Introduction To Welding Processes

Introduction to welding
Overview of joining methods
Mechanical methods
Adhesive bonding
Brazing and Soldering
Screwed fasteners, rivets,
Base metal does not fuse.

Molten filler drawn into close-fit joints by capillary
action (surface tension forces).
Brazing filler melts >450 C, solder <450 C
Welding
2
Weld
A joint produced by heat or pressure or both

So there is continuity of material.
Filler (if used) has a melting temperature

close to the base material
Welding processes
Fusion welding
Welding in the liquid state with no pressure

Union is by molten metal bridging
Solid phase welding
Carried out below the melting point without filler

additions
Pressure often used
Union is often by plastic flow
4
Basic Requirements of Welding Process
Source of Heat
Chemical Reaction
Electrical - Arc, Resistance, Induction
Mechanical
Protection from Atmosphere
Gas Shielding
Flux
Mechanical Expulsion
Vacuum
5
Fusion welding heat sources
Electric resistance
Chemical reaction
Electric arc
Power beams
Spot, seam and

projection welding
Oxyfuel gas
welding
Laser
Electron beam
Electroslag
Thermit welding
MMAW
GMAW
GTAW
FCAW
SAW
Solid phase welding
Hot processes
Forge welding
Friction welding
Diffusion bonding
Cold processes
Ultrasonic welding
Explosive welding
Some arc welding processes
MMAW - manual metal arc welding

SAW - submerged arc welding
GTAW - gas tungsten arc welding (TIG)
GMAW - gas-metal arc welding (MIG, MAG)
FCAW - flux cored arc welding
The electric arc
Peak
temperatures
18,000 K
Electric discharge between 2

electrodes through ionised gas
Cathode
drop zone
10 to 2000 amps at 10 to 500 V arc

voltage
Column of ionised gas at high

temperature
Forces stiffen the arc column
Anode
drop zone
Transfer of molten metal from

electrode to work piece
Can have a cleaning action,

breaking up oxides on work piece
Arc energy
Q=
ExI
V
Q = arc energy in kJ/mm

E = current in amps
I = arc voltage
V = travel speed in mm/min
Low arc energy
High arc energy
Incomplete fusion
High cooling rate
Unwanted phase transformations
Hydrogen cracking
Low cooling rate

Increased solidification cracking risk
Low ductility and strength
Precipitation of unwanted phases
(corrosion and ductility)
Small weld pool size
Large weld pool size
10
103 Watts/cm2 melts most metals

106 -107 Watts/cm2 vaporizes most metals
103 to 106 Watts/cm2 typical for fusion welding
11
Manual Metal Arc Welding

MMAW,
SMAW,
Stick electrode welding
Manual welding
12

Heat source - arc between metal and a flux coated
electrode (1.6- 8 mm diameter)
Current 30-400A (depends on electrode size)
AC or DC operation
Power 1 to 12 kW
13
14
Minimum equipment
Power source (ac or dc, engine driven or

mains transformer)
Electrode holder and leads
May carry up to 300 amps
Head shield with lens protects face & eyes

Chipping hammer to remove slag
Welding gloves protect hands from arc
radiation, hot material and electric shock
15
Process features
Simple portable equipment

Widely practiced skills
Applicable to wide range of materials, joints,
positions
About 1kg weld deposited per arc-hour
Portable and versatile
Properties can be excellent
Benchmark process
16
Covered electrodes
Core wire
Solid or tubular
2mm to 8mm diameter,
250 to 450mm long
Coating
Extruded as paste, dried

to strengthen
Dipped into slurry and
dried (rare)
Wound with paper or
chord (obsolete)
17
Functions of coating
Slag protects weld pool from oxidation

Gas shielding also protects weld pool
Surface tension (fluxing)
Arc stabilising (ionising)
Alloying and deoxidation
Some ingredients aid manufacture
(binder and extrusion aids)
18
AWS A5.1 classification
E XXXX - H
Tensile Strength
in KPSI
Useable positions
1=all positions
2=flat + horizontal
4=vertical down
Hydrogen level (HmR)
H = 5 ml / 100g of WM
R = low moisture pick-up
Flux type
20 = Acidic (iron oxide)

10, 11 = Cellulosic
12, 13 = Rutile
24 = Rutile + iron powder
27 = Acidic + iron powder
16 = basic
18, 28 = basic + iron powder
19
Applications
Wide range of welded products:
light structure & Heavy steel structures

Workshop and site
High integrity (nuclear reactors, pressure
equipment)
Ideal where access is difficult construction site, inside vessels,

underwater
Joins a wide range of materials
20
Limitations
Low productivity
Low power
Low duty cycle (frequent electrode
changes)
Hydrogen from flux coatings

Electrode live all the time
Arc strike, stray current and electric shock

risks
21
Submerged arc welding

SAW,
Sub-arc
22
23
24
Submerged arc welding - Features
High productivity
2 to 10 kg/hour
Up to 2m/min
Bulky, expensive and

heavy equipment
Flat and horizontal
positions only
Thicker sections (3mm
and above)
Mostly ferrous materials
(also Ni alloys)
25
Submerged arc welding - Equipment
Power source
Welding head and
control box
Welding head travel
Flux recovery system
(optional)
Positioners and
Fixtures
26
Submerged arc welding - Consumables
Solid or cored wires

Granular fluxes
Agglomerated, fused or sintered

Alloying activity
Contribution to weld metal chemistry from flux
Basicity
Acid fluxes made from manganese oxide, silica, rutile are
easy to use
Basic fluxes (MgO, CaO, CaF2, Al2O3) provide excellent
toughness welds
27
Submerged arc welding - Applications
Long straight welds in heavier material
Vessel longitudinal and circumferential

welds
Flange to web joints of I beams
Flat or horizontal position
Flux has to be supported
Access has to be good

28
Process variations
Surfacing and hardfacing
Wire and strip electrodes
Semi-automatic
Multiple electrodes
2 (and more) electrode wires

From one or more power sources
Iron powder additions to groove

29
Submerged arc welding Tandem arc
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Gas shielded arc process

Tungsten Inert Gas welding (TIG)
Gas tungsten arc welding (GTAW)
31
Gas Tungsten Arc Welding
Alternative names GTAW,TIG (Tungsten Inert
Gas), Argonarc
Heat source is an electric
arc between a nonconsumable electrode and
the workpiece
Filler metal is not added or
is added independently
32
Gas Tungsten arc welding
33
Gas Tungsten Arc Welding
Heat source - arc between a tungsten tip and the parent
metal
30-400A, AC or DC
10-20V
0.3-8kW
Inert gas shielding
Consumable filler rod can be used (1 to 4mm diameter)
34
Gas Tungsten Arc Welding - Process features
Excellent control
Stable arc at low power (80A at 11V)

Independently added filler
Ideal for intricate welds eg root runs in pipe or thin sheet
Low productivity 0.5kg/h manual
High quality
Clean process, no slag

Low oxygen and nitrogen weld metal
Defect free, excellent profile even for single sided welds
35
Gas Tungsten Arc Welding - Equipment
Welding power source with constant

current characteristic
DC for most metals, AC for Al

Arc starting by high frequency (5000V, 0.05A)
Sequence timers for arc starting, arc finishing &
gas control
Water- or gas-cooled torch with tungsten

electrode
Electrode may contain thoria or zirconia, etc

36
Gas Tungsten Arc Welding - Shielding gases
Torch is fed with an inert or reducing gas
Pure argon - widespread applications

Argon-helium - Higher arc voltage, inert
Argon-2% hydrogen - Cu alloys & austenitic steel
Torch gas must not contain oxygen or CO2
Backing (or purge) gas
Used for all single-sided welds except in carbon steel

Argon, nitrogen, formier gas (N2 + H2)
Supplementary shielding
Reactive metals: Ti, etc

Gas filled chambers or additional gas supply devices
37
Gas Tungsten Arc Welding - Filler metals
Autogenous welding (no filler)
Filler wire or rod of matching composition
C-Mn & low alloy steel

Stainless Steel
Al, Mg, Ti
Cu & Ni
Consumable inserts - filler preplaced in joint
38
Gas Tungsten Arc Welding - Automation
39
Gas Tungsten Arc Welding A TIG
40
GMAW and FCAW

Gas metal arc welding
(MIG, MAG, CO2 welding)
Flux cored arc welding
41
A continuous solid wire, small
diameter
GMAW uses solid wire, no flux

FCAW uses flux-filled wire
Fed through the gun to the arc by

wire feeder.
The weld pool may be protected
from oxidation by shielding gas.
High productivity 3 kg/h or more
Direct current (DCEP mostly)
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43
MIG Welding
Heat source - arc between parent metal
and consumable electrode wire (0.6 to
1.6mm diameter)
60-500A, DC only
16-40V
1 to 20kW
44
45
Gas metal arc welding - Equipment
Welding power source
Wire feeder mechanism
May be in power source cabinet
Gun with gas supply & trigger

switch
Manual (semi-automatic) guns

Automatic torches available
Can be fitted to robot etc.
46
Gas metal arc welding Metal transfer
Spray
Higher current & voltage, argon-rich gas
Short circuiting (dip)
Low current and voltage, CO2
Globular
Intermediate current
Pulsed current power sources
Adjustable frequency
One droplet per current pulse.
47
Gas metal arc welding Metal transfer
Burn-back
and unstable arc
Spray
Voltage
Globular
Short
circuiting
No arc (birds-nesting)
Current
48
Gas metal arc welding - Consumables
Solid Wires (GMAW)
A wide variety of alloys are available
Flux cored arc welding (FCAW)
Gas shielded flux cored wires

Self-shielded flux cored wires
Used outdoors
Metal cored wires

Light flux cover
49
Gas metal arc welding Wire size
50
Gas metal arc welding - Gas mixtures
Inert gases (MIG)
Argon or helium or mixtures of these

Active base metals, Al, Mg, Ti
Active gases (MAG and FCAW)
Carbon dioxide
Argon plus oxygen and/or carbon dioxide
Nitrogen, hydrogen
51
Gas metal arc welding - Developments
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54
55
Plasma Cutting, Welding & Surfacing
56
57
Oxy-Acetylene Welding
Oxidising Flame
Carburising Flame
Neutral Flame
58
Thermit welding
59
Laser Welding
Photons transmit energy and heat

Energy intensity up to 109 Watts/cm2
Depth to width of hole up to 50x
Automatic controllers needed
90% efficiency
Reflectors dont weld easily
60
Laser welding
61
Electron Beam Welding
Electrons strike surface and generate heat
Best performed in a vacuum
Workpiece must be a conductor
Magnetic fields affect beam
Current to 1/2 A
Power to 100 kW
X-rays produced
62
Electron Beam Welding
63
Size of weld beads in

(a) electron-beam or laser-beam welding
(b) conventional arc welding.
64
Solid-State Welding
Heat
Pressure
Time
NO Melting
NO Filler Material
Intimate Contact
Usually Requires Deformation
Works with Dissimilar Metals
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Resistance Welding
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Resistance spot welding Robots
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Flash Butt Welding
68
Friction Welding
69
Friction Stir Welding
70
Friction Stir Welding
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Explosive Welding
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ANY QUESTIONS
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Introduction To Welding Processes

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Introduction To Welding Processes

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Introduction to welding

Screwed fasteners, rivets,

Base metal does not fuse.

A joint produced by heat or pressure or both

Filler (if used) has a melting temperature

Welding in the liquid state with no pressure

Solid phase welding

Carried out below the melting point without filler

Spot, seam and

MMAW - manual metal arc welding

Electric discharge between 2

10 to 2000 amps at 10 to 500 V arc

Column of ionised gas at high

Transfer of molten metal from

Can have a cleaning action,

Q = arc energy in kJ/mm

Low arc energy

High arc energy

Low cooling rate

Small weld pool size

Large weld pool size

103 Watts/cm2 melts most metals

Manual Metal Arc Welding

Manual Metal Arc Welding

Power source (ac or dc, engine driven or

May carry up to 300 amps

Head shield with lens protects face & eyes

Simple portable equipment

Extruded as paste, dried

Slag protects weld pool from oxidation

Hydrogen level (HmR)

20 = Acidic (iron oxide)

Wide range of welded products:

light structure & Heavy steel structures

Ideal where access is difficult construction site, inside vessels,

Hydrogen from flux coatings

Arc strike, stray current and electric shock

Submerged arc welding

Bulky, expensive and

Solid or cored wires

Agglomerated, fused or sintered

Long straight welds in heavier material

Vessel longitudinal and circumferential

Flat or horizontal position

Flux has to be supported

Access has to be good

Surfacing and hardfacing

Wire and strip electrodes

2 (and more) electrode wires

Iron powder additions to groove

Gas shielded arc process

Stable arc at low power (80A at 11V)

Clean process, no slag

Welding power source with constant

DC for most metals, AC for Al

Water- or gas-cooled torch with tungsten

Electrode may contain thoria or zirconia, etc

Pure argon - widespread applications

Backing (or purge) gas

Used for all single-sided welds except in carbon steel

Reactive metals: Ti, etc

C-Mn & low alloy steel

Consumable inserts - filler preplaced in joint