Arc

welding
Resistance welding
Oxyfuel
y
gas welding
g
g
Other fusion welding processes
Solid state welding
g
Weld quality
Inspection

 In

which coalescence is accomplished by

melting two parts to be joined with/without
filler
Arc welding

Arc

time = time arc on/hours worked

Electrode
El
d
Consumable rod, wire
Non consumable - W

Arc shielding
Covering the electrode tip, arc and molten weld pool
with a blanket of gas or flux or both
Flux substance prevent oxidation, unwanted
contaminants or dissolve them and facilitate removal
Slag : flux melts and becomes a liquid slag covering
the weld area
Method of flux application

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|
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Pouring granular flux gas

Flux coating
Tubular electrodes

Functions of flux
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|
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Provide a protective atmosphere for weld

Stabilizing arc
Reduce spattering

 Power

source for arc welding

Power balance = f1*f2*V*I = Um*Aw*v

f1= heat transfer factor; f2 = melting factor
Um = unit energy required to melt metal
Aw = weld area cross-section v= travel velocity

Shielded metal arc welding (SMAW)

W ldi positions
Welding
ii
Filler must be compatible with base material
g cellulose with oxide,, carbonate and some time metals alloyy
Coating
Current 30 300 A and Voltage 10- 50 V
Application - structural, marine thick section

Ferrous and non-ferrous

Flux cored Arc welding

Self shielding FCAW
Gas shielding FCAW

Electro gas welding process

Vertical wall welding process

Molding shoe forms a container
Submerged Arc welding process
Granular flux feed front
preventing spatter,
spatter sparks
Glass-like slag
Toughness and ductility of
weld is good
Thermal insulation in weld
area

 Gas

tungsten Arc welding GTAW

with or without filler
TIG process
W arc initiation
Similar/dissimilar welding

Plasma

Arc welding
W arc constricted plasma arc
PD is high so melt temp is high

 Stub

arc welding process

Heat = I2RT

a. Overlapping spots
b. Roll spot
c. Continuous

Wheel is rotated at constant speed and

Current on at intervals
Frequency is high overlap
Frequency is low roll

Flash welding process

High frequency resistance welding process

Primary reaction
C2H2 + O2 2CO + H2 + Heat
Secondary reaction
2CO + H2 + 1.5O2 2CO2 + Heat + H2O
Acetylene is capable of higher temperature
Acetylene is replaced by MAPP

Pressure gas welding

 Electron

beam welding :

High vacuum welding

Medium vacuum welding
Non vacuum welding
g

Thermit welding

 Pressure

alone
Heat and pressure
Roll welding

Explosive welding

Friction welding

Ultrasonic welding

Cracks, cavities, solid inclusion, imprefect shape, incomplete fusion

 Brazing:
g

filler metal is melted and

distributed by capillary action between the
faying surface. Base metal is not melted.
Around 450 C
Advantage :

Dissimilar joining
j
g
Thin part joining
Inaccessable part joining
HAZ is less
Strength higher than filler rod intersolubility
and interdiffusion between base metal and filler
material
t i l

Properties of brazing metal

Temperature should be compatible to base metal
S f
t i iin th
id should
h ld b
Surface
tension
the li
liquid
be llow
Fluidity should be high
Chemical and physical interaction with base metal

Brazing rod :
Cu
Al and Si
Cu and Zn
Nickel alloy
Ag alloy

Importance of flux :
protect the joint area during the time of solidification
Increasing wet ability to the brazing material
Easy removal after brazing
Lower
L
melting
lti point
i t th
than b
brazing
i rod
d

 Torch

brazing
Furnace brazing
Induction brazing
g
Resistance brazing
Dip
p brazing
g
Infra red brazing
Braze welding

 Soldering

: similar to brazing the filler melting is

less than 450 C.
Solder material : Pb-Sn, Sn-Ag, Ti-An, etc
Solder flux is used
Soldering methods
Hand solder
Wave solder PCB
Reflow solder