Welding

Sujith R
BITS Pilani Mechanical Engineering Department
BITS Pilani Hyderabad Campus
Hyderabad Campus
Types of joining

• Mechanical joining: Bolts, Screws and Rivets

• Adhesive bonding: epoxy resins, silicone resins,

elastomers

• Brazing and Soldering

• Welding

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 Definition

A localized coalescence of metals or non-metals produced

either by heating the material to suitable temperature,
with or without the application of pressure, or by the
application of pressure alone, and with or without the use
of the filer metal.

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 Welding history
Bronze age (Forge welding of ornaments)
1890 – Arc welding (USA)
1902 – Oxy-acetlyene welding (Europe)
1903 – Thermit welding
1907 – MMAW
1935 – Submerged arc welding (SAW)
1941 – Tungsten inert gas (TIG)
1948 – Metal inert gas (MIG)
1954 – Electron beam welding (EBW) 1956 – Friction welding (FRW)
1957 – Plasma arc welding (PAW)
1959 – Vacuum diffusion welding (VDW)
1960 – Explosive welding (EXW)
1961 – Laser beam welding (LBW)
1991 – Friction stir welding (FSW
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 Applications

Pressure vessels
Bridges
Ship building
Building structures
Aircraft
Railways
Automobiles
Electronic industry
Nuclear installations
Defense

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Sources of heat

• Chemical reactions

• Electric arc

• Electric resistance

• Radiation

• Friction

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Types of welding

Welding process

Resistance
Gas welding Solid state welding
welding
Other welding
OAW Arc welding
process
OHW RSW
MMAW RSEW EBW Explosion (EXW)
SMAW RPW LBW Diffusion (DFW)
SAW UW TW Friction (FRW)
GTAW Friction stir (FSW)
GMAW Ultrasonic (USW)
PAW

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 Choice of joining process

• Type of assembly – permanent, semi-permanent or

temporary
• Materials being joined – Steels, CI, Al, Ti, similar or
dissimilar metals
• Economy
• Type of service required – Loading, temperature etc.

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 Welding terminologies

• Base metal
• Weld bead
• Crater
• Root
• Toe
• Deposition rate (kg/h)
• Penetration
• Weld pass
• Weld face

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Zones in weldment

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Fusion welding

OAW RW PAW EB Drilling

AW OAC EBW

103 105 106

W/cm2
104 107
HAZ

Travel speed
Automation

Heat efficiency

Depth to width ratio

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Summary of features

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 Gas welding
• Oxy acetylene welding (OAW): Exothermic reaction: 2
stage combustion

• Filler rod may or may not be used

• Neutral flame

• Carburizing flame

• Oxidizing flame

• Acetylene generation
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 Forehand and backhand
welding

Forehand

Backhand

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 Set-up

15 Image courtesy: www.technologystudent.com

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 Advantages

Better control over the rate of heat input, the temperature of

the weld zone, and the oxidizing or reducing potential of
the welding atmosphere.

Weld bead size and shape and weld puddle viscosity are
also controlled in the welding process because the filler
metal is added independently of the welding heat source.

OFW, Oxy Fuel welding is ideally suited to the welding of

thin sheet, tubes, and small diameter pipe. It is also used
for repair welding. Thick section welds, except for repair
work, are not economical.

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5 basic joint designs

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4 basic types of fusion weld

Building up surfaces
Weld overlay
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5 welding positions

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Classification of welding

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Physics of arc

Visual analysis of welding process: Yogi

Ogawa
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Role of gases

• Inert/inactive
• Shielding effect
• Stability of arc
• Mass transfer

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Arc characteristic + Power
characteristic

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Polarity

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SMAW

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GTAW

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 Features of GTAW
• Non-consumable W electrode: Higher arc stability
• Low current (100 -200 Amp); >300 Amp cooling system
• Low heat input – better quality – critical applications
• Inert gas
• Power source: DC (DCEN): Deeper penetration, Pulsed DC;
AC (Al): Lower arc stability (rectification)
• Manual or automatic
• CC characteristic
• Arc initiation: Field emission
• Thin plates welding; > 1 mm filler rods
• Cleanest of all arc welding
• Welding of Al, Mg and stainless steel
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GMAW

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 Features of GMAW
• Consumable electrode (bare electrode) fed at constant rate
• FCAW
• Inert gas or active gas
• Lower arc stability
• Higher voltages and currents (Thick plates)
• Power source: DC is preferred (DCEP): Higher melt
deposition rate: Higher productivity: Cleaning action: Higher
heat input (Ar/He)
• CV characteristic
• Arc initiation: Touch start/field emission
• Mass transfer: globular to spray: f(current, electrode
diameter, electrode extension (L = 8Φ), inert/active gas)
• Not as clean
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SAW

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Features of SAW

• Arc submerged in granular flux: heat loss is minimum

• Thermal efficiency: 0.8-0.9
• Electrode fed continuously
• No inert gas
• High productivity: large electrodes (Φ12 mm) + very high
current (4000 Amp): high melt deposition rate (20 kg/h)
• Thicker plates(75mm in one pass).
• Automatic
• AC or DC(DCEP): CV
• Only for flat welding positions
• High heat input
• Not a clean weld
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 Plasma Arc Welding

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 Electron beam welding

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 Laser beam welding

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 Resistance welding

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 Resistance seam welding

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 Projection welding

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 Flash Butt Welding
Flash welding

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Heat input vs Power density

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