Welding Processes

Welding Processes
Ship Structures
A Brief History of Welding
A Brief History of Welding
Late 19
th
Century
Scientists/engineers apply advances in electricity to heat
and/or join metals (Le Chatelier, Joule, etc.
!arly "#
th
Century
$rior to %%& 'elding 'as not trusted as a method to join
t'o metals due to crac( issues
19)#*s and +#*s
&ndustrial 'elding gains acceptance and is used e,tensively
in the 'ar e--ort to .uild tan(s, aircra-t, ships, etc.
/odern %elding
the nuclear/space age helps .ring 'elding -rom an art to a
science
Types of Welding
Types of Welding
Fusion Welding Pressure Welding
Homogeneous Heterogeneous
Brazing Soldering
Gas Welding
Electroslag
High Energy Beam
Electric Arc
MIG
TIG
Shielded Metal Arc Stick
Friction Welding
Weldability of a Metal
Weldability of a Metal

/etallurgical Capacity

$arent metal 'ill join 'ith the 'eld metal 'ithout

-ormation o- deleterious constituents or alloys

/echanical Soundness

Joint 'ill .e -ree -rom discontinuities, gas porosity,

shrin(age, slag, or crac(s

Servicea.ility

%eld is a.le to per-orm under varying conditions

or service (e.g., e,treme temperatures, corrosive
environments, -atigue, high pressures, etc.
Fusion Welding Principles
Fusion Welding Principles

0ase metal is melted

1iller metal may .e added

2eat is supplied .y various means

3,yacetylene gas

!lectric 4rc

$lasma 4rc

Laser
Fusion Welding
Fusion Welding
BASE METAL
WELD
SOLDFED SLA!
A"# POOL
WELD$! ATMOSPHE"E
#O"E W"E
ELE#T"ODE #OAT$!
A"# ST"EAM
PE$ET"ATO$
DEPTH
Weld Metal Protection
Weld Metal Protection

5uring -usion 'elding, the molten metal in the

'eld 6puddle7 is suscepti.le to o,idation

/ust protect 'eld puddle (arc pool -rom the

atmosphere

/ethods

%eld 1lu,es

&nert 8ases

9acuum
Weld Fluxes
Weld Fluxes

:ypical -lu,es
Si3
"
, :i3
"
, 1e3, /g3, 4l
"
3
)

$roduces a gaseous shield to prevent

contamination

4ct as scavengers to reduce o,ides

4dd alloying elements to the 'eld

&n-luence shape o- 'eld .ead during

solidi-ication
Inert Gases
Inert Gases

4rgon, helium, nitrogen, and car.on

dio,ide

1orm a protective envelope around the

'eld area

;sed in

/&8

:&8

Shield /etal 4rc

acuu!
acuu!

$roduce high<=uality 'elds

;sed in electron .eam 'elding

>uclear/special metal applications

?r, 2-, :i

@educes impurities .y a -actor o- "#

versus other methods

!,pensive and time<consuming

Types of Fusion Welding
Types of Fusion Welding

3,yacetylene Cutting/%elding

Shielded /etal 4rc (6Stic(7

/etal &nert 8as (/&8

:ungsten &nert 8as (:&8

"xyacetylene Welding
"xyacetylene Welding

1lame -ormed .y .urning a mi, o- acetylene

(C
"
2
"
and o,ygen

1usion o- metal is achieved .y passing the

inner cone o- the -lame over the metal

3,yacetylene can also .e used -or cutting

metals
nner #one% &'''()*'' deg F #om+ustion En,elo-e *.'' deg F
/*'' deg F TO"#H TP
Shielded Metal Arc #Stic$%
Shielded Metal Arc #Stic$%

4n electric arc is generated .et'een a coated

electrode and the parent metal

:he coated electrode carries the electric

current to -orm the arc, produces a gas to
control the atmosphere and provides -iller
metal -or the 'eld .ead

!lectric current may .e 4C or 5C. &- the

current is 5C, the polarity 'ill a--ect the 'eld
siAe and application
Shielded Metal Arc #con&t%
Shielded Metal Arc #con&t%

$rocessB

&ntense heat at the arc melts the tip o- the

electrode

:iny drops o- metal enter the arc stream and are

deposited on the parent metal

4s molten metal is deposited, a slag -orms over

the .ead 'hich serves as an insulation against air
contaminants during cooling

4-ter a 'eld Cpass* is allo'ed the cool, the o,ide

layer is removed .y a chipping hammer and then
cleaned 'ith a 'ire.rush .e-ore the ne,t pass.
Inert Gas Welding
Inert Gas Welding

1or materials such as 4l or :i 'hich

=uic(ly -orm o,ide layers, a method to
place an inert atmosphere around the
'eld puddle had to .e developed

;ses a consuma.le electrode (-iller 'ire made o- the

.ase metal

&nert gas is typically 4rgon

Metal Inert Gas #MIG%
Metal Inert Gas #MIG%
BASE METAL P0DDLE
POWE"
SO0"#E
D"1E WHEELS
#O$S0MABLE
ELE#T"ODE
A"# #OL0M$ SHELD$! !AS
:ungsten electrode acts as a cathode
4 plasma is produced .et'een the tungsten cathode and the
.ase metal 'hich heats the .ase metal to its melting point
1iller metal can .e added to the 'eld pool
Tungsten Inert Gas #MIG%
Tungsten Inert Gas #MIG%
BASE METAL P0DDLE
POWE"
SO0"#E
A"# #OL0M$ SHELD$! !AS
T0$!STE$
ELE#T"ODE
+ +
BASE METAL 2A$ODE3
T0$!STE$
ELE#T"ODE
2#ATHODE3
( ( (
+ +
Welding Positions
Welding Positions
FLAT
FLAT
HO"4O$TAL
HO"4O$TAL
1E"T#AL
1E"T#AL
O1E"HEAD
O1E"HEAD
$#"EAS$! DFF#0LT5
Weld 'efects
Weld 'efects

;ndercuts/3verlaps

8rain 8ro'th
4 'ide : 'ill e,ist .et'een .ase metal and 24?.
$reheating and cooling methods 'ill a--ect the .rittleness o-
the metal in this region

0lo'holes
4re cavities caused .y gas entrapment during the
solidi-ication o- the 'eld puddle. $revented .y proper 'eld
techni=ue (even temperature and speed
Weld 'efects
Weld 'efects

&nclusions
&mpurities or -oreign su.stances 'hich are -orced into the 'eld
puddle during the 'elding process. 2as the same e--ect as a crac(.
$revented .y proper techni=ue/cleanliness.

Segregation
Condition 'here some regions o- the metal are enriched 'ith an
alloy ingredient and others aren*t. Can .e prevented .y proper heat
treatment and cooling.

$orosity
:he -ormation o- tiny pinholes generated .y atmospheric
contamination. $revented .y (eeping a protective shield over the
molten 'eld puddle.
(esidual Stresses
(esidual Stresses

@apid heating and cooling results in thermal stresses

detrimental to joint strength.

$revention
!dge $reparation/4lignment D .eveled edges and space
.et'een components to allo' movement
Control o- heat input D s(ip or intermittent 'eld techni=ue
$reheating D reduces e,pansion/contraction -orces (alloys
and removes moisture -rom the sur-ace
$eening D help metal stretch as it cools .y hitting 'ith a
hammer. ;se 'ith care since it may 'or( harden the metal
2eat :reatment D 6soa(7 the metal at a high temperature to
relieve stresses
Jigs and 1i,tures D prevent distortion .y holding metal -i,ed
>um.er o- $asses D the -e'er the .etter.
)oint 'esign
)oint 'esign
BUTT JOINT BUTT JOINT
ST"AP 6O$T
LAP 6O$T
FLLET 6O$T
#O"$E" 6O$T
Generali*ed Welding Sy!bol
Generali*ed Welding Sy!bol
FAR SIDE DETAILS
ARROW SIDE DETAILS
Field 7eld sym+ol
Weld all(around 8or
-i-es9 etc:
L1-L2
L1-L2
D ; Weld De-th 2usually e<ual to -late thic=ness3
L> ; Weld Length
L/ ; Distance +et7een centers 8or stitched 7elds
:he 1ield %eld Sym.ol is a guide -or installation. Shipyards
normally do not use it, e,cept in modular construction.
Electrode
Material
D
D
Weld !eometry
+xa!ple Welding Sy!bol
+xa!ple Welding Sy!bol
>?/@ >?/@
>?/
>?/
3ne<sided 'elds are ma, E#F e--icient
:'o sided are 1##F e--icient
!eometry sym+ol 8or 1(groo,e
Weld Sy!bols #Butt )oints%
Weld Sy!bols #Butt )oints%
Backing
Weld Sy!bol #Fillet )oints%
Weld Sy!bol #Fillet )oints%
Weld Sy!bol #,orner )oints%
Weld Sy!bol #,orner )oints%