Welding Shop

WELDING SHOP
Definition:
Welding is the process of joining together two pieces of metal so that bonding takes
place at their original boundary surfaces”. When two parts to be joined are melted
together, heat or pressure or both is applied and with or without added metal for
formation of metallic bond.
Types of welding:
Electric arc welding:
Arc welding is one of the most common kinds of welding. The concentrated heat of an
electric arc joins metal by fusing the parent metal to a joint using a consumable
electrode. Direct or alternating current could be used, and which one depends on the
welding material and the electrode. There are different forms of arc welding, such as
MIG or stick welding.
 Gas metal arc welding:
Gas metal arc welding, also known as MIG welding, shields the welding arc with a gas
such as argon or helium or even a mixture. Deoxidizers in the electrodes can prevent
oxidation which makes it possible to weld multiple layers. It’s a simple, versatile, and
economical welding process. The temperatures are also relatively low and it is used for
thin sheet and sections. It can easily be automated.
 Gas tungsten arc welding:

Gas tungsten arc welding is also known as TIG welding. It uses tungsten electrodes as
one pole of the arc in order to create the required heat. The gas is argon, helium, or a
mixture of those two. Filler wires provide the molten material if it is necessary. This
process is good for thin materials and the filler wires are similar in composition to
whatever is being welded.
Resistance welding:
Resistance welding is a welding technology widely used in manufacturing industry for
joining metal sheets and components. The weld is made by conducting a strong current
through the metal combination to heat up and finally melt the metals at localized point(s)
predetermined by the design of the electrodes and or the workpieces to be welded. A
force is always applied before, during and after the application of current to confine the
contact area at the weld interfaces and, in some applications, to forge the workpieces.
 Resistance spot welding:

Spot welding is a resistance welding process for joining metal sheets by directly
applying opposing forces with electrodes with pointed tips. The current and the heat
generation are localized by the form of the electrodes. The weld nugget size is usually
defined by the electrode tip contact area.
 Resistance seam welding:
Seam welding is a resistance welding process for joining metal sheets in continuous,
often leak tight, and seam joints by directly applying opposing forces with electrodes
consisting of rotary wheels. The current and the heat generation are localized by the
peripheral shapes of the electrode wheels.
Oxy-Fuel welding:
Gas welding involves the use of a gas-fed flame torch to heat the metal work piece and
the filler material to create a weld. The gas is generally a mixture of a fuel gas and
oxygen to create a clean, hot flame. Many different gases can be used as fuel for gas
welding, and electricity is not needed to power the welding system, resulting in a flexible
and portable fabrication method.
 Oxy-Acetylene welding:
Oxy-acetylene welding uses a mixture of acetylene gas and oxygen gas to feed the
welding torch. Oxy-acetylene welding is the most commonly used gas welding
technique. This gas mixture also provides the highest flame temperature of available
fuel gases, however acetylene is generally the most expensive of all fuel gases.
Acetylene is an unstable gas and requires specific handling and storage procedures.
Welding joints:
A welding joint is a point or edge where two or more pieces of metal or plastic are joined
together. They are formed by welding two or more workpieces (metal or plastic)
according to a particular geometry.
Types of welding joints:

 Butt joint:
The joint which is formed by placing the ends of two parts together is called butt joint. In
butt joint the two parts are lie on the same plane or side by side. It is the most simplest
type of joint used to join metal or plastic parts together.
 Corner joint:
The joint formed by placing the corner of two parts at right angle is called corner joint (
see fig above). Two parts which is going to be weld with corner joint forms the shape of
L.
 T-joint:
The joint which is made by intersecting two parts at right angle (i.e at 90 degree) and
one part lies at the centre of the other. It is called as T joint as the two part welded look
like english letter ‘T’.
 Lap joint:
The lap joint is formed when the two parts are placed one over another and than welded
( see fig above). It may one sided or double sided. This types of welding joints are
mostly used to join two pieces with different thickness.
 Edge joint:
The joint formed by welding the edges of two parts together are called edge joint. This
joint is used where the edges of two sheets are adjacent and are approximately parallel
planes at the point of welding.
Welding Defects:
Welding Defects can be defined as the irregularities formed in the given weld metal due
to wrong welding process or incorrect welding patterns, etc. The defect may differ from
the desired weld bead shape, size, and intended quality. Welding defects may occur
either outside or inside the weld metal.
Types of welding defect:

 Weld Crack:
This is the most unwanted defect of all the other welding defects. Welding cracks can
be present at the surface, inside of the weld material or at the heat affected zones.
Causes of Weld Crack:

1. Poor ductility of the given base metal.
2. The presence of residual stress can cause a crack on the weld metal.
3. The rigidity of the joint which makes it difficult to expand or contract the metals.
 Undercut:
When the base of metal melts away from the weld zone, then a groove is formed in the shape of
a notch, then this type of defect is known as Undercut. It reduces the fatigue strength of the
joint.
Causes of Undercut:
1. If the arc voltage is very high then this defect may occur.
2. If we use the wrong electrode or if the angle of the electrode is wrong, then also the
defect may form.
3. Using a large electrode is also not advisable.
 Spatter:
When some metal drops are expelled from the weld and remain stuck to the surface,
then this defect is known as Spatter.
Causes of Spatter:
1. High Welding current can cause this defect.
2. The longer the arc the more chances of getting this defect.
3. Incorrect polarity.
 Porosity:
Porosity in the condition in which the gas or small bubbles gets trapped in the welded
zone.
Causes of Porosity:
1. It occurs when the electrode is not coated properly.
2. Using a longer arc may also increase its chances.
3. Increased welding currents.
 Overlap:
When the weld face extends beyond the weld toe, then this defect occurs. In this condition the
weld metal rolls and forms an angle less than 90 degrees.
Causes of Overlap:
1. Improper welding technique.
2. By using large electrodes this defect may occur.
3. High welding current
 Incomplete Fusion:
Incomplete fusion occurs when the welder does not accurately weld the material and
the metal pre solidifies which leads to a gap which is not filled with the molten metal.
Causes of Incomplete fusion:

1. It occurs because of the low heat input.
2. When the weld pool is very large and runs ahead of the arc.
3. When the angle of the joint is too low.
Types of flame:
As we know there are three basic welding flames. These are as follow.
 Natural Flame:
As the name implies, this flame has equal amount of oxygen and gases fuel by the
volume. This flame burns fuel completely and does not produce any chemical effect on
metal to be welded. It is mostly used for welding mild steal, stainless steel, cast iron etc.
It produces little smoke. This flame has two zones. The inner zone has white in color
and has temperature about 3100 degree centigrade and outer zone has blue color and
have temperature about 1275 degree centigrade.
 Carburizing Flame:
This flame has excess of fuel gas. This flame chemically reacts with metal and form
metal carbide. Due to this reason, this flame does not used with metal which absorb
carbon. It is smoky and quiet flame. This flame has three regions. The inner zone has
white color, the intermediate zone which is red in color and outer cone has blue color.
The inner cone temperature is about 2900 degree centigrade. This flame is used to
weld medium carbon steel, nickel etc.
 Oxidizing Flame:
When the amount of acetylene reduces from natural flame or amount of oxygen
increases, the inner cone tend to disappear and the flame obtain is known as oxidizing
flame. It is hotter than natural flame and has clearly defined two zones. The inner zone
has very bright white color and has temperature of about 3300 degree centigrade. The
outer flame has blue in color. This flame is used to weld oxygen free copper alloy like
brass, bronze etc.

Welding Shop

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WELDING SHOP

 Gas tungsten arc welding:

 Resistance spot welding:

Types of welding joints:

Types of welding defect:

Causes of Weld Crack:

Causes of Incomplete fusion:

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