WELDING

Welding is a materials joining process which produces coalescence of materials by heating them to suitable temperatures with or without the application of pressure or by the application of pressure alone, and with or without the use of filler material.
Welding is used for making permanent joints. It is used in the manufacture of automobile bodies, aircraft frames, railway wagons, machine frames, structural works, tanks, furniture, boilers, general repair work and ship building.

WELDING PROCESSES
1. 2. 3. 4. 5. 6. 7. 8. Arc Welding Resistance Welding Oxyfuel Gas Welding Other Fusion Welding Processes Solid State Welding Weld Quality Weldability Design Considerations in Welding

Classification of welding processes:

(i). Arc welding Carbon arc Metal arc Metal inert gas Tungsten inert gas Plasma arc Submerged arc Electro-slag (ii). Gas Welding
Oxy-acetylene Air-acetylene Oxy-hydrogen (iv)Thermit Welding (v)Solid State Welding

Friction Ultrasonic Diffusion Explosive

(vi)Newer Welding Electron-beam Laser (vii)Related Process Oxy-acetylene cutting Arc cutting Hard facing Brazing Soldering

(iii). Resistance Welding Butt Spot Seam Projection Percussion

Two Categories of Welding Processes

Fusion welding - coalescence is accomplished by melting the two parts to be joined, in some cases adding filler metal to the joint Examples: arc welding, resistance spot welding, oxyfuel gas welding Solid state welding - heat and/or pressure are used to achieve coalescence, but no melting of base metals occurs and no filler metal is added Examples: forge welding, diffusion welding, friction welding

Arc Welding (AW)

A fusion welding process in which coalescence of the metals is achieved by the heat from an electric arc between an electrode and the work Electric energy from the arc produces temperatures ~ 10,000 F (5500 C), hot enough to melt any metal Most AW processes add filler metal to increase volume and strength of weld joint

What is an Electric Arc?

An electric arc is a discharge of electric current across a gap in a circuit It is sustained by an ionized column of gas (plasma) through which the current flows To initiate the arc in AW, electrode is brought into contact with work and then quickly separated from it by a short distance

Arc Shielding
At high temperatures in AW, metals are chemically reactive to oxygen, nitrogen, and hydrogen in air Mechanical properties of joint can be degraded by these reactions To protect operation, arc must be shielded from surrounding air in AW processes Arc shielding is accomplished by: Shielding gases, e.g., argon, helium, CO2 Flux

Why Welding is Important

Provides a permanent joint Welded components become a single entity Usually the most economical way to join parts in terms of material usage and fabrication costs Mechanical fastening usually requires additional hardware (e.g., screws) and geometric alterations of the assembled parts (e.g., holes) Not restricted to a factory environment Welding can be accomplished "in the field"

Limitations and Drawbacks of Welding

Most welding operations are performed manually and are expensive in terms of labor cost Most welding processes utilize high energy and are inherently dangerous Welded joints do not allow for convenient disassembly Welded joints can have quality defects that are difficult to detect

Five Types of Joints

(a) Butt joint, (b) corner joint, (c) lap joint, (d) tee joint, and (e) edge joint

Fillet Weld
Used to fill in the edges of plates created by corner, lap, and tee joints Filler metal used to provide cross section in approximate shape of a right triangle Most common weld type in arc and oxyfuel welding Requires minimum edge preparation

 (a) Inside single fillet corner joint; (b) outside single fillet corner joint; (c) double fillet lap joint; (d) double fillet tee joint (dashed lines show the original part edges)

TYPE OF JOINT

APPLICABLE WELDS FILLET PLUG SLOT SQUARE GROOVE BEVEL GROOVE J-GROOVE FLARE BEVEL GROOVE SPOT PROJECTION SEAM

TYPE OF JOINT

APPLICABLE WELDS SQUARE GROOVE V-GROOVE BEVEL GROOVE U-GROOVE J-GROOVE FLARE V-GROOVE FLARE BEVEL GROOVE EDGE FLANGE

TYPE OF JOINT

APPLICABLE WELDS

FILLET SQUARE GROOVE V-GROOVE BEVEL GROOVE U-GROOVE J-GROOVE

FLARE V-GROOVE FLARE BEVEL GROOVE EDGE FLANGE CORNER FLANGE SPOT PROJECTION SEAM

TYPE OF JOINT

APPLICABLE WELDS
FILLET PLUG SLOT BEVEL GROOVE J-GROOVE FLARE BEVEL GROOVE SPOT PROJECTION SEAM

TYPE OF JOINT

APPLICABLE WELDS PLUG SLOT SQUARE GROOVE BEVEL GROOVE V-GROOVE U-GROOVE J-GROOVE EDGE FLANGE CORNER FLANGE SPOT PROJECTION SEAM EDGE

Arc Welding A pool of molten metal is formed near electrode tip, and as electrode is moved along joint, molten weld pool solidifies in its wake

Flux
A substance that prevents formation of oxides and other contaminants in welding, or dissolves them and facilitates removal Provides protective atmosphere for welding Stabilizes arc Reduces spattering

Groove Welds Square and double square-groove welds

Square-groove welds are the most economical to use, but are limited by thickness of the members Welds for one side are normally limited to a 1/4 inch or less

Groove Welds V-and double V-groove welds

With thicker materials joint accessibility must be provided for welding to ensure weld soundness and strength

Groove Welds Bevel- and double-bevel-groove welds

Bevel- and J- groove welds are more difficult to weld than V- or U- groove welds Bevel welds are easier in horizontal

Groove Welds flare-bevel and flare-v-groove welds

Flare -bevel and flarev-groove welds are used in connection with flanged or rounded member

Leg Face Throat Groove radius Root opening (groove weld) is the space between the pieces before welding* Root face Groove angle

Incomplete Fusion
A weld bead in which fusion has not occurred throughout entire cross section of joint Several forms of incomplete fusion are shown below

 (a) Desired profile for single V-groove weld joint, (b) undercut - portion of base metal melted away, (c) underfill - depression in weld below adjacent base metal surface, and (d) overlap - weld metal spills beyond joint onto part surface but no fusion occurs

WELDED CONNECTIONS