WELDING

CEET521: STRUCTURAL STEEL DESIGN

 TABLE OF CONTENTS

What is Welding?

Types of Welding Process

Classifications of Welds

NSCP 2015 Specifications on Welding

Basic Weld Symbols

Latest Technology on Welds

WHAT IS
WELDING?
WHAT IS WELDING?

Welding, technique used for joining metallic parts usually through the application of heat. This technique
was discovered during efforts to manipulate iron into useful shapes. (britannica.com)

Welding is the process by which two pieces of metal can be joined together. The process of welding
doesn't merely bond the two pieces together as in brazing and soldering, but, through the use of extreme
heat and sometimes the addition of other metals or gases, causes the metallic structures of the two
pieces to join together and become one. (M. Aguilar | brighthubengineering.com)

Welding is a process by which metallic parts are connected by heating their surfaces to a plastic or fluid
state and allowing the parts to flow together and join (with or without the addition of other molten
metal). (J.C. McCormac & S.F. Csernak | Structural Steel Design 5th Ed.)
TYPES OF WELDING PROCESS
TYPES OF WELDING PROCESS

ARC WELDING GAS WELDING RESISTANCE SOLID-

WELDING STATE WELDING
TYPES OF WELDING PROCESS
ARC WELDING

 Arc welding involves the use of a power supply and electrodes in order to form a welding arc
between the electrode and the material being welded (usually metal), in order to melt the materials, allowing
them to cool and fuse together. This method is probably the most popular type of welding process since it
includes many of the most popular types of welding, such as MIG, TIG, and Stick welding. Arc welding is divided
into consumable and non-consumable electrode methods.
TYPES OF WELDING PROCESS
ARC WELDING | CONSUMABLE ELECTRODE METHODS

Shielded Metal Arc Welding (SMAW) or Stick

Welding
 Shielded metal arc welding, or stick welding, is a
manual welding technique that relies on a consumable
electrode coated in flux that is then used to lay the
weld. This process is called stick welding because it uses
welding sticks or rods that are made up of filler
material and flux, the flux is used to protect the molten
metal of the weld and the filler is then used to join two
pieces of metal together.
TYPES OF WELDING PROCESS
ARC WELDING | CONSUMABLE ELECTRODE METHODS

Shielded Metal Arc Welding (SMAW) or Stick

Welding
 Stick welding offers a very low-cost welding
solution that requires minimal equipment. However,
the quality of the final weld is not always the best
as it can suffer from porosity, shallow penetration,
cracking and it is highly vulnerable to severe
weather and is generally less durable. Despite the
fact that stick welding is a very old technique, it is
still quite popular, especially in third world
countries where expensive or new equipment is
usually not widely available. Some of the fields that
still rely on stick welding include refrigeration,
plumbing, automotive and construction.
TYPES OF WELDING PROCESS
ARC WELDING | CONSUMABLE ELECTRODE METHODS

Gas Metal Arc Welding (GMAW) or MIG Welding

 Gas metal arc welding is the second most popular welding technique
used today. MIG stands for Metal Inert Gas Welding and it boils
down to the concept of combining two pieces of metal together with a
wire that is connected to an electrode current. The wire then passes
through the welding stick which is shielded by an inert gas.
 Some of the advantages that MIG welding offers over the other welding
techniques include ease of use and the lower degree of precision that is
required by the operator in order to obtain decent welds. However,
MIG welding usually ends up being a bit more sensitive to external
factors like wind, rain and dust and generally more settings like voltage
and wire speed need to be finely tuned by the operator. The two most
common quality problems associated with Metal Inert Gas Welding are
dross and porosity.
TYPES OF WELDING PROCESS
ARC WELDING | CONSUMABLE ELECTRODE METHODS

Gas Metal Arc Welding (GMAW) or MIG Welding

 MIG ends up being much easier to master for operators as it is
quite simple because the electrode is being automatically fed
through the torch. Unlike TIG welding where both hands are used,
in MIG the operator guides the welding gun across the area being
welded.
 MIG welding is most commonly used in automotive repair as it is
capable of providing a strong, sturdy weld that when done
correctly is able to withstand large forces, providing the level of
versatility and strength that is needed for such applications. MIG
welding is also commonly used in plumbing, construction, robotics
and the maritime industry and is generally considered an
improvement over the more archaic techniques.
TYPES OF WELDING PROCESS
ARC WELDING | CONSUMABLE ELECTRODE METHODS

Flux-Cored Arc Welding (FCAW)

 Flux-cored arc welding is quite similar to MIG, except for the fact that it uses
a special tubular wire filled with flux and the shielding gas is not always needed,
depending on the filler. FCAW is notable for being extremely inexpensive and
easy to learn, although there are several limitations in its applications and the
results are often not as aesthetically pleasing as some of the other types of
welding methods.
 Some of the advantages it offers over other techniques include versatility, due to
the large amount of fillers that can be used, suitability for outdoor welding and
windy conditions because no shielding gas is needed with the right type of filler
and the fact that it is a very fast technique that tends to be very forgiving on
inexperienced operators.
TYPES OF WELDING PROCESS
ARC WELDING | CONSUMABLE ELECTRODE METHODS

Submerged Arc Welding (SAW)

 Used mostly on ferrous steel and nickel-based alloys, submerged arc
welding is a rather common arc welding technique due to its minimal
emissions of welding fumes and arc lights, making it safer than most
welding processes. SAW results in deep weld penetration, and involves
minimal preparation, making it a quick and efficient form of welding.
 Patented in 1935 by Jones, Kennedy, and Rothermund, Submerged Arc
Welding involves welding beneath a blanket of granular fusible flux
consisting of silica, calcium fluoride, lime, manganese oxide, and other
compounds. As heat builds up the flux becomes conductive and provides a
path between the electrode and the welding material. Since the whole
process takes place beneath the flux, the welder is protected from
ultraviolet and infrared radiation that are a natural part of the SMAW
process.
TYPES OF WELDING PROCESS
ARC WELDING | NON-CONSUMABLE ELECTRODE METHODS

Gas Tungsten Arc Welding (GTAW) or TIG Welding

 TIG Welding stands for Tungsten Inert Gas and is a technique
that’s known for using a non-consumable tungsten electrode along
with an inert gas (usually argon). Tungsten is a rare, hard element
that offers a high purity, high-quality weld.
 In TIG welding, the heat is created by running an electric current
through a tungsten electrode, creating an arc that is then used to
melt a metal wire in order to create the weld pool.
 TIG welding is the most popular welding technique used today
because it offers a high degree of purity, a clean weld and it can be
used in many industrial, residential and commercial applications.
TIG is most commonly used to weld stainless steel together,
although other metals like magnesium, aluminum, copper and nickel
can be welded using TIG.
TYPES OF WELDING PROCESS
ARC WELDING | NON-CONSUMABLE ELECTRODE METHODS

Gas Tungsten Arc Welding (GTAW) or TIG Welding

 TIG Welding is highly popular in industries that work
with nonferrous metals and it is commonly used in the
manufacturing of vehicles, tubing, bicycles, as well as the
maintenance and repair of tools and dies made of
aluminum, magnesium and stainless steel and it is the
preferred technique by engineers who demand a high
degree of precision on their welds as it offers greater
control over the weld area than other welding
processes, although the final quality of the weld will be
affected by factors such as cleanliness, operator skill,
quality of the materials being used and other external
factors such as rust or grit.
TYPES OF WELDING PROCESS
ARC WELDING | NON-CONSUMABLE ELECTRODE METHODS

Electroslag Welding (ESW)

 Known for being a very efficient, single-pass welding process
that is generally used on thick, nonferrous metals. It is known
for using an electric arc that is struck by wire and then fed into
the welding puddle along with flux until the slag reaches the
electrode and extinguishes the arc. As stated before, this
technique is mostly used to weld thick pieces of metal as it
requires a very high level of skill and it is very popular in
maritime applications as well as the aerospace industry.
TYPES OF WELDING PROCESS
ARC WELDING | NON-CONSUMABLE ELECTRODE METHODS

Atomic Hydrogen Welding (AHW)

 This is an older arc welding process which is slowly being
replaced by gas metal arc welding. The process of atomic
hydrogen welding was invented by Irving Langmuir after
his discovery of atomic hydrogen and involves placing two
metal tungsten electrodes in a hydrogen atmosphere,
leading to the hydrogen molecules breaking up and
recombining in an explosion of heat which can reach
temperatures above 3000 degrees Celsius.
 The AHW torch is hot enough to weld tungsten, which is
highly resistant to heat and does so in a manner that does
not damage the metal and creates a strong, cohesive weld.
TYPES OF WELDING PROCESS
ARC WELDING | NON-CONSUMABLE ELECTRODE METHODS

Carbon Arc Welding (CAW)

 Developed in 1881 by Nikolay Benardos and Stanislaw Olszewski, carbon
arc welding is the first Arc welding process ever invented but is hardly
used today as it has been replaced by more efficient and less dangerous
processes such as twin carbon arc welding. The process welds metals
together by heating them with a non-consumable carbon electrode,
heating them to temperatures in excess of 3000 degrees Celsius.
TYPES OF WELDING PROCESS
ARC WELDING | NON-CONSUMABLE ELECTRODE METHODS

Electrogas Welding (EGW)

 Invented in 1961, electrogas welding is similar to
Electroslag welding in that the metal being welded is struck
with a consumable electrode, without the use of pressure.
Divergent from its ESW counterpart, in EGW the arc is not
extinguished, and remains struck during the process. It is
mainly used in the shipbuilding and storage tank industries.
TYPES OF WELDING PROCESS
GAS WELDING

 Developed in 1903 by French engineers Edmond Fouché and Charles

Picard, Gas welding, Also known as Oxyfuel welding or
oxyacetylene welding, is the process of combining fuel gasses and
pure oxygen in order to increase the welding torch’s flame
temperature to around 3500 degrees Celsius.
 It is one of the oldest welding processes and is still used today in
certain industries such as pipe and tube welding, as well as certain
repair industries. There are even some types of metal-based artists
using gas welding to this day.
TYPES OF WELDING PROCESS
RESISTANCE WELDING

 Resistance welding process involves applying force to adjacent

surfaces and then applying an electric current near and upon the
surfaces, generating intense heat. There are many variations of this
technique, namely spot welding, seam welding, butt welding,
flash welding, projection welding, and upset welding.
TYPES OF WELDING PROCESS
SOLID-STATE WELDING

 Solid-state welding produces welding through temperatures

below the melting point of the materials being welding and
does not use a filler material. This process relies on the trifecta
of time, temperature, and pressure, individually or in tandem in
order to join the metals without significantly melting them. The
curious thing about solid-state welding is that it’s one of the
oldest forms of welding, and yet some of the newest and most
modern welding techniques are based upon it as well.
 There are many variations of solid-state welding, including
ultrasonic welding, explosion welding, friction welding
(including friction stir welding), magnetic pulse welding,
co-extrusion welding, cold welding, diffusion bonding,
exothermic welding, high-frequency welding, hot
pressure welding, induction welding, and roll welding.
CLASSIFICATIONS OF WELDS
 Based on the Types of Based on the Positions of Based on the Types of
Welds made the Welds Joints used

CLASSIFICATIONS OF WELDS
CLASSIFICATIONS OF WELDS
BASED ON THE TYPES OF WELDS MADE

 Fillet Welds – those made where parts lap over each other.
 Groove Welds – used when the members to be connection
lined up in the same plane. It can be either complete-
penetration welds, which extend for the full thickness of the
part being connected, or partial-penetration welds, which
extend for only part of the member thickness.
 Plug Welds – a circular weld that passes through one member
into another, thus joining the two together.
 Slots Welds – a weld formed in a slot, or elongated hole, that
joins one member to the other through the slot. The slot may
be partyl or fully filled with weld material.
CLASSIFICATIONS OF WELDS
BASED ON THE POSITIONS OF WELDS

 Flat Welds – the welding is performed

from the upper side of the joint, and the
face of the weld is approximately
horizontal.
 Horizontal Welds – the axis of a weld is
a line through the length of the weld,
perpendicular to the cross section at its
center of gravity.
 Vertical Welds – the axis of the weld
is approximately vertical.
 Overhead Welds – the welding
is performed from the underside of a joint.
 CLASSIFICATIONS OF WELDS
BASED ON THE TYPES OF JOINTS USED

 Butt-joint Welds – is also known as a square

grove weld. It consists of two flat pieces that are side by
side parallel.
 Lap-joint Welds – are used most often to joint two pieces
with differing thicknesses together. A Lap Joint is formed
when 2 pieces are placed in an over lapping pattern on
top of each other.
 Tee-joint Welds – are formed when two
members intersect at a 90° angle which makes the edges
come together in the center of a plate or component
 Edge-joint Welds – are often applied to sheet metal parts
that have flanging edges or are placed at a location where a
weld must be made to attach to adjacent pieces
 Corner-joint Welds – is used on the outer edge of the
piece. This weld is a type of joint that comes together at
right angles between two metal parts to form an L.
NSCP 2015
SPECIFICATIONS
ON WELDING
NSCP 2015 SPECIFICATIONS ON WELDING
SEC. 555.2: WELDED CONNECTIONS
NSCP 2015 SPECIFICATIONS ON WELDING
SEC. 555.2.1: GROOVE WELDS IN BUTT JOINTS
NSCP 2015 SPECIFICATIONS ON WELDING
SEC. 555.2.2:ARC SPOT WELDS
NSCP 2015 SPECIFICATIONS ON WELDING
SEC. 555.2.3:ARC SEAM WELDS
NSCP 2015 SPECIFICATIONS ON WELDING
SEC. 555.2.4: FILLET WELDS
NSCP 2015 SPECIFICATIONS ON WELDING
SEC. 555.2.4: FILLET WELDS
NSCP 2015 SPECIFICATIONS ON WELDING
SEC. 555.2.6: RESISTANCE WELDS
NSCP 2015 SPECIFICATIONS ON WELDING
SEC. 555.2.7: RUPTURE IN NET SET SECTION OF MEMBERS OTHER THAN FLAT SHEETS (SHEAR LAG)
BASIC WELD SYMBOLS
BASIC WELD SYMBOLS
BASIC WELD
SYMBOLS
BASIC WELD SYMBOLS
BASIC WELD
SYMBOLS

SAMPLE WELD SYMBOLS

LATEST
TECHNOLOGY
ON WELDS
EFFECTS OF WELDING TECHNOLOGY ON
THE OCCURRENCE OF FRACTURE IN
WELDED JOINTS (2018)
  Welded joints represent locations where failure is most likely to occur in
welded structures. Welded joint failure depends on their vulnerability to
crack initiation and growth. These factors are significantly influenced by the
welding technology.
EFFECTS OF WELDING  The effect of welding technology on the frequency of welded joint failure is
complex, and has been thoroughly researched in literature. However, there
TECHNOLOGY ON are still numerous factors whose influence is not sufficiently explained.
THE OCCURRENCE OF  In this paper, the ratio of strength and plasticity of parent materials and weld
metals on deformation properties of welded joint zones were analyzed,
FRACTURE IN WELDED along with the effects of groove.
JOINTS (2018)

 By R. Jovičić et al.
 Procedia Structural Integrity
13, 1682-1688
 https://doi.org/10.1016/j.prostr.
2018.12.351
EFFECTS OF WELDING TECHNOLOGY ON THE
OCCURRENCE OF FRACTURE IN WELDED JOINTS (2018)

 The selection of filler material can affect the distribution of stresses and
strain in welded joints. In this way, it is possible to avoid the localization
of strain in welded joint parts with lower deformability, or to localize the
strain in welded joint parts with high deformability. By doing so, the
probability of crack initiation and growth, i.e. fracture is reduced.
 Parent material temperature increases along the groove edge, due to its
heating via the arc. This temperature increase affects the cooling time
t8/5 in the same way as the increasing of preheating
or interpass temperatures. Cooling times t8/5 are shortest at the start
of a welded joint and increase in duration towards their end.
EFFECTS OF WELDING TECHNOLOGY ON THE
OCCURRENCE OF FRACTURE IN WELDED JOINTS (2018)

 Welded joints typically contain multiple forming defects at the same

location. Defects grouped in this way cause a local increase in stresses,
thus contributing to crack initiation. Due to this, a larger number of less
dangerous defects concentrated at a single location in a welded joint can
cause higher local stress concentration, and thus, higher vulnerability to
fracture, compared to an individual, also typically unacceptable, defect.
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SUBMITTED BY:
RUSSEL D. ESPERIDA
CEE52