What is Welding?

• A method of joining metals by heating to a

suitable temperature to cause them to melt
and fuse together.
• This may be with or without the application
of pressure, and with or without the use of a
filler material of a similar composition and
melting point as the base metal.

Maxwell Jackson MSc.

 Welding methods
• The four most important are:
• Arc Welding : Using heat produce by electric
arc.
• Resistance Welding: Using heat produce by
resistances to the flow of an electric current.
• Gas Welding: Using the heat of a gas torch.
• Brazing: The heat applied is not high enough
to melt the parts.
Maxwell Jackson MSc.
 Types of welding
• Gas welding is a process of burning gases such
as acetylene to produce heat as required to
cause the metal to melt and fuse.
• Filler material of similar composition and
melting temperatures as the base metal may or
may not be used.
• Acetylene and oxygen mixed in correct
proportions are commonly used for gas
welding.
Maxwell Jackson MSc.
 Gas Welding Equipment
• Basically, oxyacetylene equipment consists of:
• A source of supply of gases.
• A mechanism for reducing the pressure and
controlling the gases as they come from the
cylinders. (oxygen and acetylene regulators)
• A method for transferring the gas to the point of
use ( oxygen hose and acetylene hose, oxygen
hose is green and acetylene hose is red.

Maxwell Jackson MSc.

 Welding Torch
• A device to mix and control the gases in
proper proportion when welding ( welding
torch)
• In addition, a wrench that fits the various
connections, a spark lighter for lighting the
torch, and a pair of suitable goggles are
needed.

Maxwell Jackson MSc.

 Welding Rods
• Often, a filler rod is added to the joint to build
it up and make it as strong as the base metal.
• To produce a satisfactory joint, it must be
clean and free of all dirt, grease, oil and
oxidation.

Maxwell Jackson MSc.

 Fluxes
• Fluxes must be used on most nonferrous and
cast iron welds.
• Flux cleans the metal, prevents oxidation and
other forms of corrosion and promotes a
better weld.
• A flux should not be used as substitute for
cleaning the base metal.

Maxwell Jackson MSc.

 Welding Methods
• The four most important are:
• Arc Welding : Using heat produce by electric
arc.
• Resistance Welding: Using heat produce by
resistances to the flow of an electric current.
• Gas Welding: Using the heat of a gas torch.
• Brazing: The heat applied is not high enough
to melt the parts.
Maxwell Jackson MSc.
 Arc Welding
• Arc welding is a joining process that makes use
Of an electric arc to produce heat necessary
to cause the metals to melt and fuse together.
Filler metal in the form of an electrode, may
be added to the joint.

Maxwell Jackson MSc.

 Electrodes
• Electrodes are metal rods covered with a
baked flux coating.
• Rods are used to support the welding arc and
to provide filler metal to the joint.
• The flux melts under the high temperature
and cleans the oxides from the base metal and
acts as insulation, slowing down the cooling of
the joint. This helps to relieve the internal
strains which develop from the sudden
changes of temperature.
Maxwell Jackson MSc.
 Resistance Welding
Spot welding is the best known of the resistance
welding techniques.
The weld is produced by heat obtained from the
resistance of work to a flow off electric current
and by the application of pressure.

Maxwell Jackson MSc.

 Types of Joints
• There are five basic types of joints and they
are common to both gas and arc welding.
• Butt Joint
• Tee Joint
• Lap Joint
• Edge Joint
• Corner joint

Maxwell Jackson MSc.

 Soldering
• Soldering is a method of joining metals
with a non ferrous metal filler without
having to heat them to a point where
the base metals melt.

Maxwell Jackson MSc.

 What are solders?
• Solders are tin-lead alloy.
• A 50-50 alloy, that is, 50 per cent tin-50 per
cent lead (tin is always the first figure
mentioned) is most commonly used.
• It melts at about 420 deg. F.
• A 60-40 solder is suited for electrical work. A
higher percentage of tin results in a lower
melting temperature alloy.
• Solder is available in solid wire, acid or resin
core wire and bar form.
Maxwell Jackson MSc.
 Soldering Conditions
• The correct solder alloy must be
used
• The proper flux must be applied
• An adequate source of heat must be
available
• The surfaces to be soldered must be
clean.
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 Fluxes
• All metals oxidize to some extent when exposed to
the atmosphere. This film of tarnish or rust must be
eliminated before the solder will adhere to the work
surface.
• A chemical mixture, called FLUX, is applied to the
joint to remove the oxides, prevent further oxides
from forming while the metal is heated to soldering
temperature, and lowers the surface tension of the
molten solder enabling it to cover the area and to
alloy with the work.
Maxwell Jackson MSc.
• Fluxes fall into two categories , CORROSIVE
and NON CORROSIVE

• Corrosive fluxes (acid) are more effective for

some purposes, however , after soldering the
residue encourages oxidation that may cause
the eventual failure of the soldered joint.

• Joints soldered using corrosive fluxes should

be cleaned with hot water after soldering.

Maxwell Jackson MSc.

• Resin in a noncorrosive flux that works best on
tin plate , solder coated surfaces, brass and
tin.

Maxwell Jackson MSc.

• Noncorrosive: Resin is a noncorrosive flux that
works best on tin plate, solder coated surfaces,
brass and tin.
• Aluminum can be soldered when a flux specially
designed for this material is used. Regular fluxes
will not work.
• It is advisable to use commercially prepared
fluxes because of their consistent results rather
than trying to prepare them in the shop.
Maxwell Jackson MSc.
• THANK YOU

Maxwell Jackson MSc.