Contents Abstract 1. Introduction: 2. Overview of Welding a. The Weld b. TYPE OF WELD JOINTS 3. Selection of Welding Process a.

Step 1 Analysis of Joint Requirements. i. Fast Fill ii. Fast Freeze iii. Fast Follow b. Step 2 Matching Joint Requirements With Processes c. Step 3 The Checklist i. Volume of Production ii. Weld Specifications iii. Operator Skill. iv. Auxiliary Equipment. v. Accessory Equipment. vi. Base Metal Conditions vii. Fixturing Requirements. viii. Production Bottlenecks. d. Step 4 i. Systemizing the Systematic Approach. 4. Ten Steps for Reducing the Welding Costs a. Analyze the delivery of consumables and accessories to the welding point s b. Analyze whether material handling is effective c. Look for ways to correct over welding d. Enhance current welding processes and procedures e. Eliminate any extra welds from the design f. Look for items that can be welded rather than cast g. Look for ways to eliminate costly record keeping h. Adding robotics or hard automation to the operation i. Examine safety concerns 5. SHIELDED METAL ARC WELDING OVERVIEW a. DEFINITION AND GENERAL DESCRIPTION b. PRINCIPLES OF OPERATION c. Covered Electrodes d. Arc Shielding e. PROCESS CAPABILITIES AND LIMITATIONS 6. FLUX CORED ARC WELDING OVERVIEW a. PRINCIPAL FEATURES b. PRINCIPAL APPLICATIONS c. SEMIAUTOMATIC EQUIPMENT d. SHIELDING GASES e. Carbon Dioxide f. Gas Mixtures g. BASE METALS WELDED h. ELECTRODES i. EXXT1. j. Protection from Moisture k. PROCESS CONTROL l. WELDING CURRENT m. ARC VOLTAGE n. TRAVEL SPEED o. SHIELDING GAS FLOW p. DEPOSITION RATE AND EFFICIENCY q. ADVANTAGES OF FCAW r. LIMITATIONS OF FCAW 7. Case Study Details

a. b. c. d. e. f. g. 8.

Test data for SMAW: Test data for FCAW: Test Data OF SMAW Process with E6010 + E7018 Test data for FCAW Process E6010 + E71 T1 with 75% Argon+25% Co2 WELD METAL RECOVERY DATA TAKEN FROM ACTUAL TESTS FINAL DATA AND CASE STUDY REPORT BASED ON SUMMARY OF ALL TESTS CONDUCTED Conclusion of Case Study: References

Abstract: Every welding process possess its own advantages and limitations and selected af ter careful analysis and study of variables related to the process /product form and application criteria. Factors governing the selection of welding process in cludes the type of the product to be welded, material, joint geometry, field and service conditions, productivity expectations, capital cost, availability of re sources, quality requirements, net cost savings etc. Currently in India, shielded metal arc welding is the major welding process domi nates the welding industry and plays a key role compared to other welding proces ses. To achieve the higher productivity and cost saving, it is necessary to adop t suitable welding process, which can be superior to SMAW and can be justified f ully in terms of productivity, quality and cost. Comparative production studies were conducted to establish the facts and to arrive conclusion. This concept will be applicable for pipe spools welding in a fabrication shop fo r welding groove and fillet weld joints in out of position. Assumptions include only large bore spools i.e. for Pipe diameter equivalent or greater than 168 mm OD and wall thickness of 7.11 mm and above. For study purpose only two welding p rocesses were taken into account i.e. SMAW and FCAW. Since carbon steel pipe spo ols fabrication is 85% of the total scope, selection of the high productive and cost economic welding process plays a vital role. Introduction: For carbon steel (A 106 GR.B OR Equivalent) Pipe spools welding, E6010 is used f or root pass application and rest passes by E7018 for conditions where back chip ping is not possible. We want to use E71T-1 and E7018 in our Studies for compari son. Gas shielded FCAW will be used for the studies due to its various advantage s over self shielded. Since the pipe spool joints will be welded normally in out of position, studies were conducted to simulate the same i.e. in 5G positions. Considering the various pipe diameters and thickness involved in welding, it is decided to use the common minimum pipe diameter and thickness aiming the minimum deposition rates that can be achieved by using these welding processes. Shieldi ng gas selection for FCAW will be either Co2 or 75%Argon+ 25% Co2 mixture. We ha ve conducted trials by using both for calculating the cost difference. Overview of Welding What is Welding? Welding is a joining process in which metals are heated, melted and mixed to pro duce a joint with properties similar to those of the materials being joined.