WELDING

Welding is a materials joining process which produces coalescence of materials by heating them to suitable temperatures with or without the application of pressure or by the application of pressure alone, and with or without the use of filler material. Welding is used for making permanent joints. It is used in the manufacture of automobile bodies, aircraft frames, railway wagons, machine frames, structural works, tanks, furniture, boilers, general repair work and ship building.

Classification of welding processes

welding
Forge or Pressure Welding ( Under pressure without additional filler metal ) Fusion or non pressure welding ( With additional filler metal )

Forge or Pressure welding :- The work piece are heated to plastic state & then work pieces are joined together by applying pressure on them. In this case no filler material is used.

Fusion or non- pressure welding :- Here edge of work piece to be joined & filler material both are heated to a temp. above the melting point of the metal & then allow to solidify

Forge or pressure welding

Welding heat created by

Furnace

Electric current

friction

Forge or furnace welding welding

Resistance welding

friction

Spot

seam

projection

flash

butt

Fusion or non pressure welding

Welding heat created by

gas

Electric Arc

chemical reaction

Oxy-acetylene welding

Thermit welding

Carbon arc

metal arc

atomic hydrogen

submerged arc

plasma arc electro slag MIG TIG

Other processes of welding are : Solid State welding : The solid state welding depends upon the theory that if two perfectly clean metallic surfaces are placed in an intimate contact , the cohesive force between atoms of the two surfaces is sufficient to hold them together. The various solid state welding process are: Friction Welding Ultrasonic Welding Diffusion Welding Explosive Welding

Modern Welding Processes:

Electron Beam Welding Laser Beam Welding

Classification of welding processes:

(i). Arc welding Carbon arc Metal arc Gas Metal arc Gas Tungsten arc Plasma arc Submerged arc Electro-slag Atomic hydrogen arc Flux core arc (ii). Gas Welding Oxy-acetylene Air-acetylene Oxy-hydrogen (iii). Resistance Welding Butt Spot Seam Projection Percussion

(iv)Thermit Welding
(v)Solid State Welding Friction Ultrasonic Diffusion Explosive (vi)Newer Welding Electron-beam Laser (vii)Related Process Oxy-acetylene cutting Arc cutting Hard facing Brazing Soldering

Resistance Welding
Resistance Welding is a pressure welding technique using high current and low voltage The current passing through the two overlapping work pieces causes local heating and temperature of the metallic pieces raises to the fusion point due to resistance offered by the work pieces to flow of current Subsequent application of pressure results in permanent joining of the work pieces by the formation of weld without the use of filler material Work pieces are placed between two rods or wheels(rolls), which serve as conductor for producing welds AC electric current is supplied through copper electrodes or rolls connected to the secondary coil of a welding transformer. It is used for welding thin sheets of similar metallic materials

The following metals may be welded by Resistance Welding: Low carbon steels - the widest application of Resistance Welding Aluminum alloys Medium carbon steels, high carbon steels and Alloy steels (may be welded, but the weld is brittle)

Advantages of Resistance Welding: High welding rates; Low fumes; Cost effectiveness; Easy automation; No filler materials are required; Low distortions. Disadvantages of Resistance Welding: High equipment cost; Low strength in case of discontinuous welds; Thickness of welded sheets is limited - up to 6 mm

Resistance Welding (RW) is used for joining vehicle body parts, fuel tanks, domestic radiators, pipes of gas oil and water pipelines, wire ends, turbine blades, railway tracks. The most popular methods of Resistance Welding are:

Resistance spot welding Resistance seam welding Resistance butt welding Resistance flash welding Resistance projection welding

Spot Welding (RSW) Spot Welding is a Resistance Welding (RW) process, in which two or more overlapped metal sheets are joined by spot welds. .

Spot welding is widely used in automotive industry for joining vehicle body parts.

Spot Welding is a Resistance Welding (RW) process, in which two or more overlapped metal sheets are joined by spots ,accompanied by heating relatively small sections of the parts or pieces between suitable electrodes under pressure. The method uses pointed copper electrodes providing passage of electric current. The electrodes also transmitt pressure required for formation of strong weld

Diameter of the weld spot is in the range (3 - 12 mm).

Spot Welding Cycle

(a) Spot welding cycle, (b) plot of squeezing force & current in cycle (1) parts inserted between electrodes (2) electrodes close, force applied (3) current on (4) current off (5) electrodes opened.

Seam Welding is a Resistance Welding (RW) process of continuous joining of overlapping sheets by passing them between two rotating electrode wheels. Heat generated by the electric current flowing through the contact area and pressure provided by the wheels are sufficient to produce a leak-tight weld. Seam Welding is high speed and clean process, which is used when continuous tight weld is required (fuel tanks, drums, domestic radiators).

Side view

Resistance Seam Welding

Resistance Welding

Seam Spot 1. The electrodes are a pair of copper rods between which the sheets to be welded are positioned 2. The welding takes place at discrete intervals 3. It is used for components such as flat sheets , panels as in car bodies. 1. Electrodes are a pair of rotating copper rolls between which sheets to be welded are passed 2. The seam weld joints are continuous 3. It is used to weld components such as a fuel tank shells & other application which require the joint to be leak proof

Flash Welding (FW) or Flash butt welding is a Resistance Welding (RW) process, in which ends of rods (tubes, sheets) are heated and fused by an arc struck between them and then brought into a contact under a pressure) producing a weld. The welded parts are held in electrode clamps, one of which is stationary and the second is movable.

Flash Welding (FW)

Flash Welding method permits fast (about 1 min.) joining of large and complex parts.

Steels, Aluminum alloys, Copper alloys, Magnesium alloys, Copper alloys and Nickel alloys may be welded by Flash Welding. Thick pipes, ends of band saws, frames, aircraft landing gears are produced by Flash Welding.

Resistance Butt Welding or Upset butt welding is a Resistance Welding (RW) process, in which ends of wires or rods are held under a pressure and heated by an electric current passing through the contact area and producing a weld.

Resistance Butt Welding (UW) The process is similar to Flash Welding, however in Butt Welding pressure and electric current are applied simultaneously in contrast to Flash Welding where electric current is followed by forging pressure application. Butt welding is used for welding small parts. The process is highly productive and clean. In contrast to Flash Welding, Butt Welding provides joining with no loss of the welded materials.

Resistance Projection Welding (RPW) A resistance welding process in which coalescence occurs at one or more small contact points on parts Contact points determined by design of parts to be joined May consist of projections, embossments, or localized intersections of parts
Resistance projection welding (RPW): (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.

Percussion welding

Arc welding
Equipments:
A welding generator (D.C.) or Transformer (A.C.) Two cables- one for work and one for electrode Electrode holder Electrode Protective shield Gloves Wire brush Chipping hammer Goggles

Arc Welding Equipments

Metal arc welding

Arc Welding
Uses an electric arc to coalesce metals Arc welding is the most common method of welding metals Electricity travels from electrode to base metal to ground

Carbon Arc Welding

Arc welding
Advantages
Most efficient way to join metals Lowest-cost joining method Affords lighter weight through better utilization of materials Joins all commercial metals Provides design flexibility

Limitations
Manually applied, therefore high labor cost. Need high energy causing danger Not convenient for disassembly. Defects are hard to detect at joints.

Comparison of A.C. and D.C. arc welding

Alternating Current (from Transformer)
More efficiency Power consumption less Cost of equipment is less Higher voltage hence not safe Not suitable for welding non ferrous metals Not preferred for welding thin sections Any terminal can be connected to the work or electrode

Comparison of A.C. and D.C. arc welding Direct Current (from Generator)
Less efficiency Power consumption more Cost of equipment is more Low voltage safer operation suitable for both ferrous non ferrous metals preferred for welding thin sections Positive terminal connected to the work Negative terminal connected to the electrode

GAS WELDING
Sound weld is obtained by selecting proper size of flame, filler material and method of moving torch The temperature generated during the process is 33000c When the metal is fused, oxygen from the atmosphere and the torch combines with molten metal and forms oxides, results defective weld Fluxes are added to the welded metal to remove oxides Common fluxes used are made of sodium, potassium. Lithium and borax. Flux can be applied as paste, powder,liquid.solid coating or gas.

GAS WELDING EQUIPMENT...

1. Gas Cylinders Pressure Oxygen 125 kg/cm2 Acetylene 16 kg/cm2 2. Regulators Working pressure of oxygen 1 kg/cm2 Working pressure of acetylene 0.15 kg/cm2 Working pressure varies depends upon the thickness of the work pieces welded. 3. Pressure Gauges

4. Hoses 5. Welding torch 6. Check valve 7. Non return valve

Oxy-Acetylene welding

TYPES OF FLAMES
Oxygen is turned on, flame immediately changes into a long white inner area (Feather) surrounded by a transparent blue envelope is called Carburizing flame (30000c) Addition of little more oxygen give a bright whitish cone surrounded by the transparent blue envelope is called Neutral flame (It has a balance of fuel gas and oxygen) (32000c) Used for welding steels, aluminium, copper and cast iron If more oxygen is added, the cone becomes darker and more pointed, while the envelope becomes shorter and more fierce is called Oxidizing flame Has the highest temperature about 34000c Used for welding brass and brazing operation

Three basic types of oxyacetylene flames used in oxyfuel-gas welding and cutting operations: (a) neutral flame; (b) oxidizing flame; (c) carburizing, or reducing flame.

Three basic types of oxyacetylene flames used in oxyfuel-gas welding and cutting operations: (a) neutral flame; (b) oxidizing flame; (c) carburizing, or reducing flame.

GAS CUTTING
Ferrous metal is heated in to red hot condition and a jet of pure oxygen is projected onto the surface, which rapidly oxidizes Oxides having lower melting point than the metal, melt and are blown away by the force of the jet, to make a cut Fast and efficient method of cutting steel to a high degree of accuracy Torch is different from welding Cutting torch has preheat orifice and one central orifice for oxygen jet PIERCING and GOUGING are two important operations Piercing, used to cut a hole at the centre of the plate or away from the edge of the plate Gouging, to cut a groove into the steel surface

GAS CUTTING

Manual Gas Cutting

Weld joints

 Brazing

Brazing and Soldering

It is a low temperature joining process. It is performed at temperatures above 840 F and it generally affords strengths comparable to those of the metal which it joins. It is low temperature in that it is done below the melting point of the base metal. It is achieved by diffusion without fusion (melting) of the base

Brazing can be classified as

Torch brazing Dip brazing Furnace brazing Induction brazing

Brazing

Advantages

Advantages & Disadvantages

Dissimilar metals which canot be welded can be joined by brazing Very thin metals can be joined Metals with different thickness can be joined easily In brazing thermal stresses are not produced in the work piece. Hence there is no distortion Using this process, carbides tips are brazed on the steel tool holders

Disadvantages
Brazed joints have lesser strength compared to welding Joint preparation cost is more Can be used for thin sheet metal sections

Soldering
It is a low temperature joining process. It is performed at temperatures below 840F for joining. Soldering is used for, Sealing, as in automotive radiators or tin cans Electrical Connections Joining thermally sensitive components Joining dissimilar metals