Welding process and

applications

Presented by-Phani Sridhar

Application of welding in various
Industries
Application of welding in various
Industries
Definition of welding
Welding process is "a materials joining
process which produces coalescence of
materials by heating them to suitable
temperatures with or without the
application of pressure or by the
application of pressure alone and with
or without the use of filler material".
Content

Welding Joint design

Welding processes
Shielding gases
Welding consumables and equipment
Welding joint design
How to choose a welding process
Industrial application & raw material
Atmospheric conditions
Depending on medium
On the quality of weld
Productivity
Welding Economics
Types of Welding processes
Arc Welding process
Manual metal arc welding (MMAW)/SMAW

Gas metal active welding (GMAW/MIG)

Submerged arc Welding (SAW)

SMAW/MMAW PROCESS
MMAW
Basic type of electrodes in MMAW
Rutile: This type of electrodes are made of
titanium dioxide (Ti02).

Basic: This type of electrodes are made of lime

coating, they are very hygroscopic in nature.

Cellulose: This type of electrodes are made of

up with cellulose, produces a large amount of
hydrogen, typically 30 to 45ml
hydrogen/100gm weld metal
Types of electrodes contd.
Welding Positions
Basic Electricity and the Science of
Welding
Voltage The electrical potential or pressure that causes
current to flow
Measured in Volts

Current The movement of charged particles in a specific

direction
Measured in Amps DC+
DC -
Polarity
DC- (Direct Current
Electrode Negative)
DC+ (Direct Current AC
Electrode Positive)
AC (Alternating Current)
Basic Electricity and the Science of
Welding
Changes of State and Chemical Reactions
During the welding process the metal changes states or
forms.

What are the states of matter?

Solid
Liquid
Gas
Plasma
Basic Electricity and the Science of
Welding
Changes of State and Chemical Reactions
So what changes of state occur during welding?
Initially the metal is a solid
When the arc starts the solid is converted into a liquid
Some of the liquid is converted into a gas vapor
When the arc stops the liquid cools to form a solid
again this is the newly formed weld joint

Solid Liquid Solid

(gas vapor)
Quivers & ovens to bake & rebake
electrodes
Contd.
Product catalogue for E6013
Packing of electrodes
SMAW electrode 7018 test certificate
Raw material & electrodes specification recommended
for SMAW PROCESS
Steel Specification Recommended Electrodes
electrodes as per used in
AWS D1.1 PEB/structural
steel
ASTM A 572-Gr-50 E-7015,E-7016,E- E-7018
7018,E-7028
ASTM A 572-Gr-55 -DO- -DO-

ASTM A 572-Gr-42 -DO- -DO-

IS 2062 Fe 410, 490 -DO- & E-6013 -DO-

SMAW contd

Advantages
Versatility - readily applied to a variety of applications and a wide choice of
electrodes
Relative simplicity and portability of equipment
Low cost
Adaptable to confined spaces and remote locations

Suitable for out-of-position welding

Disadvantages:

Not as productive as continuous wire processes

Likely to be more costly to deposit a given quantity of metal
Frequent stop/starts to change electrode
Relatively high metal wastage (electrode stubs)
Current limits are lower than for continuous or automatic
processes (reduces deposition rate) & improper shielding
GMAW
GMAW WELDING MACHINES IN SHOP FLOOR
Shielding gases
Flux Cored Arc Welding
Electrode designation
GMAW & FCAW ELECTRODES
Submerged Arc Welding (SAW)
Twin arc
SAW Machines in PEB
Conrac butt weld Machine Conrac twin arc fillet weld
-1,Wire Dia,2mm Machine-1,Wire Dia-2mm
Contd..
Zing gong butt weld machine-1 Zing gong twin arc fillet weld
Wire Dia,2mm Machine-1,Wire Dia,2mm
Contd.
Zing gong butt weld machine- Zing gong twin arc fillet weld
2 Wire Dia,2mm Machine-2,Wire Dia,1.6mm
Contd
Conrac butt weld Machine Conrac twin arc fillet weld
-1,Wire Dia,2mm Machine-1,Wire Dia-2mm
SAW-Electrodes
Flux Designation system
Raw material used in structural
industry
Plates

Angles

Channels

Beams
Plates
Angles & channels
Beams
Quality control
Dimensional

Visual inspection

Chemical analysis

Destructive testing

Non destructive testing

Raw material cleaning
Wire brush cleaning

Sand Blasting

Pickling or Acid cleaning

Flame cleaning
Multi torch gas cutting
Shear cutting machine
Drilling machine
Welding and assembly