Welding is a process for joining different materials with the help of a number of processes in which heat is supplied either electrically or by means of a gas torch. There are about 35 different welding and brazing processes and several soldering methods in use by industry today.
Welding is a process for joining different materials with the help of a number of processes in which heat is supplied either electrically or by means of a gas torch. There are about 35 different welding and brazing processes and several soldering methods in use by industry today.
Welding is a process for joining different materials with the help of a number of processes in which heat is supplied either electrically or by means of a gas torch. There are about 35 different welding and brazing processes and several soldering methods in use by industry today.
Welding is a process for joining different materials.
The large bulk of materials that are welded are metals and their alloys, although the term welding is also applied to the joining of other materials such as thermo plastics. Welding joins different metals/alloys with the help of a number of processes in which heat is supplied either electrically or by means of a gas torch. In order to join two or more pieces of metals together by one of the welding processes, the most essential requirement is Heat. Pressure may also be employed. Since a slight gap usually exists between the edges of the work pieces, a 'filler metal is used to supply additional material to fill the gap. But, welding can also be carried out without the use of filler metal. The filler metal is melted in the gap, combines with the molten metal of the work piece and upon solidification forms an integral part of the weld.
PRINCIPLE OF WELDING
An ideal joint between two pieces of metal or plastic
can be made by heating the workpieces to a suitable temperature. In other words, on heating, the materials soften sufficiently so that the surfaces fuse together.
The bonding force holds the atoms, ions or molecules
together in a solid. This 'bonding on contact' is achieved only when: the contaminated surface layers on the workpiece are removed, recontamination is avoided, and the two surfaces are made smooth, flat and fit each other exactly.
In highly deformable materials, the above aims can
be achieved by rapidly forcing the two surfaces of the workpiece to come closer together so that plastic deformation makes their shape conform to each another; at the same time, the surface layers are broken up, allowing the intimate contact needed to fuse the materials.
This was the principle of the first way known to weld
metals; by hammering the pieces together while they are in hot condition.
CLASSIFICATION OF WELDING PROCESSES
There are about 35 different welding and brazing
processes and several soldering methods in use by industry today.
There are various ways of classifying the welding and
allied processes. For example, they may be classified on the basis of: Source of heat, i.e., flame, arc, etc Type of interaction i.e. liquid/liquid (fusion welding) or solid/solid (solid state welding).
In general, various welding and allied processes are
General welding equipment is not very costly. Portable welding equipments are available. Welding permits considerable freedom in design. A large number of metals/alloys both similar and dissimilar can be joined by welding. Welding can join workpieces through spots, as continuous pressure tight seams, end-to-end and in a number of other configurations. Welding can be mechanized.
DISADVANTAGES 0F WELDING
Welding gives out harmful radiations (light), fumes and
spatter. Welding results in residual stresses and distortion of the work-pieces. Edge preparation of the workpieces is generally required before welding them. A skilled welder is a must to produce a good welding job.
Welding heat produces metallurgical changes. The structure
of the welded joint is not same as that of the parent metal. A welded joint, for many reasons, needs stress-relief heattreatment.
PRINCIPLE
The source of heat for arc welding process is an
'electric arc' generated between two electrically conducting materials. One of the workpiece material called 'electrode' is connected to one pole of the electric circuit, while the other workpiece which forms the second conducting material is connected to the other pole of the circuit. When the tip of the electrode material is brought in contact with the workpiece material and momentarily separated by small distance of 2-4 mm, an arc can be generated. The electrical energy is thus converted to heat energy. The high heat of the arc melts the edges of the workpieces. Coalescence takes place where the molten metal of the one workpiece combines with the molten metal of the other workpiece. When the coalesced liquid solidifies, the two workpieces join together to form a single component.
The electrode material can be either a nonconsumable material or a Consumable material.
The non-consumable electrode made of tungsten, graphite etc., serve only to strike the arc and is not consumed during the welding process. Whereas, the consumable electrode which is made of the same material as that of the workpiece metal helps to strike the arc and at the same time melt (gets consumed) and combines with the molten metal of the workpiece to form a weld.
TIG MACHINES
Introduction of tig welding
TIG welding is an arc welding process, which requires th e welder to manipulate an electric arc in a manner simil ar to the technique used for OxyAcetylene welding. A tu ngsten electrode provides a jumping off point for an ele ctric arc. The electrode, the arc and the base material a re protected from atmospheric effects, by the flow of a nonreactive gas. The nonreactive gas, which it is used i n our shops, is Argon. The process of melting the parent material, combined with filler material, produces a grea t metallurgical bond.
Here are some advantages to MIG welding:
1.The ability to join a wide range of metals and thicknesses 2.All-position welding capability 3.A good weld bead 4.A minimum of weld splatter 5.Easy to learn
Here are some disadvantages of MIG welding:
1.MIG welding can only be used on thin to medium thick metals 2.The use of an inert gas makes this type of welding less portable than arc welding which requires no external source of shielding gas 3.Produces a somewhat sloppier and less controlled weld as compared to TIG (Tungsten Inert Gas Welding)