Krishna Engineering College Department of Mechanical Engineering

KRISHNA ENGINEERING COLLEGE
DEPARTMENT OF MECHANICAL ENGINEERING

COMPENDIUM OF MST-II (RME-503)
UNIT-IV METAL JOINING
function of the coating on an arc welding electrode

The electrode is coated in a metal mixture called flux, which gives off gases as it decomposes to
prevent weld contamination, introduces deoxidizers to purify the weld, causes weld-protecting
slag to form, improves the arc stability, and provides alloying elements to improve the weld
quality.
Shielding gases are used
Carbon dioxide in concentration of 1-2% is commonly used in the mix with argon to reduce the
surface tension of the molten metal. Another common blend is 25% carbon dioxide and 75%
argon for GMAW. Helium is lighter than air; larger flow rates are required. It is an inert gas, not
reacting with the molten metals.
"inert gas" as used in Metal Inert Gas (MIG) Welding
Shielding gases are inert or semi-inert gases that are commonly used in several welding
processes, most notably gas metal arc welding and gas tungsten arc welding (GMAW and
GTAW, more popularly known as MIG (Metal Inert Gas) and TIG (Tungsten Inert Gas),
respectively).
Best shielding gas for MIG welding
Carbon Dioxide (CO2) is the most common of the reactive gases used in MIG welding and the
only one that can be used in its pure form without the addition of an inert gas. CO2 is also the
least expensive of the common shielding gases, making an attractive choice when material costs
are the main priority.
MIG welders applications
MIG welding is useful because you can use it to weld many different types of metals: carbon
steel, stainless steel, aluminum, magnesium, copper, nickel, silicon bronze and other alloys. Here
are some advantages to MIG welding: The ability to join a wide range of metals and thicknesses.
Resistance welding
Principle of Resistance Welder. Resistance welding is used for joining two metals. It consists of
a welding head, which holds the metal between its electrodes and applies pressure, and
a welding power supply, which applies electric current to the metal to be welded.
Squeeze time in spot welding

Squeeze time. Squeeze Time is the time interval between the initial application of the electrode
force on the work and the first application of current. Squeeze time is necessary to delay
the weld current until the electrode force has attained the desired level.
Nugget in spot welding
Weld Nugget. In resistance spot welding, "the welding of overlapping pieces of metal at small
points by application of pressure and electric current" creates a pool of molten metal that quickly
cools and solidifies into a round joint known as a "nugget." Also see resistance spot welding.
Seam welding
Seam welding is a variation of resistance spot welding. In resistance seam welding, however,
the welding electrodes are motor driven wheels as opposed to stationary rods. The result is a
'rolling' resistance weld or non-hermetic seam weld.
flash welding
Flash welding is a type of resistance welding that does not use any filler metals. ... Once the
pieces of metal reach the proper temperature, they are pressed together, effectively
forge welding them together.
Thermite weld
Exothermic welding, also known as exothermic bonding, thermite welding (TW), and thermite
welding, is a welding process that employs molten metal to permanently join the conductors. The
chemical reaction that produces the heat is an aluminothermy reaction between aluminum
powder and a metal oxide.
four basic welding positions
Four basic welding positions defined by the American Welding Society
 1 refers to a flat position, either 1F or 1G.
 2 refers to a horizontal position, either 2F or 2G.
 3 is a vertical position, either 3F or 3G.
 4 is an overhead position, either 4F or 4G.
Difference between seam and seamless pipe
The difference between seam and seamless pipe is in manufacturing process. Seam pipes are
made by seam or electric resistant welding process i.e. sheet of steel is rolled in a shape
of pipe and its sides are welded through electric resistance welding.
Hydrogen is used in welding
The hydrogen that is used in the welding process acts as a gas shield and protects the metal
being welded from contaminants such as carbon, oxygen and nitrogen, which can cause
defects in many metals.
GMAW welding procedure?
Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert gas
(MIG) welding or metal active gas (MAG) welding, is a welding process in which an electric
arc forms between a consumable wire electrode and the work piece metal(s), which heats the
work piece metal(s), causing them to melt and join
oxy acetylene welding
Oxy-fuel welding (commonly called oxyacetylene welding, oxy welding, or gas welding in
the U.S.) and oxy-fuel cutting are processes that use fuel gases and oxygen to weld and cut
metals, respectively.
Type of flame is used for cutting steel
The welder can adjust the oxy-acetylene flame to be carbonizing (aka reducing), neutral, or
oxidizing. Adjustment is made by adding more or less oxygen to the acetylene flame. The
neutral flame is the flame most generally used when welding or cutting.
Brazing VS soldering
The basic difference between soldering and brazing is the temperature necessary to melt the
filler metal. That temperature is defined to be 842ºF/450ºC by the American Welding Society
(AWS) but is often rounded to 840ºF. If the filler metal melts below 840ºF the process being
performed is soldering.
Brazing
Brazing is a metal-joining process in which two or more metal items are joined together by
melting and flowing a filler metal into the joint, the filler metal having a lower melting point than
the adjoining metal.
HAZ
HAZ (Heat Affected Zone) The Heat Affected Zone (aka HAZ) is the volume of material at or
near the weld which properties have been altered due to the weld heat. Since the resistance
welding process relies on heating two parts, some amount of HAZ is inevitable.
fusion zone
The weld interface, which is also referred to as mushy zone, is a narrow zone consisting of
partially melted base material which has not got an opportunity for mixing. This zone separates
the fusion zone and heat affected zone.
Weaving in welding
Your hand can perform a zig-zag, crescent or curlycue technique. Besides allowing a
wider bead, weaving is used to control heat in the weld puddle. Besides that, you'll usually want
to pause on each side of the weld to achieve good tie in and prevent undercutting of the edges.
Residual stress
Residual stress is the Internal stress distribution locked into a material. These stresses
are present even after all external loading forces have been removed. They are a result of the
material obtaining equilibrium after it has undergone plastic deformation.
Residual stress in metal
Residual stresses are locked-in stresses within a metal object, even though the object is free of
external forces. Residual stresses can be tensile or compressive. In fact, tensile and
compressive residual stresses co-exist within a component.
stress relieving in welding and why is it performed
Relieving residual stress through welding technique as well as temperature control can greatly
reduce weld distortion. It's a shame arc welding works so well. Immediately after being
deposited and subsequent fusion between the base and weld metal, the metal cools quickly,
Distortion in welding
Distortion or deformation can occur during welding as a result of the non-uniform expansion and
contraction of the weld and base metal during the heating and cooling cycle.
Transverse distortion in welding
Contraction of the weld area on cooling results in both transverse and longitudinal shrinkage.
Hence, balanced welding in a double side V butt joint can be used to produce uniform
contraction and prevent angular distortion.
What is 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.

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KRISHNA ENGINEERING COLLEGE

DEPARTMENT OF MECHANICAL ENGINEERING

UNIT-IV METAL JOINING

function of the coating on an arc welding electrode

MIG welders applications

Squeeze time in spot welding

Type of flame is used for cutting steel

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