WELDING AND JOINING PROCESS

Welding is an alternative method for casting or forging and as a replacement for bolted and
riveted joints. It is also used as a repair medium, i.e., to reunite metal at a crack to build up a small
part that has broken off such as gear tooth or to repair a worm surfaces such as bearing surfaces.
The following are the main key features of welding:
1. The welding structures are normally lighter than riveted or bolted structures.
2. The welding joints provide maximum efficiency, which is not possible in other type of joints.
3. The addition and alterations can be easily made in the existing structure.
4. A welded joint has a great strength.
5. The welding provides very rigid joints.
6. The process of welding takes less time than other type of joints

BASIC CONCEPT OF WELDING

Welding is a process of joining two similar or dissimilar metals with the help of heat or
pressure or by some other means. The cost of welding is very less as compared to other processes and
formsa strong joint.
For this reason it is largely used in the following fields of engineering:
1. Manufacturing of machine tools, auto parts, cycle parts, etc.
2. Fabrication of farm machinery & equipment.
3. Fabrication of buildings, bridges & ships.
4. Construction of boilers, furnaces, railways, cars, aeroplanes, rockets and missiles.
5. Manufacturing of television sets, refrigerators, kitchen cabinets, etc.
A weld will inherit the common drawback of brittleness, which is a disadvantage. The
emphasis in welding technique should, therefore, be preventing this brittleness to the maximum
possible extent.

Flux-Cored Arc Welding

Flux-cored arc welding (FCAW) is an arc-welding process in which the electrode is
continuous consumable tubing that contains flux and other ingredients in its core. Other ingredients
may include deoxidizers and alloying elements. The tubular flux cored ‘‘wire’’ is flexible and can
therefore be supplied in the form of coils to be continuously fed through the arc-welding gun. There
are two versions of FCAW: (1) self-shielded and (2) gas shielded.
In the first version of FCAW to be developed, arc shielding was provided by a flux core, thus
leading to the name self-shielded flux-cored arc welding. The core in this form of FCAW includes not
only fluxes but also ingredients that generate shielding gases for protecting the arc. The second version
of FCAW, developed primarily for welding steels, obtains arc shielding from externally supplied
gases, similar to gas metal arc welding. This version is called gas-shielded flux-cored arc welding.
Because it utilizes an electrode containing its own flux together with separate shielding gases, it might
be considered a hybrid of SMAW and GMAW. Shielding gases typically employed are carbon dioxide
for mild steels or mixtures of argon and carbon dioxide for stainless steels. Figure illustrates the
FCAW process, with the gas (optional) distinguishing between the two types
Oxy-acetylene Welding
The process of oxy-acetylene welding can be used for almost all metals and alloys for
engineering purposes. A high temperature flame (3200°C) can be produced by this method. There are
two systems of oxygen-acetylene welding.
(a) High Pressure System: In this process the oxygen and acetylene are taken for use from
high pressure cylinders.
(b) Low Pressure System: In this system oxygen is taken from high pressure cylinder and the
acetylene is produced by the action of Calcium carbide and water.
CaC2 + 2H2O = Ca (OH)2 + C2H2
(a) Apparatus
Apparatus used for oxy-acetylene (high pressure) welding is shown in the fig. 7.2 and consists of
the following:
1. Oxygen cylinder
2. Acetylene cylinder
3. Pressure gauges
4. Valves
5. Hose pipes
6. Torch
7. Welding tip
8. Pressure regulators
9. Lighter
10. Goggles
(b) Principle of Oxy-acetylene Welding
A very hot flame is produced by burning of the gases coming through the torch tip. The edges
to be welded are heated up to melting. A filler metal is also added to complete the welding. This
molten metal mixture when solidifies on cooling forms a welded joint.
Oxygen cylinder and acetylene cylinder are filled with gases. Both the cylinders are attached
with pressure gauges, regulators and cylinder valves. The cylinder containing oxygen is painted black
whereas the acetylene cylinder is painted maroon. Hose pipes, are provided with each cylinder. These
pipes are connected to welding torch.

(c) Welding Process

To start welding, the acetylene control valve is turned first. When acetylene comes out of the nozzle, it
should be ignited with spark lighter. It will give a yellow-colored smoke flame. After it, oxygen
cylinder valve is opened and supply is increased until a most suitable flame is obtained. Then the
flame is focused on the edges to be welded. Flux and filler metal are also added with the heat of
flame. The edges and filler metal melt and a joint are formed after cooling of the molten metal.
The joint may be formed with or without using filler metal.

(d) Applications
Oxy-acetylene welding is particularly used for sheet metal work. All the metals can be welded
with proper filler metals. Same equipment may be used for cutting purposes.
(e) Advantages of Oxy-acetylene Welding
The main advantages of oxy-acetylene welding are given below:
1. Equipment is cheap as compared to other welding process.
2. It can be used for welding of all types of metals.
3. Maintenance of equipment is very less.
4. It is a portable process.
5. It can be used far cutting of metals of small thickness.
6. It is specially used for sheet metal work.
(f) Disadvantages
1. It takes long time for heating the job as compared to the arc welding.
2. The heat affected area is more.
3. This is prone to corrosion and brittleness.
4. Gases are expensive and difficult to store.
7.4.2 Types of Gas Flames
There are three types of gas flames:
1. Oxidizing Flame 2. Carburising Flame 3. Neutral Flame
1. Oxidizing Flame: When the volume of oxygen gas is more than the volume of acetylene mixed into
the torch. This flame is used for welding brass and is also used for cutting the metals.
2. Carburising Flame: When the volume of acetylene mixed is more than oxygen, carburising
flame is formed. This flame is used for welding nickel, monel etc.
3. Neutral Flame: It is known as balanced flame. Oxygen and acetylene gases are mixed in
equal volumes. Neutral flame is used for normal welding of steel, cast iron etc.
TYPES OF RESISTANCE WELDING
1. Spot welding 2. Butt welding
3. Flash welding 4. Seam welding
5. Projection welding 6. Percussion welding

1 Spot Welding
Spot welding is used to lap weld joints in thin metallic plates (up to 12.7 mm thick) for
mechanical strength and not for tightness.
The metallic plates are overlapped and held between two copper electrodes. A high current,
depending upon plate thickness, at a very low volt-age (4-12 volts), is passed between the electrodes.
The contact resistance of the plates causes to heat rapidly to a plastic state. Mechanical
pressure is applied. Supply is cut-off for the metal to regain strength. The pressure is released. The
process is repeated at another portion of the plates.
Thus, spot joints at regular interval depending upon the strength required are obtained. The
electrodes are water cooled to avoid overheating and softening of the tips.
Spot welding is mainly used in the manufacture of automobile parts refrigerators, metallic toys,
racks, frames, boxes, radio chassis, etc.

2.Seam Welding
The metallic plates are held by two copper roller electrodes with one roller driven by motor so
that the plates are moved between the rollers at a suitable speed. The high current is passed between
the electrodes holding metallic plates pressed together with suitable force and pushes together to travel
between the revolving electrodes as showing in Fig. 7.29. The plates between the electrodes get heated
to welding (fusion) heat and welded continuously under constant pressure of rotating electrodes. This
is a quicker operation than spot welding and gives a stronger joint.
The process is employed for pressure tight joints on oil drums, tanks and boiler water pipes,
refrigeration parts, motorcar body, utensils, stoves, etc
3.Projection Welding
There are raised projections in the work piece at all points where a weld is desired as shown in
Fig. As the current is switched on the projection are melted and the work pieces pressed together to complete
the weld. The melted projections form the welds. This method enables production of several spot welds
simultaneously

SOLDERING
Soldering is a process of joining two metals by using another low temperature metal alloy. The
metal used for the joining purpose is called solder. Solders are of two types:
1. Hard solder (alloy of copper and zinc)
2. Soft solder (alloy of tin and lead)
Process
The surfaces to be joined are cleaned and are placed on each other. A flux is employed to prevent
oxidation. Zinc chloride is commonly used for this purpose. The soldering iron is heated either
electrically or by some external heat. Then the hot end is dipped into the flux and solder is pressed
against the surfaces to be joined. A joint is formed by melting the solder.
Applications
Soldering is widely used for sheet metal work and in radio and television work for joining wires.
Advantages
1. Joining cost is low
2. Equipment is very simple and cheap
3. Good sealing in fabrication as compared to other processes like rivet, spot weld and bolts
4. It provides a positive electrical connection
5. Due to low operating temperature the properties of base metal are not affected
Disadvantage
1. Joints formed are weak

BRAZING
The process of joining two metal surfaces by heating and adding a non-ferrous alloy with
melting
point above 400°C is known as brazing process.
The surfaces to be joined are cleaned from all oil, dirt or oxides. Then both the surfaces are
placed in joining position. Flux is sprinkled or placed on it. The heat is given to the surface and the
filler metal. The molten filler metal flows to the surfaces to be joined. On cooling, brazing joint is
formed. The filler metals used are copper, copper alloy, silver alloy and aluminium alloys. In brazing,
the filler metal melts but the surfaces to be joined remain unmelted.
The various methods used to melt the filler metal and flux are:
(a) Gas Torch Brazing: It is a commonly used process in which oxy-acetylene torch is used.
(b) Furnace Brazing: The surfaces to be joined are placed in a furnace already hot.
(c) Dip Brazing: The surfaces to be joined are dipped in molten filler metal.
(d) Electrical Brazing: In electric brazing heat is produced by resistance or induction method.
Applications
Brazing is used for electrical items, radiators, heat exchangers, pipes & pipe fittings and tool tips.
Advantages
1. It is useful for joining dissimilar metals.
2. Thin sections can be easily joined.
3. Good finish is obtained on joint.
4. Less skill is required.
5. Cost of operation is less as compared to other welding processes.
Disadvantages
1. Low strength.
2. Not applicable for hardened steel and aluminium alloys.