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FOR THE TOPIC ON:
by: C B Singh
SCIENCE & TECHNOLOGY OF WELDING
It is needless to emphasize that the welding
has become, now, the most efficient, economical &
popular means of joining materials; Because:
It enables act as one .
It improves strength.
Reduces the over-all weight.
Reduces labor time & the cost.

WELDING
Definition :
A localized coalescence 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
Fusion
Diffusion
Pressure
Non-pressure
* Soldering < 427
0
C
* Brazing > 427
0
C
* Braze-welding
&
* Resistance welding
* Explosive welding
* Forge welding
* Friction/Inertia welding
*Ultrasonic welding
* Cold welding
* Thermit welding
* Pressure gas welding
* Oxy-Fuel gas welding
* Electric Arc welding
* Plasma Arc welding
* Electron Beam welding
* Laser Beam welding
* Electro Slag / Gas welding
Ag100%
Cu100%
500
700
900
1100
0
C
72%Ag + 28%Cu
Solid + Liquid
Solid
(Eutectic composition)

SilverCopper Equilibrium Diagram
Molten liquid
BRAZING & SOLDERING
Brazing & Soldering:
Low temp. Brazing 450-850
0
C
Medium temp. Brazing 850-950
0
C
High temp. Brazing > 950
0
C
There is no bead formation, but only with capillary attraction.& diffusion.
Low temp. Soldering 427
0
C Max.
Steel
Steel
Bronze
Copper
Copper
Steel
Steel
Copper
Steel
Pb-Sn Eutectic Steel
Copper
Brazing & Soldering
Some Typical Brazing Applications:
Ring
Foil
BRAZE WELDING
Braze welding:
There is a bead formation, but without the fusion & capillary attraction.
An age-old joining technique
OPERATION Manual/ mechanized/ auto.
ADVANTAGE Usually no distortion & heat damages; easy
adaptability for the mass production of several intricate component
parts.
TYPICAL APPLICATIONS Repair & maintenance, tool-tips, heat-
exchangers, electrical switches, electric motor parts, gas turbine
parts, bicycle frames, utensils & kitchen-wares etc.
BRAZE WELDING, BRAZING & SOLDERING
An age-old metal joining techniques:
BRAZING & SOLDERING
THERMIT WELDING (TW)
Thermit Powder
Molten
Crucible
R
A
I
L
S
Mould
Igniter
Molten metal flows down
developed in 1893
Flame heating gate
Thermit powder:
Fe
2
O
3
+ 2Al = 2Fe + Al
2
O
3
THERMIT WELDING (TW)
THERMIT WELDING (TW)
OPERATION Manual skill .
TYPICAL APPLICATIONS Confined to the railway tracks only, but
can also be used for reinforced concrete bars & copper conductors &
easy to use on site.
LIMITATIONS Limited range of joints and materials., difficult to
ensure consistency in its weld quality, slow & expansive, require a
group of five people to work in tandem.

Oxy-Acetylene Gas
G
a
s

F
l
a
m
e

Weld Bead
OXY- FUEL GAS WELDING (OFW)
developed in 1904
OPERATION Manual skill.
ADVANTAGE No power supply needed, low investment,
highly - portable, excellent performance on Cast-iron,
Cast-steel, depositing Tungsten-carbide & Stellite for hard
surfacing.
TYPICAL APPLICATIONS Repair & reclamation
welding of motor vehicle parts, sheet metal & light
fabrication welding.
OXY- FUEL GAS WELDING
OXY-FUEL GAS CUTTING
CARBON ARC WELDING (CAW)
Carbon electrode
Weld Bead
Developed in 1884
1. Power source
2. Holder cable
3. Earth cable
4. Work
5. Carbon electrode &
6.Filler rod
CARBON ARC GOUGING
(C. A. G.)
CARBON/AIR ARC GOUGING (CAG)
1. Power source
2. Holder cable
3. Earth cable
4. Work
5. Carbon electrode &
6. Compressed Air.






SHIELDED METAL ARC WELDING (SMAW)
_
+
_
1. Power source
2. Holder cable
3. Earth cable
4. Work &
5. Electrode
developed in 1907
MANUAL METAL ARC WELDING (MMAW)
OPERATION Manual skill.
ADVANTAGE Low capital investment, wide variety of
application even in restricted areas.
TYPICAL APPLICATIONS Ship building, Structural steel
work, High-rise Buildings, Locomotive, Rail-road,
Armament, Automotive, Transmission Pipeline, Mining,
Repair & Construction of plant and machinery of all types.
It is used for joining, rebuilding & hard-surfacing.
SHIELDED METAL ARC WELDING (SMAW)
MANUAL METAL ARC WELDING (MMAW)
An arch-bridge on river Chenab in Kashmir by Konkan Rly,
Usage 26,000 Tons of steel,
1.3K.M. long & 359 M high > Affil tower (324M)
This will be the tallest bridge made within 30Months
Ref: www.bbchindi.com dated 17
th
, Apr, 2006
Mechanized wire feed
Mechanized
arc tracking
SUBMERGED ARC WELDER (SAW)
Granulated SAW flux
developed in 1936
SUBARC WELDER
SUBARC WELDER
WELDING POSITIONERS
REBUILDING BY SAW
SUBMERGED ARC WELDER (SAW)
OPERATION Usually mechanized or automatic.
ADVANTAGE High deposition rate, high quality
radiographic sound weld, invisible arc underneath the flux
granules causes least fatigue to the operator.
TYPICAL APPLICATIONS High quality pressure vessel,
chemical plant, ship building, structural engineering
component parts, and also for rebuilding & surfacing.
Mechanized wire
feed
FCAW - with or without external gas shield
Flux Cored Electrode
FLUX CORED ARC WELDING (FCAW)
developed in 1955
OPERATION Usually semi-automatic but also mechanized or
automated, if the need arises.
ADVANTAGE High deposition rate, high quality weld for shop & site
welding, it causes lesser fatigue than GMAW to the welder.
TYPICAL APPLICATIONS Pressure vessel, chemical plant, pipe
work, structural work, ship building, and also popular for rebuilding &
surfacing on shop and site.
FLUX CORED ARC WELDING (FCAW)
GAS-SHIELDED METAL ARC WELDING (GMAW)
GMAW , SIGMA, MIG/MAG or CO
2
/MIG Welding
Mechanized
wire feeding
Consumable
Electrode
Inert/active
gas feed
MIG developed in 1950 &
MAG welding during 1953
GAS-SHIELDED METAL ARC WELDING (GMAW)
OPERATIONUsually semi-automatic but also mechanized or
robotic.
ADVANTAGE Continuous process with reduced finishing operation,
high quality weld including in vertical down with extra low hydrogen.
TYPICAL APPLICATIONS Light, medium & heavy fabrication such
as ship-containers, light and heavy vehicle, earth movers, heavy
machinery fabrication etc.
GAS-SHIELDED METAL ARC WELDING (GMAW)
H
2
gas
Tungsten
Electrodes
~
~
ATOMIC HYDROGEN WELDING (AHW)
developed in around 1940, but it
was made to disappeare soon
OPERATION Usually manual but also mechanized.
ADVANTAGE Similar to those of GTAW process.
TYPICAL APPLICATIONS Welds in thin materials particularly stainless
steel; mechanized thin sheet welding.
GTAW / TIG Welding
Inert gas feed
Non-consumable
Tungsten Electrode
GAS-SHIELDED TUNGSTEN ARC WELDING (GTAW)
developed in 1942
GAS-SHIELDED TUNGSTEN ARC WELDING
OPERATION Usually manual but also scarcely mechanized for tube
to tube sheet & orbital welding.
ADVANTAGE Wide range of metals, produces high quality standard
weld with extra low hydrogen.
TYPICAL APPLICATIONS High quality weld in stainless steel for
nuclear reactors, chemical & fertilizer plants, industrial piping, nickel
alloys for aircraft engines, aluminum alloys for food industry.
GAS-SHIELDED TUNGSTEN ARC WELDING (GTAW)
PAW
Plasma gas
Shielding Gas
PLASMA ARC WELDING (PAW)
+
developed in 1959
TRANSFER & NON-TRANSFER PLASMA ARC
PLASMA ARC WELDING (PAW)
OPERATION Usually mechanized.
ADVANTAGE Wide range of metals, produces high quality deep
penetration weld with extra low hydrogen.
TYPICAL APPLICATIONS High quality weld in stainless steel sheet
foil butt welds, electronics cans, thermo couples, bellows, capsuls,
filters by MPW and high speed tube manufacturing, high speed
unprepared butt joint making in chemical plant.
E.B.W. Gun
Beam alignment coil
Optics
Vacuum Chamber
Deflection Coil
Focus Coil
Work
ELECTRON BEAM WELDER (EBW)
developed in 1960
OPERATION Fully mechanized.
ADVANTAGE Excellent penetration; Low distortion; Non-
contaminated weld; High speed welding; Ability to weld several non-
weld-able materials. Any metal may be welded compatible with the
vacuum while in molten state.
TYPICAL APPLICATIONS Gear clusters/shafts joint; Turbine blade
root joint; Fully mechanized.
ELECTRON BEAM WELDER (EBW)
LASER BEAM WELDER (LBW)
Capacitor Bank
Flash tube
Focusing lens
Work
Laser beam
developed in 1967
OPERATION:
Fully mechanized.
ADVANTAGE:
Wide range of materials.
TYPICAL APPLICATIONS:
Continuous laser for the develop-
mental activities; Pulsed laser for
reputed application to some small
assemblies such as electronic
component parts.
ELECTRO SLAG WELDER (ESW)
Electrode wire
Copper shoe
Weld metal
Work
Developed in 1956
OPERATIONMechanized only.
ADVANTAGE Fast completion of
thick joint in singular run.
TYPICAL APPLICATIONS Thick
wall pressure vessels; Thick civil
engineering & structural fabric-ation
work and Ship-building.
CONSUMABLE GUIDE ESW
COLD WELDING (CW)
Split die
Split die
ADVANTAGE Large area of weld
made in high conducting materials
such as copper and aluminum; Low
cost welding.
TYPICAL APPLICATIONS:
Welding of copper overhead
conductors for electric traction;
Aluminum - copper joints for electric
cables.
FORGE WELDING (FOW)
F
o
r
c
e
An age-old welding technique
FORGE WELDING (FOW)
TECHNIQUE Pressure welding .
OPERATION Manual or mechanized.
APPLICATION Black-smiths artistic iron ware only; dimensions not
easily controlled and difficult to assure quality. Limited low carbon &
some alloy steels only.
~
~
ELECTRIC RESISTANCE SPOT WELDER (ERW)
Developed in 1887
RESISTANCE SPOT WELDER (ERW)
OPERATION Mechanized or robotized.
ADVANTAGE Consumable & skill is not required thus consistent
weld quality with high productivity. Commonly used ferrous & non-
ferrous metals but difficult to weld copper.
TYPICAL APPLICATIONS Light fabrication from pressed sheet
parts such as motor vehicle bodies, domestic washing machines, and
cabinets for refrigerators etc.
ELECTRIC RESISTANCE SPOT WELDER (ERW)
PROJECTION SPOT WELDER (RPW)
~
~
Step-1
Step-2
Ideal for making multiple spots, where the spacing may be the designers constraint.
RESISTANCE SEAM WELDER (RSEW)
~
~
RESISTANCE FLASH-BUTT WELDER (FW)
~ ~
Developed in 1927
RESISTANCE UPSET- BUTT WELDER (UW)
Upsetting
~ ~
H.F. RESISTANCE BUTT WELDER (HFRW)
~ ~
INDUCTION BUTT WELDER (IW)
~
~
CD STUD - WELDER
Step-1 Step-2 ~ ~
ARC STUD WELDER (SW)
Stud
Weld metal
Ceramic ferrule
Step-1 Step-2
~ ~
FRICTION WELDER (FRW)
Developed in 1955
OPERATION Mechanized.
ADVANTAGE Produces consistently high quality welds; Fast joining
of large area; Suitable for wide range of materials; Mechanized &
works on simple principle; & Consumable is not required.
TYPICAL APPLICATIONS Internal combustion engin valves; Head to
stem joint of dissimilar metals; Stud welding; Rear axle casings;
Transmission and steering components for vehicles and Electrical part
connections .
EXPLOSIVE WELDING (EXW)
Flyer
plate
Explo
-sive
Buffer
APPLICATIONS Manufacture of steel to aluminum or copper
transition pieces for fabrication; Cladding steel parent plate; Tube - to -
tube sheet joints. The wide range of metals studied to date give good
results The process is particularly suited to dissimilar metals.
ADVANTAGE Cladding large plates without preheat; Suitable for
wide range of dissimilar metals; Fast as a large area is joined in single
shot.
PROCESSES & THEIR LETTER DESIGNATIONS
LETTER DESIGNATION WELDING PROCESS GROUP
Arc welding Carbon Arc
Flux Cored Arc
Gas Metal Arc
Gas Tungsten Arc
Plasma Arc
Shielded Metal Arc
Stud Arc
Submerged Arc
CAW
FCAW
GMAW
GTAW
PAW
SMAW
SW
SAW
Brazing Diffusion Brazing
Dip Brazing
Furnace Brazing
Induction Brazing
Infrared Brazing
Resistance Brazing
Torch Brazing
DFB
DB
FB
IB
IRB
RB
TB
Continued
Oxyfuel Gas Welding
Oxyacetylene Welding
Oxyhydrogen Welding
Pressure Gas Welding
OAW
OHW
PGW
Resistance Welding Flash Welding
High Frequency Resistance
Percussion Welding
Projection Welding
Resistance-Seam Welding
Resistance-Spot Welding
Upset Welding
FW
HFRW
PEW
RPW
RSEW
RSW
UW
Solid State Welding Cold Welding
Diffusion Welding
Explosion Welding
Forge Welding
Friction Welding
Hot Pressure Welding
Roll Welding
Ultrasonic Welding
CW
DFW
EXW
FOW
FRW
HPW
ROW
USW
PROCESSES & THEIR LETTER DESIGNATIONS
Soldering
Other Welding
Processes
Dip Soldering
Furnace Soldering
Induction Soldering
Infrared Soldering
Iron Soldering
Resistance Soldering
Torch Soldering
Wave Soldering
DS
FS
IS
IRS
INS
RS
TS
WS
Electron Beam Welding
Electro Slag Welding
Induction Welding
Laser Beam Welding
Thermit Welding
EBW
ESW
IW
LBW
TW
PROCESSES & THEIR LETTER DESIGNATIONS
Ref: AWS