MECHANICAL AND ELECTRICAL ENGINEERING - PLANT TECHNOLOGY
021 PLANT INSTALLATION AND MAINTENANCE
TUTORIAL EIGHT - WELDING
Notes taken from www.freestudy.co.uk Operations trainee program Manual
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Oxy fuel gas welding (Oxyacetylene welding) This is a manual process in which the metal surfaces to be joined are melted progressively by heat from a gas flame, with or without filler metal, and are caused to flow together and solidify.
The equipment for oxy fuel welding consists of an oxygen tank, acetylene tank, pressure regulators, torch and connecting hose. Each tank has a pressure regulator attached to its top which reduces the high internal pressure. The hoses then connect these regulators to the torch. The torch includes a mixing section where oxygen and acetylene are combined and burned.
Application Used in the air conditioning industry to weld copper tubes as well as brazing and soft soldering of components.
Manual metal arc welding Stick welding is a process which melts and joins metals by heating them with an arc between a coated metal electrode and the work piece. The stick electrode has an outer coating, called flux, that assists in creating the arc and provides the shielding gas and slag covering to protect the weld from contamination. The electrode core provides most of the weld filler metal. PREPARED BY ADESH BAHADOOR Page 3
Applications used in the fabrication industry to weld steel in burgular proofing, cooling towers and the majority of pipeline works.
Metal arc gas shielded welding (MAGS) or Metal inert gas (MIG) welding In this type of welding, a solid wire electrode is fed continuously through a welding gun. An arc is created between this wire and the work piece to heat the base and fill up the material. All of the shielding for welding is provided from an inert gas which is also emitted from the gun by some external source. The MIG welding process operates on D.C. usually with the wire electrode positive. Continuing developments have made the MIG process applicable to the welding of all commercially important metals such as steel, aluminum, stainless steel, copper and several others.
Applications used in large manufacturing industries to weld aluminium, magnesium, alloys, plain and low carbon steels, stainless steel, copper and bronze. Used to weld very thick sections usually above 8mm.
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Tungsten arc gas shielded welding (TAGS) The most significant feature of this process is that the electrode use is not intended to be consumed during the welding operation. It is made of pure or alloyed tungsten which has the ability to withstand very high temperatures. When a current flows, an electric arc is established between the work piece and the tungsten electrode. The arc can fuse two metals together without the use of a filler metal. A hand-held filler rod can be placed near the arc and melted to fill any gaps. The arc is protected by a flow of a shielding gas, commonly argon (also helium or mixtures of these two gases), which displace atmospheric gases from the weld zone.
Applications used in large manufacturing industries to weld aluminium, copper, stainless steel, heat resistant steel and bronze.
Plastic welding Welding takes place by the use of a gent of hot air. A thin filler of the same material to be weld is heated by the hot air and used to form a weld.
Application - welding rigid PVC, used in the automobile industry and manufacturing sporting goods.
Oxy-Acetylene Welding and Cutting
Electric, Forge and Thermit Welding together with related methods and materials used in metal working and the oxygen process for removal of carbon
Heat-Treatment of Steel: A Comprehensive Treatise on the Hardening, Tempering, Annealing and Casehardening of Various Kinds of Steel: Including High-speed, High-Carbon, Alloy and Low Carbon Steels, Together with Chapters on Heat-Treating Furnaces and on Hardness Testing
Oxy-Acetylene Welding and Cutting: Electric, Forge and Thermit Welding together with related methods and materials used in metal working and the oxygen process for removal of carbon