LECTURE-10 and 11

WELDING PROCESS, CLASSIFICATION,

ADVANTAGES, APPLICATION
ARC WELDING, PRINCIPLES, EQUIPMENT,
WELDING JOINTS, WELD POSITIONS,
POLARITY, ELECTRODES, TYPES.

Welding processes
Welding is a process of joining two similar or dissimilar
metals by application of heat with or without application of
pressure and addition of filler material.
The heat may be obtained from the blacksmiths fire,
electric arc, electric resistance or chemical reaction.
Modern methods of welding may be classified into two major types.

(i) Fusion process

(ii) Non fusion process

Advantages of welding:
1. Welding structures are normally lighter than riveted or
bolted structure.
2. Welded joints are strong, rigid and tight.
3. Alteration and additions can be easily made in the
existing structure.
4. Welding structure is smooth in appearance.
5. Welded joint has a great strength.
6. Cost effectiveness.
7. Simplicity of welded structures design.
8. Possiblity of welding at any part of a structure.
9. Consumes less time when compared to other type of
joints.

Disadvantages of welding:
Internal stresses, distortions and change of
micro-structure in the weld region;
Harmful effects: light, ultra violate radiation,
fumes, high temperature.
Requires highly skilled labour
Edge preparation is required before welding

Applications of welding

Buildings and bridges structures

Automotive, ship and aircraft

constructions

Pipe lines

Tanks and vessels

Rail roads

Machinery elements

Classification of welding processes

Fusion welding or non-pressure welding
The material at the joint is heated to a molten
state and allowed to solidify. This includes gas
welding, arc welding and thermit welding etc.
Non-fusion or pressure welding
The pieces of metal to be joined are heated to a
plastic state and then forced together by
external pressure. This procedure is used in
forge welding, resistance welding, Thermit
welding and gas welding in which pressure is
required.

Classification of welding processes

I.Arc welding
1. Carbon Arc Welding (CAW)
2. Shielded Metal Arc Welding (SMAW)
3. Submerged Arc Welding (SAW)
4. Metal Inert Gas Welding (MIG, GMAW)
5. Tungsten Inert Gas Arc Welding (TIG, GTAW)
6. Electroslag Welding (ESW)
7. Plasma Arc Welding (PAW)

II.Resistance Welding (RW)

1. Spot Welding (RSW)
2. Flash Welding (FW)
3. Resistance Butt Welding (UW)
4. Seam Welding (RSEW)

Gas Welding (GW)

1. Oxyacetylene Welding (OAW)
2. Oxyhydrogen Welding (OHW)
3. Pressure Gas Welding (PGW)
Solid State Welding (SSW)
1. Forge Welding (FOW)
2. Cold Welding (CW)
3. Friction Welding (FRW)
4. Explosive Welding (EXW)
5. Diffusion Welding (DFW)
6. Ultrasonic Welding (USW)
Thermit Welding (TW)
Electron Beam Welding (EBW)
Laser Welding (LW)

Weldability
The property of a metal, which indicates the ease with
which two similar or dissimilar metals are joined by
fusion with or without the application of pressure.
Factors affecting the weldability of a metal:
1.
2.
3.
4.
5.
6.

Composition of the metal

Melting point
Thermal conductivity
Thermal expansion
Surface condition
Change in micro structure

Arc welding
The discharge of electric
Current across a gap of two
Electrodes.

Arc welding is the welding process, in which heat is

generated by an electric arc struck between an electrode
and the work piece. Electric arc is luminous electrical
discharge between two electrodes through ionized gas.

Basic arc-welding circuit

Electric arc between the electrode and work piece

closes the electric circuit.
The arc temperature may reach 10000F (5500C),
which is sufficient for fusion of work piece edges
and joining them.
This heat melts both the base metal and the
electrode, producing a pool of molten metal
sometimes called a "crater."
The crater solidifies behind the electrode as it is
moved along the joint. The result is a fusion bond.

Arc welding equipment

Arc welding equipment

i. AC or DC machine

ii.

Electrode

iii. Electrode holder

iv.

Cables, cable connections

v. Cable lug

vi.

Chipping hammer

viii. Earthing clamps

ix.

Wire brush

x. Helmet

xi.

Safety goggles

xii. Hand gloves

xiii.

Apron, sleeves etc.

AC or DC Machine

Generators driven by electric motors or IC

engines obtain DC welding supply.

For AC welding supply, transformers are mostly

used to step down the voltage (200-400 volts) to
welding voltage of 50-90 volts.

100A - 200A - Light manual welding

300 - 400A - Average manual welding

800 - 3000A - Automatic welding

A.C. arc welding

D.C.Welding

The A.C. Welding transformer The D.C welding generator has

has no moving parts and is rotating parts and is more
simpler.
complicated.
The transformer costs less and The generator costs more and its
maintenance cost is high.
its maintenance cost is low.
Since the distribution of heat is
equal, therefore there is no need
for changing the polarity. Hence
only ferrous metals are usually
welded by A.C.

Heat distribution is different in

two poles, i.e., 2/3 in positive and
1/3 in negative. By changing the
polarity, all types of metals can be
welded by D.C.

All types of electrodes can not

be used in A.C. arc welding
because the current constantly
reverses with every cycle.

All types of electrodes, bare or

coated can be used in D.C. arc
welding because the polarity can
be changed to suit the electrode.

The problem of 'arc blow' In D.C. the 'arc blow' is

does not arise, as it is very serve and cannot be
easy to control.
controlled easily.
The arc is never stable.

The arc is more stable.

In can be used only when In the absence of A.C.

A.C. supply from the main supply, an engine
mains is available.
driven D.C. generator set
can be used.
A.C. is more dangerous

D.C. is comparatively less

dangerous

AC or DC machine
The transformer consists of a rectangular steel tank.
An oil cooled double wound step down transformer
reduces the supply main voltage to a welding voltage
of 80. All windings are totally enclosed in the steel
tank.
Rotating the hand wheel can vary the output of the
transformers and the weld current can be directly
read at the window on the tank cover. The set is
connected 400-440 volts 3 phase, 50 cycles ac supply.

Electrode
It is filler metal in the form of a wire or rod used
as a terminal in an electric current for the
purpose of producing an electric arc.
The electrodes are classified as consumable
electrode and non-consumable electrode.
A consumable electrode is similar in composition
to the metal being welded and it melts to become
a part of weld.
A non-consumable electrode may be made of
carbon, graphite or tungsten, which do not
consume during the welding operation.

Specific electrodes are available for welding:

1.Mild steel
2.Cast iron
3.Stainless steel
4.Copper, bronze, brass, etc
5.High tensile steels

Specification of electrode
The coding consists of a prefix letter, a code number of
digits in numerals and in some cases one or more suffix
letters, each indicating a specific property or
characteristic or both of electrode.
e-g. E 616 515
E - The prefix letter indicate the method of manufacturing
6 -The first digit indicate the type of covering
1 -The second digit indicates the welding position
6 -The third digit indicates the welding current
5 & 1-The fourth and fifth digit indicates the tensile
strength of the weld metal
5- The sixth digit indicates the percentage elongation of
deposited metal.

Angularity of electrode
The quality of weld is determined to a

marked degree by the angular deposition of

the electrode to the work. In flat welding,
electrode should not be held at not more
than 20 from the vertical and 3 mm away
from the work.

Polarity
In DC welding machine, the heat generated by the
flow of current is split into two parts, in the ratio of
66% at the positive pole and 33 percent at the
negative pole.
In straight polarity the electrode is negative and the
work is positive.
In the reverse polarity the electrode is positive and
the work is negative.

Wire Brush
Wire brush is a cleaning tool.
It is used for removing loose
slag, spatter and oxides.

Chipping Hammer

A chipping hammer is used for removing slag and spatter.

It is advisable to wear chipping goggles while using
chipping hammer so that particles of slag may not strike
the eyes.

Helmet
A helmet is used by the welder for
protection of his eyes, face and the
throat from harmful rays of electric arc
and from the hot flying particles or
spatter.

Hand Gloves
For protection of wrist and hands,
gloves and worn by the welders.
They are made of leather or asbestos.
They should be as flexible as possible.

Welding joints
i.

Lap joint

ii.

Butt joint

iii.

Corner joint

iv.

Edge joint

v.

T-joint

Lap joint
This used to joint two overlapping
plates so that the edge of each plate
is welded in the other.
These joints are employed on plates
having thickness less than 3 mm.
The lap joints may be single
transverse, double transverse and
parallel lap joints.

Butt joint
It is used to joints two ends or two edges or surfaces located
in the same plane with each other.
In butt welds, the plate edges do not require beveling if the
thickness of plate is less than 5 mm.

On the other hand, if the plate thickness is 5 mm to 12.5

mm, the edges should be beveled to V or U-groove and
plates having thickness above 12.5 mm should have a V
or U-groove on both sides.

Types of butt joints

1. Square butt joint

2. Single V-butt joint
3. Double V-butt joint
4. Single U-butt joint
5. Double U-butt joint

Corner joint

It is used to joint two edges of two plates whose

surfaces are at right angles to each other.
It is used for both light and heavy gauge sheet metal.
In some cases corner joint can be welded, without any
filler metal, by melting off the edges of the parent metal.

Edge joint

It consists of joining the edge of parallel plate by means of

weld.
The edge joint is obtained by joining two parallel plates.
It is economical for plates having thickness less than 6 mm.
This joint is unsuitable for members subjected to direct
tension or bending.

T-joint

It is used to weld two plates or sections, which

are right angles to each other.
It is widely used to weld stiffeners in aircraft and
other thin walled structures.
These joints are suitable upto 3 mm thickness.

Welding Positions
1. Flat position
2. Horizontal position
3. Vertical position
4. Overhead position

Flat position

In this position, the filler metal is deposited

from the upper side of the joint with the face of
the weld horizontal.

Horizontal position

In this position, the weld is deposited upon the

side of a horizontal and against a vertical
surface.

Vertical position

In this position, the line of welding is in a

vertical plane and the weld is deposited
upon a vertical surface.

Overhead position

In this position, the weld is deposited from the

under side of the joint and the face of the weld
is horizontal.
It is the reverse of flat welding.

Welding Terminologies
Bead - It describes the neatness of
ripples formed by the metal while it
was in semi liquid state. It denotes the
appearance of the finished weld.
Face of the weld - The exposed surface
of the weld
Flux - A fusible material used to
prevent formation of oxides, nitrites
and promote fusion of metal.

Base metal - The metal to be welded. It is

also known as parent metal.
Fillet - Weld metal in the internal corner
point formed by two pieces of metal,
giving the joint additional strength to with
stand unusual stresses.

Tack - A relatively small weld to hold parts

together to assist assembly or maintain
alignment of exist during welding.

 Spatter - Globules of weld metal or

filler expelled during welding and
adhering to the surface of the
parent metal or solidified weld
metal. Use of shorter arc, reduced
current, and correct electrode
minimize the spatter.

Slag - Molten flux absorbs oxide

from the surface of the parent metal
and floats on the molten metal.

Arc Crater
The blast of the arc forces the molten metal out of the
pool, thus forming a small depression in the parent metal
around which molten metal is piled up. This is known as
arc crater
Arc Length
The distance through the centre of the arc from the tip of
the electrode to the bottom of the arc crater is the arc
length. Arc length is vital variable and should be 3 to 4 mm
Arc Blow
A large current produces arc blow. The space around the
arc and on the adjacent metal is always influenced by
magnetic field, which tends to deflect the arc. This is
known as arc blow. It can be minimized by changing the
angle of electrode and direction of welding.