Welding Technology

ME692

Dr. Virkeshwar Kumar

NL1-115R, Manufacturing Science Lab
Department of Mechanical Engineering
IIT Kanpur
Email: [email protected]
Phone: 0512-259-2334
Course details: L18
✓ Tuesday and Friday (2-3:15 PM): 3 hrs/ week
✓ Prerequisites for UG: TA 201 and TA202
✓ There are no prerequisites for PG students.

Evaluation/Grading
✓ Attendance (10%): less than 80%: 0 marks, ≥80%: 10 marks

✓ Quiz (20%): Two quizzes

✓ Mid-sem (28%)

✓ End-sem (42%)
 Grading Policy: Relative and
Granular Grading
Quiz Weightage % Date of Quizzes: L18, L19 and L20
Quiz 1 10 13th Feb evening (6:00 PM-7:30 PM)
Quiz 2 10 6th April evening (6:00 PM-7:30 PM)

Mid Sem 28%

End Sem 42%

First-class: 5th Jan, Last class: 19th Apr

Holiday: 26th Jan,8th Mar, 29th Mar

Mid-Sem Exam: Feb 19-24, 2024

Mid-Sem Recess: Mar 23-31, 2024
Course Policy
✓ Any form of academic misconduct (cheating, use of a mobile or
carrying the mobile during exams or quizzes and talking with
classmates during exams) will be rewarded with an F grade.
Additional action may also be taken.

✓ Do not Use Mobiles: Switch off/Silent Mode

✓ Those who do not have 75% attendance at any point of time may
be de‐registered from the course.

✓ For the end-semester exam, a candidate may not be allowed to

appear if their attendance falls below 80%.

✓ Without Mid Sem and End Sem: Direct Fail (F grade)

Textbooks:
1. Principles of Welding (R. W. Messler)

2. Principles of Welding Technology (L. M. Gourd)

3. Phase transformations in metals and alloys (D. A. Porter & K. E. Easterling)

4. Heat conduction (D. W. Hahn & M. N. Ozisik)

5. Fundamentals of solidification (W. Kurz & D. Fisher)

6. Welding Metallurgy (S. Kou)

7. Metallurgy of welding (J. F. Lancaster)

8. Manufacturing Science (A. Ghosh &A. K. Mallik)

TAs
1. Radhika Sarawagi [email protected]
2. C. Narendra Kumar ([email protected])
3. Abhishek Kumar Singh ([email protected])
4. Naisarg Harishbhai Sagathiya ([email protected])
5. Moloy Sarkar ([email protected])
6. Arjun Singh Patel ([email protected])
7. Rajkumar ([email protected])
Introduction to welding
 Manufacturing Processes

Manufacturing
Processes

Machining
Casting Forming Process Joining
+ Non-
Traditional
Additive Manufacturing Machining
✓ Manufacturing: Turning raw materials into finished products.
✓ Casting is also one of the oldest known manufacturing
processes.
✓ Example: Green sand casting, Investment Casting,
Permanent Mould Casting, Die Casting, Centrifugal
Casting
Manufacturing Processes
 Manufacturing Processes

Manufacturing
Processes

Machining
Casting Forming Process Joining
+ Non-
Traditional
Additive Manufacturing Machining

✓ Forming: Using plastic deformation to obtain the desired shape.

✓ Examples: Open/Close Die forging, Drop/ Press Forging,
Rolling, Extrusion, Deep drawing, Sheet metal forming, etc.
 Manufacturing Processes
F F
V V

V
V F
F
Manufacturing Processes
 Manufacturing Processes

Manufacturing
Processes

Machining
Casting Forming Process Joining
+ Non-
Traditional
Additive Manufacturing Machining

✓ Machining Process: It is a secondary manufacturing process

where the removal of materials forms the product. It delivers very
good dimensional accuracy and a good surface finish.
✓ Example: Turning, Drilling, Milling, Grinding, etc.
✓ Advanced processes such as EDM, ECM, AJM, etc., are non-
traditional machining.
Manufacturing Processes
 Joining
Joining is important when a product is impossible to
manufacture as a single piece or different material properties
are required for different parts.
Example: Welding in Ships, size is very large, so it can not be
manufactured in one part.

https://fsmdirect.com/mission-dust-control/ https://www.diversinstitute.edu/pr
ograms/underwater-welding/
 Joining Classification
There are 3 main classifications of joining:

✓Mechanical
➢Nails
➢Rivets
➢Bolts

✓Chemical
➢Adhesives
➢Glues

✓Physical (either phase change/diffusion)

➢Welding, soldering, brazing etc.
 Introduction: Welding
✓Welding is a fabrication process where two interfaces are
physically and chemically coalesced using heat, pressure, or
both.
✓Welding does not apply just to metals.
✓Thermoplastic polymers, crystalline oxide or non-oxide
ceramics, intermetallic compounds, and glasses can all be
welded.
✓ Maybe these processes can be named "thermal bonding for
thermoplastics or fusion bonding or fusing for glasses,” but it
is part of welding!
 Overview of Welding
✓Welding: Multiple parts can be used to make a single entity by

material continuity

✓Continuity implies the absence of any physical disruption on

an atomic scale, that is, no gaps.

✓Unlike mechanical attachment or fastening, where a physical

gap always remains, no matter how tight the joint is.

✓The tendency for atoms to bond is the fundamental basis for

welding.
 Overview of Welding
✓All that is required to produce a weld is to bring atoms

together to their equilibrium spacing in large numbers to

produce aggregates and to bring separate aggregates together

to do the same for atoms comprising their surfaces at mating

interfaces.

✓The result of bonding is the creation of continuity between

aggregates or crystals and the formation of an ideal weld.

 Ideal weld: achieving continuity
✓When two or more atoms are separated by infinite distance:

There is no force of attraction or repulsion between them.

✓As they are brought together from this infinite separation: A

force of electrostatic or Coulombic attraction arises

between the positively charged nuclei and negatively

charged electron shells or clouds.

 Ideal weld: achieving continuity
✓As the separation distance decreases to the order of a few

atom diameters, the outermost electron shells of the

approaching atoms begin to feel one another’s presence,

and a repulsion force between the negatively charged

electron shells increases more rapidly than the attractive

force.
 Ideal weld: achieving continuity
+
✓The attractive and repulsive forces

Bonding force (F)

Attractive force
combine to create a net force, Net
force
which at some separation
Atomic separation
distance becomes zero: the Repulsive force (x)
-
equilibrium interatomic distance
𝑑𝑈
AF α 1/(x)n , n~2-6
𝐹=−
𝑑𝑥 RF α (x)m , m~12
+
✓At this equilibrium spacing, the

Bonding Energy (U)

Attractive P.E.
net potential energy is minimal,
Atomic
the aggregate of atoms is stable, Net separation (x)
Energy Repulsive P.E.
and the atoms are bound to be
-
bonded.
Ideal weld: achieving continuity
 Ideal weld: achieving continuity
✓Welding process Goal: bring atoms together to their

equilibrium spacing.

✓There are three distinctive mechanisms for obtaining

metallic continuity

✓Solid-phase plastic deformation, without or with

recrystallization,

✓Diffusion

✓Melting/solidification.
Advantages and Disadvantages of Welding
Advantages Disadvantages
The welded joint has high Impossible to disassemble joints
strength, sometimes more than without destroying detail part
the parent metal
Wide variety of process Heat of welding degrades base
embodiments properties
They can be done in any shape Members may become distorted due
and any direction. to uneven heating and cooling
during welding.
Manual or automated operation Requires considerable operator skill
Leak-tight joints with continuous Can be expensive (e.g., thick
Welds sections)
Process cost is usually reasonable, Capital equipment can be expensive
Welding can be performed any (e.g., electron-beam guns and
place, no need for enough vacuum chambers)
clearance.
 Classification of welding
Use of Heat and pressure
✓One extreme: no pressure but sufficient heat to cause
melting
✓Another extreme: a sufficiently large pressure to cause
gross plastic deformation without the addition of heat
Fusion Welding Non-Fusion Welding

✓Electric Arc ✓Pressure

Welding Processes Welding
✓Chemical Fusion Processes
✓Resistance
Welding Processes ✓Friction Welding
Welding
✓High-Intensity Processes
Radiant Energy or ✓Diffusion Joining
High-Density Beam Processes
Welding Processes
 Terminology in Fusion Welding
✓The parts that are joined are known
as the parent/base material. Electrode
Filler material
✓The completed welded joint may be
referred to as a weldment.
Arc
✓The material added to help form the Base Weld
join is called filler or consumable. materials pool
✓The filler material can be the same Weldment
type as the base material, even if not
the same composition as the base
material(s).

✓Sometimes, the filler material may

not be required.
Terminology in Fusion Welding
 Energy for Arc Welding
For an electric arc, the available input power at the source:

Q (Watt)=IU

U: the arc (or electron beam) voltage

I: the arc (or electron beam) current.

✓ Energy density: Transferred power per unit area (effective

contact between a heat source and the workpiece)

✓ The units of energy density: Watts per square meter.

 Energy for Arc Welding
Heat input in welding:
The net energy input is computed as the ratio of the total input
power of the heat source (in watts) to its travel speed.

H input=Heat input =P/V=IU/V

H input = Energy input (in watt-seconds per mm or joules per mm)

P = IU=Total input power of the heat source (in watts),
V= Travel or welding speed or velocity (in mm per second).

The higher the heat input to a workpiece, the greater the effect
of the heat, both good and bad.
 Energy for Arc Welding
Heat input in welding:
 Energy loss during fusion welding
TSurrounding
Electrode
(Conduction)

Radiation
Filler rod (light) Convection
(Conduction)
Arc
Metal vapours+ gases
Convection
Molten droplet Convection

Weld Conduction
Pool

Base materials
 Mode of Heat Transfer
Conduction mode of heat transfer
Conduction in solids: lattice vibrations of the molecules
and the movement of free electrons.
In gases and liquids: collisions and diffusion of the
molecules during their random motion.
Fourier’s law of heat conduction T

𝑹𝒂𝒕𝒆 𝒐𝒇 𝒉𝒆𝒂𝒕 𝒄𝒐𝒏𝒅𝒖𝒄𝒕𝒊𝒐𝒏:

𝒅𝑻
𝑸𝒄𝒐𝒏𝒅 = −𝒌𝑨
𝒅𝒙
Th
Heat is conducted from high to low
temperature.
Heat is conducted in the positive x- Tl
direction. 0
x
l