03 - Overview of Welding Process

TNB Integrated Learning Solution (ILSAS)
Overview of Welding Process
Engineering Maintenance & Services (GEN) Mac 2011
R0SLAN BIN ALI
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 gas welding

Oxyfuel gas welding Other processes Laser beam welding
Shielded metal arc welding Gas tungsten arc welding Submerged arc welding Atomic hydrogen welding Plasma arc welding
Thermit welding
Electron beam welding
Flux cored arc welding

Electrogas welding Electroslag welding
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JOINING
Soldering Produces coalescence of materials by heating to soldering temperature (below solidus of base metal) in presence of filler metal with liquidus < 450C Brazing Same as soldering but coalescence occurs at > 450C Welding Process of achieving complete coalescence of two or more materials through melting & resolidification of the base metals and filler metal
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Engineering Maintenance & Services (GEN) Mac 2011 R0SLAN BIN ALI
Soldering & Brazing

Advantages Low temperature heat source required Choice of permanent or temporary joint Dissimilar materials can be joined Less chance of damaging parts Slow rate of heating & cooling Parts of varying thickness can be joined Easy realignment Strength and performance of structural joints need careful evaluation
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Welding
Advantages Most efficient way to join metals Lowest-cost joining method Affords lighter weight through better utilization of materials Joins all commercial metals Provides design flexibility
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Weldability
Weldability is the ease of a material or a combination of materials to be welded under fabrication conditions into a specific, suitably designed structure, and to perform satisfactorily in the intended service
Common Arc Welding Processes Shielded Metal Arc Welding (SMAW) or MMA Gas Tungsten Arc Welding (GTAW) or, TIG Gas Metal Arc Welding (GMAW) or MIG/MAG Flux Cored Arc Welding (FCAW) Submerged Arc Welding (SAW)
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Alternating Current
Alternating current:
The type of current where the flow of electrons
reverses direction
(polarity) at regular intervals.
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Direct Current
Direct current: The type of current where the flow of electrons (polarity) is in one direction. Controlling the polarity allows the welder to influence the location of the heat. When the electrode is positive (+) DCRP or DCEP it will be slightly hotter than the base metal.
When the base metal is positive (+), DCSP or DCEN, the base metal will be slightly hotter than the electrode. DC current is required for some electrodes and recommended for out of position welding.
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Ampere
Amperes: the unit of measure for current flow.
Voltage
Volt The volt is the measure of electromotive force. It is defined as the potential difference across a conductor when a current of one ampere dissipates one watt of power. The voltage at the electrode determines the harshness of the arc. Voltage is only adjustable in dual control machines.
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Polarity
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Polarity
Electrode Negative
Electrode Positive
(-)
(+)
Ions
Electrons
Ions +
+
+
+ +
Electrons
(+)
Work Piece Positive
(-)
Work Piece Negative
Straight Polarity DCEN
Reverse Polarity DCEP

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Type of welding
Manual Welding
SMAW GTAW
2 parameters: Feed Speed
Semi automatic
GMAW
Automatic
Robotic welding
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Shielded Metal Arc Welding

(SMAW)
Shielded metal arc welding (stick welding) performed by a (human) welder using consumable electrodes.
Also known as MMA (Manual Metal Arc Welding).
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Shielded metal arc welding (SMAW).

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Welding Rod Classification (ex. E-6010)

The E- stands for electrode. The first two numbers indicate the tensile strength The next-to-last number gives the welding positions The last digit of the weld rod number indicates the type of current for which the rod may be used (ac, dc straight, dc reverse), the penetration, and the type of flux around the rod. Example: E-6010 would have a tensile strength of 60,000 psi, could be used in all positions, has a cellulose-sodium flux, could give deep penetration, and must be used with dc reverse current.
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Video Presentation of SMAW
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Gas Metal Arc Welding (GMAW)

Is a process where a continuously fed metal electrode (wire) contacts the base metal and produces heat . The arc is shielded by an inert gas or active gas.
Also known as MIG/MAG (Metal Inert Gas / Metal Active Gas)

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GMAW component diagram
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Gas Metal Arc Welding
Gas metal arc welding (GMAW).

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Video Presentation of GMAW
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Submerged Arc Welding

(SAW)
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(SAW)
Filler wire spool Flux hopper Power supply
+ Slide rail Flux
Wire electrode
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Submerged arc welding.
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Video Presentation of SAW
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Gas Tungsten Arc Welding

Is a process where a tungsten electrode contacts the base metal and produces heat and filler rod were also utilized. The arc is shielded by an inert gas (argon gas).
Also known as TIG (Tungsten Inert Gas Arc Welding)
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Gas Tungsten Arc Welding
Gas tungsten arc welding.

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Video Presentation of GTAW
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Plasma Arc Welding
Plasma arc welding (PAW).

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Oxyacetylene Welding
A typical oxyacetylene welding operation

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Oxyacetylene Torch
Maximum temperature reached at tip of inner cone, while outer envelope spreads out and shields work surfaces from atmosphere
The neutral flame from an oxyacetylene torch indicating temperatures achieved.

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Thermit Welding
Thermit welding: (1) Thermit ignited; (2) crucible tapped, superheated metal flows into mold; (3) metal solidifies to produce weld joint.
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Thermit Welding
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Underwater Welding
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Resistance Welding
Resistance welding, showing the components in spot welding, the main process in the RW group.
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Spot Welding Cycle
(a) Spot welding cycle, (b) plot of squeezing force & current in cycle (1) parts inserted between electrodes, (2) electrodes close, force applied, (3) current on, (4) current off, (5) electrodes opened.
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Resistance Seam Welding

Resistance seam welding (RSEW).
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Friction Welding
Friction welding (FRW): (1) rotating part, no contact; (2) parts brought into contact to generate friction heat; (3) rotation stopped 43 and axial pressure applied; and (4) weld created.
Friction Welding
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Joints, Welds & Positions

Five (5) types of joints, Five (5) types of welds and Five (5) positions (plate)
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Five (5) joints:
Corner
Butt
Lap
Edge
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Five types of welds
1. 2. 3. 4. 5. Surface Groove Fillet Plug Slot
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1. Surface Welds
Surface welds are welds were a material has been applied to the surface of another material.
Two common applications are for hard surfacing and padding
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2. Groove Welds
Groove welds are used to fuse the sides or ends of two pieces of metal.
The primary use of groove welds is to complete butt joints.

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3. Fillet Welds
Fillet welds have a triangular cross section and are used to fuse two faces of metal that are at a 90 degree angle to each other.
Lap Joint Outside Corner T Joint

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4. Plug Welds
Plug welds are used to attach two surfaces together when a complete joint is not required and the design does not allow for any weld bead outside the dimensions of the metal. The holes can be made with a drill bit or punch.
The weld is completed by establishing the arc on the bottom plate and then continuing to weld until the hole is full.
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5. Slot Welds
Slot welds are identical to plug welds except for the shape of the holes. For slot welds, slots are machined or stamped in the upper plate.
They are complete the same as plug welds.

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Positions
Five types of position
Flat
Horizontal
Vertical Up
Vertical Down
Overhead
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Welding Positions
OVERHEAD
VERTICAL HORIZONTAL
INCREASING DIFFICULTY
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FLAT
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UNDERSTANDING ABOUT WELDING POSITION ON BUTT JOINTS.

HORIZONTAL POSITION FLAT POSITION VERTICAL POSITION
OVERHEAD POSITION
PLATES AND AXIS OF WELD HORIZONTAL
1G
PLATES VERTICAL AND AXIS OF WELD HORIZONTAL
PLATES VERTICAL AND AXIS OF WELD VERTICAL
PLATES AND AXIS OF WELD HORIZONTAL
2G
3G
4G
WELDING POSITIONS -- GROOVE WELDS -- PLATE.

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FLAT POSITION
HORIZONTAL POSITION
1F
2F
AXIS OF WELD HORIZONTAL
AXIS OF WELD VERTICAL
VERTICAL POSITION
OVERHEAD POSITION
3F
4F
WELDING POSITIONS --FILLET WELDS --PLATE
AXIS OF WELD VERTICAL AXIS OF WELD HORIZONTAL
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PIPE OR TUBE HORIZONTAL FIXED WELD FLAT, VERTICAL & OVERHEAD POSITION:
5G.
PIPE INCLINED FIXED ( 45 + - ) AND NOT ROTATED DURING WELDING. POSITION:
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45 0 + - 50
6G
WELDING POSITION -- PIPE WELDS.

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Weld Nomenclature
Penetration Bead
Base metal Joint Angle Reinforcement Bead
Root Face Root Opening

Excessive Penetration
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Weld Nomenclature-cont.
Reinforcement Toe Leg Face Throat
Toe
Root
Leg
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Weld Nomenclature-cont.
In multiple pass welds, each pass has a specific function.

A tack weld is used to hold the joint at the desired gap. If it is not used, the heat of the weld will cause the joint to close. The root pass is used to fuse the root of the weld. If the root pass does not have adequate penetration, it must be cut or gouged out before the weld is completed.
Cover Pass Filler Pass Root Pass
Tack Weld
The filler pass is used to fill in the joint. A pattern bead or multiple stringer beads will be used. The cover pass doesnt add very much strength to the weld. It is used for appearance and to fill in surface voids.
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Bead Patterns
Pattern beads are used whenever a wider bead is needed. Hardsurfacing Filler pass Cover pass Reduce penetration Common patterns: Circle Crescent Figure 8
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TNB Integrated Learning Solution TYPICAL WELD DEFECTS (ILSAS)
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Arc Welding PPE
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03 - Overview of Welding Process

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03 - Overview of Welding Process

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TNB Integrated Learning Solution (ILSAS)

Overview of Welding Process

Engineering Maintenance & Services (GEN) Mac 2011

R0SLAN BIN ALI

TNB Integrated Learning Solution (ILSAS)

Diversity of welding processes

Oxyacetylene gas welding

Flux cored arc welding

TNB Integrated Learning Solution (ILSAS)

TNB Integrated Learning Solution (ILSAS)

Soldering & Brazing

TNB Integrated Learning Solution (ILSAS)

TNB Integrated Learning Solution (ILSAS)

TNB Integrated Learning Solution (ILSAS)

TNB Integrated Learning Solution (ILSAS)

Engineering Maintenance & Services (GEN) Mac 2011

TNB Integrated Learning Solution (ILSAS)

TNB Integrated Learning Solution (ILSAS)

TNB Integrated Learning Solution (ILSAS)

Straight Polarity DCEN

Reverse Polarity DCEP

Engineering Maintenance & Services (GEN) Mac 2011

R0SLAN BIN ALI

TNB Integrated Learning Solution (ILSAS)

TNB Integrated Learning Solution (ILSAS)

TNB Integrated Learning Solution (ILSAS)

Shielded Metal Arc Welding

TNB Integrated Learning Solution (ILSAS)

Shielded Metal Arc Welding

TNB Integrated Learning Solution (ILSAS)

Shielded Metal Arc Welding

Shielded metal arc welding (SMAW).

TNB Integrated Learning Solution (ILSAS)

Welding Rod Classification (ex. E-6010)

TNB Integrated Learning Solution (ILSAS)

TNB Integrated Learning Solution (ILSAS)

TNB Integrated Learning Solution (ILSAS)

Video Presentation of SMAW

TNB Integrated Learning Solution (ILSAS)

Gas Metal Arc Welding (GMAW)

Also known as MIG/MAG (Metal Inert Gas / Metal Active Gas)

TNB Integrated Learning Solution (ILSAS)

GMAW component diagram

TNB Integrated Learning Solution (ILSAS)

Gas Metal Arc Welding

Gas metal arc welding (GMAW).

TNB Integrated Learning Solution (ILSAS)

Video Presentation of GMAW

TNB Integrated Learning Solution (ILSAS)

Submerged Arc Welding

TNB Integrated Learning Solution (ILSAS)

Submerged Arc Welding

+ Slide rail Flux

TNB Integrated Learning Solution (ILSAS)

Submerged Arc Welding

Engineering Maintenance & Services (GEN) Mac 2011

R0SLAN BIN ALI

TNB Integrated Learning Solution (ILSAS)

Video Presentation of SAW

TNB Integrated Learning Solution (ILSAS)

Gas Tungsten Arc Welding

TNB Integrated Learning Solution (ILSAS)

Gas Tungsten Arc Welding