Fundamentals of Welding

D.SELVAKUMARAN
Course Director/AWTI

Types of metal joining

Riveted joints
Bolted joints
Welded joints

RIVETED JOINTS

BOLTED JOINTS

Welded joint

Welded joint

Limitations of riveted
and
bolted joints

Load bearing
Difficult for higher thickness
Bolts can be unscrewed
Rivets and bolts are protruding
Fillet joints, butt joints curved joints,
are difficult. Additional flanges are
necessary

Limitations of riveted
and
bolted joints

Rivets and bolts are protruding

Fillet joints, butt joints curved joints,
are difficult. Additional flanges are
necessary

Advantages of welding

Permanent joint
Withstands high pressure or force or load
Occupies less space
Has less weight
Withstands high temperature
Quick process
Any profile can be welded. Different joint
types i.e. Butt, fillet, lap, corner joint
possible

Basic Joint Types

but
t
la
p

tee

edge

corn
er

Applicable Welds for Butt joint

Square Groove
weld

Single V weld

Single Bevel weld

Single U
weld

Single J weld

Applicable Welds for Butt joint

Double V weld

Double U weld

Double Bevel weld

Double J weld

Applicable Welds for Tee joint

Applicable Welds for Lap joint

Fillet
weld

Plug / slot
weld

Spot / seam
weld

Applicable Welds for Corner Joint

Applicable Welds for Edge Joint

Edge weld

Edge Preparation - Need

Poor
penetration
Poor strength
Good
penetration
Good strength
(100% joint
efficiency)

Edge Preparation
Factors which influence choice of edge
preparation
- Thickness
- Material
- Welding process
- Extent of penetration required
- Welding distortion
- Cost

Butt joint
Square Groove
weld

Root

Butt joint
Single V Groove
weld

Groove angle

Root face
Root
gap

Parts of welding joint

Root, root face, root gap

Groove
Weldment
Fusion zone
Heat affected zone
Bead width

Throat
Penetration
Fusion
Depth of fusion
Leg
Reinforcement

Quality of welding joint

Welding dimensions
Throat
Leg length
Bead width

Leg

Leg

Quality of welding joint

Fusion
Penetration

Quality of welding joint

Nice ripples

Quality of welding joint

Clean joint
Less defects

Testing of welding joint

Fracture test

tensile test

Quality of welding joint

Summary
Welding dimensions
Throat
Leg length
Bead width

Fusion
Penetration
Nice ripples
Clean joint
Less defects

Types of welding
Fusion welding
Pressure welding
Non fusion welding

Fusion welding

Manual metal
Arc welding
Gas metal arc
welding
Gas welding

Pressure welding

Forge welding
Resistance
welding
Friction stir
welding

Non fusion welding

No fusion
Brazing
Soldering

Fusion welding

Types of fusion welding

MMAW : Manual Metal Arc Welding
GMAW : Gas Metal Arc Welding
MIG/MAG welding
MIG : Metal Inert Gas welding
MAG : Metal Active Gas welding

GTAW : Gas Tungsten Arc Welding

TIG : Tungsten Inert Gas welding
SAW : Submerged Arc Welding
Plasma arc welding
Carbon arc welding
Gas welding
Laser welding

BASICS OF WELDING
WELDING PARAMETERS
POLARITY
CONSTANT CURRENT Vs CONSTAN
VOLTAGE

WELDING PARAMETERS

CURRENT
VOLTAGE
ELCTRODE TYPE
SHIELDING GAS FLOW RATE

POLARITY
Straight polarity : DCEN
Electrode ve
less fusion (suitable for thin section)
More penetration
suitable for TIG (avoids burning of tungsten)
Reverse polarity : DCEP
Electrode +ve
more common
more deposition
less penetration
arc is more stable

Constant current Vs constant

voltage
Constant Current characteristics
Manual Metal Arc Welding (MMAW)
Tungsten Inert Gas Welding (TIG)
Constant Voltage Constant Current
Gas Metal Arc Welding (GMAW)
Metal Inert Gas (MIG)/ Metal Active Gas
(MAG)

Submerged Arc Welding (SAW)

MMAW : Manual Metal Arc

Welding
SMAW : Shielded Metal Arc Welding

MMAW : Manual Metal Arc

Welding
SMAW : Shielded Metal Arc Welding
Electrode

Travel direction

4
6
6

Shielding Gas

Slag
Slag
Weld Puddle 3
Weld Puddle

3
5
5
39

Solidified Weld Metal

Solidified Weld Metal

2
2

Arc
Arc

GMAW : Gas Metal Arc Welding

MIG : Metal Inert Gas welding

MAG : Metal Active Gas welding

Basic welding parameters in

GMAW
The basic parameters which require to
be set in GMAW process are
Current ( amps )
Voltage ( volts )
Shielding gas flow rate. ( litres / min )
Stick out
Torch angle
Welding speed

TIG WELDING

GTAW PROCESS

GTAW PROCESS

Fig 1a. TIG Arc

SAW : Submerged Arc Welding

Queries &
discussions.....

Thank you

SMAW
OBJECTIVES
The process
Process variables
Selection of consumables

SMAW
Current flows through the electrode
cable, to the electrode holder,
through the electrode, and across the
arc
On the work side of the arc, the
current flows through the base
material to the work clamp and back
to the welding machine

EQUIPMENT AND ACCESSORIES USED IN THE PROCESS

>> Power source

>> Electrode holder
>> Ground cable
>> Welding cable
>> Lugs

AWTI

50

SMAW Process
Lets take a little closer look at the
Electrode
SMAW process
1

Travel direction

4
6
6

Shielding Gas

Slag
Slag
Weld Puddle 3
Weld Puddle

3
5
5
51

Solidified Weld Metal

Solidified Weld Metal

2
2

Arc
Arc

EQUIPMENT AND ACCESSORIES

USED IN THE PROCESS
>> Power source
>> Electrode holder
>> Ground cable
>> Welding cable
>> Lugs
AWTI

52

Shielded Metal Arc

Welding
Process Capabilities:
Versatile process
Indoor & Outdoor welding
Multi-position welding
Equipment is simple & portable
Universal process for repair welding
Limitations:
Productivity is less
> Fixed length of electrode
> Deslaging
AWTI

53

LIMITATIONS OF SMAW PROCESS

>> Less metal deposition Cannot be
used for heavy fabrication welding
>> Requires more number of welders
>> Control of distortion is difficult
>> Continuous & automatic Welding
is not possible
>> More strain to the welders

AWTI

54

POWER SOURCE
Either AC or DC may be used for SMAW process.
Factors to be considered for SMAW:
>>

Type of current---- AC or DC

>>

Current requirement

>>

Positon of welding

>> Primary power available at the work

station

55

SELECTION OF ELECTRODES
>> Composition or Strength of BM.
>> Penetration requirement
>> Position of welding
>> Fit-Up condition
>> Skill of the welding personnel
>> Cost of the welding operation
>> Service requirement of weld joint.

AWTI

56

Welding electrodes

AWTI

57

The Electrode
Is a consumable - it
gets melted during the
welding process
Is composed of two
parts
Core Rod (Metal Filler)
Carries welding current
Becomes part of the weld

Flux Coating
Produces a shielding gas
Can provide additional
filler
Forms a slag
58

CLASSIFICATION OF ELECTRODES (AWS 5.1)

E6010
Electrode

60 Psi
70
80
90
100
110
120

Welding
position

Coating and
current conditions

TYPES OF COVERING

Based of covering:
> Rutile electrodes
> Basic coated electrodes
> Cellulose coated electrode
>Iron powder,iron oxide electrodes
Based on application:
> carbon-manganese steel electrodes AWS A5.1
> Stainless steel electrodes A5.4
> Low alloy steel electrodes A5.5
> Copper & Copper alloy electrodes A5.6
> Aluminium & Aluminium alloy electrodes A5.10
> Nickel & Nickel alloy covered electrodes A5.11
> Hardfacing electrodes A5.13
> Covered electrodes for cast iron A5.15
AWTI

60

CHARACTERISTICS OF ELECTRODES

Rutile Electrodes:

Cellulose Electrode:

> Quite & smooth arc

>
>
>
>
>

> Forceful & noisy arc

Excellent slag removal
> Friable slag
Fine ripples
> Coarse ripples
Medium penetration
> Deep penetration
Thick slag
> Thin slag cover
Good running
> More gas shield
> vertical down
Basic Electrodes:
> Adequate penetration
> Slag removal is good
> Contains more iron powder
> Good mechanical Properties

AWTI

61

PURPOSE OF FLUX COATING

>> Gas shielding of arc
>> Stabilizes the arc
>> Provides slag blanket
>> Alloying element will improve the

mechanical

properties
>> Gives good appearance & penetration
>> Welding in all position is easy
>> Compensates for oxidation loss

AWTI

62

COMPOSITION OF FLUX IN THE ELECTRODE COATING

1. Organic substance or Cellulose material:
Wood, Flour & Cellulose
High arc force
Large volume of gas mostly hydrogen
2.

Rutile:
Found in sand
Arc stabilizer
Good slag former

3. Ball Clay:
Compound of silica & alumina
Slag former & Gives plasticity in the wet paste

AWTI

63

COMPOSITION OF FLUX IN THE ELECTRODE COATING

4.Iron powder:
Gives good operating characteristics
Improves arc stability
Makes the coating electrically conducting
5.Oxidizing Substance:
Makes the weld metal flow freely
Oxidizing substance are: iron oxide, Lamitite, Magnetite
6.Reducing Substances:
They compensate for manganese Ferro Silicon
Substances: Ferro Manganese, Ferro Silicon, Ferro Titanium
AWTI

64

COMPOSITION OF FLUX IN THE ELECTRODE COATING

7. Ionizing Substances:
Used for stabilizing the arc
Substances : Chalk, Marble
8.Binding substance:
Help the coating to grip firmly around the core wire
Substances: Sodium Silicate, Potassium Silicate

AWTI

65

Metal Transfer

Factors influencing metal transfer:

> Surface tension
> Force of gravity
> Magnetic forces
> Metallurgical factors
Surface tension forces:
> Holds the liquid metal droplet to the tip.
Force to be overcom
Force of gravity:
> Position of welding
Flat --- Helps in metal transfer
Overhead--Negative influence oppose metal transfe
Magnetic forces:
>Lorentz & Pinch forces.
AWTI
Metallurgical factors:

66

RECOMMENDED SHADE NUMBER OF THE COLOURED

GLASSES

Shade No.

Range of welding
current(Amps)

8--9

Upto 100 Amps

10--11

100300 Amps

12--14

Above 300 Amps

EWG
AWTI

67

AWTI

68

Welding Positions
GROOVE WELD

Flat position(1G)

Horizontal position(2G)

Vertical position(3G)

Overhead position(4G)
FILLET WELD

Flat position(1F)
Horizontal position(2F)

Vertical position(3F)

Overhead position(4F)
AWTI

69

AWTI

70

AWTI

71

AWTI

72

EFFECT OF VARIATION OF
PARAMETERS
1.CURRENT TOO LOW:
Uneven bead height
Poor penetration
Slag inclusion
Irregular ripples

2.CURRENT TOO HIGH:

Wide & flat beads in uneven shape

Excessive penetration parent metal
More spatter
Poor ripple appearance
Porosity
Undercut

AWTI

73

EFFECT OF VARIATION OF
PARAMETERS
3.ARC TOO SHORT:

Irregular ripple
Burn through
Unequal width & height of bead
Electrode freezing the job

4. ARC TOO LONG:

Unequal height of bead
Wide ripple
Crater with blow holes
More spatters

AWTI

74

EFFECT OF VARIATION OF
PARAMETERS
5 . TRAVEL TOO LOW:
More width & height of the bead
Slag inclusion

6. TRAVEL TOO FAST:

Narrow width of the bead
Porosity
Elongated ripples

AWTI

75

AWTI

76

ADVANTAGES OF SMAW PROCESS

>> Light & heavy gauge metals can be

>> Fabrication welding, Construction

Maintenance welding
>> All types of metals ( Ferrous, Noncan be welded

welded.

welding &
ferrous & alloys)

>> Welding operation is quick & easy

>> More suitable for short length welds
>> Less expensive
>> Less sensitive
>> It is portable

AWTI

77

APPLICATIONS OF SMAW PROCESS

>> Used for welding thin & thick gauge metals
>> Used in welding bridges, bus bodies,domestic
like grills for gates, windows, chairs,
doors .

items

>> Used in welding roof structure for workshop,

& cracked castings

broken

>> Whenever welding is done in outdoor work, this

process is very useful as a diesel generator
welding set can be used.
>> Used for hardfacing & repair welding

AWTI

78

Thank you