WELDING PROCESSES

Overview of processes
Welding

1. Process in which two (or more) parts are coalesced at

their contacting surfaces by application of:

 Heat and pressure

2. Some welding processes use a filler material added to

facilitate coalescence
 Principle of welding

Assembly two parts together by creating a fusion and/or

deformation in the interaction area, which is further based on
the physics laws such as fusion and solid state deformation.
Principle of welding Fusion welding (FW)

Heat materials to melt the materials of compositions and

melting points. Due to the high-temperature phase
transitions inherent to these processes, a heat-affected zone
is created in the material
Principle of welding Solid State welding (SSW)

On the interface between two materials there is no melting

that happens but the interface of materials is reconfigured to
form many structure.
Two Categories of Welding Processes

1. Fusion welding - coalescence is accomplished by melting

the two parts to be joined, in some cases adding filler
metal to the joint

 Examples: arc welding, oxyfuel gas welding, resistance

spot welding
2. Solid state welding - heat and/or pressure are used to
achieve coalescence, but no melting of base metals
occurs and no filler metal is added

 Examples: forge welding, diffusion welding, friction

welding
The general function of welding

1. Provides a permanent joint

2. One of the most economical ways to join parts in terms

of material usage and fabrication costs

Mechanical fastening usually requires additional hardware

(e.g., screws) and geometric alterations of the assembled
parts (e.g., holes)

3. Not restricted to a factory environment

Welding can be accomplished "in the field"

Limitations and Drawbacks of Welding

1. Most welding operations are performed manually and

are expensive in terms of labor cost.

2. Most welding processes utilize high energy and are

inherently dangerous.

3. Welded joints do not allow for convenient disassembly.

4. Welded joints can have quality defects that are difficult

to detect.
 Welding

Fusion Welding (FW)

Solid State Welding (SSW)

Arc Welding (AW)

Fusion Welding: Arc Welding (AW)

A fusion welding process in which coalescence of the metals

is achieved by the heat from an electric arc between an
electrode and the work

1. Electric energy from the arc produces temperatures ~

10,000 F (5500 C), hot enough to melt any metal.

2. Most AW processes add filler metal to increase volume

and strength of weld joint.
 What is Arc Welding?

 Arc welding is most commonly used to join two

pieces of metal
 The welder creates an electric arc that melts the base metals
and filler metal (consumable) together so that they all fuse
into one solid piece of metal

Steel Pipe – Root Pass or Final weld

Tack Welded “Stringer after several
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Bead” beads are
Fusion Welding: Arc Welding (AW)

A pool of molten metal is formed near electrode tip, and as

electrode is moved along joint, molten weld pool solidifies in
its wake
 Welding

Fusion Welding (FW)

Solid State Welding (SSW)

Arc Welding (AW)

Consumable electrodes
Non-consumable electrodes
 Two Basic Types of Arc Welding (Based on
Electrodes)

1. Consumable electrodes
 consumed during welding process
 added to weld joint as filler metal
 in the form of rods or spools of wire

2. Non-consumable electrodes
 not consumed during welding process but does get
gradually eroded
 filler metal must be added separately if it is added
Arc welding (AW): Arc Shielding

1. At high temperatures in AW, metals are chemically

reactive to oxygen, nitrogen, and hydrogen in air

 Mechanical properties of joint can be degraded by

these reactions
 Arc must be shielded from surrounding air in AW
processes to prevent reaction

2. Arc shielding is accomplished by

 Shielding gases, e.g., argon, helium, CO2

 Flux
Arc welding (AW): Flux
 A substance that prevents formation of oxides and other
contaminants in welding, which comes from
1. granules that are created from the welded material.
2. a coating on the stick electrode that melts during
welding to cover operation.
3. a core that is within tubular electrodes and is released
as electrode is consumed.

 Melts during welding to be liquid slag that hardens when

cooled. The slag should be removed for a clean look by
brushing or grinding off.
Consumable Electrode AW Processes

 Shielded Metal Arc Welding (or Stick Welding)

 Gas Metal Arc Welding (or Metal Inert Gas Welding)

 Flux-Cored Arc Welding

 Electro-gas Welding

 Submerged Arc Welding

AW: Consumable: Shielded Metal Arc Welding
(SMAW)
 Uses a consumable electrode consisting of a filler metal rod and
coating around rod.
 Coating composed of chemicals that provide flux and shielding.
 Low cost welding system: Power supply, connecting cables, and
electrode holder available for $300 to $400.
SMAW Applications
 Used for steels, stainless steels, cast irons, and certain
nonferrous alloys.
 Not used or rarely used for and its alloys,
copper alloys, and titanium.
 Can be used in windy weather.
 Can be used on dirty metals (i.e. painted or rusted
surfaces).
 Good for repair work.
 Makes thick welds.
AR: Consumable: Gas Metal Arc Welding
(GMAW) or Metal Inert Gas (MIG) Welding
Uses a consumable bare metal wire as electrode with
shielding by flooding arc with a gas

1. Wire is fed continuously and automatically from a spool

through the welding gun.
2. Shielding gases include argon and helium for aluminum
welding, and CO2 for steel welding.
3. Bare electrode wire (no flux) plus shielding gases
eliminate slag on weld bead. No need for manual
grinding and cleaning of slag
4. Medium cost welding system: $1000 to $1200
Gas Metal Arc Welding
GMAW Advantages over SMAW

1. Continuous welding because of continuous wire

electrode. Sticks must be periodically changed in SMAW.

2. Higher deposition rates.

3. Eliminates problem of slag removal.

4. Can be readily automated.

5. Has better control to make cleaner & narrower welds

than SMAW.
GMAW Applications
1. Used to weld ferrous and various non-ferrous and
metals.

2. Good for fabrications such as frames and farm

equipment.

3. Can weld thicker metal (not as thick as SMAW).

4. Metal must be clean to start weld.

Non-consumable Electrode Processes

 Gas Tungsten Arc Welding

 Plasma Arc Welding

 Carbon Arc Welding

 Stud Welding
AW: non-consumable: Gas Tungsten Arc
Welding (GTAW) or Tungsten Inert Gas (TIG)
Welding
Uses a non-consumable tungsten electrode and an inert gas
for arc shielding

1. Melting point of tungsten = 3410°C (6170°F).

2. Used with or without a filler metal. When filler metal
used, it is added to weld pool from separate rod or
wire.
3. Applications: aluminum and stainless steel mostly.
4. High cost for welding system: $4000.
Gas Tungsten Arc Welding

Filler rod
Advantages and Disadvantages of GTAW

Advantages:

1. High quality welds for suitable applications

- Welds are cleaner and narrower than MIG
2. No spatter because no filler metal through arc
3. Little or no post-weld cleaning because no flux

Disadvantages:

1. More difficult to use than MIG welding

2. More costly than MIG welding
GTAW Applications

1. Used to weld ferrous and various non-ferrous and metals.

2. Can weld various dissimilar metals together.

3. Good for fabrications such as aircraft or race car frames.

4. Used for welding thinner metal parts (not as thick as

MIG).

5. Metal must be very clean to start weld.

 Welding

Fusion Welding (FW)

Solid State Welding (SSW)

Arc Welding (AW)

Oxyfuel gas welding

Oxyfuel Gas Welding (OFW)
Group of fusion welding operations by a high temperature
flame that burns various fuels mixed with oxygen

 Oxyfuel gas is also used in flame cutting torches to cut

and separate metal plates and other parts
 Most important OFW process is oxyacetylene welding
(has high temperatures – up to 3480°C)
 Filler metal is sometimes added
 Composition must be similar to base metal
 Filler rod often coated with flux to clean surfaces and
prevent oxidation
 Low cost for welding system: $400
Oxyacetylene Welding
Oxyacetylene Torch
1. Maximum temperature reached at tip of inner cone, while
outer envelope spreads out and shields work surface from
atmosphere
2. Shown below is neutral flame of oxyacetylene torch indicating
temperatures achieved
Oxyacetylene Gas Welding Applications

 Suitable for low quantity production and repair jobs

 Used for welding thinner parts
 Brazing

A joining process in which filler metal is placed at or

between the surfaces to be joined. The temperature
is raised to melt the filler metal but not the workpiece.
 Braze melts between 840-2400 degrees F
 The filler material is in thin layers compared to
base metal
 The filler penetrates the gap by capillary attraction
 Can connect dissimilar metals
 Most common braze defect is lack of braze or a
void
 Soldering

(400-840 degrees F) joints are usually of lesser strength

than brazed but parts can be joined without exposure
to excessive heat
 Used extensively in electronics industry because
of heat sensitive components
 Surface preparation and the use of fluxes are
most important
Fluxes –prevents oxidation and removes slight oxide
films from work piece surfaces
Summary Welding

Fusion Welding (FW)

Solid State Welding (SSW)
Oxyfuel welding Arc welding Shielding
Flux
Consumable electrodes Non-consumable electrodes

Various welding processes (AW) are developed to address

the two issues: shielding and flux
Welding Safety

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 Arc Welding Safety

 Welding can be safe when sufficient measures are taken to protect

yourself and others from potential hazards
 Students should read and understand the following before welding:
 Warning Labels
 Material Safety Data Sheets (MSDS)
 Students should also be familiar with the following information
 ‘Safety in Welding, Cutting, and Allied Processes’ (ANSI Z49.1)
 Lincoln Electric’s ‘Arc Welding Safety’ (E205)

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 Warning Labels

 Understand and follow all

warning labels found:
 On welding equipment
 With all consumable
packaging
 Within instruction manuals

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 MSDS - Continued

 MSDS outlines a product’s:

 Identity and composition
 Potential hazards
 Safe use
 Handling information
 Manufacturer contact
information

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 Arc Welding Safety

 Protect yourself and

others from potential
hazards including:
 Fumes and Gases
 Electric Shock
 Arc Rays
 Fire and Explosion
Hazards
 Noise
 Hot objects

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Fumes and Gases

 Fumes and gases can be

hazardous to your health
 Keep your head out of the
fumes
 Use enough ventilation, exhaust
at the arc, or both, to keep
fumes and gases from your
breathing zone and the general
area
 See product labeling and MSDS
for ventilation and respirator
requirements
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 Electric Shock

 Electric shock can kill

 Do not touch live electrical
parts
 Primary Voltage –230, 460 volt
input power
 Secondary Voltage – 6 to 100
volts for welding
 Insulate yourself from work Do not make
and ground repairs yourself,
 Follow all warnings on welding alert your
equipment instructor
immediately!
 Arc Rays

 Arc rays can injure eyes and

burn skin
 The welding arc is brighter
than the sun
 Precaution must be taken to
protect your eyes and skin
from UV radiation
 Wear correct eye and body
protection
 Fire and Explosion Hazards

 Welding sparks can cause fires and

explosions
 Sparks and spatter from the
welding arc can spray up to 35 feet
from your work
 Flammable materials should be
removed from the welding area or
shielded from sparks and spatter
 Have a fire extinguisher ready
 Inspect area for fires 30 minutes
after welding
 Noise

 Loud noises can damage your hearing

 Keep loud noises at a safe level by using proper
hearing protection such as:
 Ear plugs
 Ear muffs
 Protective Clothing

Welders must wear protective clothing for

 Protection from sparks, spatter and UV radiation
 Insulation from electric shock

 Protective clothing includes …

 Fire-proof clothing without rolled sleeves, cuffs
or frays
 Work boots
 Welding gloves, jackets, bibs, and fire-proof
pants
 Welding cap, helmet and safety glasses
 Ear protection – ear plugs and muffs
Basic Electricity and
Welding

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 The Arc Welding Circuit

 The electricity flows

from the power
source, through the
electrode and across
the arc, through the
base material to the
work lead and back
to the power source

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 Basic Electricity

 Voltage – The electrical

potential or pressure that DC -
causes current to flow
 Measured in Volts DC+
 Current – The movement of
charged particles in a
specific direction
 Measured in Amps AC
 Polarity
 DC- (Direct Current
Electrode Negative)
 DC+ (Direct Current
Electrode Positive)
 AC (Alternating Current) 51
Metals

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 Can All Metals Be Welded?

 Most metals can be welded, but not all

 The three most common weldable metals include:
 Mild Steel - inexpensive and strong
 Stainless Steel – does not rust
 Aluminum – does not rust and is light weight

Mild steel Stainless Steel Aluminum

 Gauge

 Material thickness is sometimes measured by gauge from 36

(.004 in) to 3 (.2391 in)
 For example, steel gauge and measurement in inches:

16 gauge = .051” 14 gauge = .064” 12 gauge = .081” 10 gauge = .102”

PLEASE NOTE: As the gauge number gets smaller … the material thickness gets larger.
Types of Joints

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 Types of Joints

 There are 5 types of

joints …
Parts of a Weld

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 Fillet and Groove Welds

 Groove and fillet welds can be made on many

types of joints

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 Fillet Weld Inspection

 Fillet welds should:

 Have a flat to slightly convex face
 Be uniform in appearance
 Have equal leg size
 Have good wash-in into base materials
 This is an example of a good fillet weld:
Welding Symbols

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 What are Welding Symbols?

 Welding symbols are

 Welding symbols give the  Universally used
welder specific  Governed by the AWS
instructions about the  Found on engineering
weld including: drawings

 Placement
 Size
 Length
 Process
 Any other special notes

“How to Read Shop Drawings”

available at www.jflf.org
 Welding Symbols

 Welding symbols contain information about the weld to

be made
 S – leg dimension of the weld
 Triangle – the weld is to be made on the arrow side of this joint
 Tail – any additional information required (i.e. position the weld is to be
made)
 Arrow - the joint the welding symbol applies to
Welding Positions

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 What are Welding Positions?

 There are various positions that a weld can be made in:

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Welder Responsibilities

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 What are the
Responsibilities of a Welder?

 Welders have many areas of

important responsibilities
 These relate to:
 Arc Welding Safety
 Knowledge – Content
 Attitude – Reactions
 Skills – Performance
 Work Habits – Daily Functions
Always keep safety in
mind when welding
 Arc Welding Safety

 A welder MUST always follow safe work practices:

 Students should read and understand the following before
welding:
 Warning Labels
 Material Safety Data Sheets (MSDS)
 Students should also be familiar with the following
information
 ‘Safety in Welding, Cutting, and Allied Processes’ (ANSI
Z49.1)
 Lincoln Electric’s ‘Arc Welding Safety’ (E205)

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 Attitude

 The best welders demonstrate a

can-do attitude when performing
welding processes
 This means being able to…
 Work as a team member
 Communicate ideas to others
 Listen to opinions of others
 Promote a positive attitude
 Provide solutions to problems
 Take pride in workmanship These welders work together
to inspect a weld.