ADALYA JOURNAL ISSN NO: 1301-2746

Brief Study on Different Types of Welding Processess

Vishnu Rao K1, Vignesh B S1, Shetty Shreyas M1
Department of Mechanical Engineering, Vidyavardhaka College of Engineering, P.B. No.206, III
Stage, Gokulam, Mysuru, Karnataka, India
1
shreyassr14@gmail.com,

Abstract-
Welding is very important, as it is nearly impossible to build a modern society without
using the welding operation, i.e., it is impossible to manufacture bridges, vehicles, ships and
aircraft. There is a lot of variety of welding techniques out of which arc welding is the most
effective/efficient welding technique. As we all know a lot of research is being going on, on
heat and mass transfer, fluid flow and weld pool formation. We also know that gas
tungsten arc welding (GTAW) and gas metal arc welding (GMAW) are not able to perform
deep penetration welding. Because energy is not able to continently transfer itself through
the whole of its thickness. So, as an evolution plasma arc welding (PAW) was invented
which was able to transfer heat to greater depths and was able to joint/weld thick metallic
material over a single pass. Since it had a greater heat concentration when compared to
other welding techniques.
Keywords- Welding, GTAW, GMAW, PAW,
I. INTRODUCTION
As we know there are a number of development in computer numerical analysis technologies.
But the finite element method (FEM) is the most commonly used method since it is more
accurate and easily predictable method, that is everyone can own/use in their systems. When we
analyse any specimen/component the temperature field is able to give sufficient information on
the weld joint properties, quality, it also helps us in determining its residual stresses, distortion or
the strength of the joint around the weld. The temperature field acts as the metallurgical analysis
and phase change analysis.
There are many welding heat source models that are available on the internet but the Gaussian
model and the Double ellipsoidal model are by far the best models available. These models can
accurately predict the temperature field in the component, which can be predicted very
accurately but since it is static, it loses its validity. For some dynamic welding process such as
Pulsed current gas tungsten arc welding (PCGTAW), the welding current is periodically varied
from the peak, such that the background current is set at a low level to maintain the stable arc
required (1).

Gas metal arc welding (GMAW) is the most established or the most well worse welding
operation that is used to join a very wide range of metallic material in the industrial field. This
operation is termed as pulsed gas metal arc welding (GMAW-P), since it uses a pulsed current

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ADALYA JOURNAL ISSN NO: 1301-2746

wave form. It uses high peak current to melt the electrode wire with low base current to maintain
the arc to detach droplet of weld metal at an average current lower than that of threshold level to
form a perfect weld joint.
To form a perfect weld only one, and only one drop of weld metal must be dropped per
pulse. In order to fulfil the above parameter efforts are being made to understand the pulse
parameter effects on metal transfer behaviors. From this we come to a conclusion that, any
numerical model based on the solution of magneto hydrodynamic equation within the framework
of phase field algorithm to simulate the metal transfer process and investigate the effect of power
source dynamics on metal transfer and to investigate the effect of power source dynamic on
metal transfer and heat transfer behaviors in GMAW-P (2).
As we know from the introduction keyhole plasma arc welding is more effective in doing deep
penetration welding. Here energy can be easily transferred to the bottom of the metal by hot
plasma arc welding in keyhole. Hence a keyhole-mode heat transfer model was developed to
show this thermo-physical process. According to numerical simulation dynamic keyhole process
and the consequent keyhole-mode heat transfer and fluid flow were revealed in continuous
keyhole plasma arc welding (3).
II. LITERATURE SURVEY
As we all know welding is the most effective and reliable way to join any two similar or
dissimilar metallic material. Welding is the most common metal joining process in the existing
today life. Welding is applicable in industries such as nuclear, automobile, aerospace and also off
the shore. We know due to residual stresses, distortion in the heat affected zone (HAZ) welding
is a very complex phenomenon. As it is nearly impossible to build a modern society without
using the welding operation, i.e., it is impossible to manufacture bridges, vehicles, ships and
aircraft. There is a lot of variety of welding techniques out of which arc welding is the most
effective/efficient welding technique. As we all know a lot of research is being going on, on heat
and mass transfer, fluid flow and weld pool formation.
Rosenthal in 1946 about seven decades ago investigated on heat transfer effect on HAZ
considering different shape of the heat source such as point, line and plane heat source shape (4).
The underwater wet flux-cored arc welding (FCAW) of E40 steel was investigated for its electric
signal data, microstructure characteristics and mechanical properties at six different heat inputs.
Electrical signals resulting in the arc stability would diminish at high heat input due to the
formation of spatters which changed the chemical composition of the weld metal. If the heat
input increases the ultimate tensile strength. Buy this investigation moderate heat input was
optimum, good arc stability was obtained and mechanical properties was excellent (5).
In this experiment the non-consumable electrode diffuse the cathode spot in the wide range of
the welding current and has a longer service life compared to an cone electrode. There will be
not contamination of reactive gases on the surface while the arc welding procedure is goes on.
The efficiency will be more.

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The working area of electrode depends upon the width of the metal, geometric factor and weld
penetration depth. It is found the maximum penetration occurs when the electrode is moved
along the direction of slots in between two metals. The largest penetration depth at current above
300A which form high quality seam formations, enables welding at high speed and high input.
When helium gas is covered in the arc welding procedure increases from 50% to 100% than the
penetration of depth increases as well as the geometric factor also increases (6).
The main problem occurred in ship building industries are distortion on the material, the cost to
correct and losses of time and repair the welded defects which are formed on the material. It can
replaced by common two-side weld with gouging technique currently they are used in Thai
shipyard one-side-one welding which will save time and cost .
In this research one-side-one arc welding of ASTM A131 grade A steel plates are used by
applying different input temperatures, and using joints like v-joints of different degrees are used,
to prevent the molten effect on the materials ceramics are used. The distortion varies with
varying joints, temperature input, and constraint conditions (7).
Bubble evolution behavior has the most important effect which are done under the water,
welding the joints using wet fluxed arc welding , the bubble evolution behavior are taken using
high speed camera to study the process. In this research it is found that what are all the effect
which are occurred underwater but the results of the wet arc welding shows that it is unstable and
complicated, it can be slightly adjusted by welding parameters to obtain more stable protective
effect using low frequency, large diameter of bubble increases, speed, and increase the wire feed.
With current and arc voltage of stable parameter the welding can be done underwater with good
surface finish without effecting the materials (8).
The effect and parameter between the metal and heat transfer from gas metal arc welding they
are verified by the magneto hydrodynamic equation within the framework of phase field method.
five sets of waveforms and current are supplied (i.e 300 A-2.30ms, 350 A-1.80ms, 400 A-
1.45ms, 450 A-1.20ms, 500 A-1.00ms) with minimum average of 170A are supplied . The
results shown the experiment states that the pulse parameter affects the dynamics of the drop
transfer process with a minimum current, pulse uses the higher current but shorter duration leads
to longer pendent drop. The results are compared with high speed camera to know the procedure.
In the heat transfer process as the pulse increases the current leads to minimum temperature of
detached drop. The temperature increase is less significate compared to increase in velocity (9).
When double pulsed gas metal arc welding was tested for different variables of current
amplitude we get to know about solidification parameters, cooling rates, grain size and
microstructures. The heat input given through pulsation provides an effective and flexible
welding pool which when done with proper precautions and experimental setup provides us with
an information of how good quality welds can be made (10).
Single pulsed gas metal arc welding is achieved due to transfer of molten metal via the spray tool
which helps in giving good surface finish. This process is advantageous because in this it all
depends on the heat input given to the system, this in turn controls the cooling rate and
influences the microstructure. In double pulsed gas metal arc welding it is completely different

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because in this we can vary the pulsations of input heat. In this two different phases of sequential
pulsing is given which have high frequencies. This method provides us an advantage of
controlling the droplet transfer with affects the weld quality, the mean grain size could be
reduced, and with variation in time the solidification parameters and cooling rate varies (11).
We get to understand the complications that arise while using mechanical transducer in arc
welding, there is a problem to generate an arc of same characteristics and it all depends on the
working of the transducer and working environment of it. When a traditional transducer is used
we can get arc of same characteristics which in helps in increasing the productivity, has good
grain refinement which leads to good welded joints and mechanical property. The difficult
aspects in this is that we require a good modulation unit which has to produce pulses for welding
current at high frequency and adjusting this becomes a difficult task as the welding current keeps
altering (12)
III. DISCUSSION
An experiment was conducted where in the motel metal being deposited was filmed, and a
physical model was experimented to understand it. When these two results were combined we
get to know that there are basically three metal transfer modes which is formed with increase in
welding current i.e, flux-wall guided transfer with short-circuit, repelled globular transfer
without short-circuit and flux-wall guided transfer without short-circuit.
The quality of welding is affected while molten metal is transferred in arc welding process. To
overcome all the disadvantages a new method known as submerged arc welding is introduced in
which the arc is shielded by a layer of granular deposits known as flux, in this process the motel
metal being laid on the welding joint cannot be viewed because of the flux that is being
deposited (13)
The rotational arc welding method is a conventional form of gas metal arc welding. The
deposited bead are flat and semi-circular, it is so formed by the speed of the rotating welding
torch. By this process we can achieve better enhanced mechanical property, the gap given
between the weld plates gives us good deposition rate and even penetration is more. When
voltage and current properties are changed there is a significant change in the deposition rate
(14).
Plasma is produced when gas is ionized it is also referred to as fourth state of matter.in this
method of welding the plasma arc malts and joins the metal by heat produced by plasma when in
contact with the tungsten electrode and metal. In this experimental setup argon is used as
shielding gas and tungsten as a non-consumable electrode. At the inner orifice of the tungsten
electrode a gap is present through which argon gas flows, as this all is done inside the nozzle
there is no much space and the plasma gas rushes out of the nozzle leading to high working
temperature range of 11000C. The modes of operation in PAW are classified into two modes i.e,
melt-in and key-hole. In melt-in mode the deposition rates is usually higher than the heat
conduction process, which in turn rises the temperature and melting takes place. In key-hole
mode the plasma penetrates across the weld pool and forms a through hole. Keyhole method is
advantageous as it penetrates through a larger extent (15).

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IV. CONCLUSION
A brief review on different welding processes is presented in this paper. In this we understand
about the sensing, modelling, monitoring and plasma that is introduced. There are two different
modes of operation involved i.e, melt-in and keyhole. In this we have emphasized mainly on
keyhole process. We understand the interaction of keyhole with the weld pool. Plasma arc
machining has a coupling character because in this process there are multiple inputs and the
single output is affected due to multiple inputs. This process requires multiple sensing units for
monitoring during the welding process and all these technology have to be integrated properly in
order to get required result.
ACKNOWLEDGEMENT

The manuscript is prepared by taking assistance from Accendere Knowledge Management

Services Pvt. Ltd. We are thankful to them. We also express our gratitude to our teachers and
mentor for guiding us throughout the work.
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