INTRODUCTION OF WELDING

Welding is a process for joining different materials.

The large bulk of materials that are welded are metals
and their alloys, although the term welding is also
applied to the joining of other materials such as thermo
plastics. Welding joins different metals/alloys with the
help of a number of processes in which heat is supplied
either electrically or by means of a gas torch. In order
to join two or more pieces of metals together by one of
the welding processes, the most essential requirement
is Heat. Pressure may also be employed. Since a slight
gap usually exists between the edges of the work
pieces, a 'filler metal is used to supply additional
material to fill the gap. But, welding can also be carried
out without the use of filler metal. The filler metal is
melted in the gap, combines with the molten metal of
the work piece and upon solidification forms an integral
part of the weld.

PRINCIPLE OF WELDING

An ideal joint between two pieces of metal or plastic

can be made by heating the workpieces to a suitable
temperature. In other words, on heating, the materials
soften sufficiently so that the surfaces fuse together.

The bonding force holds the atoms, ions or molecules

together in a solid. This 'bonding on contact' is
achieved only when: the contaminated surface layers
on the workpiece are removed, recontamination is
avoided, and the two surfaces are made smooth, flat
and fit each other exactly.

In highly deformable materials, the above aims can

be achieved by rapidly forcing the two surfaces of the
workpiece to come closer together so that plastic
deformation makes their shape conform to each
another; at the same time, the surface layers are
broken up, allowing the intimate contact needed to fuse
the materials.

This was the principle of the first way known to weld

metals; by hammering the pieces together while they
are in hot condition.

CLASSIFICATION OF WELDING PROCESSES

There are about 35 different welding and brazing

processes and several soldering methods in use by
industry today.

There are various ways of classifying the welding and

allied processes. For example, they may be classified
on the basis of: Source of heat, i.e., flame, arc, etc
Type of interaction i.e. liquid/liquid (fusion welding) or
solid/solid (solid state welding).

In general, various welding and allied processes are

classified as follows:

1.Gas Welding :
1.Air Acetylene Welding
2.Oxyacetylene Welding
3.Oxy hydrogen Welding
4.Pressure gas Welding

ADVANTAGES OF WELDING

A good weld is as strong as the base metal.

General welding equipment is not very costly.
Portable welding equipments are available.
Welding permits considerable freedom in design.
A large number of metals/alloys both similar and dissimilar
can be joined by welding.
Welding can join workpieces through spots, as continuous
pressure tight seams, end-to-end and in a number of other
configurations.
Welding can be mechanized.

DISADVANTAGES 0F WELDING

Welding gives out harmful radiations (light), fumes and

spatter.
Welding results in residual stresses and distortion of the
work-pieces.
Edge preparation of the workpieces is generally required
before welding them.
A skilled welder is a must to produce a good welding job.

 Welding heat produces metallurgical changes. The structure

of the welded joint is not same as that of the parent metal.
A welded joint, for many reasons, needs stress-relief heattreatment.

PRINCIPLE

The source of heat for arc welding process is an

'electric arc' generated between two electrically
conducting materials.
One of the workpiece material called 'electrode' is
connected to one pole of the electric circuit, while the
other workpiece which forms the second conducting
material is connected to the other pole of the circuit.
When the tip of the electrode material is brought in
contact with the workpiece material and momentarily
separated by small distance of 2-4 mm, an arc can be
generated.
The electrical energy is thus converted to heat
energy.
The high heat of the arc melts the edges of the
workpieces.
Coalescence takes place where the molten metal of
the one workpiece combines with the molten metal of
the other workpiece.
When the coalesced liquid solidifies, the two
workpieces join together to form a single component.

 The electrode material can be either a nonconsumable material or a Consumable material.

The non-consumable electrode made of tungsten,
graphite etc., serve only to strike the arc and is not
consumed during the welding process.
Whereas, the consumable electrode which is made of
the same material as that of the workpiece metal helps
to strike the arc and at the same time melt (gets
consumed) and combines with the molten metal of the
workpiece to form a weld.

TIG MACHINES

Introduction of tig welding

TIG welding is an arc welding process, which requires th
e welder to manipulate an electric arc in a manner simil
ar to the technique used for OxyAcetylene welding. A tu
ngsten electrode provides a jumping off point for an ele
ctric arc. The electrode, the arc and the base material a
re protected from atmospheric effects, by the flow of a
nonreactive gas. The nonreactive gas, which it is used i
n our shops, is Argon. The process of melting the parent
material, combined with filler material, produces a grea
t metallurgical bond.

Here are some advantages to MIG welding:

1.The ability to join a wide range of metals and
thicknesses
2.All-position welding capability
3.A good weld bead
4.A minimum of weld splatter
5.Easy to learn

Here are some disadvantages of MIG welding:

1.MIG welding can only be used on thin to medium
thick metals
2.The use of an inert gas makes this type of welding
less portable than arc welding which requires no
external source of shielding gas
3.Produces a somewhat sloppier and less controlled
weld as compared to TIG (Tungsten Inert Gas Welding)