Basic Workshop Practice II

Course No. : MEng 3141

Prepared by : Mekete A. (MSc.)

1. Introduction to welding

•Welding is a process for joining two similar or dissimilar metals by fusion.

•Which means by the application of heat and/or pressure, and allowing

them to flow or coalesce together

•The fusion of metal takes place by means of heat.

•The heat may be generated either from combustion of gases, electric arc,
electric resistance or by chemical reaction.

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• Welding is a permanent joining process in which two pieces of metal join
together to form one piece.

• Welding is a fabrication/manufacturing process that joins materials, usually

metals or thermoplastics.

• Additional metal, also called filler metal, is added during the heating
process to help bond the two pieces together.

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• The welded joint can be stronger than the parent materials if a filler metal
is used that has;
Strength properties superior to those of the parents, and

If proper welding techniques are used.

• Welding is usually the most economical way to join components in terms

of material usage and fabrication costs.

• But, Most welding operations are performed manually and are expensive in
terms of labor cost.
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1.2. Terminological Elements Welding Process

• The terminological elements of welding process used with common

welding joints such as

• Base metal: the material which the welder is expected to join.

• Fusion zone: the area where new metal is situated after welding.

• Weld face: the face of the weld looking from top side of the weld.

• Root and groove face : face of the root and bevel

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• Filler rod/Electrode: commonly known as welding stick, consumable and many
more, it transmit electricity to heat up the tip of electrode which melts it along
with the base metal.

• Weld metal: a new metal formed by melting of base + filler metal.

• Flux: provides the following to the weld process: shielding gas, inter pass
cooling temperature control by slag, reinforcement alloy to weld metal.

• Slag: by-product of burning flux, needs to be remove before adding additional

weld passes.

• Root opening toe, etc. are depicted

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1.3. The Weld Joint

• Welding produces a solid connection between two pieces, called a weld joint.

• A weld joint is the junction of the edges or surfaces of parts that have been
joined by welding.

• There are five basic types of joints for bringing two parts together for joining.
The five

• joint types are not limited to welding; they apply to other joining and fastening
techniques as well.

• For welding the edges of joining surfaces of metals are prepared first.
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a) Butt joint: in this joint type, the parts lie in the same plane and are joined at
their edges.

b) Corner joint: the parts in a corner joint form a right angle and are joined at
the corner of the angle.

c) Lap joint: this joint consists of two overlapping parts.

d) Tee joint: in a tee joint, one part is perpendicular to the other in the
approximate shape of the letter ‘‘T.’’

e) Edge joint: the 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).
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• Different edge preparations may be used for welding butt joints,

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Generally, types of joints and welds based on joining systems,

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Advantages of Welding

• Welding is more economical and is much faster process as compared to

other processes (riveting, bolting, casting etc.)

• Welding, if properly controlled results permanent joints having strength

equal or sometimes more than base metal.

• Large number of metals and alloys both similar and dissimilar can be

joined by welding.
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Cont..

• General welding equipment is not very costly.

• Portable welding equipment can be easily made available.

• Welding permits considerable freedom in design.

• Welding can join welding jobs through spots, as continuous pressure tight

seams, end-to-end and in a number of other configurations.

• Welding can also be mechanized.

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Disadvantages

• Welding can also be mechanized.

• It results in residual stresses and distortion of the work pieces.

• Welded joint needs stress relieving and heat treatment.

• Welding gives out harmful radiations (light), fumes and spatter.

• Jigs, and fixtures may also be needed to hold and position the parts to be

welded
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• Edges preparation of the welding jobs are required before welding

• Skilled welder is required for production of good welding

• Heat during welding produces metallurgical changes as the structure of the

welded

• Joint is not same as that of the parent metal.

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Classification of Welding

• Welding processes divide into two major categories:

1. Fusion/liquid welding

2. Non- fusion/solid-state welding,

Fusion/liquid welding

• In which coalescence is accomplished by melting the two parts to be joined.

• Fusion-welding processes use heat to melt the base metals.

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Cont..

• In many fusion welding operations, a filler metal is added to the molten

pool to facilitate the process and provide bulk and strength to the welded
joint.

• A fusion-welding operation in which no filler metal is added is referred to

as an autogenous weld.

• Autogenous welding means when the filler material is either supplied by

melting the base material or is of identical composition.

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• The weld may be formed entirely by melting parts of the base metal, and

no additional filler rod is used.

• Fusion welding is by far the more important category. It includes;

1. Arc welding,

2. Resistance welding,

3. Oxy-fuel gas welding,

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1. Arc Welding Processes

•Arc welding is a type of welding process using an electric arc to create heat to
melt and join metals.

•A power supply creates an electric arc between a consumable or non-consumable

electrode and the base material using either direct (DC) or alternating (AC)
currents.

•An electric arc from an AC or DC power supply creates an intense heat of around
5500 °C (10,000°F) or higher, sufficiently hot to melt any metal.

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Cont..

• Because the metals react chemically to oxygen and nitrogen in the air when

heated to high temperatures by the arc.

• A protective shielding gas or slag is used to minimize the contact of the

molten metal with the air.

• Once cooled, the molten metals solidify to form a metallurgical bond.

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• Arc welding process can be categorized into two different types;
Consumable and
Non-consumable electrode methods.

• Examples of consumable electrodes

 Shielded Metal Arc Welding
 Flux Cored Arc Welding
 Gas Metal Arc/Metal inert gas (MIG) welding
 Electro-gas Welding

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Cont..

• Examples of non-consumable electrodes

 Gas tungsten arc/Tungsten inert gas(TIG) welding

 Plasma arc welding

 Carbon arc welding

 Stud welding

Atomic Hydrogen welding

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 Consumable Electrode Non-Consumable Electrode
A consumable electrode itself melts down during welding and subsequently deposits on the weld bead. A non-consumable electrode does not melt down or deposit on
the weld bead. It remains intact throughout the welding.

A consumable electrode acts as filler and thus it supplies necessary filler material intended to fill the root gap. Non-consumable electrode does not supply filler. Thus filler
material is required to supply separately.

After welding, a significant portion of the electrode becomes an integrated part of the weld bead. After welding, the electrode remains unaffected (except a
small erosion).
This type of electrode does not allow autogenous mode of welding as filler is applied inherently. It can be used It allows all three modes of welding – autogenous,
for either homogeneous or heterogeneous mode of welding. homogeneous and heterogeneous.

Electrode material must be chosen based on the parent materials in order to maintain chemical compatibility Since non-consumable electrode does not act as filler, so
between them. electrode material is independent of the parent materials to be
welded.

Since electrode material is consumed during welding, so frequent replacement of the electrode is usually A non-consumable electrode offers extended life as it is not
desired. However, the replacement frequency depends on electrode size and filler deposition rate. consumed during welding. Frequent replacement is also not
desired (it helps improving productivity).

Arc welding processes that employ a consumable electrode: Arc welding processes that employ a non-consumable
Shielded Metal Arc Welding (SMAW) electrode:
Gas Tungsten Arc Welding (GTAW) or Tungsten Inert Gas
Gas Metal Arc Welding (GMAW) (both MIG and MAG)
(TIG) welding
Flux-cored arc welding (FCAW)
Atomic Hydrogen Welding (AHW)
Submerged arc welding (SAW)
Carbon Arc Welding (CAW)
Electroslag welding (ESW)
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Electro-gas welding (EGW)
2. Non- fusion/solid-state welding

• Solid-state welding refers to joining processes in which coalescence results

from application of pressure alone or a combination of heat and pressure.

• If heat is used, the temperature in the process is below the melting point of
the metals being welded. No filler metal is utilized.

• Representative welding processes in this group include:

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Cont..

1. Diffusion welding (DFW). Two surfaces are held together

under pressure at an elevated temperature and the parts coalesce by solid-state

diffusion.

1. Friction welding (FRW). Coalescence is achieved by the

heat of friction between two surfaces.

1. Ultrasonic welding (USW). Moderate pressure is applied

between the two parts and an oscillating motion at ultrasonic frequencies is used in
a direction parallel to the contacting surfaces.
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1. Gas Metal Arc/Metal inert gas (MIG) welding

• Metal Inert Gas (MIG) is also known as gas metal arc welding (GMAW).

• This type of welding is basically an arc welding process that joins two metals.

• Is an arc welding process in which the electrode is a consumable bare metal wire,

and shielding is accomplished by flooding the arc with a gas.

• This is done by heating the metals with the help of an arc.

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• This arc is formed between the surface to be welled and a continuously
fed filler electrode.

• This type of welding uses a shielding gas to protect the molten pool of
weld metal from reacting with elements present in the atmosphere.
• Wire diameters ranging from 0.8 to 6.5mm are used in MIG welding.

• Gases used for shielding include inert gases such as argon and helium, and
active gases such as carbon dioxide.

• Inert gases are used for welding aluminum alloys and stainless steels, while
CO2 is commonly used for welding low and medium carbon steels. 26
MIG welding setup

• The first step before turning on the welder is to prepare your metal.

• Unlike stick and flux-cored electrodes, which have higher amounts of special
additives, the solid MIG wire does not combat rust, dirt, oil or other contaminants
very well.

• Use a metal brush or grinder and clean down to bare metal before striking an arc.
Make sure your work clamp connects to clean metal, too.

• Any electrical impedance will affect wire feeding performance. To produce strong
welds on thicker metal, bevel the joint to ensure the weld fully penetrates to the
base metal.
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Next, it's time to set up your machine:

•Check your cables: before striking an arc, check your welding equipment to
make sure all of the cable connections are tight and free of fraying or other
damage.

•Select electrode polarity: MIG welding requires DC electrode positive, or

reverse polarity. The polarity connections are usually found on the inside of the
machine.

•Set gas flow: turn on the shielding gas and set the flow rate to 20 to 25 cubic
feet per hour. 26
• Check tension: too much or too little tension on either the drive rolls or the
wire spool hub can lead to poor wire feeding performance. Adjust according to
your owner's manual.

• Inspect consumables: remove excess spatter from contact tubes, replace worn
contact tips and liners and discard the wire if it appears rusty.

• Select electrode polarity: MIG welding requires DC electrode positive, or

reverse polarity. The polarity connections are usually found on the inside of
the machine.

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Working principle of MIG welding

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Metal inert gas’s electrodes
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• The basic components in the MIG welding system.
The welding torch/gun

The work piece or base metal

The electrical power supply

The feed unit

The electrode (filler metal) source

The inert shielding gas source

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 Advantages and disadvantages of MIG Welding

Advantages of MIG welding

•It is versatile and works with various alloys and metals, including aluminum,
mild steel, stainless steel, copper, magnesium, nickel, and iron.

•Cleanup is quick and easy since there isn’t any slag or spatter to remove after
each pass. It is a fast and efficient way to weld metal.

•It produces high-quality welds.

•Elimination of slag removal (since no flux is used)

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Cont..

• It is less likely to produce defects than other welding methods.

• It is less likely to cause metal contamination.

• Higher welding speeds

• Greater deposition rate

• Ease of use

• MIG, uses consumable wire as both the electrode and filler material to
join large and thick materials
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Cont..
Disadvantages of MIG welding

•It is more expensive.

•The lifespan of MIG welding is limited.

•The MIG welding process has poor precision.

•MIG is perfect for thicker metals while thinner metals react better to TIG welding

•It require a constant supply of shielding gas, which can be costly.

•It can produce harmful fumes and gases.

•This is especially important for butt joints.

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2. Tungsten inert gas (TIG) welding

• It is also known as Gas tungsten arc welding (GTAW).

• It is an arc welding process that uses a non-consumable tungsten electrode

to produce the weld.

• The weld area and electrode are protected from oxidation or other
atmospheric contamination by an inert shielding gas (argon or helium).

• The shielding gases generally used are argon, helium or their mixtures

• The shielding gas protects the tungsten electrode and the molten metal weld

pool from the atmospheric contamination.

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Cont..
• It can also be used for joining various combinations of dissimilar metals.

• Its most common applications are for aluminum and stainless steel.

• Cast irons, wrought irons, and of course tungsten are difficult to weld by
GTAW

• For most uses any size between 1.6 to 3.2mm electrode diameter will do.

• Since Tungsten electrodes come in a rod form with a square cut end, an
electrode needs to be shaped.

• Some of the tip shapes used in these electrodes are pointed, rounded, and
tapered with a ball end. 30
Cont..

Tungsten electrode
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Working principle of TIG welding

• TIG welding elaborate as tungsten inert gas welding and its process works on the
basic principle.

• The basic principle leads to the joining of two base metals by providing electric arc.

• Some necessary types of equipment are essential for processing the TIG welding.
Gas cylinder
Regulator
Welding torch
Tungsten electrode
Additional Filler metal (if required)
DC electric supplier 30
Working principle of TIG welding

• TIG welding elaborate as tungsten inert gas welding and its process works on the
basic principle.

• The basic principle leads to the joining of two base metals by providing electric arc.

• Some necessary types of equipment are essential for processing the TIG welding.
Gas cylinder
Regulator
Welding torch
Tungsten electrode
Additional Filler metal (if required)
DC electric supplier 30
Cont..

• The above types of equipment are essential to process TIG welding.

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Cont..

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Advantages and disadvantages of TIG welding

Advantages of TIG welding

•Welds made using TIG welding are precise.

•The TIG welding process produces high-quality welds.

•Thin materials can be easily welded

•Stronger joint compare to shield arc welding.

•Wide verity of joint design can form

•Both AC and DC current can be used as power supply.

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Cont..

• It doesn’t required flux.

• No weld spatter because no filler metal is transferred across the arc, and

• Little or no post weld cleaning because no flux is used.

• More versatile than any other welding process

• Best to weld critical joint more precisely

• There are fewer fumes and less smoke when TIG welding.

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Cont..

Disadvantages of TIG welding

•It is more expensive than the other processes available.

•Poor gas coverage can lead to contamination issues.

•You need to remember the correct polarity for your welds.

•Overheating can be a significant problem when TIG welding.

•Harder skill to learn

•Equipment cost and etc.

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 1.4 Safety Recommendations for ARC Welding

• The body or the frame of the welding machine shall be efficiently earthed.

• Welding arc in addition to being very is a source of infra-red and ultra-violet light
also; consequently the operator must use either helmet or a hand-shield fitted with a
special filter glass to protect eyes

• Excess ultra-violet light can cause an effect similar to sunburn on the skin of the
welder

• The welder’s body and clothing are protected from radiation and burns caused by
sparks and flying globules of molten metal
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Cont..

• Gloves protect the hands of a welder.

• Leather or asbestos apron is very useful to protect welder’s clothes and his
trunk and thighs while seated he is doing welding.

• For overhead welding, some form of protection for the head is required

• Leather skull cap or peaked cap will do the needful.

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Cont..

• Leather jackets and 1ather leggings are also available as clothes for
body protection.

• Welding equipment shall be inspected periodically and maintained in

safe working order at all times.

• Arc welding machines should be of suitable quality.

• All parts of welding set shall be suitably enclosed and protected to meet
the usual service conditions.

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