Basics of Engineering Technology

GE 101
Second Term 2008/2009
Chapter 7

Welding

Dr. Khaled Mohamed Soliman
Department of Mechanical Engineering
College of Engineering at Al Kharj

AWS Classification for Welding Processes

(American Welding Society) AWS
.

Brazing
)(B

Other
Welding

Arc Welding
)(AW

Soldering
)(S

) (

Welding
Processes

Resistance
Welding
)(RW

Oxyfuel Gas
Welding
)(OFW
processes

College of Engineering at Al Kharj, ME Dept.
2008/2009

Solid State
)Welding (SSW

Classification for Welding Processes

College of Engineering at Al Kharj, ME Dept.

2008/2009

Classification for Welding Processes

College of Engineering at Al Kharj, ME Dept.

2008/2009

Electric Arc Welding

:

.

Carbon Arc Welding (CAW)

Shielded Metal Arc Welding (SMAW)
Gas Metal Arc Welding (GMAW)
Gas Tungsten Arc Welding (GTAW)

Flux Cored Arc Welding (FCAW)

Submerged Arc Welding (SAW)
Plasma Arc Welding (PAW)
Stud Arc Welding (SW)

College of Engineering at Al Kharj, ME Dept.

2008/2009

Electric Arc Welding

.

.
The Carbon Arc Welding (CAW) Process:

:



)
( . ,
.

College of Engineering at Al Kharj, ME Dept.

2008/2009

Shielded Metal Arc Welding (SMAW) Process

:


)( ) ( .
.

College of Engineering at Al Kharj, ME Dept.

2008/2009

)Shielded Metal Arc Welding (SMAW

Process

) ( Welding Machine

) ( Electrode Holder

) ( )Ground Clamp (Earth

) ( Welding Cables

) ( Welding Table

:
: 1000-100
: 80-40

College of Engineering at Al Kharj, ME Dept.

2008/2009

Shielded Metal Arc Welding (SMAW) Process

.


.

3800


.

College of Engineering at Al Kharj, ME Dept.

2008/2009

Shielded Metal Arc Welding (SMAW) Process

:

) (.

.
College of Engineering at Al Kharj, ME Dept.
2008/2009

10

Shielded Metal Arc Welding (SMAW) Process

:

:
)
(
.

:
)
(
.

College of Engineering at Al Kharj, ME Dept.

2008/2009

11

Submerged Arc Welding (SAW)

12

College of Engineering at Al Kharj, ME Dept.

2008/2009

Submerged Arc Welding (SAW)

13

College of Engineering at Al Kharj, ME Dept.

2008/2009

Gas Metal Arc Welding (GMAW)

This process is also known as MIG welding or MAG

welding:
MIG (Metal Inert Gas) welding means the use of an inert
MAG (Metal Active Gas) welding requires the use of an
active gas(i.e. carbon dioxide and oxygen). CO2 is a more
commonly used shortening of MAG welding gas.

14

College of Engineering at Al Kharj, ME Dept.

2008/2009

Gas Metal Arc Welding (GMAW)

15

College of Engineering at Al Kharj, ME Dept.

2008/2009

Gas Metal Arc Welding (GMAW)

16

College of Engineering at Al Kharj, ME Dept.

2008/2009

)Gas Metal Arc Welding (GMAW

, , .

College of Engineering at Al Kharj, ME Dept.

2008/2009

17

Gas Metal Arc Welding (GMAW)

18

College of Engineering at Al Kharj, ME Dept.

2008/2009

Gas Metal Arc Welding (GMAW)

19

College of Engineering at Al Kharj, ME Dept.

2008/2009

Gas Tungsten Arc Welding (GTAW)

Department of Mechanical Engineering

College of Engineering at Al Kharj

Gas Tungsten Arc Welding (GTAW)

Department of Mechanical Engineering

College of Engineering at Al Kharj

Oxyacetylene Welding

Department of Mechanical Engineering

College of Engineering at Al Kharj

Oxyacetylene Welding

( )

3200

Department of Mechanical Engineering

College of Engineering at Al Kharj

Oxyacetylene Welding

Department of Mechanical Engineering

College of Engineering at Al Kharj

Oxyacetylene Welding

Department of Mechanical Engineering

College of Engineering at Al Kharj

Oxyacetylene Welding

Department of Mechanical Engineering

College of Engineering at Al Kharj

Oxyacetylene Welding

Department of Mechanical Engineering

College of Engineering at Al Kharj

Oxyacetylene Cutting

Department of Mechanical Engineering

College of Engineering at Al Kharj

Thermit Welding

Department of Mechanical Engineering

College of Engineering at Al Kharj

Electric Resistance Welding

Department of Mechanical Engineering

College of Engineering at Al Kharj

31

College of Engineering at Al Kharj, ME Dept.

2008/2009

Spot Welding

Department of Mechanical Engineering

College of Engineering at Al Kharj

Electric Resistance Welding

Department of Mechanical Engineering

College of Engineering at Al Kharj

Friction Welding

Department of Mechanical Engineering

College of Engineering at Al Kharj

Brazing and Soldering

Soldering

Department of Mechanical Engineering

College of Engineering at Al Kharj

How to calculate the heat input for arc welding

V x I x 60

x Efficiency

S x 1000
Where

Q = heat input (kJ/mm),

V = voltage (Volts),
I = current (Amps),
S = welding speed (mm/min)

The efficiency is dependent on the welding process used. The efficiency of the shielded metal arc
welding process is about 75%.
%75 . .

36

College of Engineering at Al Kharj, ME Dept.

2008/2009

Example No. 1

Calculate the heat input in a manual metal arc welding process if the
current = 150 amps, the voltage = 22 volts and the welding speed = 50
mm/min?? Assume the efficiency is about 75%.
Solution:

V x I x 60

x Efficiency

S x 1000
22 x 150 x 60
Q =
x 0.75
50 x 1000
Q = 2.97 kJ/mm

37

College of Engineering at Al Kharj, ME Dept.

2008/2009

Example No. 2
Calculate the voltage required for a manual metal arc welding process if the current =
150 amps, the heat input = 2.97 kJ/mm and the welding speed = 50 mm/min?? Assume
the efficiency is 75%.

Solution:

V x I x 60

x Efficiency

S x 1000
2.97 =

V x 150 x 60
x 0.75
50 x 1000

V = 22 volts

38

College of Engineering at Al Kharj, ME Dept.

2008/2009