Dr.

Muammer Din Arif

Manufacturing Process
(Welding Introduction)
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Classification of Manufacturing Processes

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Classification of Joining Processes
▪ Assembly process: the processes that are used to join two or
more parts into an assembled entity.
▪ Joining Processes: the processes used to permanently join
two or more components by welding, brazing, soldering
and/or adhesive bonding. This type of joint cannot easily be
separated.
▪ Mechanical Fastening: the mechanical methods of fastening
parts together. Some of these methods allow for easy
disassembly, while others do not.

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Joining Process: Welding
Welding: a materials joining process in which two or more parts are
coalesced at their faying surfaces, i.e. part surfaces in contact or close
proximity, by a suitable application of heat and/or pressure.
Many welding processes are accomplished by heat alone, with no pressure
applied; others by a combination of heat and pressure; and still others by
pressure alone, with no external heat supplied.
In some welding processes a filler material is added to facilitate
coalescence.
The assemblage of parts that are joined by welding is called a weldment.
Welding is most commonly associated with metal parts, but the process is
also used for joining plastics.

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 History of Welding
▪ Around 1000 BCE, the Egyptians and others in the eastern Mediterranean
area learned to accomplish forge welding. It was a natural extension of
hot forging, which they used to make weapons, tools etc. Forge-welded
articles of bronze have been recovered by archeologists from the
pyramids of Egypt.
▪ In the Middle Ages, the blacksmith trade developed the art of welding by
hammering to a high level of maturity. Welded objects of iron and other
metals dating from these times have been found in India and Europe.
▪ In the 1800s the technological foundations of modern welding were
established. Two important discoveries were made by English scientist Sir
Humphrey Davy: (1) the electric arc and (2) acetylene gas.
▪ Nikolai Benardos (Russian) patented the carbon arc–welding process. By
the turn of the century, carbon arc welding had become a popular
commercial process for joining metals.
▪ In 1892, Charles Coffin (USA) patented the arc–welding process utilizing a
metal electrode. The unique feature was that the electrode added filler
metal to the weld joint.
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▪ Although Davy discovered acetylene gas early in the 1800s, oxyfuel gas
welding required the subsequent development of torches for combining
acetylene and oxygen around 1900
Common Commercial Welding
▪ Three types of welding operations are the most common ones
performed today:
✔ Arc welding
✔ Resistance welding
✔ Oxyfuel (oxy-acetylene) gas welding

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 Advantages of Welding
Commercial and Technological importance:
▪Welding provides a permanent joint. The welded parts
become a single entity.
▪ The welded joint can be stronger than the parent
materials if a filler metal is used that has strength
properties superior to those of the parents, and if proper
welding techniques are used.
▪ Welding is usually the most economical way to join
components in terms of material usage and fabrication
costs. Alternative mechanical methods of assembly require
more complex shape alterations (e.g., drilling of holes) and
addition of fasteners (e.g. rivets or bolts). The resulting
mechanical assembly is usually heavier than a
corresponding weldment. 7
▪ Welding is not restricted to the factory environment. It
can be accomplished ‘‘in the field.’’
Disadvantages of Welding

▪ Most welding operations are performed manually and are

expensive in terms of labor cost. Many welding operations
are considered ‘‘skilled trades,’’ and the labor to perform
these operations may be scarce.
▪ Most welding processes are inherently dangerous because
they involve the use of high energy.
▪ Since welding accomplishes a permanent bond between the
components, it does not allow for convenient disassembly
(e.g. for repair or maintenance).
▪ The welded joint can suffer from certain quality defects that
are difficult to detect. The defects can reduce the strength of
the joint.
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 Welding Details
▪ Some 50 different types of welding operations have been cataloged
by the American Welding Society. They use various types or
combinations of energy to provide the required power.
▪ Two major groups:
(1) fusion welding
(2) solid-state welding

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 (1) Fusion Welding
• Fusion-welding processes use heat to melt the base metals.
• In many fusion welding operations, a filler metal is added to the
molten pool to facilitate the process and provide bulk and strength
to the welded joint.
• A fusion-welding operation in which no filler metal is added is
referred to as an autogenous weld.
• The fusion category includes the most widely used welding
processes, which can be organized into the following general
• groups (initials in parentheses are designations of the American
Welding Society).

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 (1 a) Fusion Welding: Arc
▪ Arc welding (AW): refers to a group of welding processes
in which heating of the metals is accomplished by an
electric arc.
▪ Some arc welding operations also apply pressure during
the process and most utilize a filler metal.

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(1 b) Fusion Welding: Resistance
• Resistance welding (RW): achieves coalescence using
heat from electrical resistance to the flow of a current
passing between the faying surfaces of two parts held
together under pressure.

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(1 c) Fusion Welding: Oxy-fuel
• Oxyfuel gas welding (OFW): (AKA Torch Welding)
These joining processes use an oxyfuel gas, such as a
mixture of oxygen and acetylene, to produce a hot
flame for melting the base metal and commonly a filler
metal.

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(1 d) Fusion Welding: Others
• Other fusion-welding processes include:
1) Electron beam welding
2) Laser beam welding

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(2) Solid State Welding
• Solid-State Welding: refers to joining processes in
which coalescence results from application of pressure
alone or a combination of heat and pressure.
• If heat is used, the temperature in the process is below
the melting point of the metals being welded.
• No filler metal is utilized.

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(2a) Solid State Welding: Diffusion
• Diffusion welding (DFW): Two surfaces are held together under
pressure at an elevated temperature and the parts coalesce by
solid-state diffusion.

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(2b) Solid State Welding: Friction
• Friction welding (FRW): Coalescence is achieved by the heat of
friction between two surfaces.

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(2c) Solid State Welding: Ultrasonic
• Ultrasonic welding (USW): Moderate pressure is applied between
the two parts and an oscillating motion at ultrasonic frequencies is
used in a direction parallel to the contacting surfaces.
• The combination of normal and vibratory forces results in shear
stresses that remove surface films and achieve atomic bonding of
the surfaces. Can be used for plastics

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Automation and Robotic Welding
• Automatic welding: The equipment is capable of performing the
operation without control by a human operator.
• Robotic welding: an industrial robot or programmable manipulator is
used to automatically control the movement of the welding head relative
to the work.

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Welds & Welded Joints
• Welding produces a solid connection between two pieces, called a
weld joint.
• A weld joint is the junction of the edges or surfaces of parts that
have been joined by welding.
• Classifications related to weld joints:
(1) Types of joints
(2) The types of welds used to join the pieces that form the
joints

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Types of Welded Joints
• There are five basic types of joints for bringing two parts together
for joining.
(a) Butt joint. In this joint type, the parts lie in the same plane and
are joined at their edges.
(b) Corner joint. The parts in a corner joint form a right angle and are
joined at the corner of the angle.
(c) Lap joint. This joint consists of two overlapping parts.
(d) Tee joint. In a tee joint, one part is perpendicular to the other in
the approximate shape of the letter ‘‘T.’’
(e) Edge joint. The parts in an edge joint are parallel with at least one
of their edges in common, and the joint is made at the common
edge(s).
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Types of Welded Joints

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Types of Welds
• Differences among weld types are in geometry (joint type) and welding
process.
• A fillet weld is used to fill in the edges of plates created by corner, lap,
and tee joints. Filler metal is used to provide a cross section
approximately the shape of a right triangle. It is the most common weld
type in arc and oxyfuel welding because it requires minimum edge
preparation—the basic square edges of the parts are used. Fillet welds
can be single or double (i.e., welded on one side or both) and can be
continuous or intermittent (i.e., welded along the entire length of the
joint or with unwelded spaces along the length).

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Types of Welds
• Groove welds usually require that the edges of the parts be shaped into
a groove to facilitate weld penetration.
• The grooved shapes include square, bevel, V, U, and J, in single or
double sides.
• Filler metal is used to fill in the joint, usually by arc or oxyfuel welding.
• Preparation of the part edges beyond the basic square edge, although
requiring additional processing, is often done to increase the strength of
the welded joint or where thicker parts are to be welded.
• Although most closely associated with a butt joint, groove welds are
used on all joint types except lap.

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Types of Weld
• Plug welds and slot welds are used for attaching flat plates using
one or more holes or slots in the top part and then filling with
filler metal to fuse the two parts together.

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Types of Welds
• Spot welds and seam welds are used for lap joints.
• A spot weld is a small fused section between the surfaces of two
sheets or plates. Multiple spot welds are typically required to join
the parts. It is most closely associated with resistance welding.
• A seam weld is similar to a spot weld except it consists of a more
or less continuously fused section between the two sheets or
plates.

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Types of Weld
• A flange weld is made on the edges of two (or more) parts,
usually sheet metal or thin plate where at least one of the parts
is being flanged .
• A surfacing weld is not used to join parts, but rather to deposit
filler metal onto the surface of a base part in one or more weld
beads.
• The weld beads can be made in a series of overlapping parallel
passes, thereby covering large areas of the base part.
• The purpose is to increase the thickness of the plate or to
provide a protective coating on the surface.

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Questions??
• Thank you

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