Production Processes

WELDING PROCESSES

Md. Gulam Kibria

Lecturer
Department of IPE, BUET
 Introduction to
Welding

Welding is a material joining process

in which two or more parts are
coalesced (joined together) at their
contacting surfaces by a suitable
application of heat and/or pressure.
In some welding process a filler
material is added to facilitate
coalescence.
Filter metal/rods is the material that
is added to the weld pool to assist in
filling the gap (or groove).
 Application of
Welding

Aircraft construction
Automobile construction
Ships
Building and bridge construction
Pressure vessels and tanks
Railroads
Repair of broken and damaged
components and machinery
 Welding in
Episode IV: A New Hope
The Jawas knock R2-D2 down and weld a
metal plate to his side.
Episode V: The Empire Strikes Back
Chewbacca is seen welding on a central lifter.
Episode III: Revenge of the Sith
R2-D2 came equipped with all sorts of welding
equipment and a number of other tools built
into his body.
 Types of
Welding
Some 50 different types of welding processes have been catalogued by the
American Welding Society (AWS)
Welding processes can be divided into two major categories:
1. Fusion welding:
Joining processes that melt the base metals
In many fusion welding operations, a filler metal is added to the
molten pool to facilitate the process

2. Solid state welding:

. Joining processes in which coalescence results from application
of pressure alone or a combination of heat and pressure
. If heat is used, temperature is below melting point of metals
being welded
. No filler metal is added in solid state welding
 Types of
Welding
Arc Welding Solid State Welding
. Shielded Metal Arc Welding . Cold Welding
. Carbon Arc Welding . Explosive Welding
. TIG (or GTAW) Welding . Friction Welding
. Plasma Arc Welding . Roll Welding
. Submerged Arc Welding . Diffusion Welding
. MIG (or GMAW) Welding . Forge Welding
. Electro slag Welding . Hot Pressure
. Stud Arc Welding Welding
. Ultrasonic Welding
Resistance Welding
. Spot Welding Gas Welding Thermo-Chemical Welding
. Seam Welding . Air-acetylene Welding . Thermit Welding
. Projection Welding . Oxy-hydrogen Welding . Atomic Hydrogen
. Resistance Butt Welding. Oxy-acetylene Welding Welding
. Flash Butt Welding . Pressure Gas Welding
Radiant Energy Welding
. Percussion Welding . Electron Beam
. High Frequency Resistance Welding
Welding . Laser Beam Welding
Commonly Welded
Base Metals

Metals can be classified as

1. Ferrous 2. Non- Ferrous

Wrought Iron
Aluminium and its alloys
Cast Iron
Copper and its alloys
Carbon Steel (Low,
Magnesium and its alloys
Medium and High
Nickel and its alloys
Carbon Steels)
Zinc and its alloys, etc
Cast Steels
Alloy Steels
Stainless Steels
ages and Disadvantages of Welding

A good weld is as strong as the base metal

General welding equipment is not very costly
Portable welding equipments are available
Welding permits considerable freedom in design
A large number of metals/alloys both similar and
Welding givesdissimilar can be joined by welding.
out harmful radiations (light),
fumes and spatter
Welding results in residual stresses and
distortion of the work pieces
Jigs and fixtures are generally required to hold and
position the parts to be welded
Edge preparation of the work pieces is generally
required before welding them
A skilled welder is a must to produce a good
welding job
Welding heat produces metallurgical changes. The
structure of the welded joint is not same as that of the
parent metal
Types of welds
Square groove weld

Single bevel groove weld

Outside single fillet

Inside single fillet
Single V-groove weld

single J-groove weld

Double fillet tee joint
Double fillet lap joint

Fig: Fillet welds

Single U-groove weld

Double V-groove weld for thicker sections

Fig: Groove welds

Plug weld Slot weld
 Types of
A weldweld
joint is joint
the junction of the
edges or surfaces of parts that
have been joined by welding.
Butt Joints
A butt joint is formed when the
pieces to be welded are laid side
by side and it is one of the most
widely used types of joint. The edges
of the butt joint may be prepared for
Lap Joints
welding as shown in figure. Fig: Butt joint-edge preparation & types of w
A Lap joint is formed when one
piece to be welded is laid down
and another piece is
overlapped to form an edge.

A plug weld is made by welding

holes evenly spaced across the
length of one or both sides of the
Fig: Lap joint-edge preparation & types of w
joint. A slot weld is similar except
slots are made instead of holes.
 Types of
weld joint
T Joints
A T joint is formed when one piece of
metal to be welded is placed vertically
on another piece lying horizontally.
The vertical member is usually placed at
90 deg to the horizontal member. One of
the most widely used types of weld
applied to a T joint is the fillet weld.
When a single pass or multiple passes
are made against the joint, the weld
resembles
The edges ofathe
Triangle when viewed from
butt joint
the
mayside.
be prepared for
welding as shown in
Fig: T joint-edge preparation & types of weld
figure.
 Types of
weld
Corner joint joint
A corner joint is formed by placing
one piece to be welded on the
other so that a corner is formed.
The corner may be Flush; Half
Open; or Fully Open.
An edge preparation may be
applied to one, or both of the
Fig: Corner joint-edge preparation & types o
pieces of the joint for penetration
and strength
Edge joint
An Edge joint is formed when the
two edges of the pieces to be
welded come together. This joint
may be formed as a result of
another structural shape and is
not as widely used as some of the
other joints. Fig: Edge joint-edge preparation & types of
 Welding Filler
Metal

Filter metal/rods is
the material that is
added to the weld pool
to assist in filling the
gap (or groove).

Filler metal forms an integral part of the weld.

Filler rods have the same or nearly the same chemical
composition as the base metal.
Filler rods are available in a variety of compositions.
Welding
Flux
During welding, if the metal is heated/melted in air,
oxygen from the air combines with the metal to form
oxides which result in poor quality, low strength welds
or, in some cases, may even make welding impossible.

A flux is a material used to prevent, dissolve or

facilitate removal of oxides and other undesirable
substances.

A flux prevents the oxidation of molten metal.

The flux (material) is fusible and non metallic.

During welding, flux chemically reacts with the oxides

and a slag is formed that floats to and covers the top of
the molten puddle of metal and thus helps keep out
atmospheric oxygen and other gases.