Sigma Institute of Engineering

Electrical Engineering Department

A Presentation on
Electrical Welding

Semester : 6th Semester Shift 2

Subject : Utilization of Electrical Energy and
Traction
Subject Code
Prepared by:- : 2160907 Guided by:
1. Nikhil Kushram (140500109516) Ms. Ami Shah
2. Abhiranjan Singh (140500109501) (Assistant Professor)
3. Kuldeep Chauhan (140500109507)
4. Virpal Raj (140500109530)
5. Mayank Solanki (150503109528)
 OUTLINE OF
PRESENTATION
Electrical welding
- Advantages of Electrical Welding
- Disadvantages of Electrical Welding
Different types of electrical welding process
- Resistance welding
- Butt Welding
- Flash butt welding
- Spot welding

- Projection welding

- Arc Welding
- Metallic Arc Welding
- Carbon Arc Welding
- Atomic Hydrogen Welding
- Shielded Arc Welding

Comparison of AC and DC welding

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 Electrical Welding
Electrical Welding is defined as that branch of
welding in which electric current is used to
produce the large amount of heat required for
joining together two pieces of metal.

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Contined..
 Disadvantages Of Electric
Welding
1) Welding operation is very speedy.
2) It is reliable and accurate
3) Good quality weld can be obtained
4) It is suitable for mass production
5) No skilled worker is required to carry-out welding
6) It is very neat and clean process and does not
produce any pollution.
7) No specific work place is required and welding can
be carried out as and where required.
8) Maintains composition of metals
9) Homogeneous and uniform welding is possibel
10) It is very economic welding than other forms of
welding.
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Continued
 Disadvantages of Electric
Welding
Some limitations of electric welding one as :
1) It often needs internal inspection.
2) Some welding depends on human factor.

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 Different Types of Electrical
Welding Process

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Continue
 Resistance Welding
Resistance welding is that process in which heavy
current is made to pass through the joint to be
welded.
This heavy current generates enough heat, because
of releatively Ihigh
2 resistance of the contact point.
This heat due to . R loss melts the metal and
causes fusion at the point of contact.

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Contine
 Butt Welding
In this type of welding, the two metal to be joined are
kept close together and fitted in the copper electrode
holder as shown in fig 4.2.
Current is passed through the joint. Due to resistance
of joint heat is produced and reaches to the melting
point, at the same time pressure is applied, joint gets
upset and welded pressure is kept till joint gets cool-
down.

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Continue
 Flash butt welding
In this type of welding two metals pieces to be joined
are not kept in close contact, but are kept in loose
contact as shown in fig. 4.3.
When Current is passed due to loose contact air in
between gets ionized and forms a spark. Both metal
ends are heated to melting point by this spark, then
pressure is applied to close them and welding takes
place. Due to flash unevenness of joint is removes
and strong weld results.

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 Spot Welding
This type of welding is employed generally for over
lapping joints.
Two metal sheets are over lapped and two sharp
copper electrodes are kept at the place where
welding is required as shown in fig. 4.4.

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Continue
 Projection Welding
It is the modifies form of spot welding.
In this type welding electrodes are made flat and
hollow.
Before welding to metal sheets, projections are
created on one piece by means of press.
During welding current passes only through
projections and welding is carried out at the
projections only, as shown in fig. 4.5.

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 Electric Arc Welding
This type of welding is more popular in the
industries.
Arc welding name is given as the arc is used as
source of heat.
In this process of welding are is struck between
the joint of two metal pieces and an electrode.
The electrode first brought together in contact
with two metal pieces to be joined and than
pulled away by 2 to 4 mm. As a result arc is
struck between them. Air between electrode and
metal joint gets ionized and becomes conductive
and an arc is truck.
To sustain the arc voltage required is about 20
12 volt while current in the range of 2000 to 3000
Continued
 Metal Arc Welding
Metal arc welding has large utility.
It is mainly used for mechanical maintenance work.
As shown in fig. 4.7 same metal rod is used for
welding the two metal pieces. The metal rod is made
+ve and work piece to be welded is made ve. Metal
rod itself melts and as a filler metal for filling joint
cavity.
Both types of supply ac or dc can be used for metal
arc welding. For ac supply voltage is kept 70 to 100
volts while for dc, it is 50 to 60 volts.
In this type of welding, only disadvantage is arc blow.

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Continue
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 Carbon arc welding
In this type of welding electrode is of carbon and the
polarity of supply is changed as that in metal arc
welding.
Work piece is made +ve and electrode made ve as
shown in fig. 4.8.
If the electrode made +ve then carbon particles
makes the joint brittle. Separate filler metal is
required to fill up joint cavity.
This type of welding is carried out by two ways
1) Using flux and 2) Without using flux
Flux is used in form of pest or powder either of silicon
or of phosporous.
Normally flux is used for non-ferrous metal welding
and flux is not required for ferrous metal welding.
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Continued..
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 Atomic hydrogen welding
In this type of welding arc is not struck between
electrodes and work piece but is struck between
tungsten electrode in the vicinity of hydrogen gas
around electrode and arc.
Due to high Temperature of arc hydrogen gas is
converted in forms of atomic hydrogen.
This atomic hydrogen passes through welding
chamber, it again comes to molecular form emitting
large amount of heat. Total amount of heat reaches
temp. of about 4000 c.
This heat is utilized for fusion welding. Welding is
done in the atmosphere of hydrogen makes the joint
free from oxygen and nitrogen. Filler of same metal is
used.
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Contined
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 Shielded Arc Welding
In this process, molten metal is protected from action
of atmosphere by an envelope of chemically reducing
or inert gas. Due to some chemical reactions metal
becomes weak, brittle and corrosion resistance.
Thus, several methods of shielding have been
developed.
Simplest is the use of a flux coating on electrode
which in addition to producing a slag which floats on
top of molten metal and protects it form atmosphere
and produce an envelope of inert gas around arc and
weld Shown in fig. 4.11

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 Comparision of A.C and D.C
Welding
A.C Welding
Efficiency of transformer
is 80 to 85%
Zero current twice in
each complete cycle
Equipments cost is low
Less space required
Use of intermittent
current reduces energy
consumption
Coated electrode
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Speedy welding work
D.C Welding
Efficiency of motor
generator set is 60 to 65%
Uniform temperature
during entire process
Equipment cost is high
ore space as compared
to A>C system is required
Continuous use of dc
generator set cost more.
Both coated and
uncoated electrode can be
used
Normal working speed
 THANK
YOU

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