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Presented by
Parveen Kumar{05110}
INTRODUCTION
ØAs we all know that whatever the product
that is impossible to manufacture as a
single piece.
ØWelding is a process which is used to join
the two parts to get a desired product.
ØWelding is a joining process. The types of
welding processes are:-
cont……….
Diversity of welding processes
welding
Resistance Soldering
welding
Brazing
Cold welding
Friction welding Electrical energy Chemical energy
Diffusion welding
Oxyacetylene welding
Flash welding
Oxyfuel gas welding
Ultrasonic welding
Explosion welding Consumable electrode Non consumable Other processes
electrode
Gas metal arc welding Laser beam welding
Shielded metal arc welding Gas tungsten arc welding Thermit welding
Submerged arc welding Atomic hydrogen welding Electron beam welding
Flux cored arc welding Plasma arc welding
Electrogas welding
Electroslag welding
FUSION WELDING
ØIt is defined as the melting of two
material parts by attaching together by
means of heat
ØHeat may be supplied by chemical or
electrical means.
ØIn this filler metal may or may not be
use .
FUSION WELDING
COMPRISES:-
ØOxyfuel gas welding
ØArc welding processes
4. Consumable electrode
5. Nonconsumable electrode
Ø Thermit welding
Ø Electron beam welding
Ø Laser beam welding
● OXYFUEL GAS WELDING
ØOxyfuel gas welding is the welding
process that use a fuel gas combined
with oxygen to produce a flame.
ØThis frame is the source of the heat
that is used to melt the metal at the
point of joint.
ØThe most common gas welding process
which is oxyacetylene welding and is
used for automotive bodies, and various
other repair works.
Ø In this process, heat is generated in
two steps:-
2. Primary combustion process:-
In this process, acetylene reacts with O2
and give CO and H2 and it produces
1:3 of the total heat generated in the
flame.
2. Secondary combustion process:-
It consist of further burning of H2 and
CO with O2 and this reaction
produces about 2:3 of the total heat.
The temp. developed in the flame is
Types of flame:-
2. When there is no excess oxygen, then it is
known as neutral flame.
3. If the oxygen is notin large amount, then it
is known as oxidizing flame.
• This is harmful for steel, because it oxidizes
the steel.
• It is used only for Cu and Cu alloys because
in those cases, a thin protective layer of
slag forms over the molten metal.
3. If the ratio of O2 is deficient, then the flame
becomes reducing flame.
The temp. of reducing flame is lower, so it is
suitable for applications requiring low temp.
OXYACETYLENE FLAMES USED IN
WELDING
OXYACETYLENE TORCH AND SETUP
FILLER METALS
•Filler metals are used to supply additional
material to the weld zone during welding.
•They are available as rod or wire made of
metals compatible with those to be
welded.
•These consumable filler rods may be
coated with flux .
•The function of the flux is to retard
oxidation of the surface of the parts being
welded by generating a gaseous shield
ARC WELDING
• Arc welding processes use a welding
power supply to create and maintain
an electric arc between an
electrode and the base material to
melt metals at the welding point.
• They can use either direct (DC) or
alternating (AC) current, and
consumable or non-consumable
electrodes.
• The welding region is sometimes
protected by some type of inert or
semi-inert gas, known as a shielding
gas, and filler material is sometimes
used as well.
Types of arc welding:-
1.Shielded metal arc welding:-
ØShielded metal arc welding is one of the
oldest, simplest and most versatile
welding process.
ØThe electric arc is generated by touching
the tip of a coated electrode against the
work piece and then withdrawing it quickly
to a distance sufficient to maintain the arc.
ØThe electrode arc in the shape of thin,
long stick, so this process is also known as
stick welding.
ØAbare section at the end of the
electrode is clamped to one terminal of
the power source , while the other
terminal is connected to the work piece
being welded.
ØThe current usually ranges from 50A to
300A,power requirements are generally
less then 10KW.
ØThe current may be dc or ac . For sheet
metal welding dc is preferred because
of the steady arc it produces .
Cont……
ØThe polarity of the dc current is
important and its selections is depend
upon the metal to be welded , types of
electrode and the depth of the heated
zone.
ØIn straight polarity , the work piece is
positive and electrode is negative.
ØIt is preferred for sheet metals ,
because it produces shallow penetration
, and for joints with very wide gaps.
ØIn reverse polarity , the electrode is
positive and deeper weld penetration is
possible
SHIELDED METAL ARC
WELDING
SMAW SYSTEM SETUP
• Advantages - The process is very versatile, requiring
little operator training and inexpensive equipment.
• Disadvantages – 1. the process is generally limited to
welding ferrous materials, though speciality
electrodes have made possible the welding of cast
iron, nickel, aluminium, copper, and other metals.