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KSC-STIST
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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
CLASSIFICATION OF WELDING
Thermo-Chemical welding process
Thermit welding Atomic hydrogen 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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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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WELDING TORCH
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WELDING TORCH
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ACETYLENE C2H2
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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Vertical Welding
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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
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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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Face shields Hand Gloves Safety Goggles Skull Caps Safety boots Tools- Chipping Hammer, Brushes, Fixtures
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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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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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FRICTION WELDING
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EXPLOSIVE WELDING
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ULTRASONIC WELDING
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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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UNDERCUT SPATTER
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