Welding

Welding is the process of joining two metallic components for the desired purpose, can be defined as the process of joining two similar or dissimilar metallic components with the application of heat, with or without the application of pressure and with or without the use of filler metal. Heat may be obtained by chemical reaction, electric arc, electrical resistance, frictional heat, sound and light energy. Welding is used for making permanent joints. If no filter metal is used during welding then it is termed as Autogenous Welding Process. Application: 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 processes can be classified based on following criteria; Plastic welding or Pressure welding 1) The pieces are heated to a plastic state and then forced together by external pressure. 2) Forge Welding 3) Friction Welding 4) Diffusion Welding Fusion welding or non pressure welding: In fusion welding the material at the joint is heated to a molten state and allowed to solidify. 1) Metal arc welding 2) Carbon arc welding 3) Tungsten arc welding 4) Gas welding 5) Resistance welding 6) Laser beam welding 7) Electron beam welding Types of welding Based on filler metal: Autogeneous : No filler metal, electrode acts as filler metal (Pressure welding, Resistance welding) Homogeneous : Filler metal used is same as base metal (Arc Welding, Gas Welding) Heterogeneous: Filler of different metal (Soldering, Brazing).

Edge preparation:

Types of welded joints:

Principle of Arc An electric arc is formed when an electric current passes between two electrodes separated by a short distance from each other. In arc welding one electrode is the welding rod or wire, while the other is the metal to be welded. The electrode and the plate are connected to the supply, one to the positive pole and one to the negative pole. The arc is started by momentarily touching the electrode on to the plate and then withdrawing it to about 3 to 4 mm from the plate. When the electrode touches the plate, a current flows, and as it is withdrawn from the plate the current continues to flow in the form of a spark across the very small gap first formed. This causes the air gap to become ionized or made conducting, and as a result the current is able to flow across the gap, even when it is quite wide, in the form an arc. The electrode must always be touched on to the plate before the arc can be started, since the smallest air gap will not conduct a current 9 at the voltages used in welding) unless the air gap is first ionized or made conducting. The arc is generated by electrons flowing from the negative pole to the positive pole and the Electrical energy is changed in the arc into heat and light. Approximately two-thirds of the heat is developed near the positive pole , which burns into the form of a crater, the temperature near the crater being about 6000-70000C, while the remaining third is developed near to the negative pole. As a result an electrode connected to the positive pole will burn away 50 % faster than if connected to the negative pole. The welding current may vary from 20 to 600 A in manual metal arc welding. When alternating current is used, heat is developed equally at the plate and rod, since the electrode and the plate are changing polarity at the frequency of the supply. Arc Welding Equipment The main requirement in an arc welding setup is the source of electric power. 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 a) Alternating Current Machines 1. Transformer 2. Motor or engine driven alternator b) Direct Current Machines 1. Transformer with DC rectifier 2. Motor or engine driven generator

In AC welding normally transformer is used. It has following operational characteristics. 1. No moving parts and less noise; 2. Less maintenance; 3. Higher efficiency; 4. Cheaper power source. In DC arc welding a rectifier or a generator can be used to supply the required DC power. At first input voltage is stepped down to required voltage and then through silicon controlled rectifier (SCR) is converted from AC to DC. Advantages of Arc welding: 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 of Arc welding: Manually applied, therefore high labor cost. Need high energy causing danger Not convenient for disassembly. Defects are hard to detect at joints. 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 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

Electrode and Coating: Welding electrodes are metal wires with baked on chemical coatings. The rod is used to sustain the welding arc and to provide the filler metal required for the joint to be welded. The coating protects the metal from damage, stabilizes the arc, and improves the weld. The diameter of the wire, less the coating, determines the size of the welding rod. This is expressed in fractions of an inch such as 3/32", 1/8", or 5/32." The smaller the diameter means it requires less current and it deposits a smaller amount of filler metal. Fluxes: The type of flux is used will depend upon the types of metals being welded. 1) For Al and Al alloys: mixture of alkaline fluorides, chlorides. 2) Copper and copper alloys: Mixtures of sodium and potassium borates, carbonates chlorides sulphates. 3) Ferrous metals: for welding Cast iron, mixtures of borax, sodium carbonate and potassium carbonate.

4) 5)

For carbon steels: calcium oxides dissolved in liquid are common fluxes. Alloy steels: Mixtures of boric acid and calcium fluoride.

GAS WELDING: Group of fusion welding operations that burn various fuels mixed with oxygen, most important OFW (Oxyfuel Gas Welding) process is oxyacetylene welding. Fusion welding performed by a high temperature flame from combustion of acetylene and oxygen OAW is a manual process in which the welder must personally control the the torch movement and filler rod application Flame is directed by a welding torch Filler metal is sometimes added 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 FLAME: There are three types of oxy-acetylene flames, usually termed: Neutral Carburizing (or excess acetylene) Oxidizing (or excess oxygen ) 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) 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) Used for welding steels, aluminum, 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

ADVANTAGES: The relative cost of the equipment is low. No electricity is required for this process. Can be used for welding in all positions because no electrical cables are required and the operator has precise control of the process. This process is also extremely portable. Can be used on both thick and thin materials, which makes it a very versatile process. Very clean, producing no slag or spatter that must be removed from the weld. Produces high quality welds when done properly.

Welding rods for gas welding:

Materials to be welded Mn- steel Cr-steel L-C steel

Welding rod for chemical composition 0.14%C, 0.12%Si, 0.81%mn, 0.25%Ni. 0.24%C, 0.21%Si, 0.42%Mn, 0.96Cr, 0.17%Ni, 0.35%S. 0.08%C, 0.36%Mn, 0.13Cr, 0.013%Ni, 0.02%P.

Brazing & Soldering: It is a low temperature joining process. It is performed at temperatures above 450o C 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.

Application: Automotive Aerospace Plumbing

jet engine parts rocket engines larger piping in multistory buildings

Advantages Dissimilar metals which cannot 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 450o C for joining. Soldering is used for, Sealing, as in automotive radiators or tin cans Electrical Connections Joining thermally sensitive components Joining dissimilar metals