WELDING

WELDING IS AN ART OF JOINING METALS.

THE FACES TO BE JOINED ARE BROUGHT

TO PLASTIC OR LIQUID STATE AND WITH
OR WITHOUT THE APPLICATION OF
PRESSURE THE JOINT TAKES PLACE.
SOMETIMES, ADDITIONAL FILLER ROD IS
USED TO COMPLETE THE JOINT
 WELDING
FUSION NON-FUSION
ARC FORGE WELDING

GAS RESISTANCE WELDING

TIG THERMAL SPRAYING

MIG/MAG BRAZING

SAW SOLDERING
BRAZING TERMS &
DEFINITION
OXYGEN CYLINDER
D.A. CYLINDER
REGULATOR
RUBBER HOSE
BLOW PIPE
 Brazing
Definition:
A process which a filler metal is placed at or
between the faying surfaces, the temperature is
raised high enough to melt the filler metal but
not the base metal.

The molten metal fills the spaces by capillary
attraction.
Torch Brazing
Oxy-fuel torch with a carburizing flame
First heat the joint then add the filler metal
Oxy-Acetylene
cylinder
ACCESSORIES
SPARK LIGHTER
CYLINDER KEY
WIRE BRUSH
TONGS
PROTECTION GUARD
WELDING GOGGLES
ASBESTOS APRON
ASBESTOS GLOVES
LEG GUARD
Fork Type torch for Condenser
Joints
SAFETY PRECAUTIONS
IMPORTANCE
PREVENT ACCIDENT
INCREASE PLANT LIFE
AVOIDS BREAK DOWN
INCREASE PRODUCTIVITY
KINDS OF SAFETY
PERSONAL SAFETY

PLANT SAFETY

GENERAL SAFETY
 BACKFIRE / FLASH BACK
RETURN OF FIRE BACK TO THE SYSTEM

CAUSES:
INSUFFICIENT GAS PRESSURE

OVER HEATING OF NOZZLE

DEFECTIVE NOZZLE

LOOSE FITTING

LACK OF TRAINING
GASES
COMBUSTABLE GAS

SUPPORT OF COMBUSTABLE GAS

INERT GAS
 FUEL GAS TEMPERATURE
FUEL AIR C OXYGEN C
*
ACETYLENE 2650 3485
HYDROGEN 2205 2985
PROPANE 2095 2925
BUTANE 2150 2985
NATURAL 2095 2775
GAS
* OXIDISING FLAME TEMPERATURE
OXY-ACETYLENE FLAMES
NEUTRAL FLAME

CARBURIZING FLAME

OXIDISING FLAME
Oxy-Acetylene Flames
Oxy-Acetylene Flames
Oxy-Acetylene Flames
 Cutting Nozzle Nozzle mixing
Type

Heating O2 Cutting
O2
Heating
Acetylene Cutting O2
Jet
Heating Fuel
Mixture
Heating
Flame
Steel Being cut ..
 Cutting
Definition:
A stream of oxygen is directed against a piece of heated
metal, causing the metal to oxidize or burn away.
Making a Cut
Mark a line as a guide.
Turn on acetylene as for welding and light.
Turn on oxygen adjusting flame to neutral.
Make sure the oxygen lever flame remains neutral.
Place metal on the cutting table so metal will fall clear.
Flame Types:
CHEMISTRY OF OXY-ACETYLENE
FLAME

C2H2 + 02 2 CO + H2

2 CO + 02 CO2

H2 + O2 2H2O2
FLAME SETTING
OPEN ACETYLENE GAS AND IGNITE
FLAME WITH SPARK LIGHTER

ENSURE NO CARBON SOOT IN THE

FLAME

OPEN OXYGEN GAS UNTILL THE

DESIRED FLAME IS SET
BRAZING

PROCESS OF JOINING METALS.

FACES TO BE JOINED ARE
BROUGHT TO PLASTIC STATE WITH
THE APPLICATION OF HEAT AND
WITH ADDITIONAL FILLER ALLOY
THE JOINT IS COMPLETED
PRINCIPLE

WHEN THE METAL IS IN PLASTIC

STATE (SOLID PHASE DIFFUSION),
FILER ALLOY PENETRATES ALONG
THE GRAIN BOUNDARIES BY
CAPILLARY ATTRACTION
Brazing a micro view
BRAZING

SOFT BRAZING

HARD BRAZING
 SOFT BRAZING
TEMPERATURE <750 C

BRAZING ALLOY SILVER BRONZE

APPLICATIONS THINSECTION,
WIREMESH, TOOLS, ALLOY
STEELS, NICKEL, STAINLESS
STEEL ETC
 SOFT BRAZING
ADVANTAGES
LOW HEAT INPUT
NO DISTORTION
HIGH DEGREE OF WETTABILITY
HIGH FLUDITY
DISSIMILAR METAL JOINING
FAST
EXCELLENT PENETRATION
METHODS OF SOFT
BRAZING
FLAME BRAZING
ARC BRAZING
FURNACE BRAZING
INDUCTION BRAZING
RESISTANCE BRAZING
HARD BRAZING
TEMPERATURE >800C

BRAZING ALLOY SILICON BRONZE

APPLICATIONS THICK SECTIONS,CAST IRON, STEEL,

COPPER ALLOYS ETC

ADVANTAGES ECONOMY
JOINING OF THICK SECTIONS, GALVANISED
COMPONENTS,
BEAD FORMING
LIMITATIONS
HIGH HEAT INPUT
FEAR OF OXIDE FORMATION
THIN SECTION
LOW FLUIDITY
HIGH SKILL
DISTORTION
LOSS OF ELEMENT
BRAZING ALLOY
BONDING TEMPERATURE
WELDABILITY
BONDING & CAPILLARY ATTRACTION
SLAGS ILL EFFECT
FUMES/SMOKES
IRRITATION TO THE SKIN
THIN FLOWING
DISSIMILAR COMBINATIONS
VISIBILITY OF MOLTEN POOL
 FLUX
FORM OF POWDER, PASTE, LIQUID
AND GAS

:
 FUNCTION OF FLUX
DEGREASING
WETTING
FLUIDITY
BONDING TEMPERATURE
CAPILLARY ATTRACTION
OXIDATION
ALLOY EVAPORATION
ADD ELEMENT
TENSILE STRENGTH
FASTER
BRAZING PROCEDURE
CLEANING
ALIGN THE COMPONENT
APPLY FLUX
HEAT UNTILL FLUX LIQUIFIES
APPLY FILLER ALLOY
AIR COOL
REMOVE FLUX RESIDUES
Thin flowing
alloys
Six Basic Steps in Brazing

Good Fit and Proper Clearances

Cleaning the Metals
Fluxing the Parts
Assembly for Brazing
Brazing the Assembly
Cleaning the Brazed Joints
Good Fit and Proper Clearances
Laboratory Experiment
Joining SS to SS by Ag Alloy
 Cleaning the Metals

Sequence
1. Oil and Grease
2. Acid Pickle for Oxide Layer
3. Cleaning in Hot water
4. Dry and cover the part
 Fluxing the Parts

Heating accelerates formation of Oxides

Flux acts as Shield between metal and Air
Brushing / Dipping / Spraying
When to Flux
Which Flux
How Much
 Assembly for Brazing
Gravity
Clamping
Brazing Support Fixture
Use Poor Conductor of Heat like
SS/Inconel / Refractory
Sharp corners minimised
 Brazing the Assembly
Apply heat to Base Metal
Let Flux Change State Uniformly
Uniform Heating
Filler Alloy Flows Towards High Heat
Filler Alloy Forms Surface Alloy
Brazing - Slow Cooling
Eutectic Composition
 Cleaning the Brazed Joints

Removing of Flux Residues

Flux Residues are Corrosive
Hot Water / Mechanical
Oxides Scales by Pickling
ADVANTAGES
LOW HEAT INPUT
HIGH TENSILE STRENGTH
THIN FLOWING
HIGH WELDABILITY
DISSIMILAR METAL COMBINATIONS
FERROUS AND NON-FERROUS METALS
GALVANISED SHEETS
ADVANTAGES
EXCELLENT PENETRATION
JOINT CAN BE SEPERATED
HIGH PRODUCTIVITY
JOINING OF THIN SECTION
IDEAL FOR ALLOY STEELS, BLADES AND
TOOLS JOINING
CAN BE DONE BY OXY-ACETYLENE
FLAME, CARBON ARC, INDUCTION, TIG
FURNACE ETC.
LIMITATIONS
THICK SECTIONS
LONG SEAM
THERMAL EXPANSION
THOROUGH CLEANING
DUCTILE
DEFECTS
LACK OF BONDING
OVER LAP
WARPAGE
CRATER
SLAG INCLUSION
LACK OF PENETRATION
INSPECTION AND TESTING

JOINT FAILURE CONTRIBUTE LOSS

OF MATERIAL, MONEY, LABOUR,
ACCIDENT AND TIME
TYPES OF TEST

DESTRUCTIVE TEST

SEMI-DESTRUCTIVE TEST

NON-DESTRUCTIVE TEST