Welding

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WELDING
Welding is a materials joining process which produces coalescence of materials by heating them to suitable temperatures with or without the application of pressure or by the application of pressure alone, and with or without the use of filler material. By,
The American Welding Society

Arcwelding :
Shielded metal arcwelding(SMAW):
Arc welding is a process in which an electric arc is established between the electrically grounded work piece and a 9-18 length of covered consumable metal rod, called the electrode. The heat of the arc melts the base metal in the immediate area, the electrodes metal core, and any metallic elements in the coating of the electrode.
The process produces a protective slag that will need to be removed for cleanliness . metal inert gas welding (MIG) or(GMAW):
It is an arc welding process in which coalescence by heating the job with an electric arc established between continuously fed metal electrode and the job . No flux is used but the arc and the molten metal are shielded by an inert gas Argon, Helium, Carbondioxide or a gas mixture. Used commonly for welding nonferrous metals like Al .
Tungsten inert gas welding (TIG):
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A very similar process to MIG welding but the electrode used here is Tungsten . The high melting point of Tungsten makes it a non consumable electrode . TIG is suitable for welding Titanium ,Al etc and for welding smaller size components . High quality of welding is achieved .
Resistance welding:
Spot welding:
Spot welding is a resistance welding process in which over lapping sheets are joined by local fusion at one or more spots by the heat generated by the resistance to the flow of electric current through work pieces that are held together under force by two electrodes which are held together as shown in the figure . Mild steel , HSS , stainless steel , Al , Al-Mg alloys can be welded . Has replaced riveting in many applications and has its applications in aircraft and automobile industries .
Seam welding:
The weld produced here is a series of spot welds as shown in the figure and the principle of this welding process is similar to spot welding . It find its application mainly in welding thin sheets . so the electrodes used here is in the form of rollers as shown aside. Al , Al alloys , Nickel and its alloyas and Stainless steel sheets can be welded by this process and it is capable of producing air tight and liquid tight joints
Gas welding:
Gas welding is a type of welding process that uses a flame that is fed by a pressurized gas fuelGas welding operations center on a torch that creates the welding flame. Download Anna university previous year question bank for mechanical engineering [all semesters],Anna university previous year question papers for mechanical engineering all semester Anna university syllabus for BE/ B. Tech. www.mechanical.in
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The welder can adjust the amount of gas being used by the torch and the oxygen used to feed the flame. By controlling the ratio of the gas and oxygen, the welder can create different flames with different characteristics, depending on the material being welded. The welder uses a filler rod coated with flux to add material to the weld and to displace the air from the weld location.
Oxy-acetylene welding :
Types of flames produced:
Oxygen is turned on, flame immediately changes into a long white inner area (Feather) surrounded by a transparent blue envelope is called Carburizing flame (30000c) Addition of little more oxygen give a bright whitish cone surrounded by the transparent blue envelope is called Neutral flame (It has a balance of fuel gas and oxygen) (32000c) Used for welding steels, aluminium, copper and cast iron If more oxygen is added, the cone becomes darker and more pointed, while the envelope becomes shorter and more fierce is called Oxidizing flame(34000c). Used for welding brass and brazing operation.
Oxygen tank (green) .Acetylene tank (red, or black with a red top) .Oxygen pressure valves have a right-hand internal thread. Acetylene pressure valve has an external left-hand thread.
Welding defects:
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Some common defects:

Undercut, porosity, overlap, incomplete fusion, underfill , spatter, excessive convexity, excessive concavity, excessive reinforcement , excessive penetration, incomplete penetration .
Welding symbols: BASIC ELEMENTS OF WELD SYMBOL REPRESENTATION.
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SAFETY RECOMMENDATIONS: PROPER SET UP:
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WORKER SAFETY:
Wear dry, hole-free insulating gloves Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless pants,
high shoes, and a cap

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Use approved helmets and safety goggles
BRAZING:
A joining process in which filler metal is placed at or between the surfaces to be joined. The temperature is raised to melt the filler metal but not the workpiece.
Metallic parts are joined by a non ferrous filler metal or alloy Braze melts between 840-2400 degrees F The filler material is in thin layers compared to base metal The filler penetrates the gap by capillary attraction Can connect dissimilar metals Most common braze defect is lack of braze or a void Filler in welding process penetrates into the base metals whereas in brazing there is no penetration of filler into the base metals. Brazing is not suitable for very large sized components and in this process the base metals should be tightly placed to achieve the capillary attraction.
Soldering:
Soldering is joining of metals using a filler material of a lower melting point than that of the parent metals to be joined. The melting point of the filler used in soldering is less than 427c .
Tin, Copper and Brass are far easier to solder than Steel or Aluminium. Traditional Solder is an amalgam of Tin and Lead. The percentage of each of these materials defines the use for the solder %Tin 60 %Lead 40 Use Good for all electrical and mechanical work
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45 50
55 32
Very liquid used in plumbing Low melt solder for white-metal casings
Welding of different metals:

Welding of cast iron: Metal arc welding , oxy acetylene welding,thermit welding ,brazing .
Welding of carbon steels :(common for low,medium and high carbon steels) Flux shielded Metal arc welding , oxy acetylene welding, thermit welding, resistance welding, submerged arc welding .
Welding of Al and its alloys: Oxy-gas welding, resistance welding, MIG, TIG, Metallic arc welding.
Welding of Magnesium and its alloys: Gas welding, resistance (spot)welding, MIG, TIG.
Welding of copper and its alloys : TIG, MIG, gas welding, brazing, soldering.
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Residual welding stress:

Residual stresses are those, existing within the body after the completion of the welding process in the absence of external forces . They are in static equilibrium within the body and are internally balanced. Residual stresses are very disastrous as they can even lead to the failure of the welded joints by initiating cracks at the stress concentration points .
Methods to reduce residual welding stresses: Peening Vibratory stress relief Thermal treatment(heat treatment) Thermo-mechanical treatment Overstressing technique
Inspection:
Manual Vision Inspection Visual inspection is commonly defined as the examination of a material, component, or product for conditions of nonconformance using light and the eyes, alone or in conjunction with various aids. Visual inspection often also involves, shaking, listening, feeling, and sometimes even smelling the component being inspected.
Automated or Machine Vision Inspection Machine vision technology uses an imaging system and a computer to analyze an image and to make decisions based on that analysis. In inspection applications, the machine vision optics and imaging system enable the processor to "see" objects precisely and thus make decisions about which component meet a specific inspection criteria.
Common features of machine inspection: Image acquisition Image processing Feature extraction Decision and control
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Classification of welding processes: (i). Arc welding Carbon arc Metal arc Metal inert gas Tungsten inert gas Plasma arc Submerged arc Electro-slag (ii). Gas Welding Oxy-acetylene Air-acetylene Oxy-hydrogen (iii). Resistance Welding Butt Spot Seam Projection Percussion (iv)Thermit Welding (v)Solid State Welding Friction Ultrasonic Diffusion Explosive (vi)Newer Welding Electron-beam Laser (vii)Related Process

Oxy-acetylene cutting Arc cutting Hard facing Brazing Soldering
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Welding

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Welding

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2013 Mechanical Corporation.

The American Welding Society

Tungsten inert gas welding (TIG):

2013 Mechanical Corporation.

2013 Mechanical Corporation.

Types of flames produced:

2013 Mechanical Corporation.

Some common defects:

Welding symbols: BASIC ELEMENTS OF WELD SYMBOL REPRESENTATION.

2013 Mechanical Corporation.

SAFETY RECOMMENDATIONS: PROPER SET UP:

2013 Mechanical Corporation.

high shoes, and a cap

2013 Mechanical Corporation.

Use approved helmets and safety goggles

2013 Mechanical Corporation.

Welding of different metals:

2013 Mechanical Corporation.

Residual welding stress:

2013 Mechanical Corporation.

2013 Mechanical Corporation.

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