WELDING

 1.0 Definition
 1.1 History
 1.2 Classification
a. Welding Electrodes
b. Welding Processes
c. Welding Positions
1.0 Definition
 Welding is a process of
permanent joining two materials
(usually metals) localised
coalescence resulting from a
suitable combination of
temperature , pressure and
metallurgical conditions.
 Weldability
 The weldability, also known
as joinability, of a material refers to its
ability to be welded. Many metals and
thermoplastics can be welded, but some
are easier to weld than others. A
material's weldability is used to
determine the welding process and to
compare the final weld quality to other
materials.
Materials that can be welded
1.1 History
 The history of joining metals goes
back several millennia called Forge
Welding . The ancient Greek historian
Herodotus states in The Histories of
the 5th century BC that Glaucus of
Chios "was the man who single-
handedly invented iron-
welding". Welding was used in the
construction of the Iron Pillar in Delhi.
 Early welding history
In Germany, metals were joined by
electric fusion as early as 1782.
English, French, and Russian
experiments in the 1800s
established the principles of
striking and maintaining an electric
arc with controlled voltage, and the
first arc welding process resulted
from ongoing efforts.
Cont.

 Recent welding history

New arc welding processes such
as GTAW and GMAW were
developed to meet the special
needs of industrial production and
there were ongoing improvements
and advances in electrode
technology
Cont.

 Modern welding history

Advances continued in electric arc
welding and brought such processes as
arc spot welding, atomic-hydrogen
welding, electro-slag and electro-gas
welding, plasma-arc welding and cutting,
submerged arc welding, and other
processes to answer special industry
needs.
1.Coating Flow
2.Rod
3.Shield Gas
4.Fusion
5.Base metal
6.Weld metal
7.Solidified Slag
Welding Electrodes
 E60XX indicates the minimum tensile
strength (in thousands of pounds per
square inch)
 EXX1X is for use in all positions.
 EXX2X is for use in flat and horizontal
positions.
 EXX3X is for flat welding.
Cont.
 The last two digits together, indicate the type of coating on the electrode and the
welding current the electrode can be used with. Such as DC straight, (DC -) DC
reverse (DC+) or A.C.
I won't describe the type of coatings of the various electrodes, but will give
examples of the type current each will work with.
 EXX10 DC+ (DC reverse or DCRP) electrode positive.
 EXX11 AC or DC- (DC straight or DCSP) electrode negative.
 EXX12 AC or DC-
 EXX13 AC, DC- or DC+
 EXX14 AC, DC- or DC+
 EXX15 DC+
 EXX16 AC or DC+
 EXX18 AC, DC- or DC+
 EXX20 AC ,DC- or DC+
 EXX24 AC, DC- or DC+
 EXX27 AC, DC- or DC+
 EXX28 AC or DC+
Welding Processes
 Shielded Metal Arc Welding (SMAW) - 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.
 Gas Metal Arc Welding (GMAW) - is a welding process in which an
electric arc forms between a consumable wire electrode and the
workpiece metal(s), which heats the workpiece metal(s), causing them
to melt, and join. Along with the wire electrode, a shielding gas feeds
through the welding gun, which shields the process from contaminants
in the air.
 Gas Tungsten Arc Welding (GTAW) - is an arc welding process that
uses a non-consumable tungsten electrode to produce the weld. The
weld area is protected from atmospheric contamination by an inert
shielding gas (argon or helium), and a filler metal is normally used,
though some welds, known as autogenous welds, do not require it.
Cont.
 Submerged Arc Welding (SAW) - is a common arc welding
process. Originally developed by the Linde - Union Carbide
Company. It requires a non-continuously fed consumable solid or
tubular (flux cored) electrode. The molten weld and the arc zone
are protected from atmospheric contamination by being
"submerged" under a blanket of granular fusible flux consisting of
lime, silica, manganese oxide, calcium fluoride, and other
compounds.
 Plasma Arc Welding (PAW) - is an arc welding process similar to
gas tungsten arc welding (GTAW). The electric arc is formed
between an electrode (which is usually but not always made of
sintered tungsten) and the workpiece. The key difference from
GTAW is that in PAW, by positioning the electrode within the body
of the torch, the plasma arc can be separated from the
shielding gas envelope.
Welding Positions

1F 2F 3F 4F

1G 2G 3G 4G