TOPICS

1)Introduction of welding 2)Welding Electrodes 3)Advances in welding Equipments 4)New technology in welding 5) Solid State Welding

Welding: - It is a joining process of two or more parts of material by 1) Heat, 2) with or without pressure, 3) with or without filler wire It is a permanent joint. For conducting welding essential requirement are 1) Right type of welding electrode 2) Power source 3) Welder 4) Welding skill 5) Right type of welding process

Classification of welding electrodes A)Consumable electrodes B) Non consumable Electrodes A)Consumable Electrodes I) II) III) IV) Coated Electrodes Filler Wires Tubular Electrodes Flux Cored Wires

B) Non Consumable Electrodes i) Tunguston electrodes used in TIG welding Process ii) Copper and its alloy electrodes used in resistant welding process

I)

Coated Electrodes A) Conventional electrodes: as per AWS Coding Like E-6013, E-7018 E-electrode 60-multiple of 1000 (60000 T.S) it shows Tensile.Strength 1 welding position (all position) 8 Flux Coating Mostly used for general Fabrication purpose B) Low Heat Input welding Electrodes Used for Repair maintenance and reclamation

Difference Between fabrication welding and Repair and maintenance welding S.No 1 2 3 Attribute Base Metal Condition Welding rod Selection Welding Position Edge preparation Time Working Life Fabrication Welding Known Clean Easy Maintenance welding Not known Contaminated Not Easy due to Unknown composition Out of Position

4 5 6 7

Down Hand

60 Deg. V 90 Deg. U Grove Grove Sufficient Urgent Not Important Important, Because no Spar Available

Classification of electrode According to Material 1) Ferrous material and Alloys 2) Non Ferrous Material and Alloys a) Copper and its alloys b) Aluminium and its alloys c) Nickel and its alloys 1) Ferrous Metal and its Alloys a) Steels i) Mild steel ii) Carbon steel iii) Manganese Steels b) Stanlesss steel I) 300 SERIES- Austenitic Steel and Duplex Steel II) 400 series Martens tic steel and Ferrite Steel Austenitic Steel:- Excellent Corrosion Resistant, High Ductile and Impact resistant, superior welding, Fatigue resistant Martens tic Steel: - Wear Resistant, pitting and cavitations resistant SS welding electrodes; SS-304, SS-308, SS-309, SS-310 SS-310

CAST IRON WELDING

Cast Iron is an alloy of iron with C=2-5%, Si =1-3% and upto 1%manganese Major types of cast iron are: 1. 2. 3. 4. Grey cast iron Nodular cast iron Malleable Case iron White cast iron

Cast Iron welding is considered difficult so following procedures have to be followed: 1.Weldability test. To check whether or not the job is weldable with a particular product. 2. Use of low current 3. Short arc gap 4. Short bead 5. Skip welding technique 6. Hot peening 7. Block technique 8.Keeping the job at hand temperature

Following steps should be kept in mind when welding CI : 1. 2. 3. 4. Joint angle should be wider than for mild steel All sharp angles should be rounded off Perferably use U-grooves For repairing cracks either gouge grind the entire crack or drill sall holes at each end of the crack. 5. Welding should start from the center of the crack and proceed in both directions. 6. If the absorbed oil and liquid cannot be removed fully use electrode giving a sprey transfer fro an anchoring buffer layer 7. In critical welds, buffer with a ductile layer to save the crack susceptible Heat Affected Zone (HAZ)

HARDFACING Hardfacing is primarily used to restore worn out parts back to usable condition order to extend their service life. It is also used on new components enabling manufacture from cheaper material with wear resistance overlay providing the surface properties. Higher hardness does not necessarily mean better service life, so appropriate hardfacing alloy has to be used considering the following aspects: 1. 2. 3. 4. Wear factors Base material of the component Surface finish required Process to be used.

WELDING DISSIMILAR STEELS Joining stainless steel to low alloy or carbon steel WELDING MANGANESE STEEL WELDING DIFFICULT TO WELD STEELS Following steels are considered difficult to weld for their high hardenability 1. High carbon steel 2. tool steels 1. High strength steel 2. Spring steels 3. Wear-resistant steels. These steels require preheated and post weld heat treatment, which is sometimes not available. Therefore safest way to weld is with austenitic stainless or with nickel based consumable. Hydrogen cracking is prevented by greater solubility of Hydrogen in austenite and also due to higher ductility. For steels of unknown composition, best choice is a ferritic-austenitic duplex type of consumable.

NICKLE AND NICKLE ALLOYS Nickle and nickel alloys are used in industrial applications for : 1. Corrosion resistance 2. Heat resistant and high temperature properties 3. Cryogenic properties COPPER AND COPPER ALLOYS Main features of copper and its alloys are : 1.Corrosion resistance 2. Electrical and thermal conductivity ALUMINIUM AND ALUMINIUM ALLOYS Al and its alloys are amenable to fabrication as : 1. Light weight 2. Good corrosion resistance

COBALT ALLOYS Cobalt alloys are known for excellent wear resistant at high temperatures and the weld metal is used in cutting and shearing operations at temp. exceeding 600 degrees. These deposits exhibit high shock resistance, high hardness at elevated temp. & scaling resistance and can be used in stamping dies/ trimming cutters, trimming punches etc.

CUTTING AND GOUGING

Cutting, gouging and piercing by shielded metal arc welding is a flexible and economic method of removing metal. It can be done with standard welding equipments.

RUPESH KUMAR SINGH Sr. Application Engineering Specialist Ador Fontech Limited