SYLLABUS OF WELDING TRAINING

DEFINITION OF WELDING

Welding is a process of joining two similar or dissimilar metals where

joining is done by heating to a suitable temperature, with or without the
application of pressure and with or without the use of filler metal. The filler
metal either has a melting point approximately the same as base metal or has
a melting point below that of the base metal but above 8000F (4300C).

After welding, the weld metal should have similar physical properties and
chemical composition as that of the base metal.

WELDING PROCESSES

Common Types of Welding Processes are:

1. Shielded Metal Arc Welding. (SMAW)

2. Gas welding or Oxy-Fuel Welding. (OFW)

3. Gas Tungsten Arc Welding. (GTAW)

4. Flux Cored Arc Welding. (FCAW)

5. Gas Metal Arc Welding. (GMAW)

6. Submerged Arc Welding. (SAW)

 1. SMAW PROCESS

DEFINITION OF ARC
An arc is created between the covered metal electrode and the work
piece due to flow of electricity.

This arc provides the heat or energy to melt the base metal and
electrode coating. Electrode is consumed in the arc and provides the
filler metal for the joint.

The process is suitable for the entire range of plate or pipe

thicknesses, for almost all commercial metals and alloys and for
surfacing and repair work.

ARC WELDING POWER SOURCE

ARC WELDING
POWER
SOURCE

AC DC
OUT PUT OUT PUT

INVERTER
TRANSFORMER GENERATOR RECTIFIER

There are 2 types of welding machines.

1) A.C. Welding Machine: Input current is A.C and output current (i.e.,
current available in the electrode holder) is A.C.
Example: Transformer type.
2) D.C. Welding Machine: Input current is A.C and output current
(i.e., current available in the electrode holder) is D.C.

Example:
1. Rectifier type
2. Generator type
3. Inverter type

MAIN FEATURES OF WELDING ARC

1. A welding arc is the passage of electricity across a gap between an

electrode and the parent metal or work piece.

2. Heat is generated at the surface of the electrode and of the parent

metal.

3. Heating of the electrode end causes melting and this causes transfer of
metal to the weld pool.

4. Heating at the parent metal produces fusion of the joint faces.

5. Heat input to the weld is a function of arc voltage, arc current and
travel speed.

6. Arc length is related to arc voltage.

7. The current supplied to an arc is generally AC or DC.

STRAIGHT POLARITY OR DC ELECTRODE NEGATIVE (DCEN)

When the electrode holder is connected to the negative pole it is known as

straight polarity. As the holder is connected to negative pole, it is also known
as DC Electrode Negative (DCEN).

Example: All Rutile coated electrodes are connected to negative pole

REVERSE POLARITY OR DC ELECTRODE POSITIVE (DCEP)

When the electrode holder is connected to the positive pole it is known as

reverse polarity. As the holder is connected to positive pole, it is also known
as DC Electrode Positive (DCEP).

Example: E6010 (Cellulosic) and E7018 (Low Hydrogen Iron Powder)

are connected to positive pole.

WELDING ACCESSORIES

The following items are required for conducting welding:-

Welding cables.
Electrode holders.
Earthing clamp.
Chipping hammer.
File Round and Flat.
Trisquare.
Hammer.
Chiesel.