German Jordanian University

School of Applied Technical Sciences

Industrial Engineering Department

Manufacturing Processes Lab

Welding

Khaled Tafesh
20142102056

Introduction
Welding is a fabrication process used to join materials, usually metals or
thermoplastics, together. During welding, the pieces to be joined are melted
at the joining interface and usually a filler material is added to form a pool of
molten material that solidifies to become a strong joint.
Welding is usually an industrial process, however it can be performed in many different
environments including open air, under water, and in outer space. It can be done both manually
and automatically. This science continues to advance and flourish and today robot welding is
commonly used in industries.

Types of Welding
There are many different types of welding processes and in general they can
be classified according to the combination of pressure and temperature used in them.

Welding Type
Gas Welding
Arc Welding

Resistance Welding

Solid State Welding

Radiant Energy
Welding
Thermo-Chemical
Welding

Subtypes
Air-acetylene welding, Oxy-acetylene welding, Oxy-hydrogen welding,
Pressure gas welding
Carbon arc welding, TIG welding, MIG welding, Submerged arc
welding, Shielded metal arc welding, Plasma arc welding, Flux cored
arc welding, Stud arc welding, Electro slag welding
Spot welding, Steam welding, Percussion welding, High frequency
welding, Projection welding, Resistance butt welding, Flash butt
welding
Friction welding, Cold welding, Ultrasonic welding, Hot pressure
welding, Diffusion welding
Laser beam welding, Electron beam welding
Thermite welding, Atomic welding

Gas Welding: In this method a focused high temperature flame

generated by gas combustion is used to melt the workpieces (and filler)
together. The most common type of gas welding is Oxy-fuel welding where
acetylene is combusted in oxygen.

Resistance Welding: Resistance welding involves the generation of

heat by passing a high current (1000100,000 A) through the resistance
caused by the contact between two or more metal surfaces where that
causes pools of molten metal to be formed at the weld area. The most
common types of resistance welding are Spot-welding (using pointed
electrodes) and Seam-welding (using wheel-shaped
electrodes).

Solid-State Welding: In contrast to other welding methods, solid-state

welding processes do not involve the melting of the materials being joined.
Common types of solid-state welding include; ultrasonic welding, explosion
welding, roll welding, friction welding, etc.

However in the workshop only the three types were carried out , Arc welding(SMAW,GMAW)
and Spot welding ).

Arc Welding: A welding power supply is used to create and

maintain an electric arc between an electrode and the base material to
melt metals at the welding point. In such welding processes the power
supply could be AC or DC, the electrode could be consumable or nonconsumable and a filler material may or may not be added. The electrode
and the base metal are given opposite charges, so that a current flows between them.

The most common types of arc welding are:

Shielded Metal Arc Welding (SMAW): A process that uses a
coated consumable electrode to lay the weld. The electrode should be made
of a material that is compatible with the base metal, because after welding it should
become a continuous part of the base metal.As the electrode melts, the (flux)
coating disintegrates, giving off shielding gases that protect the weld
area from atmospheric gases and provides molten slag which covers
the filler metal as it travels from the electrode to the weld pool.

Figure 1:SMAW machine

Source :GJU workshop

Figure 2: welding bed

Source : GJU workshop

*More about the flux: It is a substance that coats a consumable electrode which
stabilizes the arc and it undergoes fusion producing gases that act as shields from the
surrounding atmosphere.It also controls the rate at which the electrode melts and prevents the
formation of oxides, nitrides, and other inclusions.
Applications of SMAW
*Construction machinery
*Motor cycle frames
*Shaped steel
*Train chassis
*Boiler parts

 Gas Metal Arc Welding (GMAW): A process in which a continuous

and consumable wire electrode and a shielding gas (usually an argon
and carbon dioxide mixture) are fed through a welding gun.
It has two types: MIG (Metal Inert Gas) and MAG (Metal Active Gas) welding & In the
workshop, MIG welding was used.
For MIG welding, an inert gas is used for shielding, carbon dioxide is usually used as
said before because it is an oxygen repellant so it reduces chanced of welding defects.
The gas used should never react with the metals being welded.

Figure 3: GMAW machine

Figure
4:MIGWelding&required
precautions
Source : GJU workshop

Applications of GMAW:
*Welding of different joint types (butt, corner, edge, lap, and tee joints).
*Pipe joints can be made with special MIG welding machines
*Can be used for softer metals such as aluminium.

Spot Welding:A form of resistance welding.Two or more overlapped metal sheets

are joined by spot welds.For sure both pressure and localized heat are used to make
the weld.The sheets being welded should be only 0.5 3.0 mm thick depending on
the machine .The sheets to be welded are placed between two electrodes. Then
pressure is applied by pressing on a foot step and heat is provided, the two electrodes
come in contact so that a weld is made.It can deliver high energy density to the spot
in a very short time of few seconds. A perfect spot weld is achieved only if
appropriate pressure, current intensity and duration of contact are chosen properly.

Figure 5: Spot welding machine

Source:GJU workshop
Applications of Spot Welding:
*Welding of door panels
*Welding of rear bodies.
*Used in automobile car manufacturing industry
*Used in dental prosthesis
*Used in refrigerators.

Materials:123456-

Piece of Iron (which the welding experiment was done on it).

Sheet metal (which the welding experiment was done on it).
Spot welding machine.
Arc Welding machine
MIG or Co2 Welding machine
Electrode

Calculations:-

H= 6000^2 * 200 * 10^-3 * 0.1 = 720000

H = 0.7* 720000 = 504000

3. Experimental
1. In a spot welding processes, two 1 mm thick steel sheets are being
welded. The current used for the processes is 6000 A at a flow time of t=0.1
s. Assuming an effective resistance of 200 ,

a) Estimate the electrical energy generated during the

process
H= I^2RT = 6000^2 * 200 * 10^-3 * 0.1 = 720000

b) Calculate the usable heat assuming an efficiency factor

of K=0.65
H = 0.65* 720000 = 468000

c) Assuming the volume of the nugget to be V=30 mm3, the density

of steel to be 8000 kg/m3. K,and the heat needed to melt 1 g of
steel to be 1400 J.

2. What possible defects can occur in spot welding?

1- Stick weld or no weld

2- Undersize weld

3- Excessive indentation

3. What are the main differences between SMAW and MIG

welding?

We dont use MIG in the air in order not to let the gas spreads away.
SMAW is a slower process than MIG
The electrode in SMAW is consumable while its not in MIG welding

4. From your observations what parameters affect the arc

welding process?
1- Arc welding

3- Current

2- Travel speed

4- Torch position

5- Materials diameter

5. What possible defects can occur in shielded metal arc

welding?

Lack of fusion
Porosity
Incomplete penetration
Cracking

Discussions and Conclusion:Welding is joining two materials or more especially metals to form a
particular shape of material.
In all kinds of welding, the operation depends on the connection between the
negative pole with positive pole.
There are many types of welding such as:

Spot Welding which is one method in which two overlapped metal sheets
are joined by spot welds. It is one of the most important ways of welding and
its used to connect small thicknesses in one point.

Arc Welding: in this way of welding, it will be with a long rod of iron
covered with material of powder, its job is to hold up the impurities and
make better connect of current. It is used to weld big thicknesses and
to increase metal thickness by consuming the powder around the
.electrode

MIG or Co2 Welding: in this method, powder is not used, Co2 gas is
used instead. So that this method is called Co2 welding where a particular
machine is used called co2 welding machine that has an iron wire made of
copper. And it is endless. It can be used in many ways (up, down, vertically,
horizontally, and overhead)