ELECTRICAL WELDING

WELDING
• Welding is the process of joining two pieces of
metal or non-metal together by heating them to
their melting point.
• Filler metal may or may not be used to join two
pieces.
• Welding is nowadays extensively used in
automobile industry, pipe-line fabrication in
thermal power plants, machine repair work etc.

• Depending upon how the heat applied is created

we get different types of welding such as

 Thermal welding
 Gas welding
 electric welding
 Advantages:
• Welding is the most economical method to permanently
join two metal parts.

• Welding equipment is not so costly and is portable.

• Both similar and dissimilar metals can be joined by

welding.

• It provides design flexibility.

• Welding joints are easier to inspect.

 Disadvantages
• Welding gives out harmful radiations and
fumes.

• Welding process requires skilled operators.

• If welding is not done carefully, it may result

in the distortion of work piece.

• Welding needs internal inspection

 Electric Welding:

• It is defined as the process of joining two

metal pieces, in which the electrical
energy is used to generate heat at the
point of welding in order to melt the joint.
Classification of electric welding
 Factors for selection of proper welding process .

• The type of metal to be joined.

• The techniques of welding adopted.
• The cost of equipment used.
• The nature of products to be fabricated.
 Resistance welding
• Resistance welding is the process of joining two metals
together by the heat produced due to the resistance
offered to the flow of electric current at the junctions of
two metals.

• The heat produced by the resistance to the flow of current

is given by:
H = I2Rt
H = Amount of heat generated at the contacting area of the elements to be welded ( Joules)
I = current ( Amperes )
R = resistance of the ckt at contacting area ( ohms)
T = time for which electric current passes through the joint. ( sec ) ( 0 . 25 sec )
 The total resistance offered to the flow of
current is given by
• The resistance of current path in the work.
• The resistance between the contact surfaces of the parts
being welded.
• The resistance between electrodes and the surface of parts
being welded.
• In this process of welding, the heat developed at the
contact area between the pieces to be welded reduces the
metal to plastic state or liquid state, then the pieces are
pressed under high mechanical pressure to complete the
weld.

• The electrical voltage input 4 and 12 V depending upon

area, thickness, composition, etc.

• Power ranges from about 60 to 180 W for each sq. mm

of area.

• AC supply is found to be most suitable for the

resistance welding.
 The electrical circuit diagram for the resistance welding

It consists of
 A tap-changing transformer
 A clamping device (for holding the metal pieces)
 Some sort of mechanical arrangement for forcing the pieces
(Applying prssure) to form a complete weld.
• In resistive welding a heavy current (above 100 A) at
low voltage is passed directly through the work piece .

• The magnitude of current is controlled by changing the

primary voltage of the welding transformer, which can
be done by using an auto-transformer or a tap-
changing transformer

• Automatic arrangements are provided to switch off the

supply after a pre-determined time from applying the
pressure, why because the duration of the current flow
through the work is very important in the resistance
welding.
• Pressure may be applied manually , air
pressure , by springs or by hydraulic means.
• After switching off the supply the pressure is
maintained on the electrodes until the weld
cools
 Advantages
• Welding process is rapid and simple.

• Localized heating is possible, if required.

• No need of using filler metal.

• Both similar and dissimilar metals can be welded.

• Comparatively lesser skill is required.

• It can be employed for mass production.

• Difficult shapes and sections can be welded.

 Drawbacks
• High equipment cost;
• Low strength in case of discontinuous welds;
• Thickness of welded sheets is limited - up to 1/4”
(6 mm);

Applications :
•used for joining

vehicle body parts, fuel tanks, pipes of gas oil and water
pipelines, wire ends, turbine blades, railway tracks.
 • Metals welded by Resistance Welding:
• Low carbon steels - the widest application of Resistance
Welding
• Aluminum alloys
• Medium carbon steels, high carbon steels and Alloy steels
(may be welded, but the weld is brittle)

Types of resistance welding:

Depending upon the method of weld obtained and the type of

electrodes used, the resistance welding is classified as:

1. Spot welding.
2. Seam welding.
3. Projection welding.
4. Butt welding.
 Resistance Spot Welding (RSW)

The method uses pointed copper electrodes providing passage of

electric current. The electrodes also transmit pressure required for
formation of strong weld.
This spot welding provides localized heating where welding
need to be done
 Diameter of the weld spot is in the range 1/8” - 1/2” (3 - 12 mm).
 It consist of a transformer core having primary and
secondary Winding. One end of secondary winding is
connected to upper Electrode and other electrode is
connected to lower electrode.
 In this The lower arm is fixed whereas the upper one is
movable
• The work pieces to be weld are pressed between tips of the
electrodes and high current at low voltages is passed
through the work pieces.
• Due to resistance offered by the work pieces ( sheet metal )
to the flow of current , the temperature at the contact
surfaces and the weld is done. The operation is repeated by
changing the position of the work piece plate to get the weld
at another point.
 RATINGS
H = I2Rt

• Welding current (I) = 1,000 to 10,000 A (widely

depending upon the thickness and composition of the
plates)
• Voltage between the electrodes (V)= less than 2 V.

• T = The period of the flow of current (depending

upon the thickness of sheets to be joined)
 Electrodes used
• Problem :The generation of heat at junctions 1 and 3 will
effect electrode sticking.
• Remedy :Using water-cooled electrodes electrodes in
which cold water circulated continuously (or)
• The material used for electrode should have high electrical
and thermal conductivity
 Appilications Resistance Spot Welding :

 Automotive industry for joining vehicle body parts.

 Metal furniture
 Diameter of the weld spot is in
the range (3 - 12 mm).

Figure : Resistance welding, showing the components in spot welding, the main
process in the RW group.
 Spot Welding Cycle

(a) Spot welding cycle,

Figure : (b) plot of squeezing force & current in cycle (1) parts inserted between
electrodes, (2) electrodes close, force applied, (3) current on, (4) current off,
(5) electrodes opened.
 Typical car body has about 10,000 spot welds
 Seam Welding
• Seam Welding is a Resistance Welding process of continuous
joining of overlapping sheets by passing them between two rotating
electrode wheels.

• Heat generated by the electric current flowing through the contact

area and pressure provided by the wheels are sufficient to produce a
leak-tight weld.

Roller electrodes
instead
of
pointed
electrodes
• In this welding, the contact area of electrodes
should be small, which will localize the current
pressure, to the welding point

• After forming weld at one point, the weld so

obtained can be cooled by splashing water over
the job by using cooling jets.
 Providing Interrupter
• Problem : if we make a continuous weld, leads to
continuous current which leads to high heat results in
burning and wrapping of the metal piece.
• Remedy : An interrupter is provided on the circuit which
turns on and off supply for a certain period
•
 With Interrupter

The series of weld spots depends upon the number of

welding current pulses.
Figure : Resistance seam welding (RSEW).
Side view

Resistance Seam Welding

Seam Welding Machine
 Resistance Welding
Spot
1. The electrodes are a pair of copper
rods between which the sheets to
be welded are positioned
2. The welding takes place at
discrete intervals (localized
points)
3. It is used for components such as
flat sheets , panels as in car
bodies.
Seam
1. Electrodes are a pair of rotating
copper rolls between which
sheets to be welded are passed
2. The seam weld joints are
continuous
3. It is used to weld components
such as a fuel tank shells & other
application which require the
joint to be leak proof
 Resistance Butt Welding (UW)
• Butt welding is similar to the spot welding;
however, the only difference is, in butt welding,
instead of electrodes the metal parts that are to
be joined or butted together are connected to the
supply.

• The two basic types of the butt welding process

are:
 Upset butt welding.
 Flash butt welding.
 Upset butt welding
• In upset welding, the two metal parts to be welded
are joined end to end and are connected across the
secondary of a welding transformer is used to join
the pieces end to end
• When current is made to flow through the two
electrodes, heat will develop due to the contact
resistance of the two pieces and then melts.

• By applying high mechanical pressure either manually

or by toggle mechanism, the two metal pieces are
pressed.

• This action of pressing together is called upsetting.

• This type of welding is usually employed for welding of

rods, pipes, and wires and for joining metal parts end to
end.
Upset Butt Welding
 Flash Welding (FW)

• Flash welding is similar to upset welding except

that the heat is obtained by means of an arc than
the simple resistance heating.

• Flash butt welding is a combination of

resistance, arc, and pressure welding
• In this method of welding, the two pieces to be
welded are brought very nearer to each other
under light mechanical pressure.
• These two pieces are placed in a conducting
movable clamps.
• When high current is passed through the two metal
pieces and they are separated by some distance, then
arc established between them.

• This arc or flashing is allowed till the ends of the

work pieces reach melting temperature, the supply
will be switched off and the pieces are rapidly
brought together under light pressure.

• This squeezes out liquid metal and oxides , formed

on the joint surfaces and the two parts are welded
together.
Flash Butt Welding
• Applications : This method of welding is mainly
used in the production welding

• Advantages over upset welding:

• Less requirement of power.
• Weld obtained is so clean and pure; due to the
foreign metals appearing on the surfaces will
burn due to flash or arc.
 Projection welding
• It is a modified form of the spot welding.
• In the projection welding, both current and pressure
are localized to the welding points as in the spot
welding.
•
• The electrodes used for such welding are flat metal
plates.
• The two pieces of base metal to be weld are held
together in between the two electrodes, one is
movable and the other is fixed
• One of the two pieces of metal is run through a machine that
makes the bumps or projections of required shape and size in
the metal.
• As current flows through the two metal parts to be welded,
which heat up and melt.
• These weld points soon reach the plastic state, and the
projection touches the metal then force applied by the two
flat electrodes forms the weld.
• This welding process reduces the amount of current and
pressure in order to join two metal surfaces, so that there
is less chance of distortion of the surrounding areas of
the weld zone.

• Advantages: (over spot welding)

 Simplicity in welding process.
 It is easy to weld some of the parts where the spot welding is not
possible.
 It is possible to join several welding points.
 Welds are located automatically by the position of projection.

• Appilications :
 welding of refrigerators, condensers, crossed wire welding,
refrigerator racks, grills, etc
 ELECTRIC ARC WELDING
• Electric arc welding is the process of joining two metallic
pieces or melting of metal is obtained due to the heat
developed by an arc struck between an electrode and the
metal to be welded or between the two electrodes.
• In this process, an electric arc is produced by bringing
two conductors (electrode and metal piece) connected
to a suitable source of electric current, momentarily
in contact and then separated by a small gap, arc
blows due to the ionization and give intense heat.
• The heat so developed is utilized to melt the part of work
piece and filler metal and thus forms the weld.

• In this method of welding, no mechanical pressure is

employed; therefore, this type of welding is also known
as 'non-pressure welding’.

• The length of the arc required for welding depends upon

the following factors:

 The type of electrodes used.

 The amount of current used.
 The position of welding.
 Concept behind arc formation
• When the supply is given across the conductors separated by
some distance apart, the air gap present between the two
conductors gets ionized, as the arc welding is in progress, the
ionization of the arc path and its surrounding area increases.

• This increase in ionization decreases the resistance of the

path. Thus, current increases with the decrease in voltage of
arc. it also known as negative resistance characteristics of an
arc.

• This can be avoided, with the supply should fall rapidly with
the increase in the current so that any further increase in the
current is restricted.
 SPECIFICATIONS
 Temperature of the arc : 3,500°C. (At this temperature,
mechanical pressure for melting is not required.)

 Both AC and DC can be used in the arc welding.

 Usually 70-100 V on AC supply and 50-60 V on DC supply

system to struck the arc in the air gap between the electrodes.

 Once the arc is struck, 20-30 V is only required to maintain it.

 To avoid danger of electric shock to the operator, low voltage

should be used for the welding purpose. Thus, DC arc welding of
low voltage is generally preferred.
 APPLICATION
• Electric arc welding is extensively used for the joining of
metal parts, the repair of fractured casting, and the
fillings by the deposition of new metal on base metal,
etc.
Various types of electric arc welding are :
1. Carbon arc welding.
2. Metal arc welding.
3. Atomic hydrogen arc welding.
4. Inert gas metal arc welding.
5. Submerged arc welding.
 CARBON ARC WELDING
• It is one of the processes of arc welding in which
arc is struck between two carbon electrodes or
the carbon electrode and the base metal.
 PROCESS
• The process is started by bringing the electrode into
contact with the work piece.

• After the arc column starts, electrode is withdrawn 25 –

40 mm away and the arc is maintained at this distance.

• The arc can be extinguished by simply removing the

electrode from the work piece completely.

• The only function of the carbon arc is to supply heat to the

base metal
• In this process of welding, the electrodes are placed in an
electrode holder used as negative electrode and the base
metal being welded as positive.
Reason :
• The arc produced between electrode and base metal; heat
the metal to the melting temperature, on the negative
electrode is 3,200°C and on the positive electrode is
3,900°C.
• Unless, the electrode is negative relative to the work, due
to high temperature, there is a tendency of the particles
of carbon will fuse and mix up with the base metal,
which causes brittleness.

• DC is preferred for carbon arc welding than AC.

 Electrodes used
• In the carbon arc welding, carbon or graphite rods
are used as electrode.

• Due to longer life and low resistance, graphite

electrodes are used, and thus capable of conducting
more current.
 OTHER FEATURES
• This process of welding is normally employed
where addition of filler metal is not required.

• No need of mechanical pressure.

• The carbon arc is easy to maintain, and also the

length of the arc can be easily varied
 ADVANTAGES
• The heat developed during the welding can be easily
controlled by adjusting the length of the arc.

• It is quite clean, simple, and less expensive when

compared to other welding process.

• Easily adoptable for automation.

• Both the ferrous and the non-ferrous metals can be

welded.
 Disadvantages
• Input current required in this welding, for the work
piece to rise its temperature to melting/welding
temperature, is approximately double the metal arc
welding.

• In case of the ferrous metal, there is a chance of

disintegrating the carbon at high temperature and
transfer to the weld, which causes harder weld deposit
and brittlement.

• Since arc serves only as a heat source, it does not

transfer any metal to help reinforce the weld joint.
 APPLICATIONS
• It can be employed for the welding of stainless
steel with thinner gauges.

• Useful for the welding of thin high-grade

nickel alloys and for galvanized sheets using
copper silicon manganese alloy filler metal.
 Metal arc welding
• In metal arc welding, the electrodes used must be of
the same metal as that of the work-piece to be
welded.
• The electrode itself forms the filler metal.
 PROCESS
• An electric arc is stuck by bringing the electrode
connected to a suitable source of electric current,
momentarily in contract with the work pieces to
be welded and withdrawn apart.
 TEMP & METAL DEPOSITION
• The arc produced between the work piece and the
electrode results high temperature of the order of about
2,400°C at negative metal electrode and 2,600°C at
positive base metal or work piece.
• This high temperature of the arc melts the metal as well
as the tip of the electrode, then the electrode melts and
deposited over the surface of the work piece, forms
complete weld.
 RATINGS
• Both AC and DC can be used for the metal arc welding.

• The voltage required for the DC metal arc welding is

about 50-60 V and for the AC metal arc welding is about
80-90 V

• The current required for the welding varies from 10 to

500 A depending upon the type of work to be welded.
 ARC BLOW EFFECT FOR DC
• The main disadvantage in the DC metal arc welding is
the presence of arc blow, i.e., distortion of arc stream
from the intended path due to the magnetic forces
created by the current.

• AC arc blow is reduced because each magnetic force is

immediately followed by one in opposite direction so
arc deflection forces are automatically canceled.
 coated electrodes
• Metal in molten state will be effected due to
foreign elements such as oxygen, nitrogen etc.

• In order to prevent the impurities entering the

weld modern arc welding electrodes are covered
with a coating(flux coating) which under welding
heat generates a gas shield round the arc and also
form a slag which is deposited on and around the
molten metal which protect against foreign
materials
 Comparison between A.C and D.C
Welding:
D.C Welding A.C Welding
As power supply available is usually a.c For a.c welding, only transformer is
a rectifier is required for d.c welding required which is relatively cheap in
hence the cost is high. cost.
Maintenance of a rectifier is some what Maintenance of transformer is less
difficult. difficult.
Operational efficiency is low Operational efficiency is high( > 85 %)

The electric energy consumption per KgThe electric energy consumption per Kg
of deposited metal in d.c welding of deposited metal in a.c. welding is
ranges between 6-10 kwh. 3-4 Kwh.
In case of a.c welding, the no load
In case of d.c welding the no load voltage is high and hence somewhat
voltage is low and hence safer in dangerous in operation
operation.
 Comparison between A.C and D.C
Welding:
Heat produced is uniform. Heat produced is not uniform.

Power factor is unity due to Power factor is low hence

resistance. capacitors are required

Cheap electrodes can be used Only coated electrodes are used or

because no coated electrodes expensive electrodes are used
are used.
The arc produced is stable and is The arc produced is not so stable.
suitable for welding of non-ferrous
metals.

Arc blow is high Arc blow is low

 Comparison between Resistance and Arc Welding:

Resistance Welding Arc Welding

It uses only AC. It uses both A.C and D.C
External pressure is required. No external pressure is required
hence the equipment is more
simple and easy to control.
Heat is developed due to flow Heat is developed due to the arc
of current through the electrode and the work piece.
contact resistance mainly.
No material is added in any form to get Suitable filler metal electrodes
the two pieces joined. are necessary to get proper
strength.
Maintenance required is less as the Maintenance is more as
temperature reached is not high. temperature of the arc is high and
so likely to damage the work if
not properly handled.
It can not be used for repair work Not suitable for mass production
hence it is most suitable for mass and hence not suitable for repair
production. work and where more metal is to
be deposited.
 Electric Welding Equipment

Equipment required for welding are:

 Welding power source.

 Welding cables.
 Electrode holder.
 Welding helmet and hand shield.
 Protective clothing including hand gloves.
 Chipping hammer, wire brush e.t.c.
  Welding power Sources[Electric Welding Sets]

• The power sources may be either D.C. or A.C

type.

• D.C welding Sets:

• DC welding sets are of two types:

 Generator sets.
 Rectifier sets
 GENERATOR SETS
• A dc generator produces direct current in either normal or
reversed polarity and it is powered either by an electric motor or a
diesel engine.
• Diesel operated generator sets are suitable for outdoor
applications where power is not available.
• The current supplied by dc generator is obtained by use of a
commutator, a generator is designed such that it will compensate
for any change in voltage thus ensuring a stabilized arc.
 Since most of welding processes requires low voltages
with high value of current therefore differential
compound dc generator in an ideal selection.
 In a differential compound generator the terminal voltage
falls automatically with the increase in load current
 The control may be obtained by tapping series field or a
suitable shunt across series field winding.
 Advantages of Dc generator sets:

• Normal and reversed polarity can be employed.

• Welding can be carried out in any position.
• Nearly all ferrous and non-ferrous metals can be
welded.
• D.C is most universal in application. it can be used in
practically all applications.
• Generator output is not affected by normal variations
in power line voltage.
 Disadvantages of Dc generator sets:

 High initial cost.

 Higher maintenance cost.
 Noisy machine operation.
 RECTIFIER SETS
 These sets essentially consists of a transformer containing an
electrical device called rectifier which changes AC to DC
 The rectifier may consists silicon diodes each unit having the
special property of allowing current flow in one direction only.
 A rectifier is installed with a fan to cool the transformer.
 A rectifier unit may be designed for a single phase or three phase
supply
 ADVANTAGES

 They can provide both straight and reversed polarity.

 They have good performance as it can be precisely

controlled.

 Their current can be adjusted by using a remote

control kept near the operator.
 A.C Welding Sets
 A.C welding sets are singe phase or three phase step
down transformer which provide low voltage (80-100V)
power for welding with some means of output control.
 An A.C. transformer takes power directly from the mains
and transforms it to voltage/current required for welding.
 Disc. welding
 Problem : Since A.C. passes through zero twice every cycle, it
means that there are two periods in every cycle when the welding
current is zero during which arc would extinguish and make
continuous welding difficult for arc welding
 Remedy: which is prevented by development of electrode
coatings that produce a more complete ionization in the arc
stream and keep that arc igniting as current passes through zero.
 Transformer cooling
• The transformer is housed in a steel tank
which has external tubes.

• The tank is filled with transformer oil to cool

the transformer core by convection thereby
preventing its overheating when working
under heavy load conditions.

• Instead of being oil cooled, some transformers

employ electric fans and are thus air cooled.
 Transformer core (limited)
• The transformer consists of a limited core on
which primary and secondary circuits are wire
wound tightly around the core.

• The two circuits are thoroughly insulated from

one another.
 ADVANTAGES

 It is least expensive, lightest and small welding

machine.

 There is freedom from magnetic arc blow that often

occurs when welding with a d.c. machine.

 Operating and maintenance costs are low.

 Since there are no moving parts in transformer, the

operation is noise less and there is hardly any wear.

 Over all electrical efficiency is high.

  
DISADVANTAGES:

 Because of alternating nature of current flow,

starting the arc is more difficult than with d.c.

 Low power factor.

 WELDING CABLES:

• Two cables are needed for welding one of which

connects the electrode holder or electrode to the
welding power source and other connects the job with
the welding source.
• These cables are well insulated with rubber above
which a durable layer of rubber is woven and the
cables are checked periodically for insulation.
 ELECTRODE HOLDER

• Electrode holder is a device used for mechanically

holding the electrode and conducting current to it.
• The electric jaws are made in electrode holder to hold
the bare end of the electrode in either a vertical or an
angular position and are completely insulated to
protect the operator against electric shocks.
 WELDING HELMET AND SHIELD:
• Helmet is a protective used for shielding and protecting the face
and neck of the welder and is also be worn on the head of the
operator.
• Hand shield is also a protective device used for shielding and
protecting the face and neck of the welder and is held in the hand
of the welder.
• The use of hand shields and helmet protect the operator eyes from
getting damaged due to the UV rays and infrared rays of welding
arc.
 PROTECTIVE CLOTHING:
 Protective clothing usually includes the apron and
gloves.
 Apron provides protection to the clothes of welder from
hot spattering particles may be made of chrome leather.
 Gloves protect the hands of the welder from UV rays
and a spattering metal which may be made of leather.
 Chipping hammer and Wire brush:

 A chipping hammer is chisel shaped and is pointed on

the end to aid in the removal of slag from over the weld
bead.
 A wire brush made up of stiff steel wire embedded in
wood removes small particles of slag from the weld
after chipping hammer have done its job.