WELDING

INTRODUCTION
Welding is process of joining two metal pieces as a result of significant diffusion of the atoms of the welded pieces into the joint region. Welding is carried out by heating the joined pieces to melting point and fusing them together or by applying pressure to the pieces in cold or heated state. CLASSIFICATION OF WELDING PROESCESS Arc welding Resistance welding {RW} Gas welding {GW} Solid state welding {SSW} Laser welding {LW} Electron Beam welding {EBW}

ARC WELDING

INTRODUCTION
The arc welding process in which coalescences of metal is produced by heat from an electric arc that is maintained between the tip of a consumable covered electrode and the surface of the base metal in joint being welded. It is one of the most widely used processes, particularly for short welds in production,maintanance and repair work, and for field construction.

PRINCIPLES OF OPERATION

 The electric arc is produced between two conductors. The electrode is one conductor and the work piece is another conductor. The electrode and work piece are nearer with a small air gap in three mm (3). When current is passed, an electric arc is produced between electrode and workpiece.The work piece is melted by the arc. Electrodes used in arc welding are generally coated with a flux. The flux produces a gaseous shield around the molten metal. This prevent the reaction of the molten metal with oxygen and nitrogen in the atmosphere. The flux removes the impurities from the molten metal and form a slag. This slag gets deposit over the weld metal. This protects the weld seam from rapid cooling.

Equipments needed for arc welding

A welding generator (DC) or transformer (AC) Two cables one for work and another for electrode Electrode holder Electrode Protective shield Gloves Apron Wire brush Chipping hammer Goggles

Advantages
The equipment is relatively simple, in expensive, and portable. The filler metal, and the means of protecting it and the weld metal from harmful oxidation during welding, are providing by the covered electrodes Auxiliary gas shielding or granular flux is not required. It can be used in areas of limited access. Suitable for outdoor applications. Wide variety of metals, welding position and electrodes are applicable.

DISADVANTAGES
The process is discontinuous due to limited length of the electrodes Weld may be contain slag inclusions.

Fumes make difficult the process control.

APPLICATIONS
Buildings and bridges structures .

Furniture, boilers, general repair work.

Automotive, ship and aircraft constructions. Pipe lines. Tanks and vessels. Rail tracks.

Machinery elements.
Generally fabrication work etc