Welding Process

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WELDING PROCESSES
 Earliest known form of welding, called forge
welding, dates back to 2000 B.C.
 Forge welding is a primitive process of
joining metals by heating and hammering
until the metals are fused (mixed) together
 Now limited to the blacksmith trade.

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Welding Processes
 Shielded metal arc welding-SMAW
 Gas metal arc welding-GTAW
 Flux cored arc welding-FCAW
 Gas tungston arc welding-GTAW
 Plasma arc welding-PAW
 Submerged arc welding-SAW
 Oxy acetylene welding-OAW

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Difference between Processes
 Shielding used
 Weld metal composition
 Joint preparation & fit-up
 Type of electrode/filler –metal
 Welding pattern

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 Factors that affect weld Quality
 Shielding quality
 Base metal quality
 Filler-metal quality
 Base metal weld metal compatibility
 Heat input
 Electrode size
 Travel speed
 Current and Voltage
 Welding position
 Environment for welding
 Wind, temperature & fit-up
 Knowledge & Experience of welders

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 Filler metals
 filler metal or material
 material added to fill-up the space in between two
welding pieces during the welding process
 Two types of filler metals commonly used
 welding rods
 welding electrodes.
 welding rod refers to a form of filler metal that does
not conduct an electric current during welding
process
 The purpose of a welding rod is to supply filler
metal to the joint.
 used for gas welding.

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 Electrode
 Electrode
 component that conducts the current from the electrode
holder to the metal being welded.
 Electrode types:
 consumable and non-consumable.
 Consumable electrodes
 provide a path for the current and also supply filler metal to
the joint.
 Eg.electrode used in shielded metal-arc welding.
 Non-consumable electrodes
 used as a conductor for the electrical current-GTAW
 filler metal for GTAW, hand fed consumable welding rod.

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FLUXES
 Base metal has always impurities, called oxides
 result from oxygen combining with metal & other
contaminants in the base metal.
 if these oxides are not removed a faulty weld may
result
 Fluxes
 Cleaning agents that dissolve oxides and release trapped
gases
 combines with impurities in the base metal, floating them
away in the form of a heavy slag which shields the weld
from the atmosphere.
 allow the filler metal and the base metal to be fused
 formulated for a specific base metal on the expected
welding temperature
 Available in the form of a paste, powder, or liquid

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 ARC WELDING
 common to all arc-welding processes
 a heat source, filler metal, and shielding
 source of heat
 by arcing of an electrical current between two contacts.
 concentration of heat
 less heat spread reduces buckling and warping
 increases depth of penetration and
 speeds up welding operation
 A distinct advantage of arc welding over gas welding
 more practical and economical than gas welding
 In gas welding flame spreads over a large area, causing
heat distortion

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Shielded Metal Arc Welding (SMAW)

 performed by striking an arc between a coated-metal

electrode and the base metal.
 molten metal from the tip of the electrode flows
together with the molten metal from the edges of the
base metal to form a sound joint, process known as
fusion
 The coating from the electrode forms a covering over
weld deposit, shielding it from contamination
 common types of welding
 Oxy-fuel gas welding (OFW)
 arc welding
 resistance welding
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SMAW
 high-quality welds are made rapidly at a
low cost
 Weld surfaces have valleys and ripples
 Makes interpretation difficult
 Discontinuities have random orientation
in the weld with other welding processes
 Contains entire spectrum of weld
discontinuities

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Oxy-fuel gas welding (OFW) Shielded metal arc welding
(SMAW) 12
GAS Metal Arc WELDING
 source of heat
 oxy-fuel gas, such as acetylene, mixed with oxygen
 used in maintenance and repair works
 Primary gases used
 helium, argon, carbon dioxide or a mixture of
these gases
 Difference between SMAW & GMAW
type of shielding
 GTAW
 both the arc and the molten puddle covered by a
shield of inert gas.
 The shield of inert gas prevents atmospheric
contamination-producing a better weld.

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GMAW
 Gas metal arc welding
 No flux used
 Suitable for thin wall
sections < 10 mm
 Has Low base metal
penetration
characteristics leading to
 Incomplete penetration
 Cold lap
 Porosity -if loss of
shielding occurs
 Slag ???
 Oxides in base metal
may be drawn into the
weld as slag

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GTAW
 Gas Tungsten arc
welding
 High quality welds with
good base metal
penetration with
operator skill
 Discontinuities
common to GTAW
 Incomplete fusion

 Cold lap

 Porosity -if loss of

shielding occurs
 Tungsten inclusions

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 FCAW
 Flux cored arc welding
 Has good penetrating capability
 Discontinuities common to
FCAW
 Slag
 Porosity

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 SAW
 Submerged arc welding
 Has good penetrating capability
 Discontinuities common to SAW
 Slag
 Lack of fusion

 Follow welding direction and will be in

Straight lines
 Porosity

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Evaluation of weldments

Welding discontinuities

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 Welding discontinuities
 Discontinuities become defects
 when exceed welding standard
requirements
 Cracks
 Incomplete penetration (ICP)
 Incomplete fusion (LF & SWLF)
 Slag Inclusions (isolated & linear)
 Porosity

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 Welding discontinuities
 Defective profile
 Undercut
 overlap
 Under-fill
 Excess reinforcement
 Excess root reinforcement
 Root concavity
 burn through
 spatter

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 Welding defects- Causes
 Cracks
 Hydrogen Assisted cold cracking (HACC)
 Hydrogen induced cold cracking (HICC)
 solidification, liquation causes

 Incomplete fusion
 Sidewall, inter run, root pass, weld toes ( cold
lap )
 Electrode angle implicated or poor joint profile

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 Welding defects- Causes
 Porosity
 Gas entrapment / ejection
 poor shielding
 Inclusions
 Slag, oxide, tungsten
 Usually operator induced
 Defective weld profile / finish
 Under-weld, over-weld, lack of root bead, burn through,
undercut
 Usually operator induced

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weld defects

Incomplete sidewall fusion Slag inclusion

Incomplete root fusion
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weld defects

Undercut

Cold lap

Incomplete penetration

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Solidification cracks

Crater crack

Longitudinal crack Centreline Crack

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 Solidification cracking

 Low melting point constituents

 Grain boundary segregation
 Strains arising during solidification
 Expansion coefficient
 Differing between base material and weld
material
 Clad materials
 Weld pool shape and size

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Methods of control
 Preheat
 Slow down cooling rate
 between 800°C and 500°C

 Remove hydrogen before weld cools below

150°C
 Stress relief immediately after welding
 Low temp temperature heat treatment
 (150°C to 250°C, known as out-gassing)

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Lamellar tearing
 Separation or cracking along planes parallel
to the principal plane of deformation.
 Occurs in rolled sections mainly but can also
occur in extrusions and forgings.
 Does not occur in castings
 Not to be confused with plate lamination.

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Lamellar tearing

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