COLLEGE OF ENGINEERING AND TECHNOLOGY

SCHOOL OF MECHANICAL AND AUTOMOTIVE

ENGINEERING

Department Of Mechanical Engineering

Manufactureing Engineering (MEng3092)

Group Assignment
Name Id.No.
1.Wana Bulti.......................................................................RNS-1492/20
2.Abraham Girma................................................................RNS-9438/20
3.Latu Yohannes........................................................................RNS-3714/20

1)Discuss briefly with neat sketch on the following arc welding processes that
uses consumable and non-consumable electrodes.

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Arc welding is welding using the heat of an arc as a heat source. In arc welding, positive voltage
is applied to the electrode (welding rod/wire) and negative voltage is applied to the base material.
This makes an arc occur from the base material to the electrode.

1.1.Shielded metal arc welding (SMAW)

SMAW is considered as one of the least efficient welding process because the operator’s factor
of chipping away slag and changing of worn-out electrodes during the process.

Figure 1.1
Welding Process
 Electric arc started by striking work with electrode.
 Heat of arc melts electrode and surface of base metal.
 Tiny globules of molten metal form on tip of electrode and transferred by arc into molten
pool on work surface.
 After weld started, arc moved along work.
 The electrode used in his process is consumable (a rod covered with flux).
 The flux burns to form the protective layer/cover for the weld.
 The current type used in this process can either be AC or DC depending on
the design of the weld.
 Because of the versatility and simplicity of this process, it is most generally and widely
used across the world, it is mostly used for repair and maintenance in the heavy steel
industry.
1.2.Submerged arc welding (SAW)
Submerged Arc Welding (SAW) is a joining process that involves the formation of an electric
arc between a continuously fed electrode and the work piece to be welded. A blanket of
powdered flux surrounds and covers the arc and, when molten, provides electrical conduction
between the metal to be joined and the electrode. It also generates a protective gas shield and a
slag, all of which protects the weld zone.
Submerged arc welding is an arc welding process in which heat is generated by an arc which is
produced between bare consumable electrode wire and the work-piece.

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 Figure 1.2
Welding processes
Submerged Arc Welding (SAW) is a joining process that involves the formation of an electric
arc between a continuously fed electrode and the workp iece to be welded. A blanket of
powdered flux surrounds and covers the arc and, when molten, provides electrical conduction
between the metal to be joined and the electrode.

1.3.Metel inert gas welding (MIG, GMAW)

MIG welding is an arc welding process that joins two metals together using a consumable wire
electrode.

Metal Inert Gas (MIG) welding is an arc welding process that uses a continuous solid wire
electrode heated and fed into the weld pool from a welding gun. The two base materials are
melted together forming a join. The gun feeds a shielding gas alongside the electrode helping.

Figure.C.
What is MIG Welding?
 It is also known as Gas Metal Arc Welding.
 In Gas Metal arc welding,
 If gas used is inert gas like Helium, Argon, then it’s called Metal Inert Gas (MIG)
Welding.
 If gas used is reactive gas like CO2, O2, then it’s called Metal Active Gas (MAG)
Welding.
 It is a high deposition rate welding process.
 The metal wire is fed from a spool.
 This is a semiautomatic welding process.
 MIG welding is a gas shielded metal arc welding process using the heat of an electric arc
between a continuously fed, consumable electrode wire and the material to be welded.

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 Figure.1.3
MIG Welding Process
 Metal is transferred through a protected arc column of inert gas to the work.
 A wire of copper coated mild steel is fed continuously from a reel through a gun with
melting rate up to 5 m/min.
 Current through wire ranges from 100 to 400 A depending upon the diameter of wire.
 The welding machine is a dc constant voltage machine.

1.4.Tungsten inert gas welding (TIG, GTAW)

Gas tungsten arc welding (GTAW) uses a non consumable tungsten electrode that must be
shielded with an inert gas. The arc is established between the tip of the electrode and works to
melt the metal being welded.
Gas tungsten arc welding
Gas tungsten arc welding (GTAW) is employed for welding thin section tube and sheet (up to
about 7 mm wall thickness) and for root runs (and second pass) in thicker products. Such joints
may be completed using processes with higher deposition rates, like GMAW, SMAW, SAW,
FCAW, etc. GTAW offers a high degree of control and usually gives a good quality root profile
with mechanical and corrosion properties approaching the base materials.

Figure 1.4
What is the process of tungsten inert gas welding?
Tungsten Inert Gas (TIG) Welding | Linden Gas
Tungsten Inert Gas (TIG) welding uses the heat generated by an electric arc struck between a
non-consumable tungsten electrode and the work piece to fuse metal in the joint area and
produce a molten weld pool.

1.5.Plasma arc welding (PAW)

Plasma arc welding (PAW) is an arc welding process similar to gas tungsten arc welding
(GTAW). The electric arc is formed between an electrode (which is usually but not always made
of sintered tungsten) and the work piece. The key difference from GTAW is that in PAW, the
electrode is positioned within the body of the torch, so the plasma arc is separated from the
shielding gas envelope. The plasma is then forced through a fine-bore copper nozzle which

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constricts the arc and the plasma exits the orifice at high velocities (approaching the speed of
sound) and a temperature approaching 28,000 °C (50,000 °F) or higher.

Arc plasma is a temporary state of a gas. Plasma arc welding PAW is a fusion welding process
that uses a non-consumable electrode and an electric plasma arc to weld metals.

Figure 1.5
The processes of the plasma arc welding.
Plasma arc welding (PAW) is an arc welding process very similar to TIG welding as the arc is
formed between a pointed tungsten electrode and the work piece. However, by positioning the
electrode within the body of the torch, the plasma arc can be separated from the shielding gas
envelope.
The plasma welding process was introduced to the welding industry as a method of bringing
better control to the arc welding process in lower current ranges. Today, plasma retains the
original advantages it brought to industry by providing an advanced level of control and accuracy
to produce high quality welds in miniature or precision applications and to provide long
electrode life for high production requirements.

2)Explain briefly the following Radiant Energy Welding processes.

Radiant energy welding is a type of welding process that uses radiant energy in the form of
electromagnetic waves, such as infrared, ultraviolet, or visible light, to provide heat for welding.

2.1.Electron beam welding (EBW)

Electron beam welding (EBW) uses a high-velocity beam of electrons to melt and fuse metals
together. The electron beam can be focused to create a small weld area, which makes it ideal for
welding delicate parts or complex designs. is a fusion welding process in which a beam of high-
velocity electrons is applied to two materials to be joined.

THE PROCESSES OF EBW

Electron beam (EB) welding is a fusion welding process whereby electrons are generated by an
electron gun and accelerated to high speeds using electrical fields. This high speed stream of
electrons is tightly focused using magnetic fields and applied to the materials to be joined. The
beam of electrons creates kinetic heat as it impacts with the workpieces, causing them to melt
and bond together.

Electron beam welding is performed in a vacuum environment as the presence of gas can cause
the beam to scatter. Due it being a vacuum process and because of the high voltages used, this
welding method is heavily automated and computer controlled. As a result, specialised fixtures
and CNC tables are used to move the workpieces inside the welding vacuum chamber.

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2.2.LASER BEAM WELDING (LBW)
Laser beam welding (LBW) is a welding technique used to join pieces of metal or thermoplastics
through the use of a laser. The beam provides a concentrated heat source, allowing for narrow,
deep welds and high welding rates.

THE PROCESSES OF LBW

The process is frequently used in high volume and precision requiring applications using
automation, as in the automotive and aeronautics industries. It is based on keyhole or penetration
mode welding.

 These are the generic steps in the laser welding process:

Clean the parts to be welded and position them accurately. The contact line should be closed and
gap-free to improve weld quality.
Use manual clamps or automated fixtures to hold parts in place and keep them stable during the
welding process.
Adjust the beam’s focal point onto the welding area. The optical gear in the welding torch
usually provides for easy adjustment of focus.
Adjust the beam power and test it on scrap material and trial parts. Before moving to the work
piece, make sure it is putting out sufficient energy to melt the material but not enough to
excessively heat parts.
Apply the beam at the start of the welding area. Once an appropriate melt pool has formed, it
must be traversed along the weld in a steady motion. Traditional welding techniques such as hot
point rotation will encourage good fusion and improve the weld quality.
Cool the part naturally once the welding is complete. You can also quench it in water or use
other cooling methods.

3)Discuss on these most important types of resistance welding processes.

Resistance welding, sometimes called electric resistance welding (ERW),is a process by which
metals can be joined together by applying pressure and conducting a strong electric current
through the metal combination to heat up the welding joint and melt the metals, forging them
together.
There are many resistance welding processes with different uses, such as spot welding, seam
welding, and butt welding. Each one has a different specific welding application that makes it
optimal for a particular situation.

3.1. Resistance Spot Welding

Resistance spot welding has been used extensively in the automotive industry for the joining of
steel and in the aerospace industry for airframe components made from aluminium alloys. It is
one of the oldest and simplest forms of resistance welding, in which a weld nugget is produced
by passing an electric current between the two metal components whilst they are held together
between electrodes, typically made from copper-based alloys due to its superior conductive
properties.

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3.2. Resistance Butt Welding
Resistance butt welding is a process in which the two components of similar cross section can be
joined together in one operation that takes place simultaneously across the entirety of the
affected object, rather than just in small spots. The welding application of butt welding is often in
wires and rods with small diameter measurements, generally up to about 16mm diameter.

3.3. Resistance Seam Welding

Resistance seam welding is a variation of the standard spot welding form, however instead of
spot one nugget, a series of overlapping nuggets is produced. This is usually done by replacing
the conventional spot welding electrodes with wheels, which turn as the parts are fed between
them. The process thus produces a continuous welded seam rather than a single spot. Seam
welding is often used in the production of thin sheet, leak-tight containers such as fuel tanks, and
is generally unsuitable for welding aluminum.