JOINING PROCESSES

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 TYPES OF WELDING

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 TYPES OF WELDING
FUSION WELDING Plastic WELDING
 Non Pressure Welding  Pressure Welding

 The piece of metal to be joined are heated to a

 The material at the joint is heated
plastic state and forced together by external
to a molten state and allowed to pressure

solidify.  Under pressure without additional filler metal

 With additional filler material.

– Friction welding (FRW) – heating by
– Arc Welding (AW) – heating with
friction
electric arc – Ultrasonic welding (USW) – moderate
pressure with ultrasonic oscillating
motion

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 Gas Welding

• Gas welding is the process in which a gas flame is

used to raise the temperature of the metal to be
Non pressure welding

joined.

• Many combination of gases are used in Gas welding.

But most common of these in oxygen and acetylene.

 Oxy – Acetylene welding

 Oxy – hydrogen welding
 Air- hydrogen welding
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 Oxy Acetylene welding
• In gas welding, a gas flame is used to melt the edges of metals
to be joined. The flame is produced at the tip of welding torch.
• Oxygen and Acetylene are the gases used to produce the
Non pressure welding

welding flame
• A very hot flame is produced by burning of the gases coming
through the torch tip. The edges to be welded are heated up to
melting. A filler metal is also added to complete the welding.
This molten metal mixture when solidifies on cooling forms a
welded joint.

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 Oxy Acetylene welding
Non pressure welding – Gas Welding

• The process of oxy-acetylene welding can be used for almost all metals

and alloys for engineering purposes.

– A high temperature flame (3200 C) can be produced by this method. There

are two systems of oxygen-acetylene welding.

• High pressure system: In this process the oxygen and acetylene are taken

for use from high pressure cylinders.

• Low pressure system: In this system oxygen is taken from high pressure

cylinder and the acetylene is produces by the action of calcium carbide and

water

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 Oxy Acetylene welding
Non pressure welding – Gas Welding

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 Oxy Acetylene welding
• Apparatus used for oxy-acetylen welding are:
1. Oxygen cylinder
2. Acetylene cylinder
3. Pressure gauges
4. Valves
5. Hose pipes
6. Torch
7. Welding tip
8. Pressure regulator
9. Lighter
10. Goggles

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 Non pressure welding – Gas Welding

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 PRINCIPLE OF OXY-ACETYLENE WELDING
Non pressure welding – Gas Welding

• The acetylene control value is turned first when acetylene comes

out of the nozzle, it should be ignited with spark lighter. It will

give a yellow-coloured smoke flame.

• After it oxygen cylinder valve is opened and supply is increased

until a best suitable flame is obtained.

Then the flame is focussed on the edges to be welded.

• Flux and filler metal are also added with the heat of flame, the

edges and the filler metal melts and a joint is formed after cooling

of the molten metal.

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 Types of Gas flames
Non pressure welding – Gas Welding

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 Types of Gas flames
Non pressure welding – Gas Welding

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 FLUX
Non pressure welding – Gas Welding

• The chemicals which de-oxidises the metal surface and provides

inert atmosphere around the molten metal are known as fluxes.

• Function:
1.To prevent oxides from the hot surfaces.

2.To reduce the viscosity of molten metal.

3. It maintains a steady arc in case of arc welding

• Fluxes are available as liquid, powder, paste and gas.

– Powder flux is sprinkled on the surfaces to be welded or the filler rod is dipped

into the powder.

– Liquid and paste fluxes are sprayed on the surfaces to be welded.

– Gas fluxes are used to form inert atmosphere around the joint to be welded.

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 FILLER
Non pressure welding – Gas Welding

• The rod which provides additional metal in

completing the welding is known as filler. The
composition of filler metal should be the same as
that of the metal to be welded.

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 Oxy Acetylene welding
Non pressure welding – Gas Welding

• ADVANTAGES

1. Equipment is cheap.

2. It can be used for welding all metals.

3. Maintenance of equipment is very less.

4. It is portable process.

5. It can be used for cutting of metals.

6. It is specially used for sheet metal work.

• DISADVANTAGES

1. It takes long time for heating the job as compared to the arc welding.

2. Heat affected area is more.

3. Gases are expensive and difficult to store.

• Application:

• Oxy-acetylene welding is particularly used for sheet metal work.

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 Electric Arc welding
Non pressure welding - Electric Arc

• The welding in which the electric arc is produced to give heat for
the purpose of joining two surfaces is called Electric arc welding.
• Power supply is given to electrode and the work. A suitable gap is
kept between the work and the electrode.
• A high current is passed through the circuit. An arc is produced
around the area to be welded.
welding

• The electric energy is converted into heat energy, producing a

temperature of 3000 to 4000 C.
• This heat melts the edges to be welded and the molten pool is
formed. On solidification the welding joint is obtained.

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 Non pressure welding - Electric Arc
welding

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 ELECTRIC POWER OF WELDING
Non pressure welding - Electric Arc

• AC current or DC current can be used for arc welding. For

most purposes, DC current is preferred. In DC welding, a DC
generator or a solid state rectifier is used. DC machines are
made upto capacity range of 600A. The voltage in open circuit
is kept around 17-25V. DC current can be given in two ways:
• Straight polarity
welding

• Reverse polarity

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Non pressure welding - Electric Arc

• Straight polarity: In straight polarity welding

work piece is made anode and the electrode is
made cathode. Electron flow from cathode to
anode thus heat is produced at the materials to be
welded.
welding

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Non pressure welding - Electric Arc

• Reverse polarity: In reverse polarity system the work is

made cathode and the electrode is made anode. This

welding is done specially for thin sections.

welding

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 Non pressure welding - Electric Arc
welding

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 EQUIPMENTS USED IN ARC WELDING
Non pressure welding - Electric Arc
welding

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ELECTRODES

Electrodes are of two types

(1)Consumable Electrodes
(a) Bare Electrodes
(b) Coated Electrodes
(2) Non-consumable Electrodes
(a) Carbon or Graphite Electrodes
(b) Tungsten Electrodes

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 Consumable Electrodes
Non pressure welding - Electric Arc

Not only used to produce arc between work piece and

electrode but also provides filler material during welding.

Coated electrodes:
• These electrodes are generally applied in arc welding processes. A metallic
core is coated with some suitable material. The material used for core is
mild steel, nickel steel, chromium molybdenum steel etc. One end of the
coated core is kept bare for holding
welding

Bare electrodes:
• These electrodes produce the welding of poor quality. These are cheaper
than coated electrodes. These are generally used in modern welding
processes like MIG welding.

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 Non Consumable Electrodes
Non pressure welding - Electric Arc

• Non consumable electrodes are made up of high

melting point materials like carbon, pure tungsten
or alloy tungsten etc.
• These electrodes do not melt away during welding.
• But practically, the electrode length goes on
decreasing with the passage of time, because of
oxidation and vaporization of the electrode
welding

material during welding.

• The materials of non consumable electrodes are
usually copper coated carbon or graphite, pure
tungsten,and zirconiated tungsten

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 SPECIFICATIONS OF ELECTRODES
Non pressure welding - Electric Arc

• An electrode is specified by six digits with profile letter M. These six

digits indicate the following matter:
•
M:
• It indicates that it is suitable for metal arc welding.
First digit:
• First digit may be from 1 to 8, which indicate the type of coating on the electrodes.
Second digit:
• It denotes the welding position for which electrode is manufactured. It varies from 1 to 6.
Third digit:
welding

• It denotes the current to be used for an electrode. It is taken from 0 to 7.

Fourth digit:
• Fourth digit is form 1 to 8. Each digit represents the tensile strength of welded joint.
Fifth digit:
• It carries any number from 1 to 5. This digit denotes a specific elongation in percentage of
the metal deposited.
Sixth digit:
• It carries any number from 1 to 5 and denotes impact strength of the point

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Non pressure welding - Electric Arc

• FUNCTIONS OF COATINGS
1. To prevent oxidation.
2. Forms slags with metal impurities.
3. It stabilizes the arc.
4. Increases deposition of molten metal.
5. Control depth of penetration.
welding

6. Controls the cooling rate.

7. Adds alloy elements to the joint.

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 Electric Arc welding
Non pressure welding - Electric Arc

Advantages
• Most efficient way to join metals
• Lowest-cost joining method
• Affords lighter weight through better utilization of
materials
• Joins all commercial metals
• Provides design flexibility
welding

Limitations
• Manually applied, therefore high labor cost.
• Need high energy causing danger
• Not convenient for dis assembly.
• Defects are hard to detect at joints.
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