Welding: ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

Welding
Joining process in which two (or more) materials

are coalesced at their contacting surfaces by
application of heat and/or pressure
 Many welding processes are accomplished by
heat alone, with no pressure applied
 Others by a combination of heat and pressure
 Still others by pressure alone with no external
heat
 In some welding processes a filler material is
added to facilitate coalescence
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Why Welding is Important
 Provides a permanent joint
 Welded components become a single entity
 Usually the most economical way to join parts
in terms of material usage and fabrication costs
 Mechanical fastening usually requires
additional hardware components (e.g.,
screws and nuts) and geometric alterations
of the parts being assembled (e.g., holes)
 Not restricted to a factory environment
 Welding can be accomplished "in the field"
Limitations and Drawbacks of Welding
 Most welding operations are performed
manually and are expensive in terms of labor
cost
 Most welding processes utilize high energy and
are inherently dangerous
 Welded joints do not allow for convenient
disassembly
 Welded joints can have quality defects that are
difficult to detect
Groove Welds
 Usually requires part edges to be shaped into a

groove to facilitate weld penetration
 Edge preparation increases cost of parts
fabrication
 Grooved shapes include square, bevel, V, U,
and J, in single or double sides
 Most closely associated with butt joints
Groove Welds
 Figure 1 Some groove welds: (a) square groove weld,

one side; (b) single bevel groove weld; (c) single
V‑groove weld; (d) single U‑groove weld; (e) single
J‑groove weld; (f) double V‑groove weld for thicker
sections. Dashed lines show original part edges.
Types of welding Positions
 Welding positions defined here for groove
welds: (a) flat, (b) horizontal, (c) vertical, and
(d) overhead
The Weld Joint
The junction of the edges or surfaces of parts that
have been joined by welding
 Two issues about weld joints:
 Types of joints
 Types of welds used to join the pieces that
form the joints
Five Types of Joints
1. Butt joint
2. Corner joint
3. Lap joint
4. Tee joint
5. Edge joint
Butt Joint
Parts lie in same plane and are joined at their
edges
Figure : Five basic types

of joints: (a) butt
Corner Joint
Parts in a corner
joint form a right
angle and are joined
at the corner of the
angle
Figure (b) corner
Lap Joint
Consists of two
overlapping parts
Figure (c) lap
Tee Joint
One part is
perpendicular to the
other in the
approximate shape of
the letter "T"
Figure (d) tee
Edge Joint
Parts in an edge joint
are parallel with at
least one of their
edges in common,
and the joint is made
at the common
edge(s)
Figure (e) edge
Types of Welding Processes
 Welding processes can be divided into two major
categories:
 Fusion welding - coalescence is accomplished by
melting the two parts to be joined, in some cases
adding filler metal to the joint
 Examples: arc welding, resistance spot
welding, oxyfuel gas welding
 Solid state welding - heat and/or pressure are
used to achieve coalescence, but no melting of
base metals occurs and no filler metal is added
 Examples: forge welding, diffusion welding,
friction welding
Classification of welding processes
(i). Arc welding  (iv)Thermit Welding
 Carbon arc  (v)Solid State Welding
 Metal arc  Friction
 Metal inert gas  Ultrasonic
 Tungsten inert gas  Diffusion
 Plasma arc
 Explosive
 Submerged arc
 Electro-slag  (vi)Newer Welding
(ii). Gas Welding  Electron-beam
 Oxy-acetylene  Laser
 Air-acetylene  (vii)Related Process
 Oxy-hydrogen  Oxy-acetylene
(iii). Resistance Welding cutting
 Butt
 Arc cutting
 Spot
 Seam  Hard facing
 Projection  Brazing
 Percussion  Soldering
GAS WELDING
 Sound weld is obtained by selecting proper size of
flame, filler material and method of moving torch
 The temperature generated during the process is 3300 0c
 When the metal is fused, oxygen from the atmosphere

and the torch combines with molten metal and forms
oxides, results defective weld
 Fluxes are added to the welded metal to remove oxides
 Common fluxes used are made of sodium, potassium.

Lithium and borax.
 Flux can be applied as paste, powder, liquid, solid

coating or gas.
GAS WELDING EQUIPMENT...
. Gas Cylinders
Pressure
Oxygen – 125 kg/cm2
Acetylene – 16 kg/cm2
2. Regulators
Working pressure of oxygen 1 kg/cm2
Working pressure of acetylene 0.15 kg/cm2
Working pressure varies depends upon the
thickness of the work pieces welded.
3. Pressure Gauges
4. Hoses
5. Welding torch
6. Check valve
7. Non return valve
Oxyacetylene Welding (OAW)
Fusion welding performed by a high
temperature flame from combustion of
acetylene and oxygen
 Flame is directed by a welding torch
 Filler metal is sometimes added
 Composition must be similar to base
metal
 Filler rod often coated with flux to clean
surfaces and prevent oxidation
Oxyacetylene Welding
Figure : A typical oxyacetylene welding operation

(OAW).
Acetylene (C2H2)
 Most popular fuel among OFW group because

it is capable of higher temperatures than any
other ‑ up to 3480C (6300F)
 Two stage chemical reaction of acetylene and
oxygen:
 First stage reaction (inner cone of flame):
C2H2 + O2  2CO + H2 + heat
 Second stage reaction (outer envelope):
2CO + H2 + 1.5O2  2CO2 + H2O + heat
Oxy-Acetylene welding
TYPES OF FLAMES…
 Oxygen is turned on, flame immediately changes into a long
white inner area (Feather) surrounded by a transparent blue
envelope is called Carburizing flame (30000c)
 Addition of little more oxygen give a bright whitish cone

surrounded by the transparent blue envelope is called
Neutral flame (It has a balance of fuel gas and oxygen)
(32000c)
 Used for welding steels, aluminium, copper and cast iron
 If more oxygen is added, the cone becomes darker and more

pointed, while the envelope becomes shorter and more fierce
is called Oxidizing flame
 Has the highest temperature about 34000c
 Used for welding brass and brazing operation
TYPES OF FLAMES…
TYPES OF FLAMES…
Arc Welding (AW)
A fusion welding process in which
coalescence of the metals is achieved by
the heat from an electric arc between an
electrode and the work
 Electric energy from the arc produces
temperatures ~ 10,000 F (5500 C), hot
enough to melt any metal
 Most AW processes add filler metal to
increase volume and strength of weld joint
What is an Electric Arc?
An electric arc is a discharge of electric
current across a gap in a circuit
 It is sustained by an ionized column of gas
(plasma) through which the current flows
 To initiate the arc in AW, electrode is
brought into contact with work and then
quickly separated from it by a short
distance
Arc Welding
 A pool of molten metal is formed near

electrode tip, and as electrode is moved
along joint, molten weld pool solidifies in its
wake
Figure : Basic configuration of an arc

welding process.
Two Basic Types of AW Electrodes
 Consumable – consumed during welding
process
 Source of filler metal in arc welding
 Non consumable – not consumed during
welding process
 Filler metal must be added separately
Consumable Electrodes
 Forms of consumable electrodes
 Welding rods (a.k.a. sticks) are 9 to 18
inches and 3/8 inch or less in diameter
and must be changed frequently
 Weld wire can be continuously fed from
spools with long lengths of wire, avoiding
frequent interruptions
 In both rod and wire forms, electrode is
consumed by arc and added to weld joint as
filler metal
Nonconsumable Electrodes
 Made of tungsten which resists melting
 Gradually depleted during welding
(vaporization is principal mechanism)
 Any filler metal must be supplied by a
separate wire fed into weld pool
Flux
A substance that prevents formation of oxides
and other contaminants in welding, or
dissolves them and facilitates removal
 Provides protective atmosphere for welding
 Stabilizes arc
 Reduces spattering
Power Source in Arc Welding
 Direct current (DC) vs. Alternating current
(AC)
 AC machines less expensive to purchase
and operate, but generally restricted to
ferrous metals
 DC equipment can be used on all metals
and is generally noted for better arc
control
Gas Metal Arc Welding (GMAW)/MIG
Uses a consumable bare metal wire as electrode
and shielding accomplished by flooding arc
with a gas
 Wire is fed continuously and automatically from
a spool through the welding gun
 Shielding gases include inert gases such as
argon and helium for aluminum welding, and
active gases such as CO2 for steel welding
 Bare electrode wire plus shielding gases
eliminate slag on weld bead - no need for
manual grinding and cleaning of slag
Gas Metal Arc Welding/ MIG Welding
Gas metal arc welding (GMAW).

Gas Tungsten Arc Welding (GTAW)/ TIG
Uses a nonconsumable tungsten electrode and
an inert gas for arc shielding
 Melting point of tungsten = 3410C (6170F)
 A.k.a. Tungsten Inert Gas (TIG) welding
 In Europe, called "WIG welding"
 Used with or without a filler metal
 When filler metal used, it is added to weld
pool from separate rod or wire
 Applications: aluminum and stainless steel
most common
Gas Tungsten Arc Welding/TIG Welding
Figure: Gas tungsten arc welding.

Welding: ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

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Welding: ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

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Welding

Joining process in which two (or more) materials

 Usually requires part edges to be shaped into a

 Figure 1 Some groove welds: (a) square groove weld,

Figure : Five basic types

Figure (b) corner

Figure (c) lap

Figure (d) tee

Figure (e) edge

 The temperature generated during the process is 3300 0c

 When the metal is fused, oxygen from the atmosphere

 Fluxes are added to the welded metal to remove oxides

 Common fluxes used are made of sodium, potassium.

 Flux can be applied as paste, powder, liquid, solid

Figure : A typical oxyacetylene welding operation

 Most popular fuel among OFW group because

 Addition of little more oxygen give a bright whitish cone

 If more oxygen is added, the cone becomes darker and more

 A pool of molten metal is formed near

Figure : Basic configuration of an arc

Gas metal arc welding (GMAW).

Figure: Gas tungsten arc welding.

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