Welding is a fabrication process that joins materials,

usually metals or thermoplastics, by causing coalescence.

This is often done by melting the workpieces and adding a
filler material to form a pool of molten material (the weld
puddle) that cools to become a strong joint, with pressure
sometimes used in conjunction with heat, or by itself, to
produce the weld. This is in contrast with soldering and
brazing, which involve melting a lower-melting-point
material between the workpieces to form a bond between
them, without melting the workpieces.
 Welding Processes

Fusion Brazing & Soldering Solid State

Chemical Electrical Electrical Chemical Mechanical

Fusion
Chemical
Oxyfuel Gas
 Oxyfuel Gas

Oxy-fuel welding (commonly called oxyacetylene welding, oxy welding, or gas

welding (US)) and Oxy-fuel cutting are processes that use fuel gases and
oxygen to weld or cut metals.
In Oxy-fuel welding, a welding torch is used to weld metals. Welding metal
results when two pieces are heated to a temperature that produces a shared
pool of molten metal. The molten pool is generally supplied with additional
metal called filler. Filler material depends upon the metals to be welded.
Fusion
Electrical
Arc
Shielded Metal-Arc Welding Submerged Arc Welding

Gas Metal-Arc Welding Gas Tungsten-Arc Welding

Flux Cored Arc Welding Electroslag Welding

Electrogas Welding Plasma Arc Welding

Shielded Metal-Arc Welding [SMAW]
 Shielded Metal-Arc Welding [SMAW]

Shielded Metal Arc Welding (SMAW) is frequently referred to as stick or

covered electrode welding. Stick welding is among the most widely
used welding processes.

The flux covering the electrode melts during welding. This forms the
gas and slag to shield the arc and molten weld pool. The slag must be
chipped off the weld bead after welding. The flux also provides a
method of adding scavengers, deoxidizers, and alloying elements to
the weld metal.
 Shielded Metal-Arc Welding [SMAW] Benefits

1- Equipment used is simple, inexpensive, and portable.

2- Electrode provides and regulates its own flux.

3- Lower sensitivity to wind and drafts than gas shielded

Welding Processes.

4- All position capability

 Shielded Metal-Arc Welding [SMAW] Problems

1- Arc Blow. 2- Arc Stability.

3- Excessive sp 4- Incorrect weld profile.
5- Rough surface. 6- Porosity
Submerged Arc Welding. [SAW]
 Submerged Arc Welding. [SAW]

Submerged arc welding (SAW) is a high

quality, very high deposition rate welding
process. Submerged arc welding is a high
deposition rate welding process commonly
used to join plate
 Submerged Arc Welding. [SAW] Benefits

1- Extremely high deposition rates possible.

2- High quality welds.
3- Easily automated.
4- Low operator skill required
 Submerged Arc Welding. [SAW] Problems

1- Solidification Cracking.
2- Hydrogen Cracking.
3- Incomplete fusion.
4- Irregular wire feed.
5- Porosity.
Gas Metal-Arc Welding. [GMAW] MIG Welding
Gas Metal-Arc Welding. [GMAW] MIG Welding

Gas Metal Arc Welding (GMAW) is frequently

referred to as MIG welding. MIG welding is a
commonly used high deposition rate welding
process. Wire is continuously fed from a
spool. MIG welding is therefore referred to as
a semiautomatic welding process.
 MIG Welding [Benefits]

1- All position capability.

2- Higher deposition rates than SMAW.
3- Less operator skill required.
4- Long welds can be made without starts and stops.
5- Minimal post weld cleaning is required.
 MIG Welding Shielding Gas

1- Argon.
2- Argon - 1 to 5% Oxygen.
3- Argon - 3 to 25% CO2.
4- Argon/Helium.

CO2 is also used in its pure form in some MIG welding

processes. However, in some applications the presence of CO2 in the
shielding gas may adversely affect the mechanical properties of the weld
 MIG Welding [Problems]

1- Heavily oxidized weld deposit.

2- Irregular wire feed.
3- Burnback.
4- Porosity.
5- Unstable arc.
6- Difficult arc starting.
Gas Tungsten-Arc Welding.[GTAW] TIG Welding
Gas Tungsten-Arc Welding.[GTAW] TIG Welding

Gas Tungsten Arc Welding (GTAW) is frequently referred to as TIG

welding. TIG welding is a commonly used high quality welding
process. TIG welding has become a popular choice of welding
processes when high quality, precision welding is required.

In TIG welding an arc is formed between a nonconsumable

tungsten electrode and the metal being welded. Gas is fed
through the torch to shield the electrode and molten weld
pool. If filler wire is used, it is added to the weld pool separately
 TIG Welding [Benefits]

1- Superior quality welds.

2- Welds can be made with or without filler metal.
3- Precise control of welding variables (heat).
4- Free of spatter.
5- Low distortion.
 Shielding Gases

1- Argon.
2- Argon + Hydrogen.
3- Argon/Helium.

Helium is generally added to increase heat input (increase welding

speed or weld penetration). Hydrogen will result in cleaner looking
welds and also increase heat input, however, Hydrogen may promote
porosity or hydrogen cracking
 TIG Welding [Problems]

1- Erratic arc
2- Excessive electrode consumption.
3- Oxidized weld deposit.
4- Arc wandering.
5- Porosity.
6- Difficult arc starting.
Soldering and Brazing are joining processes where
parts are joined without melting the base metals.

- Soldering filler metals melt below 840 F.

- Brazing filler metals melt above 840 F.

Soldering is commonly used for electrical

connection or mechanical joints, but brazing is only
used for mechanical joints due to the high
temperatures involved
4.1. Production Technology: Dr\ M. El-Shennawy.
4.2. http://www.fortunecity.com/village/lind/247/weld_book/fig11-9.gif
4.3. http://en.wikipedia.org/wiki/Welding
4.4. http://en.wikipedia.org/wiki/Arc_welding
4.5. http://www.weldingengineer.com/
4.6. http://www.weldingengineer.com/ Very Important
4.7. http://www.khake.com/page89.html