Metal-Welding

Welding is a one of the material joining process. Material joining processes can be
classified as follows

welding: two metal are joined by taking them to reach their melting point and fused together, soldering
and brazing: joining two metal by applying another metal which is melted and cooled down over the
joint..
Metal-Welding
Metal-Welding is the joining of metallic materials by
application either heat along or by application both heat and
pressure

Welding can be categorized in to two main types

(Solid state) Plastic Welding or Pressure Welding `
The pieces of metal to be joined are heated to a
plastic state and forced together by external pressure. (Ex) spot
welding

(Liquid state) Fusion Welding or Non-Pressure Welding

The material at the joint is heated to a molten
state and allowed to solidify (Ex) Gas welding, Arc welding
Different welding processes

01 Shielded Metal Arc Welding (SMAW)

02 Metal inert gas welding (MIGW)
03 Tungsten inert gas welding (TIG, GTAW)
04 Gas welding
05 Spot welding
01 Shielded Metal Arc Welding (SMAW)
Shielded metal arc welding is one of the liquid state (fusion) welding
operation.
Uses a metallic consumable electrode for generate electric arc between
itself and the parent work piece.
Generated arc, molten the work material and filler material.
The molten electrode metal fills the weld gap and joins the work pieces.
The arc temperature ranges from 3500 ْC to 15000 ْC depending on the
current rating
 Weld Fluxes in arc welding
During the arc welding, the molten metal in the weld pool is
highly tendency to oxidation. So in arc welding, to protect the weld
pool from oxidation slag layer is used. Slag layer is generated by
melting electrode coating.
Typical fluxes
SiO2, TiO2, FeO, MgO, Al2O3
 Arc welding circuit
For arc welding is used either direct current (DC) or alternating current (AC) depending on the
process and the materials.
The open circuit voltages must not exceeds 100V at DC and 70V at AC current because of
accidental danger.
Current up to 500A common in manual welding

U R  U B U L
UL
Example: Calculate the welding
Power source

UB Voltmeter current for different arc lengths

UR Voltage at power source 60V,
Resistance 0.2Ω, Voltage for
A shorter arc length 20V,voltage
J Ampere meter
Resister to limit
for longer arc 03V
short circuit
current

U  U L 2 60  30 30 U B  U L1 60  20 40
J2  B    150 A J1     200 A
R 0.2 0.2 R 0.2 0.2
 Volt- ampere characteristic curve
Each setting of the control
device of the power source (e.g.
hand wheel, lever , crank)
represents a fixed static
characteristic curve. So each arc
voltage is related to a fixed
welding current
 Diagram of a arc welding transformer

By adjusting the position Supply power line

(AC)
of the Movable iron core,
can changed the
secondary winding Current weaker
current. When it is move
Movable iron
towards to the primary core
coil current will be weaker
and it is move towards to Current stronger
Magnetic flux
the secondary coil current
will be stronger

Welding current (AC)

 Advantages of Shielded Metal Arc Welding
(SMAW):
1. Simple, portable and inexpensive equipment

2. Wide variety of metals, welding positions and electrodes are

applicable

3. Suitable for outdoor applications.

4. Depth of penetration is high so strong weld can be generated

 Disadvantages of Shielded Metal Arc
Welding (SMAW):

1. The process is discontinuous due to limited length of the

electrodes;
2. Weld may contain slag inclusions;
3. Due to emitting fumes make difficult the process control
 02. Metal inert gas welding (MIGW)

Consumable electrode wire is

continuously fed from a spool to
the arc zone.
The arc heats and melts both the
work pieces edges and the
electrode wire.
The fused electrode material fills
the weld pool and forms joint.
Metal inert gas welding illustrating
diagram
Use of inert gas in MIG welding
During the MIG welding, the molten metal in the
weld pool is highly tendency to oxidation. So in MIG
welding to protect the weld pool from oxidation inert
gas is used. Inert gas covered the weld pool and avoids
the oxidation.

Inert gas used in MIG welding

Argon, helium, nitrogen, and carbon dioxide
 Advantages of Metal Inert Gas Welding
(MIG, GMAW)
• Continuous weld may be produced (no interruptions);
• High level of operators skill is not required;
• Slag removal is not required (no slag);

Disadvantages of Metal Inert Gas Welding

(MIG, GMAW)
• Expensive and non-portable equipment is required;
• Outdoor application are limited because of effect of wind,
dispersing the shielding gas
03. Tungsten inert gas welding (TIG, GTAW)

Tungsten Inert Gas Arc

Welding (Gas Tungsten Arc
Welding) is a welding process,
in which heat is generated by
an electric arc between a
tungsten non-consumable
electrode and the work piece.
The heat produced by the arc
melts the work pieces edges
and joins them. Filler rod may
be used.
Tungsten Inert Gas Arc
Welding produces a high
quality weld of most of
metals.
Tungsten inert gas welding illustrating
diagram
 Use of inert gas in TIG welding
During the TIG welding, the molten metal in the weld pool is
highly tendency to oxidation. So in TIG welding to protect the
weld pool from oxidation inert gas is used. Inert gas covered
the weld pool and avoids the oxidation.

Inert gas used in TIG welding

Argon, helium, nitrogen, and carbon dioxide
 Advantages of Tungsten Inert Gas Arc
Welding (TIG, GTAW)
1. Slag removal is not required (no slag)
2. Thermal distortions of work pieces are minimal due to
concentration of heat in small zone.
3. Weld composition is close to that of the parent metal.
4. High quality weld structure.
Disadvantages of Tungsten Inert Gas Arc
Welding (TIG, GTAW):
1. Low welding rate;
2. Relatively expensive;
3. Requires high level of operators skill
 05. GAS WELDING
Gas Welding is a liquid state welding process utilizing
heat of the flame from a welding torch.
The torch mixes a fuel gas with Oxygen in the proper ratio
and flow rate providing combustion process at a required
temperature.
The hot flame fuses the edges of the welded parts, which
are joined together forming a weld after Solidification.
Types of flames
• Neutral flame: The neutral flame is usually used for welding.

• Oxidizing flame: The oxidizing flame is used for gas cutting

operation

• Carburizing flame: The carburizing flame is used for work

hardening.
 Advantages of gas welding
1. Versatile process
2. Low cost, portable equipment
3. Electricity supply is not required

Disadvantages of gas welding

1. High skill operator is required
2. Flame temperature is lower, than in arc welding
3. Fumes evolved when welding
4. Some metals cannot be welded (reactive and refractory metals)
 06. Spot welding
Spot welding is one of the solid state welding process
In spot welding thin sheets are joint by applying pressure and high current.
This is achieved by delivering a large amount of energy in a short time
in order to create controlled and reliable welds.
 Pressure and current graph for spot welding

Water cool lines are used to reduce the heat generation at the
electrodes
Nugget growth and temperature variation
in spot welding
 Advantages of spot welding
1. No filler rod: electrical current is passed through metal under pressure
2. Low skill level required
3. Easy to automate
4. Low heat input and no weld bead: distortion and grain growth are minimized

Disadvantages of spot welding

1 The electrodes have to be able to reach both sides of the pieces of metal that
are being joined together
2. The size and shapes of the electrodes will determine the size and strength of
the weld.
3. The join forms only at the spot where the electrodes are in contact with the
metal.
4. Difficulty for maintenance or repair
Home work
Read the Chapter 27,28,29,30 In
Manufacturing Engineering and Technology
By
Serope Kalpakjian
Steven R. Schmid