Académique Documents
Professionnel Documents
Culture Documents
Realization
Technology (IC141)
Dr. Satvasheel Powar
Assistant Professor
Indian Institute of Technology Mandi
Classification of joining processes
Arc welding
Consumable electrode: Non consumable electrode:
– Shielded metal arc – Gas tungsten arc welding
welding – Atomic hydrogen welding
– Submerged arc welding – Plasma arc welding
– Gas metal arc welding
h"ps://www.youtube.com/watch?v=P5m9-
Xmqrk8
Gas tungsten arc welding
• Also known as Tungsten inert gas (TIG) welding
• Capability of making high quality welds with small heat affect zone
Laser beam machining
h"ps://www.youtube.com/watch?
v=oUEbMjtWc-A
h"ps://www.youtube.com/watch?
v=ptEmX9O4nDw
Laser beam welding
Laser beam welding
• Heat is generated by high-power laser beam
• Can be focused on very small area, very high energy density and
deep penetration capability
h"ps://www.youtube.com/watch?
v=5EhMYMr834o
Explosion welding
• Pressure applied by detonating a layer of explosive that
has been placed over one of the components being
joined
h"ps://www.youtube.com/watch?
v=XN5TR_Vssj0
Cold welding
• Pressure is applied to the work piece through dies or
rolls
• Reasons:
– Incorrect welding parameters
• Percentage basis:
– 41% poor process conditions , 32% operator error, 12% wrong technique,
10% incorrect consumables and 5% bad weld grooves.
– (according to : American Society of Mechanical Engineers)
Classification of welding defects
• Cracks
• Cavity
• Incomplete fusion & Penetration
• Solid inclusion
• Imperfect shape
• Miscellaneous defects
Cracks
• Hair line separation in base metal/weld metal
• Most dangerous of all defects
• Occurs when localized stresses exceed the UTS of
material
• May be microscopic or macroscopic size
Cracks
Causes: Remedies:
• Poor ductility of base metal • Controlling composition
• High C & S – Content of of metal to be welded
base metal/ weld metal
• Pre-heating
• Electrode with high
• Use low H2 electrode
hydrogen content
• Avoid rapid cooling
• High residual stress in weld
metal
• Starts a crack at the sharp point where the weld metal and
base metal come together at the over-lapped surface
Overlaps
Causes: Remedies:
diameter electrode
Lack of Fusion
• Improper melting/fusion of some portion of the weld
metal in a joint
• Improper current
• Long arcs
Application of welding
• Automobile: Resistance welding, Laser beam welding