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ADVANTAGES
A welded joint is as strong as the base metal Welding equipment is not very costly and is portable Welding permits considerable freedom in design A large number of metals and alloys can be welded, and is suitable for similar and dissimilar metals. Weldments (welding products) are lighter and stronger Joints are easier to inspect
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DISADVANTAGES
Welding requires skilled operator Welding results in residual stresses and distortion of work piece. Therefore it needs heat treatment to relieve internal stresses. Welding requires edge preparation, and use of jigs and fixtures Welding gives out harmful radiation and fumes The structure of welded joint is not same as the base metal
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CLASSIFICATION OF WELDING
Gas Welding
Oxy-Acetylene welding Oxy- other fuel gas welding

Arc welding
Carbon Arc welding Shielded arc welding Submerged arc welding MIG welding TIG welding Plasma arc welding Electroslag welding
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CLASSIFICATION OF WELDING
Resistance Welding
Spot Welding Seam Welding Projection Welding Flash Butt Welding

Solid state Welding

Friction welding Ultrasonic welding Forge welding Explosive welding
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CLASSIFICATION OF WELDING
Thermo-Chemical welding process
Thermit welding Atomic hydrogen welding

Radiant energy welding

Electron beam welding Laser beam welding

 Weldability of a material refers to its ability to be welded. A material's weldability is used to determine the welding process. Weldability depends on
Melting point Thermal conductivity Thermal expansion Surface condition Change in microstructure

WELDABILITY

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HEAT AFFECTED ZONE [HAZ]

The portion of the base metal that has not been melted, but its mechanical properties have been altered by the heat of welding. The size of heat affected zone depends on metallurgical factors (such as grain size, grain orientation) and properties like specific heat & thermal conductivity.

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 In Gas welding, the heat necessary for melting base metal and filler rod is obtained by gas flame. The composition of filler rod is same as that of the base metal. In Oxy-Acetylene welding, heat is produced by burning acetylene in the presence of oxygen at the tip of a nozzle which is fitted to a torch body. The temperature of the oxy-acetylene flame is 3250C and is used to melt parent metal to form a weld pool. No flux is used for gas welding and the molten metal is protected by gaseous products of the flame.
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OXY-ACETYLENE FLAME

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TYPES OF OXY-ACETYLENE FLAME

Oxidising Flame Neutral Flame Reducing Flame (Carburising flame)
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OXY-ACETYLENE WELDING EQUIPMENTS & ACCESSORIES

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WELDING TORCH

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WELDING TORCH

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ACETYLENE C2H2

CaC2 + 2H2O = Ca (OH)2 + C2H2

Slaked Lime Acetylene Gas

Acetylene production: Calcium Carbide Water Water to Carbide method (high pressure system) Carbide to Water method (low pressure system)

ACETYLENE Storage

The cylinder contains 80% porous substance such as charcoal or asbestos which is saturated (completely filled) with liquid acetone (hydro-carbon liquid). The liquid acetone dissolves the acetylene gas in large quantity as safe storage medium; one volume of liquid acetone can dissolve 25 volumes of acetone gas for each bar of pressure.
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GAS WELDING TECHNIQUES

Material being welded Thickness of work material Shape & size of the work piece Properties of the joint

1.Leftward or Forward welding 2.Rightward or Backward Welding 3.Vertical Welding

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Leftward or Forward welding

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Rightward or Backward Welding

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Vertical Welding

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Advantages of Gas welding

High portability Less welding skills required Easy control of filler metal Equipment are low cost Maintenance cost is less

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Disadvantages of Gas welding

Takes longer time to weld Larger Heat Affected Zone Oxygen & Acetylene are costlier Shielding provided by flame is not effective Flame temperature is less than the temperature of the arc Safety problems in handling and storage of gases
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 In this process, the work piece to be joined are held together and a strong electric current of low voltage (6 to 10 volts) and high amperage (60 to 4000 amperage) is passed through them. When the current passes through the metal, the high resistance at the point of contact raises the temperature at the junction. The mechanical pressure applied at this moment completes the weld
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Spot Welding

Butt Welding

Flash Welding

Seam Welding

Projection Welding

Percussion Welding

RESISTANCE WELDING
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SPOT WELDING

BUTT WELDING

SEAM WELDING

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FLASH WELDING

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 Used for making lap welds in thin sheets Sheets are held between metal electrodes Secondary current from transformer is passed between the electrodes, causing the metal temperature in contact spot to be rapidly raised to welding temperature. The weld at this contact spot is then completed by applying pressure by the electrodes itself. Used for welding ferrous and non-ferrous alloys.

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 Work pieces of the same cross section are held in suitable clamps butting each other. The current is switched on and the contacting surface gets fused and joined by mechanical pressure.
Similar to butt welding The ends of the work pieces to be welded are put together and the required current is passed through the work pieces. Sudden separation of the ends by a short distance produces an arc in the space between the work resulting very high heat. Immediately the current is cut off and work pieces are joined together by pressure
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 Similar to Spot welding The electrodes are disk shaped rollers The electrode roll over the sheet and a continuous weld is obtained. The current passing from wheel to wheel through the work pieces heats the parts to be joined and due to the pressure, the weld is formed. Also known as CONTINOUS SPOT WELD PROCESS. Used for welding sheet metals, radiator, drums etc.
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 Modification of Spot welding The current and pressure are localized at the weld section by the use of some projections on one or both pieces of the work. The flattening out of these projections under pressure results in good welds at all points of contact.

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BUTT WELD

SPOT WELD

SEAM WELD

SEAM WELD KSC-STIST

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The source of heat in Arc welding is an electric arc. The electric arc develops when current flows across the air gap between the end of metal electrode and the work surface. This arc is strong stable electric discharge occurring in the air gap between an electrode and the work. The temperature of this arc is about 3600C which can melt and fuse the metal very quickly to produce joint. The temperature of the arc at the centre is around 6500C. Only 60 to 70% of the heat is utilized in arc welding to heatup and melt the metal. The remaining 40 to 30% is dissipated into surroundings. The principle of arc welding is based upon the formation of an electric arc between a consumable electrode (bare or coated) and the base metal. The heat of the arc is concentrated at the point of welding; as a result, it melts the electrode and base metal. When the weld metal solidifies, the slag gets deposited on its surface as it is lighter than metal and weld metal is allowed to cool gradually and slowly. After cooling (solidification) a sound joint is formed. The slag is removed by chipping hammer.
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 Non-Consumable electrodes Consumable electrodes

Bare electrodes Coated electrodes

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Advantages of Arc Welding

Faster than Gas welding Low cost Versatile process Suitable for wide range of ferrous and non ferrous metals and their alloys

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Disadvantages of Arc Welding

Not suitable for thin sections Electrode replacement is necessary for long joints Not suitable for welding large metal pieces Need to remove slag at the end of welding process
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ARC WELDING EQUIPMENTS

1. 2. 3. 4.
a) b) c) d)

Transformer Generator Rectifier Accessories

Face shields Hand Gloves Safety Goggles Skull Caps Safety boots Tools- Chipping Hammer, Brushes, Fixtures
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Electrodes Electrode Holder Cables Safety devices

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AC Advantages
Low cost & Easily available Low maintenance cost, no moving parts

DC Advantages
For Ferrous & Non ferrous metals Stable arc Safer
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AC Disadvantages
Not suitable for Non-ferrous metals Not safe

DC Disadvantages
More expensive High maintenance
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Kinds of Polarity

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Types of Flux Coating Purpose of Welding Fluxes Coating Factor Electrode Specifications Types of Welded Joints Basic Weld symbols Selection of Electrodes
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CARBON ARC WELDING

Non consumable carbon/graphite electrode.
Single electrode arc welding- DC Straight polarity Twin carbon electrode arc welding- AC

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WELD POSITIONS
FLAT POSITION

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WELD POSITIONS

HORIZONTAL POSITION
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WELD POSITIONS
VERTICAL POSITION

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WELD POSITIONS
OVERHEAD POSITION

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 Fusion welding process Heat required is obtained by an exothermal chemical reaction 8Al + 3Fe3O4 = 9Fe + 4Al2O3
Iron (Thermit)
Aluminium Iron Oxide Aluminium Oxide (Slag)

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Wax joint

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 Process of joining two metallic surfaces without using filler materials. The surfaces to be joined are heated to a temperature higher than the ordinary forging temperature and joined together by hammering.

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PERCUSSION WELDING

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ELECTRON BEAM WELDING

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FRICTION WELDING

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EXPLOSIVE WELDING

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ULTRASONIC WELDING

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TESTING & INSPECTION OF WELD

VISUAL INSPECTION RADIO-GRAPHICAL TESTING
X-RAY TESTING -RAY TESTING

EDDY CURRENT INSPECTION LIQUID PENETRANT TEST ULTRASONIC TESTING

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WELD DEFECTS
Weld Crack Lack of Penetration Slag Inclusion Porosity Undercut Spatter Wraping & Distortion
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WELD CRACK

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LACK OF PENETRATION

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SLAG INCLUSION POROCITY

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UNDERCUT SPATTER

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WRAPING & DISTORTION

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