1 Introduction of Fundamental Welding

1.1 Steel Welding

1.2 Welding Equipment And Consumable
1.3 Basic Weld Types

2 Introduction of Basic Welding Symbol

2.1 Elements of Weld Symbol

2.2 Definition of Weld Elements
2.3 Basic weld symbol

3 Introduction of Methods of Welding Inspection

Non-Destructive Test: Penetration Test, Radiography, Ultrasonic Test,

Magnetic Test.
1. Introduction of Fundamental Welding

1.1 Steel Welding

Steel Welding is a process that joins steel workpiece by

ausing 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.
1 Introduction of Fundamental Welding

1.2 Welding Equipment and consumable

Arc welding uses a welding power supply to create an

electric arc between an electrode and the base material to
melt the metals at the welding point. They can use either
direct (DC) or alternating (AC) current, and consumable or
non-consumable electrodes. The welding region is sometimes
protected by some type of inert or semi-inert gas, known as a
shielding gas, and/or an evaporating filler material. The
process of arc welding is widely used because of its low
capital and running costs.
1 Introduction of Fundamental Welding

1.2 Welding Equipment and consumable

Electrode
Carbon Steel, Stainless Steel, Copper, Tin

Electrode Cable

Electrode Holder
1. Introduction of Fundamental Welding
1.3 Basic Weld Types
Shielded metal arc welding (SMAW)

Shielded metal arc welding (SMAW), also known as manual metal arc (MMA) welding or informally
as stick welding, is a manual arc welding process that uses a consumable electrode coated in flux to lay
the weld. An electric current, in the form of either alternating current or direct current from a welding
power supply, is used to form an electric arc between the electrode and the metals to be joined. As the
weld is laid, the flux coating of the electrode disintegrates, giving off vapors that serve as a shielding gas
and providing a layer of slag, both of which protect the weld area from atmospheric contamination.
Because of the versatility of the process and the simplicity of its equipment and operation, shielded metal
arc welding is one of the world's most popular welding processes. It dominates other welding processes
in the maintenance and repair industry, and though flux-cored arc welding is growing in popularity,
SMAW continues to be used extensively in the construction of steel structures and in industrial
fabrication. The process is used primarily to weld iron and steels (including stainless steel) but
aluminum, nickel and copper alloys can also be welded with this method
1 Introduce of fundamental welding

1.3 Basic Weld Types

Gas metal arc welding (GMAW)

Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert gas (MIG) welding or metal active gas
(MAG) welding, is a semi-automatic or automatic arc welding process in which a continuous and consumable wire electrode and
a shielding gas are fed through a welding gun. A constant voltage, direct current power source is most commonly used with
GMAW, but constant current systems, as well as alternating current, can be used. There are four primary methods of metal
transfer in GMAW, called globular, short-circuiting, spray, and pulsed-spray, each of which has distinct properties and
corresponding advantages and limitations.
Originally developed for welding aluminium and other non-ferrous materials in the 1940s, GMAW was soon applied to steels
because it allowed for lower welding time compared to other welding processes. The cost of inert gas limited its use in steels until
several years later, when the use of semi-inert gases such as carbon dioxide became common. Further developments during the
1950s and 1960s gave the process more versatility and as a result, it became a highly used industrial process. Today, GMAW is
the most common industrial welding process, preferred for its versatility, speed and the relative ease of adapting the process to
robotic automation. The automobile industry in particular uses GMAW welding almost exclusively. Unlike welding processes that
do not employ a shielding gas, such as shielded metal arc welding, it is rarely used outdoors or in other areas of air volatility. A
related process, flux cored arc welding, often does not utilize a shielding gas, instead employing a hollow electrode wire that

1) Direction of travel, (2) Contact
tube/electrode wire guide, (3)
Electrode, (4) Shielding gas, (5)
Molten weld metal, (6) Solidified
weld metal, (7) Workpiece.
(1) Torch handle, (2) Molded phenolic
dielectric (shown in white) and threaded metal
nut insert (yellow), (3) Shielding gas nozzle,
(4) Contact tip, (5) Nozzle output face
1 Introduce of fundamental welding

1.3 Basic Weld Types

Gas tungsten arc welding (GTAW)
Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding, is an
arc welding process that uses a nonconsumable tungsten electrode to produce the weld. The
weld area is protected from atmospheric contamination by a shielding gas (usually an inert gas
such as argon), and a filler metal is normally used, though some welds, known as autogenous
welds, do not require it. A constant-current welding power supply produces energy which is
conducted across the arc through a column of highly ionized gas and metal vapors known as a
plasma.
GTAW is most commonly used to weld thin sections of stainless steel and light metals such as
aluminum, magnesium, and copper alloys. The process grants the operator greater control over
the weld than competing procedures such as shielded metal arc welding and gas metal arc
welding, allowing for stronger, higher quality welds. However, GTAW is comparatively more
complex and difficult to master, and furthermore, it is significantly slower than most other
welding techniques. A related process, plasma arc welding, uses a slightly different welding
torch to create a more focused welding arc and as a result is often automated.[1]
1 Introduce of fundamental welding

1.3 Basic Weld Types

Laser beam welding

Laser beam welding (LBW) is a welding technique used to join multiple pieces of metal
through the use of a laser. The beam provides a concentrated heat source, allowing for narrow,
deep welds and high welding rates. The process is frequently used in high volume applications,
such as in the automotive industry.

Robot Welding

Robot welding is the use of mechanized programmable tools (robots), which

completely automate a welding process by both performing the weld and
handling the part. Processes such as gas metal arc welding, while often
automated, are not necessarily equivalent to robot welding,
2 Introduction of Basic Welding Symbol

2.1 Elements of Welding Symbol

Reference line
Placement of symbol

Effective groove weld size

Depth of preparation, size
Dimensions and other data
Tail
Basic weld symbol
Supplementary symbols
Finish symbols
Other Specification

Other side
Field weld

Spec., S (E)
Process, All around
Other reference
Arrow side
Connected
to reference
side
2 Introduction of Basic Welding Symbol

2.1 Elements of Welding Symbol

First-angle projection
In first-angle projection, the object is conceptually
located in quadrant I, i.e. it floats above and before the
viewing planes, the planes are opaque, and each view is
pushed through the object onto the plane furthest from it.
(Mnemonic: an "actor on a stage".) Extending to the 6-
sided box, each view of the object is projected in the
direction (sense) of sight of the object, onto the (opaque)
interior walls of the box; that is, each view of the object is
drawn on the opposite side of the box:
2 Introduction of Basic Welding Symbol

2.1 Elements of Welding Symbol

Third-angle projection
In third-angle projection, the object is conceptually located in
quadrant III, i.e. it lurks below and behind the viewing planes, the
planes are transparent, and each view is pulled onto the plane
closest to it. (Mnemonic: a "shark in a tank", esp. that is sunken into
the floor.) Using the 6-sided viewing box, each view of the object is
projected opposite to the direction (sense) of sight, onto the
(transparent) exterior walls of the box; that is, each view of the
object is drawn on the same side of the box. The box is then
unfolded to view all of its exterior walls.
Here is the construction of third angle projections of the same
object as above. Note that the individual views are the same, just
arranged differently.
2 Introduction of Basic Welding Symbol

2.1 Elements of Welding Symbol

Placement of welding symbol

Arrow side

Other side
2 Introduction of Basic Welding Symbol

2.2 Definition of Weld Dimension

¼ : Weld size
Toe
L
Throat length
¼
Toe
6 : Weld Length(L)
¼
Root
(Leg)

¼ 6
2 Introduction of Basic Welding Symbol

2.2 Definition of Weld Elements 60°

Effective groove weld size

Depth of preparation, size
3 1
(S) (E)
8 2

3 1
8 2 () 0
60°

S E

3
Depth of Bevel---
8
1
Groove weld size---2
1
8 Root opening---0
Groove Angle--60°
2 Introduction of Basic Welding Symbol

2.2 Definition of Weld Elements

Tail of reference line

Note: The specifications placed in the tail of the reference line usually
conform to the practices of each company.
If notations are not used, the tail of the symbol may be omitted

Welding process
Brand of filler metal
Preheating…
2 Introduction of Basic Welding Symbol

2.3 Basic weld symbol

Fillet Weld

The fillet weld is used to make lap joints, corner joints, and T joints.
As its symbol suggests, the fillet weld is roughly triangular in cross-
section, although its shape is not always a right triangle or an
isosceles triangle. Weld metal is deposited in a corner formed by the
fit-up of the two members and penetrates and fuses with the base
metal to form the joint.

The perpendicular leg of the triangle is always drawn on the left

side of the symbol, regardless of the orientation of the weld
itself. The leg size is written to the left of the weld symbol. If the
two legs of the weld are to be the same size, only one
dimension given; if the weld is to have unequal legs (much less
common than the equal-legged weld), both dimensions are
given and there is an indication on the drawing as to which leg
is longer.

Equal leg Unequal leg

2 Introduction of Basic Welding Symbol

2.3 Basic weld symbol

Fillet Weld

The length of the weld is given to the right of the symbol.

If no length is given, then the weld is to be placed between specified dimension

lines (if given) or between those points where an abrupt change in the weld
direction would occur (like at the end of the plates in the example above).
For intermittent welds, the length of each portion of the weld and the spacing of
the welds are separated by a dash (length first, spacing second) and placed to
the right of the fillet weld
symbol

Notice that the spacing, or pitch, is not the clear space between the welds, but
the center-to-center (or end-to-end) distance.
2 Introduction of Basic Welding Symbol

2.3 Basic weld symbol

Fillet Weld

Intermittent Welding
2 Introduction of Basic Welding Symbol

2.3 Basic weld symbol

Groove Welds

The groove weld is commonly used to make edge-to-edge joints, although it is

also often used in corner joints, T joints, and joints between curved and flat pieces.
As suggested by the variety of groove weld symbols, there are many ways to make
a groove weld, the differences depending primarily on the geometry of the parts to
be joined and the preparation of their edges. Weld metal is deposited within the
groove and penetrates and fuses with the base metal to form the joint.

The square groove weld, in which the "groove" is created by either a

tight fit or a slight separation of the edges. The amount of separation, if
any, is given on the weld symbol
2 Introduction of Basic Welding Symbol

2.3 Basic weld symbol

Groove Welds
The V-groove weld, in which the edges of both pieces are chamfered, either singly or doubly, to
create the groove. The angle of the V is given on the weld symbol, as is the separation at the root (if
any).

If the depth of the V is not the full thickness--or half the thickness in the case of a double V--the depth
is given to the left of the weld symbol.

If the penetration of the weld is to be greater than the depth of the groove, the depth of the effective
throat is given in parentheses after the depth of the V.
2 Introduction of Basic Welding Symbol

2.3 Basic weld symbol

Groove Welds

The bevel groove weld, in which the edge of one of the pieces is
chamfered and the other is left square. The bevel symbol's
perpendicular line is always drawn on the left side, regardless of the
orientation of the weld itself. The arrow points toward the piece that is
to be chamfered. This extra significance is emphasized by a break in
the arrow line.

The U-groove weld, in which the edges of both pieces are given
a concave treatment.

The J-groove weld, in which the edge of one of the pieces is given a
concave treatment and the other is left square. It is to the U-groove weld
what the bevel groove weld is to the V-groove weld. As with the bevel, the
perpendicular line is always drawn on the left side and the arrow (with a
break, if necessary) points to the piece that receives the edge
treatment.
2 Introduction of Basic Welding Symbol

2.3 Basic weld symbol

Groove Welds

The flare bevel groove weld,

The flare-V groove weld, commonly commonly used to join a round or
used to join two round or curved parts. curved piece to a flat piece.
2 Introduction of Basic Welding Symbol

2.3 Basic weld symbol

Groove Welds

Common supplementary symbols used with groove welds are the melt-thru and
backing bar symbols. Both symbols indicate that complete joint penetration is to
be made with a single-sided groove weld. In the case of melt-thru, the root is to be
reinforced with weld metal on the back side of the joint. The height of the
reinforcement, if critical, is indicated to the left of the melt-thru symbol, which is
placed across the reference line from the basic weld symbol.

When a backing bar is used to achieve complete joint penetration, its symbol is
placed across the reference line from the basic weld symbol. If the bar is to be
removed after the weld is complete, an "R" is placed within the backing bar symbol.
The backing bar symbol has the same shape as the plug or slot weld symbol, but
context should always make the symbol's intention clear.
2 Introduction of Basic Welding Symbol

2.3 Basic weld symbol

Plug and Slot Welds

Plug welds and slot welds are used join overlapping members, one
of which has holes (round for plug welds, elongated for slot welds) in it.
Weld metal is deposited in the holes and penetrates and fuses with the
base metal of the two members to form the joint. (Note: for the sake of
graphical clarity, the drawings below do not show the penetration of the
weld metal. Recognize, however, that the degree of penetration is
important in determining the quality of the weld.) For plug welds, the
diameter of each plug is given to the left of the symbol and the plug-to-
plug spacing (pitch) is given to the right. For slot welds, the width of
each slot is given to the left of the symbol, the length and pitch
(separated by a dash) are given to the right of the symbol, and a detail
drawing is referenced in the tail. The number of plugs or slots is given
in parentheses above or below the weld symbol. The arrow-side and
other-side designations indicate which piece contains the hole(s). If the
hole is not to be completely filled with weld metal, the depth to which it
is to be filled is given within the weld symbol.
3 Introduction of Methods of Welding Inspection

Non-Destructive Test: Penetration Test, Radiography, Ultrasonic Test, Magnetic Test.

Dye penetrant inspection (DPI), also

called liquid penetrant inspection (LPI), is
a widely applied and low-cost inspection
method used to locate surface-breaking
defects in all non-porous materials (metals,
plastics, or ceramics). Penetrant may be
applied to all non-ferrous materials, but for
inspection of ferrous components magnetic-
particle inspection is preferred for its
subsurface detection capability. LPI is used
to detect casting and forging defects, cracks,
and leaks in new products, and fatigue DPI is based upon capillary action,
cracks on in-service components. where low surface tension fluid
penetrates into clean and dry
surface-breaking discontinuities.
Penetrant may be applied to the
test component by dipping,
spraying, or brushing. After
adequate penetration time has
been allowed, the excess penetrant
is removed, a developer is applied.
The developer helps to draw
penetrant out of the flaw where a
visible indication becomes visible to
the inspector. Inspection is
performed under ultraviolet or white
light, depending upon the type of
dye used - fluorescent or
nonfluorescent (visible).
3 Introduction of Methods of Welding Inspection

Non-Destructive Test: Penetration Test, Radiography, Ultrasonic Test, Magnetic Test.

Radiographic Testing (RT), or industrial radiography, is a nondestructive testing (NDT) method of inspecting
materials for hidden flaws by using the ability of short wavelength electromagnetic radiation (high energy photons)
to penetrate various materials.
Either an X-ray machine or a radioactive source (Ir-192, Co-60, or in rare cases Cs-137) can be used as a source
of photons. (NR) is a variant of radiographic testing which uses neutrons instead of photons to penetrate materials.
This can see very different things from X-rays, because neutrons can pass with ease through lead and steel but
are stopped by plastics, water and oils.
Since the amount of radiation emerging from the opposite side of the material can be detected and measured,
variations in this amount (or intensity) of radiation are used to determine thickness or composition of material.
Penetrating radiations are those restricted to that part of the electromagnetic spectrum of wavelength less than
about 10 nanometres.

The beam of radiation must be directed to the middle of the section under examination and must be normal to the
material surface at that point, except in special techniques where known defects are best revealed by a different
alignment of the beam. The length of weld under examination for each exposure shall be such that the thickness of
the material at the diagnostic extremities, measured in the direction of the incident beam, does not exceed the actual
thickness at that point by more than 6%. The specimen to be inspected is placed between the source of radiation and
the detecting device, usually the film in a light tight holder or cassette, and the radiation is allowed to penetrate the
part for the required length of time to be adequately recorded.
The result is a two-dimensional projection of the part onto the film, producing a latent image of varying densities
according to the amount of radiation reaching each area. It is known as a radiograph, as distinct from a photograph
produced by light. Because film is cumulative in its response (the exposure increasing as it absorbs more radiation),
relatively weak radiation can be detected by prolonging the exposure until the film can record an image that will be
visible after development.
3 Introduction of Methods of Welding Inspection

Non-Destructive Test: Penetration Test, Radiography, Ultrasonic Test, Magnetic Test.

In ultrasonic testing, very short ultrasonic pulse-waves with center frequencies ranging from 0.1-15 MHz and occasionally up
to 50 MHz are launched into materials to detect internal flaws or to characterize materials. The technique is also commonly
used to determine the thickness of the test object, for example, to monitor pipework corrosion.
Ultrasonic testing is often performed on steel and other metals and alloys, though it can also be used on concrete, wood and
composites, albeit with less resolution. It is a form of non-destructive testing used in many industries including aerospace,
automotive and other transportation sect

An example of Ultrasonic Testing (UT) on blade roots of a V2500 IAE aircraft engine.
Step 1: The UT probe is placed on the root of the blades to be inspected with the help of a special borescope tool
(video probe).
Step 2: Instrument settings are input.
Step 3: The probe is scanned over the blade root. In this case, an indication (peak in the data) through the red line
(or gate) indicates a good blade; an indication to the left of that range indicates a crack.
3 Introduction of Methods of Welding Inspection

Non-Destructive Test: Penetration Test, Radiography, Ultrasonic Test, Magnetic Test.

In ultrasonic testing, an ultrasound transducer connected to a diagnostic machine is passed over the object
being inspected. The transducer is typically separated from the test object by a couplant (such as oil) or by
water, as in immersion testing.
There are two methods of receiving the ultrasound waveform, reflection and attenuation. In reflection (or pulse-
echo) mode, the transducer performs both the sending and the receiving of the pulsed waves as the "sound" is
reflected back to the device. Reflected ultrasound comes from an interface, such as the back wall of the object
or from an imperfection within the object. The diagnostic machine displays these results in the form of a signal
with an amplitude representing the intensity of the reflection and the distance, representing the arrival time of
the reflection. In attenuation (or through-transmission) mode, a transmitter sends ultrasound through one
surface, and a separate receiver detects the amount that has reached it on another surface after traveling
through the medium. Imperfections or other conditions in the space between the transmitter and receiver
reduce the amount of sound transmitted, thus revealing their presence.

At a construction site, a technician tests a

pipeline weld for defects using an
ultrasonic phased array instrument. The
scanner, which consists of a frame with
magnetic wheels, holds the probe in
contact with the pipe by a spring. The wet
area is the ultrasonic couplant that allows
the sound to pass into the pipe wall.