ME: 121 Engineering Practices: Types of Welding

ME: 121
Engineering Practices
Lecture 6
Types of Welding

Sunday, July 20, 2014 1 Welding
Types of Welding

Fusion Welding or Non-Pressure Welding
o The material at the joint is heated to a molten state and allowed to solidify (Ex)
Gas welding, Arc welding

Plastic Welding or Pressure Welding
o The piece of metal to be joined are heated to a plastic state and forced together
by external pressure (Ex) Resistance welding

Classifications of Welding Processes
1) Arc welding
Carbon arc
Metal arc
Metal inert gas
Tungsten inert gas
Plasma arc
Submerged arc
Electro-slag
2) Gas Welding
Oxy-acetylene
Air-acetylene
Oxy-hydrogen
3) Resistance Welding
Butt
Spot
Seam
Projection
Percussion
4) Thermit Welding

5) Solid State Welding
Friction
Ultrasonic
Diffusion
Explosive

6) Newer Welding
Electron-beam
Laser

7) Related Process
Oxy-acetylene cutting
Arc cutting
Hard facing
Brazing
Soldering
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.
Electrons collide with the oxygen and
nitrogen, formation of plasma, electron
torn 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.
Fusion Welding (Non-Pressure) Metal Arc Welding
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.
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.
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.
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.
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.
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.
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 icicle is formed.
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 has been reduced (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.

Welding Plastics (Solid State Welding)
(i) Welding with a heating element
Thermoplastics can be welded by use of heat and pressure. It is possible to use a plastic
of same type as filler
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.
(ii). Heating Coil Welding
A heating filament is embedded in the collar and remains there.

The pipe to be joined is inserted in the collar and the heating coil connected to an
electric current.

The collar of the workpiece heats up.

The welding force is generated by the thermal expansion of the workpieces.
(iii). Ultrasonic Welding
The parts are pressed against each other and the joining surfaces heated and
made to join by means of mechanical vibrations in the ultrasonic range.

Used for welding foils and soft PVC.
(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.
Classifications of Welding Processes
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.
Submerged Arc Welding
New Technology 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
expensive.
Almost any metal can be welded by the electron-
beam process, including those like zirconium,
beryllium and tungsten that are difficult to weld by
other methods
Electron beam welds typically exhibit a narrow
profile and remarkable penetrations
Typical uses
Automobile components e.g. gears and
transmission assemblies, aircraft engine
and aerospace products, and domestic
Appliances.
High capacity electron beam equipment
is used for pressure vessel, nuclear,
process plant and chemical plant.
Electron Beam Welding
New Technology Weldings
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
LASER BEAM WELDING
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

Gas Cutting
Manual Gas Cutting

ME: 121 Engineering Practices: Types of Welding

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