WELDING OF COMMERCIAL

METALS

ME 473 WELDING TECHNOLOGY

Instructor: Assist.Prof.Dr. Ouzhan Ylmaz

 Welding Technology

Welding of Commercial Metals: Introduction

Most commercial metals may be welded under suitable conditions and by
use of proper techniques

The following are some factors that affect the welding characteristics of
commercial metals:
 Oxidation at any temperatures, particularly at that of welding.
 Changes in the crystalline microstructure
 Gas absorbed or released
 Coefficient of thermal conductivity
 Coefficient of expansion
 Brittleness

The ability to be welded will be measured by the physical and mechanical
properties derived in a member as a result of welding.
 Ductility and tensile strength are the most common properties tested although
hardness, corrosion resistance, endurance strength, and the others are often
employed to qualify a weld.

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 Welding Technology

Welding of Commercial Metals: Steels

Steels usually fall into two types:
 Plain carbon steel
 Alloy steel

The element of carbon, which is present in all commercial steels, will
usually affect the final weld to a greater extent than any of the other
elements.

Hardening is directly related to the carbon content and cooling rate.

Hardening thus results brittleness that contributes failure of cracking.

In order to produce a satisfactory weld, the carbon content should be lower
values in the presence of alloys.

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 Welding Technology

Welding of Commercial Metals: Steels

Low--Carbon Steels
Low

Steels of the low-carbon type (0.08 to 0.30%) probably covers 90% of all
steels made by industry.

Steels in this carbon ranges are extensively use since they can be
fabricated by all the common welding methods.

Low-carbon steels are considered with a maximum 0.15% carbon.

All processes of welding apply to low-carbon steels, their choice
depending primarily on thickness of section, design of joint, cost of
process, volume to be manufactured, possibly other factors.

Oxy-gas welding is satisfactory to weld low-carbon steel but limited by
section.

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 Welding Technology

Welding of Commercial Metals: Steels

Medium--Carbon Steels
Medium

Steels with the carbon range 0.30 to 0.60%

Easily harden when heated to welding temperature

All processes of welding apply to medium-carbon steels.

High--Carbon Steels
High

Steels with the carbon range 0.60 to 0.90%

Mild-steel filler materials may be used for welding high-carbon base metal.

All welding processes apply to high-carbon steels, although a strong
preference is indicated for the pressure methods.

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 Welding Technology

Welding of Commercial Metals: Steels

Cutting--Tool Steels
Cutting

Steels with the carbon range 0.80 to 1.50%

The most successfull application appears to be in the field of low-
temperature brazing.

To weld alloy steels successfully, four factors must be considered:

 Always use a low-hydrogen welding procedure, process, and filler metal
 Select a filler metal that matches the strength level of the alloy steel
 Select a filler metal that comes close to matching the composition of the alloy
steel
 Match the welding heat input requirement to the alloy steel and its thickness,
and use the proper welding procedure

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 Welding Technology

Welding of Commercial Metals: Cast Iron

Cast iron, primarily an alloy of carbon and iron, is different from steel in
that carbon is present in much larger amounts in the from graphite or iron
carbide, or both.

Cast iron is not usually joined by welding methods except for repair
purposes.

Two facts are chiefly responsible for this limitation:
 The desired part can be given its final shape more quickly in the foundary
process than by welding the pieces together
 Required expensive procedure be followed to weld successfully

The welding processes commonly applied to cast iron are oxy-gas and
electric arc.

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 Welding Technology

Welding of Commercial Metals: Stainless steel

Composition of stainless steel:
 AISI 301 0.08-0.2%C, 2%Mn,0.04%P,0.03%S,1%Si,16-18%Cr,6-8%Ni..

This type of steels has a property of great significance which is not
common to other weldable metals, that is, its ability to resist attack of the
atmosphere or corrosive industrial liquids and gases (because of
chromium).

From the standpoint of welding and fabrication, stainless steels are divided
into two groups:
 The straight chromium types
 The chromium-nickel types
Chromium provides the basic corrosion resistance to stainless steel.

The welding of stainless steel is satisfactorily done by most of the
processes: shielded metal-arc, gas tungsten arc, oxy-acetylene, spot,
seam and inert-shielded gas.

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 Welding Technology

Welding of Commercial Metals: Aluminum

Aluminum is a light-weight and relatively high strength metal that is the
second most popular welded metal.

Aluminum possesses a number of properties that make welding different
than welding steels:
 Aluminum oxide surface coating
 High thermal conductivity
 High thermal expansion coefficient
 Low melting temperature
 The absence of color change as temperature approaches the melting point

With either MIG or TIG welding, the selection of filler metal should the
same.

TIG is used for welding the thinner sections, of aluminum and aluminum
alloys.

AC current is generally recommended

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 Welding Technology

Welding of Commercial Metals: Aluminum

MIG is applicable to heavier thicknesses of aluminum. Factors that must
be considered:
 The electrode wire must be clean to avoid porosity
 Pure argon is normally used
 The electrode wire tip should be oversize

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 Welding Technology

Welding of Commercial Metals: Copper and

copper--base alloys
copper

These alloys have high electrical conductivity which makes them widely
used in the electrical industries and corrosion resistance.

Copper alloys possess properties that require special attention when
welding:
 High thermal conductivity
 High thermal expansion of coefficient
 Relatively low melting point
 Brittle at elevated temperatures
 Very fluid molten metal
 High electrical conductivity
 Much of its strength due to cold working

TIG and MIG welding are the most popular processes. TIG uses dc
electrode negative. TIG is also recommended for repairing copper alloy
castings.

MIG is used for welding thicker materials. DC electrode positive is
recommended.
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 Welding Technology

Welding of Commercial Metals: Magnesium

Magnesium--base
alloys

Magnesium is the lightest structural metal. It is approximately two-thirds as
heavy as aluminum and one-fourth as heavy as steel.

Magnesium can be welded by many of the arc and resistance welding
processes, as well as by the oxyfuel gas welding process, and it can be
brazed.

Magnesium possesses that make welding different than welding steel:
 Magnesium oxide surface coating
 High thermal conductivity
 Relatively high thermal expansion coefficient
 Relatively low melting temperature
 The absence of color change as temperature approaches the melting point

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 Welding Technology

Welding of Commercial Metals: Magnesium

Magnesium--base
alloys

TIG and MIG are recommended for joining magnesium.

TIG is recommended for thinner materials; MIG is for thicker materials.

In TIG welding, AC current and high frequency should be used. Shielding
gas is Argon. However, a mixture of 75% helium and 25% argon is used
for thicker materials. For heavy thicknesses 100% helium can be used.

MIG is used for medium to thicker sections.

Resistance, spot, seam can also be used.

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 Welding Technology

Welding of Commercial Metals: Nickel

Nickel--base alloys

Nickel and high-nickel alloys are commonly used (chemical and food
industry) when corrosion resistance is required.

Nickel and nickel alloys are also widely used as filler metals for joining
dissimilar materials and cast iron.

Almost all the welding processes can be used for welding the nickel alloys.
Also they can be joined by brazing and soldering.

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