WELDING

Definition :
A localized Joining of material with or without the use of filler and also with or without the application of pressure.

or
Bringing two perfectly smooth & clean material surfaces to an intimate contact, which is an atomic distance, indeed, between the two, is known as welding.

Welding Joint Terminology

Types of Common Welded Joints

Single Vee Butt Joint Fillet Joint Spot Welded Joint Plug Welded Joint Edge Joint

Types of Common Welded Joints

Butt Joint Fillet Joint Lap Joint Open Corner Joint Closed Corner Joint

Types of Fillet Welds Mitre Fillet

Convex Fillet Concave Fillet

Leg Hieght
Face

Leg length Reinforcement

Designed throat
Actual Throat
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Weld Positions Weld Slope Weld Rotation Flat Position Horizontal Vertical Position Horizontal Position Over Head Position Vertical Up Position Vertical Down Position Inclined Position

G - Positions on Plate 1G 2G 3G 4G

G - Positions on Pipe 1G 2G 5G 6G

F - Positions on Plate

1F 2F 3F 4F

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F - Positions on Pipe
1F 2F 2FR 4F 5F

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Welding Processes
Following are the common Welding Processes Used in the Industries

1. 2. 3. 4. 5. 6. 7.

Oxy- Gas Welding Manual Metal Arc ( M.M.A ) Welding Metal Inert Gas ( MIG), Metal Active Gas ( MAG ) Welding Tungsten Inert Gas ( TIG) Welding Plasma Arc Welding( PAW ) Submerged Arc Welding ( SAW ) Electroslag Welding

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OXY-GAS WELDING

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OXY-GAS WELDING

It is a fusion welding process Uses a fuel gas and oxygen to provide a flame hot enough to melt the materials to be joined. Suitable for almost all thicknesses and types of ferrous and most non-ferrous metals. All positions welding is possible Relatively cheep method Reasonable ease of operation

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OXY-GAS WELDING This Method is suitable for

Welding of most metals including carbon steels, stainless steels, cast iron, bronze, copper, aluminum etc. Metals less than 5 mm thickness The main disadvantages are
Slow speed of travel High heat input

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OXY-GAS WELDING
Process Technique A flame temperature of 31000 C is produced This high temperature flame is used to bring a small area of parent metal tip to melting point. Separate filler wire is then dipped into the molten pool The filler is melted off and mixes with the base metal to produce the weld

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OXY-GAS WELDING
There are three distinct flame used in this method The neutral flame Equal quantities of oxygen and acetylene Distinct inner white cone with a rounded tip Suitable for all carbon steel, cast irons, low alloy steels and aluminum The carburizing (carbonizing) flame Slight excess of acetylene. Feather around the inner white cone. Used for welding of high carbon steels and for hard surfacing. The oxidizing flame Has an excess of oxygen Inner white cone is shorter and sharper than the neutral cone. This flame is suitable for brass, bronze, zinc applications, Used for bronze welding and brazing
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Three Distinct Flame

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Manual Metal Arc Welding

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Manual Metal Arc Welding

Most Versatile Welding Process Suitable for almost all types of metals and all positions Its operation is comparatively easy It is a fusion welding The heat being provided by electric arc The arc has an average temperature of around 6,000 degree C M.M.A welding is carried out using either a.c. or d.c. In case of d.c. current + ve or ve polarity may be used A high open circuit voltage (o.c.v.) required is 65-90 volts Lower welding voltage required is 20-40 volts Reasonable range of current must be available; 30-350 amps
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Effect of Amperage too low Poor penetration or fusion, unstable arc, irregular bead shape, slag inclusion, porosity, electrode freezes to the weld, possible stray arc strikes. Effect of Amperage too high Excessive penetration, burn through, porosity, spatter, deep craters, undercut, electrode overheats, high deposition (positional welding difficult).
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Effect of Voltage too low Poor penetration, Electrode freezes to work Possible stray arcs Fusion defects Slag inclusions Unstable arc Irregular bead shape. Effect of Voltage too high Porosity Spatter Irregular bead Slag inclusion Very fluid weld pool positional welding difficult.
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Travel speed too slow Excessive deposition Cold laps Slag inclusions Irregular bead shape.

Travel speed too Fast Narrow thin bead Slag inclusion Fast cooling Undercut Poor fusion and Penetration

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An electrode connected to the d.c.+ve pole will have two thirds of the available energy.The remaining one third of the energy in the parent material It will result in: wide and shallow weld pool Broad HAZ Slow Rate of Cooling Hydrogen Intrapment An electrode connected to the d.c. ve pole has One third of the energy develops at the electrode and two thirds of the energy in the parent material. This will result in Weld pool which is narrow, deep and fast freezing limited h.a.z. May lead to hydrogen entrapment and a brittle metallurgical structure
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In A.C. The polarity is reversing 100 times per second (50 c.p.s.). Effect of equalizing the heat distribution Heat at the electrode and half in the parent material.

Types of Consumables used in MMA Rutile: Titanium Dioxide, Clay , Sodium silicate Cellulosic: Cellulose( wood pulp), Titanium Dioxide, Sodium silicate Basic: Lime stone ( Calcium carbonate ), Titanium Dioxide, Sodium silicate

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The m.I.g./m.a.g. welding process uses a bare wire consumable electrode . The wire, typically 0.8-1.6 mm diameter, is continuously fed from a coil through a specially designed welding gun.

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Eliminate the possibility of atmospheric contamination by introducing a shielding gas. Argon is an efficient shielding gas, being inert, it doesnot chemically react with the weld metal. When an inert gas is used for shielding the welding process is know as metal inert-gas (m.i.g.) welding.
Deoxidizers must exist in the wire. This process is widely referred to as CO2 welding is also called metal active-gas (m.a.g.) welding. Metal transfer modes Spray or free flight transfer, Dip transfer (semi-short circuiting arc), Globular transfer, Pulsed transfer.

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Spray or free flight transfer The weld metal transfers across the arc in the form of a fine spray. High deposition rates and deep penetration welds. Suited to thick materials, The flat or horizontal welding positions.

Dip transfer (semi-short circuiting arc) Amperage and low arc volts are required. Used on thinner sections for all positional welding, Vertical down welding

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For m.I.g./m.a.g. welding is usually electrode d.c. +ve of a flat Characteristic. Advantages minimal wastage of consumable electrode, no frequent changing of consumable electrode, little or no interpass cleaning required (no slag produced) heavier weld beads are produced, faster welding process, low hydrogen process preheat may not be required. Disadvantages increased risk or porosity due to displacement of the gas shield, more maintenance of plant involved, high risk of lack or fusion.

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