Oxyfuel Welding & Cutting

Oxyfuel Welding & Cutting

Three types of
oxyfuel
flames:
1. Neutral flame
2. Oxidizing flame
3. Carburizing or
reducing flame

Electric Arc Welding -- Polarity

Welding Processes

SMAW - DC Polarity
Straight Polarity

Reverse Polarity

()
(+)
Deeper weld penetration
(thick metal)

AC - Gives pulsing arc

- Generally used for welding thick sections

(+)
()
Shallow penetration
(thin metal)

Fusion Welding Processes

Consumable Electrode
SMAW Shielded Metal Arc Welding
GMAW Gas Metal Arc Welding
SAW Submerged Arc Welding

Non-Consumable Electrode
GTAW Gas Tungsten Arc Welding
PAW Plasma Arc Welding

High Energy Beam

Electron Beam Welding
Laser Beam Welding

Welding Processes

SMAW Shielded Metal Arc Welding

Consumable electrode
Flux coated rod
Flux produces protective gas around weld pool
Slag keeps oxygen off weld bead during cooling

General purpose weldingwidely used

Thicknesses 1/8 3/4
Portable
Power... Current I (50 - 300 amps)
Voltage V (15 - 45 volts)
Power = VI 10 kW

Welding Processes

GMAW Gas Metal Arc Welding (MIG)

Welding Processes

AC unstable
arc

MIG - Metal Inert Gas

Gas Metal Arc Welding (GMAW) Torch

Consumable wire electrode

Shielding provided by gas
Double productivity of SMAW
Easily automated

Groover, M., Fundamentals of Modern Manufacturing,, p. 734, 1996

GTAW Gas Tungsten Arc Welding (TIG)

Welding Processes

TIG - Tungsten Inert Gas

Non-consumable electrode
With or without filler metal

Current I (200 A DC)

(500 A AC)

Shield gas usually argon

Used for thin sections of Al, Mg, Ti.
Most expensive, highest quality

Power 8-20 kW

SAW Submerged Arc Welding

Welding Processes
300 2000 amps (440 V)

Consumable wire electrode

Shielding provided by flux granules

Gas Metal Arc Welding (GMAW) Torch

Low UV radiation & fumes

Flux acts as thermal insulator
Automated process (limited to flats)
High speed & quality
(4 10x SMAW)
Suitable for thick plates

http://www.twi.co.uk

Plasma-Arc Welding

Figure 27.15 Two types of plasma-arc welding processes: (a) transferred, (b)
nontransferred. Deep and narrow welds can be made by this process at high welding speeds.

Resistance Welding

Welding Processes

Resistance Welding is the coordinated application of electric current and mechanical pressure in
the proper magnitudes and for a precise period of time to create a coalescent bond between two
base metals.

Heat provided by resistance to electrical current (Q=I2Rt)

Typical 0.5 10 V but up to 100,000 amps!
Force applied by pneumatic cylinder
Often fully or partially automated
- Spot welding
- Seam welding

Resistance Welding
Resistance
welding,
showing
components
in spot
welding, the
main process
in the RW
group

2010 John Wiley &

Sons, Inc. M P Groover,
Fundamentals of
Modern
Manufacturing 4/e

Components in Resistance Spot

Welding
Parts to be welded (usually sheet
metal)
Two opposing electrodes
Means of applying pressure to
squeeze parts between electrodes
Power supply from which a controlled
current can be applied for a specified
time duration
2010 John Wiley &
Sons, Inc. M P Groover,
Fundamentals of
Modern
Manufacturing 4/e

Advantages and Drawbacks of

Resistance Welding
Advantages:
No filler metal required
High production rates possible
Lends itself to mechanization and automation
Lower operator skill level than for arc welding
Good repeatability and reliability
Disadvantages:
High initial equipment cost
Limited to lap joints for most RW processes
2010 John Wiley &
Sons, Inc. M P Groover,
Fundamentals of
Modern
Manufacturing 4/e

Resistance Spot Welding

(RSW)
Resistance welding process in which fusion of faying
surfaces of a lap joint is achieved at one location
by opposing electrodes
Used to join sheet metal parts
Widely used in mass production of automobiles,
metal furniture, appliances, and other sheet metal
products
Typical car body has ~ 10,000 spot welds
Annual production of automobiles in the world is measured in
tens of millions of units
2010 John Wiley &
Sons, Inc. M P Groover,
Fundamentals of
Modern
Manufacturing 4/e

Spot Welding Cycle

(a) Spot welding

cycle
(b) Plot of force
and current
Cycle: (1) parts
inserted between
electrodes, (2)
electrodes close,
(3) current on, (4)
current off, (5)
electrodes opened
2010 John Wiley &
Sons, Inc. M P Groover,
Fundamentals of
Modern
Manufacturing 4/e

Resistance Seam Welding

(RSEW)
Uses rotating wheel electrodes to
produce a series of overlapping
spot welds along lap joint
Can produce airtight joints
Applications:
Gasoline tanks
Automobile mufflers
Various sheet metal containers

2010 John Wiley &

Sons, Inc. M P Groover,
Fundamentals of
Modern
Manufacturing 4/e

Resistance Seam Welding

2010 John Wiley &

Sons, Inc. M P Groover,
Fundamentals of
Modern
Manufacturing 4/e

Overlapping of weld nuggets may vary from 10 to

50 %. When it is approaching around 50 % then it is
termed as continuous weld. Overlap welds are used
for air or water tightness.
It is the method of welding which is completely
mechanized and used for making petrol tanks for
automobiles, seam welded tubes, drums and other
components of domestic applications.
Seam welding is relatively fast method of welding
producing quality welds. However, equipment is
costly and maintenance is expensive. Further, the

Resistance Projection Welding (RPW)

A resistance welding process in which
coalescence occurs at one or more
small contact points on the parts
Contact points determined by design
of parts to be joined
May consist of projections, embossments, or
localized intersections of parts

2010 John Wiley &

Sons, Inc. M P Groover,
Fundamentals of
Modern
Manufacturing 4/e

Resistance Projection Welding

(1) Start of operation, contact
between parts is at projections; (2)
when current is applied, weld
nuggets similar to spot welding are
formed at the projections

2010 John Wiley &

Sons, Inc. M P Groover,
Fundamentals of
Modern
Manufacturing 4/e

Projection welding bolts

Friction Welding (resistance)

(1) Rotating part, no contact; (2) parts brought into
contact to generate friction heat; (3) rotation
stopped and axial pressure applied; and (4) weld
created

2010 John Wiley &

Sons, Inc. M P Groover,
Fundamentals of
Modern
Manufacturing 4/e

Friction Welding (Inertia Welding)

One part rotated, one stationary
Stationary part forced against rotating part
Friction converts kinetic energy to thermal energy
Metal at interface melts and is joined
When sufficiently hot, rotation is stopped
& axial force increased

Welding Processes

Explosion Welding (EXW)

SSW process in which rapid coalescence of
two metallic surfaces is caused by the
energy of a detonated explosive
No filler metal used
No external heat applied
No diffusion occurs - time is too short
Bonding is metallurgical, combined with
mechanical interlocking that results from a
rippled or wavy interface between the
metals
2010 John Wiley &
Sons, Inc. M P Groover,
Fundamentals of
Modern
Manufacturing 4/e

Explosive Welding
Commonly used to bond two dissimilar
metals, in particular to clad one metal
on top of a base metal over large areas

2010 John Wiley &

Sons, Inc. M P Groover,
Fundamentals of
Modern
Manufacturing 4/e

Explosive Welding
Commonly used to bond two dissimilar metals, e.g., to
clad one metal on top of a base metal over large areas
(1) Setup in parallel configuration, and (2) during
detonation of the explosive charge

2010 John Wiley &

Sons, Inc. M P Groover,
Fundamentals of
Modern
Manufacturing 4/e

UNDERCUT

POROSITY

INCOMPLETE FUSION

OVERLAP

UNDERFILL

SPATTER

INCOMPLETE PENETRATION
&
EXCESSIVE PENETRATION

UNACCEPTABLE
WELD PROFILES