ME-101

Workshop Technology

Lecture 7
Types of Welding

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 Classifications of Welding Processes
1) Arc welding 4) Thermit Welding
Carbon arc
Metal arc 5) Solid State Welding
Metal inert gas Friction
Tungsten inert gas Ultrasonic
Plasma arc Diffusion
Submerged arc Explosive
Electro-slag
2) Gas Welding 6) Newer Welding
Oxy-acetylene Electron-beam
Air-acetylene Laser
Oxy-hydrogen
3) Resistance Welding 7) Related Process
Butt Oxy-acetylene cutting
Spot Arc cutting
Seam Hard facing
Projection Brazing
Percussion Soldering

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 Fusion Welding (Non-Pressure)
Arc Welding
The welding puddle is created by the effect of an arc. The arc burns between
the electrode and the workpieces. When the electrode melts, it functions as a
filler rod as well.
Metal Arc Welding
The arc burns between the melting electrode and the workpiece. The entrance of
atmospheric gasses into the arc and the welding puddle is prevented only by the gasses
and slag produced by the electrode.

Closed Circuit, Voltage source switched

on, no current flow because of non-
conductive air
First, electrode is touched briefly, short
circuit
Electron flow, transition resistance,
heating, electrode lifted up to a gap equals
to its own thickness.

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 Fusion Welding (Non-Pressure) Metal Arc Welding

Electrons collide with the oxygen and

nitrogen, formation of plasma, electron
tear out and smash the metal (positive
pole) with high speed, melt it, (4000 C).
Positive ions move towards electrode
(Negative pole), collide to produce high
temperature (3500 C), electrode melts and
drops fall off.

The flux coating on the rod

disintegrates and forms a gas shield.
The slag which forms prevents the
weld metal from becoming oxidized.
A suitable choice of metal and flux
coating allows the process to be used
for a wide variety of applications,
different metals and welding positions.

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 Fusion Welding (Non-Pressure) Protective Gas Arc Welding

The electrode arc and welding puddle are protected against the atmosphere by a
specially fed protective gas
Categorized on the basis of electrodes and nature of gas used

Metal Protective Arc Gas Welding

The arc burns between the wire electrode

and the workpiece.
The electrode melts and provides the
welding filler.
The wire electrode is fed into the arc by a
wire feed motor whose speed can be set
according to the wire diameter and the
current intensity.
The protective gas can be inert or active.

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 Fusion Welding (Non-Pressure) Protective Gas Arc Welding

Metal Inert Gas Welding (MIG Welding)

The protective gas is inert and does not

react with the melt.
This gives rise to a spray arc.
The transfer of material is in the form of
fine droplets and is free of short circuits.

Advantages: High rate of melting, suitable

for all alloyed and unalloyed steels,
aluminum, and its alloys , copper and its
alloys.

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 Fusion Welding (Non-Pressure) Protective Gas Arc Welding

Metal Active Gas Welding (MAG Welding)

Thin, medium and coarse (rough) sheet metals are welded with a short arc, which
heats the workpiece less.
A short circuit is caused when the drops of molten metal comes in contact with the
welding puddle.
This extinguishes the arc and the heat generation is interrupted.

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 Fusion Welding (Non-Pressure) Protective Gas Arc Welding

Tungsten Inert Gas Welding (TIG Welding)

The arc burns between a permanent electrode of tungsten and the workpiece, only
inert protective gas is used. Filler rod is fed by hand if needed.
When welding with direct current, the tungsten electrode can be used as the negative
pole, as a result of which the temperature at electrode is lower than that of positive
workpiece.
This means electrode can be pointed, and the arc is kept stable.

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 Resistance Plastic Welding (Pressure)
The heat required for welding is generated electrically by utilizing the electrical resistance
in the welding zone. The electric current is transmitted by electrodes. The workpieces are
welded under pressure.
The movement of the electrons is resisted particularly strongly at the welding joints, as a result
of which, part of their energy is converted into heat.
Spot Welding
Spot Welding is a process in which current and force are transmitted by spot welding
electrodes.
The parts are pressed between the electrodes and the current is then switched on.
A weld nugget is formed at the pressure point by electrical resistance of the material.
A welding timer switches off.

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 Resistance Plastic Welding (Pressure)
Seam Welding
Seam welding is a process in which contact rollers (upper roller generally driven) are used
in place of rod electrode. A smooth and compact, uninterrupted welding seam is produced,
because the welding points are extremely close to each other.

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 Resistance Plastic Welding (Pressure)
Flash Butt Welding
The workpieces which are held in gripping jaws are brought into light contact at the end
faces.
When the current is switched on, this results in the formation of an arc.
Once the joints begin to melt, the current is switched off and the welding surfaces are
forced together with high pressure.
A welding is formed.

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 Resistance Plastic Welding (Pressure)
Pressure Butt Welding
The workpieces are held in copper chucks which press them together and conduct the
current to the welding point.
Once the welding temperature raises (material becomes plastic), the current is switched
off and the pressure increased.
A bulge (a round swelling distorting a flat surface) forms at the welding point.

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 Welding Plastics (Solid State Welding)
Thermoplastics can be welded by use of heat and pressure. It is possible to use a plastic
of same type as filler
(i) Welding with a heating element
The workpieces are heated to a required working temperature on the joint faces with a
suitable heating element.
This element is then pulled away from the joint faces, and the heated faces of
workpieces are pressed together.

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 Welding Plastics (Solid State Welding)
(iv). Friction Welding
This process is used to join parts such as rods and pipes.
Part 1 is clamped in a friction welding machine or lather machine and rotated against
the stationary part 2 under pressure until the welding temperature is reached at the
joining point as a result of frictional heat.
The rotating part is stopped and pressed against the stationary part until the plastic at
the joint is solidified.

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 Classifications of Welding Processes
Submerged Arc Welding

The arc and the welding zone are covered by a layer of powder. The welding puddle is
protected from exposure of atmosphere by the slag formed by powder.
One of the most important automatic welding.

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 New Technology Welding
Electron Beam Welding
A metal joining process in which melting is
produced by the heat of a concentrated stream of
high velocity electrons impinging on the metal to be
welded.
The kinetic energy of the electrons is changed into
heat upon impact with the workpiece.
A vacuum chamber provides the protective
atmosphere. No filler material is used in most
applications. The process has greater efficiency
than laser beam. Electron beam equipment is very
Typical uses
expensive.
Automobile components e.g. gears and
Almost any metal can be welded by the electron- transmission assemblies, aircraft engine
beam process, including those like zirconium, and aerospace products, and domestic
beryllium and tungsten that are difficult to weld by Appliances.
other methods High capacity electron beam equipment
Electron beam welds typically exhibit a narrow is used for pressure vessel, nuclear,
profile and remarkable penetrations process plant and chemical plant.

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 New Technology Weldings
LASER BEAM WELDING
In Laser welding a focused beam of monochromatic light
(the laser beam) is focused on the joint, creating a
plasma, and local melting.

Typically, no filler metal is used. Shielding gas is blown

through a nozzle in the laser unit to protect the weld.

Because laser welding does not require a vacuum

chamber, it has taken over many applications from e-
beam welding, particularly in the microelectronics field.
The laser beam can be focused to 0.1 to 1.0 mm
diameter.
Due to narrow weld pool geometry, high travel speed of
the beam and low total heat input the molten metal
solidifies quickly producing a very thin heat affected zone
and little thermal distortion

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 Gas Cutting
Ferrous metal is heated into red hot condition and a jet of pure oxygen is
projected onto the surface, which rapidly oxidizes.

Oxides having lower melting point than the metal, melt and are blown away by
the force of the jet, to make a cut.

Fast and efficient method of cutting steel to a high degree of accuracy.

Torch is different from welding.

PIERCING and GOUGING are two important operations,

Piercing, used to cut a hole at the centre of the plate or away from the edge of
the plate
Gouging, to cut a groove into the steel surface

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Gas Cutting

Manual Gas Cutting

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MILD STEEL COATED ELECTRODES

E7018-X
E Indicates that this is an electrode

70 Indicates how strong this electrode is when

welded. Measured in thousands of pounds per
square inch.
1 Indicates in what welding positions it can be
used.
8 Indicates the coating, penetration, and current
type used. (See Classification Table below)
X Indicates what additional alloys are in this
electrode
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WELDING POSITIONS
1 Flat, Horizontal, Vertical (up), Overhead

2 Flat, Horizontal

4 Flat, Horizontal, Overhead, Vertical (down)

Flat Position - usually groove welds, fillet welds

only if welded like a V
Horizontal - Fillet welds, welds on walls (travel is
from side to side).
Vertical - welds on walls (travel is either up or
down).
Overhead - weld that needs to be done upside
down.
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CLASSIFICATION TABLE
Class Electrode Coating ,Penetration ,Current Type
Exxx0 Cellulose(Paper), Sodium Deep- DCEP

Exxx1 Cellulose, Potassium -Deep AC, DCEP

Exxx2 Rutile(Titanium Dioxide), Sodium-Medium AC, DCEN

Exxx3 Rutile, Potassium- Light- AC, DCEP, DCEN

Exxx4 Rutile, Iron Powder Medium- AC, DCEP, DCEN

Exxx5 Low Hydrogen, Sodium- Medium -DCEP

Exxx6 Low Hydrogen, Potassium- Medium- AC, DCEP

Exxx7 Iron Powder, Iron Oxide- Medium -AC, DCEN

Exxx8 Low Hydrogen, Iron Powder -Medium -AC, DCEP

Exxx9 Iron Oxide, Rutile, Potassium -Medium -AC, DCEP,

DCEN
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