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    Welding: Welding Is A Process of Metal Joining by Applying Heat and Sometime Pressure

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    Jith Viswa
    Welding is a process that joins materials by heating them to the point of melting. There are many different welding processes that use heat sources like electricity, chemical reactions, friction, lasers and electron beams. Some key welding processes are oxy-fuel welding, shielded metal arc welding, gas metal arc welding, flux-cored arc welding and plasma arc welding. Proper welding requires selecting the right technique, materials, and parameters to join metals while avoiding defects in the final weld.

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    Welding: Welding Is A Process of Metal Joining by Applying Heat and Sometime Pressure

    Uploaded by

    Jith Viswa
    209 views41 pages
    Welding is a process that joins materials by heating them to the point of melting. There are many different welding processes that use heat sources like electricity, chemical reactions, friction, lasers and electron beams. Some key welding processes are oxy-fuel welding, shielded metal arc welding, gas metal arc welding, flux-cored arc welding and plasma arc welding. Proper welding requires selecting the right technique, materials, and parameters to join metals while avoiding defects in the final weld.

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    Welding

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    Welding is a process that joins materials by heating them to the point of melting. There are many different welding processes that use heat sources like electricity, chemical reactions, friction, lasers and electron beams. Some key welding processes are oxy-fuel welding, shielded metal arc welding, gas metal arc welding, flux-cored arc welding and plasma arc welding. Proper welding requires selecting the right technique, materials, and parameters to join metals while avoiding defects in the final weld.

    Copyright:

    © All Rights Reserved
    Download as PPT or read online from Scribd
    Download as ppt
    209 views41 pages

    Welding: Welding Is A Process of Metal Joining by Applying Heat and Sometime Pressure

    Uploaded by

    Jith Viswa
    Welding is a process that joins materials by heating them to the point of melting. There are many different welding processes that use heat sources like electricity, chemical reactions, friction, lasers and electron beams. Some key welding processes are oxy-fuel welding, shielded metal arc welding, gas metal arc welding, flux-cored arc welding and plasma arc welding. Proper welding requires selecting the right technique, materials, and parameters to join metals while avoiding defects in the final weld.

    Copyright:

    © All Rights Reserved
    Download as PPT or read online from Scribd
    Download as ppt
    of 41

    WELDING

    Welding is a process of metal joining by applying heat and sometime pressure

    Diversity of welding processes


    welding
    Solid state welding Resistance welding Cold welding Friction welding Diffusion welding Electrical energy Chemical energy Fusion welding Soldering and brazing Soldering Brazing

    Flash welding
    Ultrasonic welding Explosion welding Consumable electrode Gas metal arc welding Non consumable electrode

    Oxyacetylene welding
    Oxyfuel gas welding Other processes Laser beam welding

    Shielded metal arc welding


    Submerged arc welding Flux cored arc welding Electrogas welding Electroslag welding

    Gas tungsten arc welding


    Atomic hydrogen welding Plasma arc welding

    Thermit welding
    Electron beam welding

    INTRODUCTION
    Fusion Welding Joining of similar metals by bringing them to fusion temperature and making the joint with or without filler metal

    SPECIAL WELDING PROCESS


    PLASMA ARC WELDING THERMIT WELDING ELECTRON BEAM WELDING FRICTION WELDING DIFFUSION WELDING FLAME CUTTING ELECTRON SLAG WELDING

    Welding v casting
    Weld must adhere to mould wall Heat is added continually to welds
    High temperature gradient

    Welds solidify much faster than castings In welds, the surface shape is constant There is strong mixing of weld pools

    Weld detailing

    Weld positions - plate

    Flat (1G)

    Horizontal (2G)

    Vertical (3G) Up or Down

    Overhead (4G)

    Welding positions - pipe

    Axis vertical 2G

    Axis horizontal 5G

    Axis inclined 45 6G

    Joint types

    Butt

    Tee

    Edge Lap Corner

    FUSION WELDING
    Definition : Fusion Welding is defined as melting together and coalescing materials by means of heat Energy is supplied by thermal or electrical means Fusion welds made without filler metals are known as autogenous welds

    Fusion welding
    This process involves the partial melting of the two members welded in the join region. The thermal energy required for this fusion is usually supplied by chemical or electrical means.

    Base metal melt + filler melt

    Characteristics of the fusion weld joint (Manufacturing Engineering and Technology: p820)

    Fusion weld structure


    Fusion line

    Weld preparation

    Base metal

    Weld metal

    HAZ

    HAZ

    Welding procedure
    Selection of process conditions & consumables for a weld Designed to match base material properties as closely as possible & avoid weld defects Needs to consider service conditions of the weld

    Definition of weldability
    The capacity of a material to be welded under the imposed fabrication conditions into a specific, suitably designed structure & to perform satisfactorily in intended service.
    (ANSI / AWS A3.0)

    GAS WELDING
    Oxy-fuel gas welding derives heat from the combustion of a fuel such as acetylene in combination with oxygen

    Oxyfuel Gas Welding

    Fig : Three basic types of oxyacetylene flames used in oxyfuel-gas welding and cutting operations: (a) neutral flame; (b) oxidizing flame; (c) carburizing, or reducing flame. The gas mixture in (a) is basically equal volumes of oxygen and acetylene.

    Oxyfuel Gas Welding


    Welding process that uses fuel gas combined with oxygen to produce flame This flame heat melts the metals at the joint Acetylene fuel is used in gas welding process Primary combustion process C2H2 + O2 2CO + H2 + heat This reaction dissociates into carbon monoxide and hydrogen. Secondary combustion process 2CO + H2 + 1.5 O2 2CO2 + H2O + heat

    Types of flames
    Neutral flame Oxidising flame Carburising flame Filler Metals : Additional material to weld the weld zone Available as rod or wire They can be used bare or coated with flux The purpose of the flux is to retard the

    Torch used in Oxyacetylene Welding

    Fig : (a) General view of and (b) cross-section of a torch used in oxyacetylene welding. The acetylene valve is opened first; the gas is lit with a park lighter or a pilot light; then the oxygen valve is opened and the flame adjusted. (c) Basic equipment used in oxyfuel-gas welding. To ensure correct connections, all threads on acetylene fittings are left-handed, whereas those for oxygen are righthanded. Oxygen regulators are usually painted green, acetylene regulators red.

    ARC WELDING
    An arc is generated between two conductors of electricity, cathode and anode ( considering direct current, DC) when they are touched to establish the flow of current and then separated by a small distance. An arc is a sustained electric discharge through the ionized gas column called Plasma between the electrodes. Electrons move from cathode Anode To produce the arc the sufficient voltage difference is required

    ARC WELDING

    Shielded metal arc welding process

    The electrode is provide with a flux which burns and produces gaseous protective shield around the weld zone

    Submerged arc welding:

    The arcing takes place under a blanket of flux. The unfused flux is recovered and reused .

    Submerged arc welding:


    Weld arc is shielded by a granular flux ,consisting of silica, lime, manganese oxide, calcium fluoride and other compounds. Flux is fed into the weld zone by gravity flow through nozzle Thick layer of flux covers molten metal

    Flux acts as a thermal insulator ,promoting deep penetration of heat into the work piece
    Consumable electrode is a coil of bare round wire fed automatically through a tube Power is supplied by 3-phase or 2-phase power lines

    The GMAW process


    The heat is produced by an electric arc between the continuously fed metal electrode and the base metal. Both the base metal and the filler are melt. The weld area is protected by inert shield gases.

    Weldable metals:
    -steel carbon - steel low-allow - steel stainless - aluminum - copper and its allows - nickel and its allows - magnesium - reactive metal (titanium, zirconium, tantalum)

    Characteristics of the weld joint by GMAW (Modern Welding (p63))

    The parameters of the GMAW process

    - The method used to transfer the metal across the arc. There are four metal transfer methods (short circuit, globular, spray, pulsed spray). Each one requires different settings and has divers use interests. - The shielding gas. - The electrode size. - The electric parameters: voltage and current (the GMAW use the continuous current). - The feed rate (speed of filler supply). - The travel speed.

    Advantages of the GMAW


    - wide range of weldable metals (high-quality welds on all commercially important metal) - easy to learn - can be used in all welding position - low in cost (the equipment costs less than 3000 dollars)

    - can be easily automated


    - rapid, economic - high level of productivity

    Fluxcored Arc Welding


    Flux cored arc welding is similar to a gas metal arc welding Electrode is tubular in shape and is filled with flux Cored electrodes produce more stable arc improve weld contour and produce better mechanical properties Flux is more flexible than others

    Flux-Cored Arc Welding

    Electroslag Welding:
    Arc is started between electrode tip and bottom part of the part to be welded Flux added first and then melted by the heat on the arc Molten slag reaches the tip of the electrode and the arc is extinguished Heat is then continuously produced by electrical resistance of the molten slag

    Single or multiple solid as well as flux-cored electrodes may be used

    Equipment used in Electroslag welding

    Fig : Equipment used for electroslag welding operations.

    Plasma arc
    The Coalescence is produced by striking an arc between a tungsten electrode and a water cooled nozzle.

    Electron Beam
    The Coalescence is produced by heat generated from the kinetic energy of intense beam of electron.

    Welding Defects
    Cracks
    In weld metal or HAZ

    Porosity
    Gas bubbles entrapped in weld metal

    Incomplete fusion (interrun or at preparation edge) Inclusions


    Slag or other matter entrapped in weld

    Defective profile
    Under-weld, over-weld, lack of penetration, overlap, undercut

    Causes of weld defects


    Poor design of weldment
    Lack of access to make weld

    Mistakes by welder
    Lack of skill Poor placement of weld metal Inadequate cleaning

    Poor welding procedure

    Weld defects

    Slag inclusion

    Wormhole porosity Incomplete fusion

    Overlap

    Solidification cracking
    Contraction strains cause rupture of the weld at the point where the last material solidifies.
    Solidification range Weld pool size & shape

    Residual stress & distortion


    Uneven heating leads to constrained thermal expansion At completion of the weld thermal cycle the weldment either distorts or if restrained will contain residual stress Residual stress fields are complex, but stresses as high as yield often occur Stresses may need to be removed by a stress relief heat treatment

    Solid state welding


    It merges all the welding processes in which there is no fusion of the workpieces . For example, in the solid welding process named resistance seam welding, the welding join is produced in the wheel electrodes region by applied a current and a pressure without fusion of the base metal.

    The resistance seam welding (source: Modern Welding (p73))

    Soldering or brazing
    In these processes, only the filler metals which join the two pieces to be welded are melted and not the base metal. The braze metals have higher melting temperatures than the solder metals.

    Filler metal: brass or solder Base metal

    Characteristics of a brazed or soldered joint

    Safety
    Burn hazard Protection clothes and gloves

    Eye protection against spatters and ultraviolet and infrared rays

    Helmet or special glasses

    Toxic gases: - carbon monoxide (CO) - ozone (O2) - phosgene gases produced with some metals when welded Well ventilated area

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