Utilization of Electrical Power

(M2H621476)
Electric Welding
 Electric Welding
• Welding - process of joining two metal pieces by the
application of heat (Process of creating a coalescent
bond between two base metals).
• Heat supplied electrically or by mean of a gas torch
• better way to join two or more pieces of metals – make
them act as one piece (Compare with bolt & nut joining-
reduced area of joint, additional weight & Cost) (Also
with thread joining- reduced thickness as the metal part
removed for making threads –not suitable for larger
diameter pipes)
• Widely used in manufacturing – larger structures like
steel-structured buildings, rocket engines, nuclear
reactors, ships, containers, auto mobiles, pipe lines etc.
• welding is used in refineries and pipe line fabrication.
• It may be called a secondary manufacturing process.
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 Electric Welding

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 Welding
Advantages and Disadvantages
 Lowest cost joining method
 Better utilization of material
 Flexibility of use -can be used for most commercial metals-
any locations
 Design flexibility

o Depends on human factor – can cause

failures
o Internal inspection and quality check
required

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 Classification
• Around 35 different welding methods in use by
today. the industry
• Various ways of classifying the welding for example, they may
be classified on the basis of source of heat(flames ,arc etc.)

3 Arc Welding
2. Resistance
a. Carbon Arc welding
Welding:
1. Gas Welding b. Metal Arc Welding
a. Butt welding
a. Air Acetylene b. Spot welding c. Gas Metal Arc
b. Oxy d. Atomic Hydrogen Arc
c. Projection
Acetylene e. Submerged Arc
welding
c. Oxy Hydrogen d. Seam welding f. Gas Tungsten Arc
g. Plasma Arc welding

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 Classification

4.Solid State Welding: 5: Thermo Chemical Welding

a. Friction Welding a. Thermit welding
b. Ultrasonic Welding b. Atomic welding
c. Diffusion Welding
d. Explosive Welding

6. Radiant Energy Welding

a. Electron Beam Welding
b. Laser Beam Welding

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 Resistance Welding
 Apply force across the work piece (metal parts to be
welded) and pass current through the metal pieces via
electrodes
 Due to resistance of metal parts heat is generated at the
interface of metal parts and makes a nugget, resulting in
melt joint.
• Large current (100s A), at
low voltage (4 -12V).
• AC voltage more suitable
(For high (I) – low (V)
transformation)

Resistance Welding = electric

current + mechanical
pressure in proper
magnitudes and for a precise
period of time
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 Features of Resistance Welding
 No flux such as solder is necessary.
 No Spatter and ultraviolet ray generated
 Clean and neat worksite is realized.
 Easy operation as only pressing buttons
facilitates process automation
 Trained skills not required for welding
(unlike arc welding and gas welding).
 As this welding is performed efficiently in
a short period of time, it is suited for a
high-volumes production of low-cost
products.
 Less heat-affected area on work pieces,
resulting in beautiful appearance with less
indentation.
 Proper supply is required to provide large
current & low voltage

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 Resistance Welding - Types
Butt Welding: Joining the two pieces either on face or edge,
welding done over the entire area of contact
Spot Welding
The welds are done in small localized spots on the joining faces
instead of long welds all along the edges/faces where the two
pieces of material come together.
Projection Welding
The welds are done in localized projections or intersection on
the joining faces
Seam welding
• In this method the seam between two pieces of metal is sealed
by continuous weld spots.
• Wheel-shaped electrodes are needed. The wheel shape of the
electrodes allow for long continuous welds that reinforce the
metals, making the weld as strong as possible.
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Power Supply for Resistance Welding
• ACsupply is used for
resistance
welding
• I-V transformation possible with a
transformer
• kVA ranges fro few kVA to 1 MVA
• (due
Powerto factor
reactance
will be low
of &welding
lagging
machine)
• Serious Voltage drop problems for
the power supply system
• Connect capacitors (in series to
Resistance Welding Machine
the transformer) to improve the Transformer +
power factor Electrodes+ Pressure Control
device + Current control device
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Utilization of Electric Power - Illumination 1 10
 Electric Arc Welding
 Arc welding is one of several fusion processes for joining
metals.
 By intense heating through arc, metal at the joint between
two parts is melted and caused to intermix
 Upon cooling and solidification, a strong bond is created.
 Since the joining is an intermixture of metals, the final
weld has the same strength and properties as the original
metal of the parts.
 This is in sharp contrast to non-fusion processes of
joining (i.e. soldering, brazing etc.) in which the
mechanical and physical properties of the base materials
cannot be duplicated at the joint.

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 Electric Arc Welding
• The intense heat needed to melt metal is produced by an
electric arc.
• Arc is formed between the actual work piece and an
electrode (stick or wire) that is manually or mechanically
guided along the joint.

http://www.lincolnelectric.com/en-us/support/
process-and-theory/Pages/arc-welding-detail.aspx

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 Electric Arc Welding
 Electrode can be a rod with
the purpose of simply carrying
the current between the tip
and the work.
 Or, it may be a specially
prepared rod or wire that
conducts the current and also
melts and supplies filler metal
to the joint.
 Most welding in the
manufacture of steel products
uses the second type of
electrode.

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 Electric Arc Welding -Types
Metal Arc Welding
• Metal rod of the same metal to be welded is used as one
electrode
• Serves as filler material heat produce by the arc causes
the rod to melt and make joint of the parent metal
Shielded Metal Arc Welding
• uses a metallic consumable
electrode of a proper
composition
• The molten electrode metal fills
the weld gap and joins the
work pieces
• The electrodes are coated with
a shielding flux of a suitable http://www.substech.com/dokuwiki/doku.php?id=shielded_metal_arc_weldin
composition g_smaw&DokuWiki=465bc5e8fb82acb33add95f16c664258
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 Electric Arc Welding -Types
Inert Gas Metal Arc Welding also known as MIG welding
• Inert gas such as argon or helium or even a mixture shields the
welding arc
• Deoxidizers in the electrodes can prevent oxidation
which makes it possible to weld multiple layers.
• The temperatures are also relatively low and it is used for thin
sheets and sections

• It's a simple, versatile,

and
economical welding
process

• It can easily be
automated

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 Submerged Arc Welding
• SAW has a granular flux fed into the weld zone to form a thick layer,
completely covering the molten zone and preventing sparks and
spatter
• It allows for deeper heat penetration since it acts like a
thermal insulator
• The process is limited to horizontal welds and used for high
speed
sheet or plate steel welding

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 Carbon Arc Welding
• In CAW process carbon or graphite electrodes are used
• The oldest welding process - being replaced by twin carbon arc
welding and other methods
• Carbon electrode is non
consumable
• If required, separate filler
rod may be used
• Low cost
• High level operator skill is not
required;
• Easily automated;
• Low distortion of work piece.

• Unstable quality of the weld

(porosity);
• Carbon of electrode may
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contaminates weld material
 Atomic Hydrogen Arc Welding
• Heat is generated by passing a stream of hydrogen through an
electric arc between two non consumable tungsten electrodes
• The high temperature of the arc dissociates molecules of the gas into
atoms
• Large quantity of heat being absorbed by the hydrogen during
dissociation
• When the atoms leave the influence of the arc they recombine,
forming molecules of hydrogen and liberating heat previously
absorbed

• High temperature of the

flame (4000 deg. C)
• Cost of welding higher than
other processes
• Satisfactory weld can be
made

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 Power Supply for Electric Arc Welding
• AC or DC, with various means of controlling their voltage and
ampere output
• Power source must be capable of producing the proper
arc characteristics for the welding process being used
• OC voltage to be higher – enough to produce arc but safe for
the operator (<80V)
• The short circuit current must be within safety limits of
the windings of Transformer and Generator
• Source should be capable of meeting the requirement
of varying voltages with changes in arc length
• Power source to be sufficient to give the desired current
• Welding Transformer + Rectifier => DC
• Welding Generators AC or DC (Depending on
generator)
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 AC Vs. DC Arc Welding
AC arc welding has few economic advantages over
Dc arc welding
• Exiting AC power supply can be used- no need
for additional generators/ rectifiers –only
(comparatively
transformer cheaper) is needed.
• Low initial cost as only transformer is needed additional
• Operational and Maintenance cost is less
transformer compared(of to generator)
• Energy consumption per Kg of deposited material
is comparatively less.
• Higher operating efficiency
• Low Power factor is a disadvantage which can
be corrected using Capacitors

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 Qualities of a Good
Weld
A Good Weld should be
free from external
defects like:
• Irregular beads,
• Deviation in dimensions
• Unfilled craters on the
surface
• Under cuts
• Slag on the surfaces,
• Porosity in the outer
layer,
• Cracks,
• Poor fusion between
layers
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