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LESSON 22:
What is Welding?
How one should define Welding?
Introduction
Welding can be defined as a process, of joining two dissimilar
metals or similar metals in a way it can be said as a coalescence
between two metals with or without use of filler metal with
application of heat or pressure or combination of both. So a
weld occurs when pieces of metal are joined by causing the
interface to melt and blend prior to solidifying as a uniform
metal joint. This process may be caused by heat, pressure or a
combination of both. The electric arc or gas flame can also be
used to heat the metals. When heat alone is used the process is
called fusion welding.
Pressure welding usually involves heating the surfaces to a
plastic state and then forcing the metal together. The heating
can be by electric current of by friction resulting from moving
one surface relative to the other.
The methods and equipment used for welding metal are also
associated with cutting metal. There are a large number of
welding and allied processes including the following.
Gas Welding Arc Welding Brazing Soldering
Solid State
Welding
Other Welding
Allied processes
Adhesive
Bonding
Thermal
Spraying
Oxygen
Cutting
Thermal
Cutting
Arc Cutting
Electron
Beam
Cutting
Laser
Cutting
So, by this time you all must have got clear idea of a weld or
concept of welding. Lets us move ahead and classify the various
welding processes which are based on BS EN ISO 4063 and are
used when identifying welds to BS EN 22553.
Arc welding
Metal-arc welding without gas protection
Metal-arc welding with covered electrode
Gravity arc welding with covered electrode
Bare wire metal-arc welding
Flux cored wire metal-arc welding
Coated wire metal-arc welding
Firecracker welding
Gas-shielded metal-arc welding
MIG welding: metal-arc inert gas welding
MAG welding: metal-arc active gas welding
Flux-cored wire metal-arc weldingwith active gas shield
Gas-shielded welding with non-consumable electrode
TIG welding: tungsten inert gas arc welding
Atomic-hydrogen welding
Plasma arc welding
Other arc welding processes
Carbon-arc welding
Rotating arc welding
Resistance Welding
Spot welding
Seam welding
Lap seam welding
Seam welding with strip
Projection welding
Flash welding
Resistance butt welding
Other resistance welding processes
HF (High-Frequency) resistance welding
Gas welding
Oxy-fuel gas welding
Oxy-acetylene welding
Oxy-propane welding
Oxy-hydrogen welding
Air-fuel gas welding
Air-acetylene welding
Air-propane welding
Pressure welding
Ultrasonic welding
Friction welding
Forge welding
Welding by high mechanical energy
Explosive welding
Diffusion welding
Gas pressure welding ]
Cold pressure welding
Other welding processes
Thermit welding
Electro-slag welding
Electro-gas welding
Induction welding
Light radiation welding
Laser beam welding
Arc image welding
Infrared welding
Electron beam welding
Percussion welding
Arc stud welding
Resistance stud welding
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How welding processes are classified?
What is the basis for classification?
Broad Classification of Welding Processes
The two types of welding processes, the electric welding and the
gas welding explained in above, were divided on the basis of
the sources of heat generation during welding.
Welding processes are sometimes categorized based on the
material of filler rod used during welding, for example, (a)
autogenous welding in which no filler rod is used (such as in
resistance welding or cold welding processes), (b) homogeneous
welding wherein the filler rod used is of the same material and
composition as that of the base metals being welded (such as in
are welding processes) and (c) heterogeneous welding in which
the filler rod used is of different material than the base metal
welded (such as in soldering or brazing).
However, a more widely accepted classification of welding
processes is given in the following:
Fusion Welding Processes (or Non-pressure Welding Processes)
Pressure Welding Processes (Resistance Welding Processes and
Solid State Welding Processes)
Thermo-Chemical Welding Processes
Radiant Energy Welding Processes
Under Water Welding Processes
Fusion (or Non-pressure) Welding Processes
These involve heating the work-pieces to be joined to molten
state and allowing their molten portions to fuse and flow
together to develop coalescence, which on cooling results into a
strong joint. No pressure is exerted on the work-pieces to make
a joint. Further, the welded joint may be obtained with or
without the use of a filler rod (or electrode).
Fusion welding processes are further classified as below:
Are Welding Processes such as Shielded metal are welding, Flux
cored-are welding, Carbon are welding, Submerged are welding,
Tungsten inert gas (TIG) welding, Metal inert gas (MIG)
welding, Electroslag welding, Electrogas welding, Plasma are
welding.Gas Welding Processes include Oxy-fuel gas welding
such as Oxy-acetylene welding, Oxy-hydrogen welding etc.
Brazing and Soldering
Pressure Welding Processes
Gas Welding Processes include Oxy-fuel gas welding such as
Oxy-acetylene welding, Oxy-hydrogen welding etc.
Pressure welding processes are further divided as below:
Resistance Welding Processes such as Spot welding, Seam
welding, Projection welding, Resistance (upset) butt welding,
Flash butt welding, Percussion welding and Stud welding.
Solid State Welding Processes
A Solid state welding process produces coalescence at tempera-
tures below the melting point of the base metals being joined,
without the addition of a filler metal but with application of
pressure only. Various types of Solid state welding processes
include:
Cold welding
Diffusion welding
Explosive welding
Friction welding and Inertia welding
Ultrasonic welding
Forge welding
Thermo chemical Welding Processes
The two main Thermo chemical welding processes are (a)
Thermit welding and (b) Atomic hydrogen welding. Thermo
chemical welding is, in a way, a fusion welding process in which
no outside heat source is required for melting the work pieces to
be joined, for example, the exothermic reaction of the burning
thermit mixture in Thermit welding, provides heat required for
melting the joint edges of the work-pieces. Similarly, Atomic
hydrogen welding possesses the features of both are and flame
welding processes. Are is struck between two non-consumable
tungsten electrodes in an atmosphere of hydrogen where
dissociation of hydrogen results in an exothermic reaction
providing heat for welding.
Radiant Energy Welding Processes
Radiant energy Welding processes involve focussing an energy
beam on the mating edges (or surfaces) of the two work-pieces
to be joined. Heat is generated as a consequence of the energy
beam striking the work-pieces.
Radiant energy welding processes include:
(a) Electron Beam welding
(b) Beam welding
Brazing and Soldering
These involve heating of work-pieces to the temperature range
in which the base metal -of the work-pieces become plastic and
then the two work-pieces are joined together by applying
pressure on them. The work-pieces are heated only along the
edges where the joint is to be formed. Heating may be some-
times concentrated only at a spot (or number of spots) on the
edges of the joint. No additional filler metal (or electrode) is
used in forming the weld.
Now, we have little understanding of basic definition of
welding and the various categories, now lets understand various
types of welding one by one with relevant application.
Diversity of welding processes Diversity of welding processes
welding
Solid state welding Soldering and brazing Fusion welding
Electrical energy Chemical energy
Other processes Non consumable
electrode
Consumable electrode
Resistance welding
Cold welding
Friction welding
Diffusion welding
Flash welding
Ultrasonic welding
Explosion welding
Gas metal arc welding
Shielded metal arc welding
Submerged arc welding
Flux cored arc welding
Electrogas welding
Electroslag welding
Gas tungsten arc welding
Atomic hydrogen welding
Plasma arc welding
Oxyacetylene welding
Oxyfuel gas welding
Laser beam welding
Thermit welding
Electron beam welding
Soldering
Brazing
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Mind Teasers
Suppose you are production engineer and have been asked
to fabricate a structure. Which method would you like to
select?
Why welding is preferred over other joining processes.
Discuss.
Discuss welding process in detail. Give an example to
support your answer.
Give broad classifications of welding process?
Ref erences
1. Manufacturing Technology (Vol. 1) by- PN Rao
2. Workshop Technology (Vol.1) by- Hajra Chodhry
3. Workshop Technology by- BS Raghuwanshi
4. Workshop Technology by- OP Khanna
5. Workshop technology by- B.S.Raghuvanshi
6. Workshop technology by- W A J Chapman