What is “welding”?

- is a process in which two or more pieces of metal

are joined together by the application of heat,
pressure or a combination of both.

Forge Welding - It is the welding process where the

pieces of the joint are heated in a forge, or furnace,
and are fused together with pressure produced by
hammer.
 BASIC WELDING PROCESS

SMAW – Shielded metal Arc Welding

FCAW – Flux Cored Arc Welding
GMAW – Gas Metal Arc Welding
GTAW – Gas Tungsten Arc Welding
SAW – Submerge Arc Welding
Shielded Metal Arc Welding (SMAW)
1

4
6

1. AC OR DC POWER SOURCE AND CONTROLS

2. ELECTRODE HOLDER
3. ELECTRODE
4. ARC
5. WORK
6. WORKPIECE LEAD
7. ELECTRODE LEAD
 SMAW
PROTECTIVE GAS FROM
ELECTRODE COATING ELECTRODE CORE
WIRE

ELECTRODE
MOLTEN WELD METAL COATING

ARC
SLAG

METAL
DROPLETS

SOLIDIFIED WELD
METAL

BASE METAL

DIRECTION OF TRAVEL
ADVANTAGES:

- equipment is relatively simple and inexpensive.

- newer solid-state power sources are so small and
light weight that they can be carried to the job.

DISADVANTAGES:

- relatively slow production

- a layer of solidified slag must be removed.
- low hydrogen-electrodes require special storage.
 Gas Metal Arc Welding (GMAW)

1. .WORK LEAD Shielding Gas

2. .WATER TO GUN Regulator
3. .WATER FROM GUN
4. .GUN SWITCH CIRCUIT
5. .SHIELDING GAS TO GUN
6. .CABLE ASSEMBLY
7. .SHIELDING GAS FROM CYLINDER Electrode
8. .WELDING CONTACTOR CONTROL Supply
9. .POWER CABLE 7
10. .PRIMARY INPUT POWER Electrode Feed
Unit

Shielding Gas
Supply
4
Welding Gun 8
5
Power
6 Source

2 9

3
1
10
Workpiece Water Circulator
(optional)
 GMAW

SHIELDING GAS

NOZZLE

MOLTEN WELD
METAL
ELECTRODE
SOLIDIFIED WELD
METAL ARC

BASE
METAL

DIRECTION OF TRAVEL
ADVANTAGES:

- can be used successfully in situations where the presence of

hydrogen could cause problems.

- well suited for automatic and robotic welding or high production

- Since there are little or no cleaning required following welding,

overall operator productivity is greatly improved

- This efficiency is further increased because the continuous spool

of wire does not required changing as often as the individual electrodes
used in SMAW

- is clean process, because there is no flux present.

DISADVANTAGE:

Since SMAW uses shielding gas alone to protect the

puddle from the atmosphere excessive contamination of the
base metal may cause porosity. Drafts or wind may disperse
shielding gases, which makes GMAW unsuitable for field
welding. The equipment used is more complex than that
used for SMAW, increasing the possibility of mechanical
problems that can lead to quality problems. The used of
short-circuiting transfer can lead to lack of fusion
discontinuities.
Flux Cored Arc Welding (FCAW)
Shielding Gas Regulator

Wire Feeder

Electrode
Supply

Power Source
Welding Gun
Shielding Gas Supply

Workpiece
 FCAW

NOZZLE (OPTIONAL)
GAS (OPTIONAL)

MOLTEN METAL

MOLTEN SLAG
FLUX CORED
ELEECTRODE

SILIDIFIED WELD ARC

METAL
SLAG

DIRECTION OF TRAVEL
ADVANTAGES

Due to increased deposition rates and a high tolerance for

contamination, FCAW has replaced SMAW and GMAW in many
applications. FCAW can be used in both shop and field applications, and
provides high productivity in the terms of the amount of weld metal that
can be deposited in a given period of time, particularly for the hand-held
process. FCAW can be used in all positions.

DISADVANTAGES

Because a flux is present during welding, a layer of solidified slag

must be removed. The flux also generates a significant amount of smoke,
which reduces the welder’s visibility and makes the weld puddle more
difficult to observe.
Gas Tungsten Arc Welding (GTAW)

Shielding
gas with
flow meter
regulator
GTAW Torch

Filler rod

Tungsten electrode

Base metal

Power supply
Ground cable
Welding cable
 GTAW

SHIELDING GAS NOZZLE

TUNGSTEN ELECTRODES

SHIELDING GAS

MOLTEN WELD ARC

METAL

FILLER ROD

SOLIDIFIED WELD
METAL

BASE
METAL

DIRECTION OF TRAVEL
ADVANTAGES
- The GTAW process is capable of welding virtually all metals,
even extremely thin materials.
- high-quality welds with excellent visual appearance can be
produced.
- the process is quite clean and there is no slag to remove after
welding.

DISADVANTAGES

- The skill level necessary to produce high-quality welds is

acquired only after much experience in manipulating the electrode and
feeding the filler wire.
- Because the process has a low tolerance for contamination, the
base and filler metals must be extremely clean prior to welding.
- among the slowest of the available welding processes.
Submerge Arc Welding ( SAW )

FLUX
HOPPER
CONTROL POWER
SYSTEM SOURCE

TORCH

FLUX

WORKPIECE
 SAW
FLUX RECOVERY

FROM FLUX
HOPPER

CONTACT TUBE

MOLTEN FLUX
SLAG
CONSUMABLE
ELECTRODE
GRANULAR FLUX
BLANKET

BASE METAL

SOLIDIFIED WELD MOLTEN WELD METAL ARC PATH

METAL
DIRECTION OF TRAVEL
SAW
ADVANTAGES
- SAW can be performed on numerous metals.
- It can typically deposit more metal than any of the more common
processes.
- It has operator appeal– because of the lack of an arc, the operator
has no need for a filter lens and other heavy protective clothing.
- Another benefit is that there is less smoke generated than with the
other processes.
- SAW has very deep penetrating capabilities.

DISADVANTAGES
- Cleaning the work surfaces and aligning the machine travel with the
joint are particularly important in submerged arc welding. Improper alignment
will result in offset beads with incomplete joint penetration.
- In a highly restrained joint, joint misalignment may also cause
cracks.