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Presented by
RANENDRA CHAKRABORTY
WELDING
Definition as per AWS / ASME:
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MAJOR WELDING PROCESSES
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SHIELDED METAL ARC WELDING
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Shielded Metal Arc Welding -- Polarity
SMAW - DC Polarity
(–) (+)
(+) (–)
Shallow penetration Deeper weld penetration
(thin metal)
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OVERALL ADVANTAGES
Low Equipment Cost
Usage possible with restricted access.
OVERALL LIMITATIONS
Skilled operator is required for good quality welds.
Slow, mainly because flux must be chipped away.
SAFETY
Arc emits visible and ultraviolet radiation.
High open circuit voltage present while electrode is fitted to h
older.
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GAS METAL ARC WELDING
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OVERALL ADVANTAGES
Continuous process
Reduced finishing operations
Thin sheets can be welded in all positions by dip transf
er mode.
OVERALL LIMITATIONS
No independent control of filler addition.
SAFETY
Arc emits visible and ultraviolet radiation.
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GAS TUNGSTEN ARC WELDING
GTAW is defined as an arc welding process which produces coa
lescence of metals by heating them with an arc between a tungste
n (non- consumable) electrode and the work piece.
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GAS TUNGSTEN ARC WELDING(Contd.)
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GAS TUNGSTEN ARC WELDING(Contd.)
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GAS TUNGSTEN ARC WELDING(Contd.)
OVERALL ADVANTAGES
Superior quality welds
Welds can be made with or without filler metal
Precise control of welding variables (heat)
Free of spatter
Slag free
Low distortion
OVERALL LIMITATIONS
Requires greater welder dexterity than MIG or stick welding
Lower deposition rates
More costly for welding thick sections
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SUBMERGED ARC WELDING
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SUBMERGED ARC WELDING(Contd.)
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SUBMERGED ARC WELDING(Contd.)
http://www.twi.co.uk
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SUBMERGED ARC WELDING(Contd.)
OVERALL ADVANTAGES
High weld metal Quality
Smooth and uniform weld bead with no spatters.
Extremely high deposition rate and welding speed.
High Arc time can be achieved through automation.
Minimum operator fatigue.
OVERALL LIMITATIONS
High initial cost
Limited welding positions.
Requirement of special jigs and fixtures.
Difficulty in welding low thickness metals.
Full penetration weld joints not possible from single side.
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COMPARISON
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COMPARISON(Contd.)
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Flux Cored Arc Welding
Self shielding flux cored arc welding wires are available or gas
shielded welding wires may be used. Flux cored welding is ge
nerally more forgiving than MIG welding. Flux cored welding pr
oduces a flux that must be removed. Flux cored welding has g
ood weld appearance (smooth, uniform welds having good cont
our).
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BENIFITS
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THERMIT WELDING
Thermit Welding usually uses the exothermic reaction of a mixture of iron oxide and alu
minum powder or other similar mixtures to weld or repair large forgings and castings, an
d join pipes and railroad rails.
The parts are aligned and a ceramic or sand mold is built around the joint to be formed.
The thermitic mixture reaction is initiated with a special compound (an oxidizing agent) h
eating quickly to the desired temperature which melts the ends of the parts to be joined.
After the weld cools, excess material is removed by machining, grinding, or other cutting
methods
Heat source
chemical reaction between thermit mixture components
Iron oxide and aluminum powder
ignition fuse required
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THERMIT WELDING (Contd.)
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THERMIT WELDING (Contd.)
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Weld Metal Protection
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Weld Fluxes
• Typical fluxes
•SiO2, TiO2, FeO, MgO, Al2O3
•Produces a gaseous shield to prevent contami
nation
•Act as scavengers to reduce oxides
•Add alloying elements to the weld
•Influence shape of weld bead during solidificati
on
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Inert Gases
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PREVENTION
• Rapid heating and cooling results in thermal stresses
detrimental to joint strength. Pre-caution to be followed
as below:
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Welding
Techniques
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Positions
• 1F
• 1G
• 2F
• 2G
• 2FR
• 5G
• 4F
• 6G
• 5F
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1G Position
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2G Position
Pipe Axis Vertical, Weld is Horizontal, Pipe is
considered in a “fixed” position.
Always use a split bead technique
Always work from the bottom up.
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5G Position
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6G Position
Pipe axis is fixed in position at a 45
degree incline. The position includes
flat, horizontal, vertical, and overhea
d welds.
A split bead technique is best used.
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1F Position
Pipe is rotated. The pipe axis is
at a 45 degree incline. Welding
is to occur at the top of the pipe
.
Split bead or weave technique
may be used.
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2F Position
Fixed Position
Best to use a split bead
technique
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2FR Position
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4F Position
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5F Position
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Fill Pass Cover Pass
Root Pass Hot Pass
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Joint Design
BUTT JOINT
STRAP JOINT
FILLET JOINT
CORNER JOINT
LAP JOINT 44
Generalized Welding Symbol
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Example Welding Symbol
1/2
1/2
1/2” 1/2” 46
Weld Symbols (Butt Joints)
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Weld Symbol (Fillet Joints)
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Weld Symbol (Corner Joints)
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