Welding Shop

WELDING SHOP
The process of joining together two pieces of metal so that bonding accompanied by appreciable interatomic penetration takes place at their original boundary surfaces. TYPES:1)ELECTRIC ARC 2)GAS WELDING 3)RESISTANCE ELECTRIC ARC WELDING :-
Electrical arc welding is a process utilizing the concentrated heat of an electric arc to join metal by fusion of the parent metal and the addition of metal to the joint usually provided by a consumable electrode. Electric current for the welding arc may be either direct or alternating, depending upon the material to be welded and the characteristics of the electrode used. Electrical Welding is less complicated than the intricate processes of conventional welding.
GAS WELDING:-(OXY-FUEL WELDING) Oxy-fuel is one of the oldest welding processes. Still used in industry, in recent decades it has been less widely utilized in industrial applications as other specifically devised technologies have been adopted. It is still widely used for welding pipes and tubes, as well as repair work. It is also frequently well-suited, and favored, for fabricating some types of metal-based artwork. As well, oxy-fuel has an advantage over electric welding and cutting processes in situations where accessing electricity (e.g., via an extension cord or portable generator) would present difficulties; it is more self-contained, in this sense hence "more portable".In oxy-fuel welding, a welding torch is used to weld metals. Welding metal results when two pieces are heated to a temperature that produces a shared pool of molten metal. The molten pool is generally supplied with additional metal called filler. Filler material depends upon the metals .
TYPES:1)NEUTRAL:2)RICH 3)LEAN NEUTRAL:This type of flame is the one you will use most often in the metalwork room. It is called neutral because it has no chemical effect upon the metal during welding. It is achieved by mixing equal parts oxygen and acetylene and is witnessed in the flame by adjusting the oxygen flow until the middle blue section and inner whitish-blue parts merge into a single region.
RESISTANCE WELDING:Resistance welding is defined as a process whereby force is applied to surfaces in contact and in which the heat for welding is produced by the passage of electric current through the electrical resistance at, and adjacent to, these surfaces. Resistance welding is a well-established process, having an excellent track record for producing quality joints in sheet materials. In the European automotive industry alone, over 150 million resistance spot welds are made each day.Many variations of the resistance welding process exist; commonly resistance welding techniques are divided into the following categories:
TYPES:
Resistance spot welding Resistance projection welding Resistance seam welding
SPOT WELDING:Spot welding is a technique generally used to bond metals shaped into sheets no thicker than 3 millimeters. Unlike other welding techniques, spot welding can create precise bonds without generating excessive heating that can affect the properties of the rest of the sheet. This is achieved by delivering a large amount of energy in a short time in order to create controlled.
SEAM WELDING:Seam welding is a variation of spot welding. In resistance seam welding, the welding electrodes are motor driven wheels rather than stationary rods. The result is a 'rolling' resistance weld or non-hermetic seam weld used to join two sheets together:
PROJECTION WELDING:Projection welding is a variation of spot welding. Projections are designed in one part. These act as current concentrators for the welding process. When the two parts are mated together, these projections are the high points that first make contact. As the power is cycled, the
projections simultaneously carry the current and are welded. This process is known as Resistance Projection Welding, RPW. Due to the efficiency of power transfer, thicker materials can be successfully welded. Materials as thick as 3 mm (0.125 in) can be successfully welded. For thin stock, the traditional spot welding is a preferred method. Low carbon steels, low alloy steels, stainless steels, as well as aluminum can be welded using this process. Projections are usually semi-spherical or blunt conical type.
FILLER ROD:The filler rod is fed into the molten puddle by hand. The choice of filler rod is extremely important as the rod must correctly match the material and alloy you will be welding. The thickness of the material to be welded determines the diameter of the filler rod.
DEFECTS OF WELDING:1)HAT CRACKING Hat cracks get their name from the shape of the cross-section of the weld, because the weld flares out at the face of the weld. 2)Hot cracking
Hot cracking, also known as solidification cracking, can occur with all metals, and happens in the fusion zone of a weld. To diminish the probability of this type of cracking, excess material restraint should be avoided, and a proper filler material should be utilized. 3)Longitudinal crack Longitudinal cracks run along the length of a weld bead. There are three types: check cracks, root cracks, and full centerline cracks. Check cracks are visible from the surface and extend partially into weld. 4)Reheat cracking Reheat cracking is a type of cracking that occurs in HSLA steels, particularly chromium, molybdenum and vanadium steels, during postheating. The phenomenon has also been observed in austenitic stainless steels. It is caused by the poor creep ductility of the heat affected zone. Any existing defects or notches aggravate crack formation. 5)Root and toe cracks A root crack is the crack formed by the short bead at the root(of edge preparation) beginning of the welding, low current at the beginning and due to improper filler material used for welding.Major reason for happening of these types of cracks is hydrogen embrittlement.

Welding Shop

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WELDING SHOP

Resistance spot welding Resistance projection welding Resistance seam welding

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