Introduction

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Presentation
Submitted by
Name:Bithi Mohanta
Roll:1805058
Different types of welding processes used for special fabrication applications

Welding Processes

1. Thermit welding
2. Electro-slag welding
3. Electron beam welding
4. Laser-beam welding
5. Forge welding
6. Friction welding
7. Diffusion welding
8. Explosion welding
 Thermit Welding

Principle

Thermit welding is a liquid state chemical welding process, in which joint

formation takes place in molten state.In this type of welding, a mixture of
aluminum and iron oxide is used in ratio 1:3 by weight.
8 Al + 3 Fe3O4 –> 9 Fe + 4 Al2O3 + Heat
This reaction gives aluminum oxide and iron and also liberate a huge
amount of heat which coverts this mixture into molten state. There is an
opening at bottom of the crucible from where, this molten iron poured at
the required plates where we want to create joint.  This is basic principle of
thermit welding.
 Thermit welding

Schematic diagram
 Thermit welding
Advantages and Disadvantages

Advantages

1. It is simple and easy process.

2. Low setup cost.
3. Metal joining rate is high.
4. Thermite welding can be done at
site where casting is impossible.
5. This can be used where power
supply is not available.
 Thermit welding

Disadvantages

1. It is used for limited metals like

iron and copper.
2. It is uneconomical for welding
light parts.
3. Highly depends on
environmental condition like
moisture contain, work piece
alignment etc
 Thermit welding

Application

1. It is mostly used to weld railroad at

the site.
2. They are used to repair heavy
castings.
3. It is used to weld cable connectors
of copper.
4. It is used to make structure joints
in large ships etc.
5. It is used to joint pipe, thick plate
etc. where power supply is not
available
 Electro Slag Welding

Principle

Electroslag welding process works on the principle of heat

generation due to arc and electric resistance. Arc is made
between the welding electrode and the workpiece which
starts melting the filler metal to fill the filler cavity. Now the
heat is produced due to electric resistance when the current
passes through the surface. The heat further starts melting
the filler metal which is continuously fed from the roller.  This
filler wire melts and fills the weld and makes it a strong joint.
 Electro slag welding

Schematic diagram
 Electro slag welding
Advantages and Disadvantages

Advantages

1. There is no problem of slag

inclusion or porosity.
2. The process is semi-automatic
and faster.
3. Heavier section can be welded in
a single pass.
4. High productivity can be
achieved.
5. Low cost for joint preparation.
 Electro slag welding

Disadvantages

1. Too high heat input to base.

2. High temperature of welding
needs cooling arrangement.
3. Slow rate of cooling give
columnar grain in weld.
4. It is difficult to close cylindrical
welds
5. It tends to produce large grain
sizes.
 Electro slag welding

Application

1. It is used in heavy industries

where plate thickness is up to 80
mm to be joined.
2. Welding of thick walled large
diameter pipes is done by this
welding process.
3. Welding of storage tanks is done
by it.
4. It is used to construct big and
thick parts of ships
 Electron Beam Welding

Principle

This welding works on same principle

of electron beam machining. This process uses
kinetic energy of electrons to produce heat. This
heat is further used to weld two welding plates.
When a high jet of electrons strike at welding
plates, its kinetic energy converts into heat
energy. This heat energy is sufficient to fuse two
metal plates together to form a weld joint.
 Electron beam welding

Schematic diagram
 Electron beam welding
Advantages and Disadvantages

Advantages

1. It can weld both similar and

dissimilar metals.
2. It provides high metal joining
rate.
3. Low operating cost because no
filler material and flux are used.
4. It provide high finish welding
surface.
5. It can used to weld hard
materials.
 Electron beam welding

Disadvantages

1. High capital or set up cost.

2. High skilled labor required.
3. Frequently maintenance
required.
4. Work pieces size is limited
according to vacuum chamber.
5. It cannot do at site due to
vacuum
 Electron beam welding

Application

1. It is used in aerospace industries

and marine industries for structure
work
2. It is used to join titanium and its
alloy
3. It is used to weld electronic
connectors in electronic industries.
4. This process is also used in nuclear
reactors and in medical industries
 Laser Beam Welding

Principle

It works on the principle that when electrons of

an atom gets excited by absorbing some
energy. And then after some time when it
returns back to its ground state, it emits a
photon of light. The concentration of this
emitted photon increased by stimulated
emission of radiation and we get a high energy
concentrated laser beam.
 Laser beam welding

Schematic diagram
 Laser beam welding
Advantages and Disadvantages

Advantages

1. It produces high weld quality

2. No electrode is required.
3. No tool wears because it is a
non-contact process.
4. The time taken for welding thick
section is reduced
5. It can be weld through air and no
vacuum is required
 Laser beam welding

Disadvantages

1. The initial cost is high. The

equipment used in LBW has a high
cost.
2. High maintenance cost.
3. Due to the rapid rate of cooling,
cracks may be produced in some
metals.
4. High skilled labor is required to
operate LBW.
5. The welding thickness is limited to
19 mm
 Laser beam welding

Application

The laser beam welding is dominant

in the automotive industry. It is used
in the area where large volume
production is required
 Forge Welding

Principle

Forge welding is a solid state welding process in which

both the plates are heated quite below its melting
temperature. This heating deforms the work pieces
plastically. Now a repeated hammering or high pressurize
load is applied on these plates together. Due to this high
pressure and temperature, inter-molecular diffusion
takes place at the interface surface of the plates which
make a strong weld joint. This is basic principle of forge
welding. 
 Forge welding

Schematic diagram
 Forge welding
Advantages and Disadvantages

Advantages

1. It is simple and easy.

2. It does not require any costly
equipment for weld small pieces.
3. It can weld both similar and
dissimilar metals.
4. Properties of weld joint is similar
to base material.
5. No filler material required
 Forge welding

Disadvantages

1. Only small objects can be weld. 

2. High Welding defects involve.
3. It cannot use as mass production.
4. Mostly suitable for iron and
steel.
5. It is a slow welding process.
 Forge welding

Application

1. It is used to join steel or iron.

2. It is used to manufacture gates,
prison cells etc.
3. It is widely used in cookware
4. It was used to weld weapon like
sword etc.
5. Used to weld shotgun barrels
 Friction Welding

Principle

In this welding process, the friction is used to generate heat

at the interference surface. This heat is further used to join
two work pieces by applying external pressure at the surface
of work piece.The friction is applied until the plastic forming
temperature is achieved.After this heating phase, a uniformly
increasing pressure force applied until the both metal work
pieces makes a permanent joint. This joint is created due to
thermo mechanical treatment at the contact surface.
 Friction welding

Schematic diagram
 Friction welding
Advantages and Disadvantages

Advantages

1. No filler metal required.

2. Welding strength is strong in
most cases.
3. Easily automated.
4. High welding speed.
5. High efficiency of weld.
 Friction welding

Disadvantages

1. This is mostly used only for

round bars of same cross section.
2. Non-forgeable material cannot
be weld.
3. Preparation of work piece is
more critical
4. High setup cost.
5. Joint design is limited
 Friction welding

Application

1. For welding tubes and shafts

2. Hydraulic piston rod, truck rollers
bushes etc. are join by friction
welding.
3. Used in electrical industries for
welding copper and aluminum
equipment’s.
4. Used in pump for welding pump
shaft
5. Gear levers, drill bits, connecting rod
etc. are welded by friction welding
 Diffusion Welding

Principle
This process works on basic principle of diffusion.
Diffusion means movement of molecules or atoms
from high concentration region to low
concentration region. This is fundamental principle
of diffusion welding.
In this welding process both the welding plates are
placed one over other in high pressure and
temperature for a long period of time. This high
pressure force starts diffusion between interface
surfaces. 
 Diffusion welding

Schematic diagram
 Diffusion welding
Advantages and Disadvantages

Advantages

1. The joint have same mechanical

and physical properties as parent
material.
2. Low running cost.
3. It is simple in working.
4. It does not use filler material,
flux etc. which are used in arc
welding process.
5. It can weld complex shapes
 Diffusion welding

Disadvantages

1. High initial or setup cost.

2. It is time consuming process. It
takes more time compare to other
welding process.
3. Surface preparations of welding
plates are more critical and
difficult.
4. Size of the weld is limited
according to equipment available.
5. This process is not suitable for
mass production
 Diffusion welding

Application

1. It is mostly used to weld refectory

materials used in aerospace and
nuclear industries.
2. Diffusion bonding is used to weld
titanium, zirconium and beryllium
metals and its alloy.
3. It can weld nickel alloy like
Inconel, Wrought Udimet etc.
4. It is used to weld dissimilar metals
like Cu to Ti, Cu to Al etc
 Explosion Welding

Principle
This welding process works on basic principle of
metallurgical bonding. In this process, a controlled
detonation of explosive is used on the welding
surface. This explosion generates a high pressure
force, which deform the work plates plastically at
the interface. The detonation process occurs for a
very short period of time which cannot damage the
parent material. This is basic principle of explosion
welding.
 Explosion welding

Schematic diagram
 Explosion welding
Advantages and Disadvantages

Advantages

1. It can join both similar and

dissimilar material.
2. Simple in operation and handling.
3. Large surface can be weld in
single pass.
4. High metal joining rate. Mostly
time is used in preparation of the
welding.
5. It does not effect on properties of
welding material.
 Explosion welding

Disadvantages

1. It can weld only ductile metal

with high toughness.
2. It creates a large noise which
produces noise Pollution.
3. Welding is highly depends on
process parameters.
4. Higher safety precautions
involved due to explosive.
5. Designs of joints are limited
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