one the most simply designed weld joint
mainly used in TIG and MIG Welding.
 The fillet weld
Fillet joint also known as lap joint is obtained by overlapping of the plates and then
welding the edges of the plates. The cross section of the fillet is almost triangular. The
fillet joints may be: 1. single transverse joint,
2. Double transverse joint,
3. Parallel fillet joint.
While designing fillet joints some cases have to
be considered like strength, type and magnitude
of applied load. Joint subjected to torsion and
bending moment also have to be considered.
 Welding
in
kharagpur railway workshop
 Concluding discussion

Welding is the most economical and satisfactory joining procedure that be

carried out anywhere to overcome the defects and to give the welding joints
maximum strength welding design have to be considered. In Indian Railways
the welding in my view is the most used and most effective fabrication
process. From rails to the engines, all the big structures must have gone through
this process. So little miscalculation could lead to a disaster so design is must
be one of the main concerns and should be looked after carefully.
Thank You.