Introduction to welding
Introduction to welding
Overview of joining methods
Mechanical methods
Adhesive bonding
Brazing and Soldering
Screwed fasteners, rivets,
Base metal does not fuse.
Molten filler drawn into close-fit joints by capillary
action (surface tension forces).
Brazing filler melts >450 C, solder <450 C
Welding
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Introduction to welding
Weld
A joint produced by heat or pressure or both
So there is continuity of material.
Filler (if used) has a melting temperature
close to the base material
Introduction to welding
Welding processes
Fusion welding
Welding in the liquid state with no pressure
Union is by molten metal bridging
Solid phase welding
Carried out below the melting point without filler
additions
Pressure often used
Union is often by plastic flow
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Introduction to welding
Basic Requirements of Welding Process
Source of Heat
Chemical Reaction
Electrical - Arc, Resistance, Induction
Mechanical
Protection from Atmosphere
Gas Shielding
Flux
Mechanical Expulsion
Vacuum
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Introduction to welding
Fusion welding heat sources
Electric resistance
Chemical reaction
Electric arc
Power beams
Spot, seam and
projection welding
Oxyfuel gas
welding
Laser
Electron beam
Electroslag
Thermit welding
MMAW
GMAW
GTAW
FCAW
SAW
Introduction to welding
Solid phase welding
Hot processes
Forge welding
Friction welding
Diffusion bonding
Cold processes
Ultrasonic welding
Explosive welding
Introduction to welding
Some arc welding processes
MMAW - manual metal arc welding
SAW - submerged arc welding
GTAW - gas tungsten arc welding (TIG)
GMAW - gas-metal arc welding (MIG, MAG)
FCAW - flux cored arc welding
Introduction to welding
The electric arc
Peak
temperatures
18,000 K
Electric discharge between 2
electrodes through ionised gas
Cathode
drop zone
10 to 2000 amps at 10 to 500 V arc
voltage
Column of ionised gas at high
temperature
Forces stiffen the arc column
Anode
drop zone
Transfer of molten metal from
electrode to work piece
Can have a cleaning action,
breaking up oxides on work piece
Introduction to welding
Arc energy
Q=
ExI
V
Q = arc energy in kJ/mm
E = current in amps
I = arc voltage
V = travel speed in mm/min
Low arc energy
High arc energy
Incomplete fusion
High cooling rate
Unwanted phase transformations
Hydrogen cracking
Low cooling rate
Increased solidification cracking risk
Low ductility and strength
Precipitation of unwanted phases
(corrosion and ductility)
Small weld pool size
Large weld pool size
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Introduction to welding
103 Watts/cm2 melts most metals
106 -107 Watts/cm2 vaporizes most metals
103 to 106 Watts/cm2 typical for fusion welding
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Introduction to welding
Manual Metal Arc Welding
MMAW,
SMAW,
Stick electrode welding
Manual welding
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Introduction to welding
Manual Metal Arc Welding
Heat source - arc between metal and a flux coated
electrode (1.6- 8 mm diameter)
Current 30-400A (depends on electrode size)
AC or DC operation
Power 1 to 12 kW
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Introduction to welding
Manual Metal Arc Welding
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Introduction to welding
Manual Metal Arc Welding
Minimum equipment
Power source (ac or dc, engine driven or
mains transformer)
Electrode holder and leads
May carry up to 300 amps
Head shield with lens protects face & eyes
Chipping hammer to remove slag
Welding gloves protect hands from arc
radiation, hot material and electric shock
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Introduction to welding
Manual Metal Arc Welding
Process features
Simple portable equipment
Widely practiced skills
Applicable to wide range of materials, joints,
positions
About 1kg weld deposited per arc-hour
Portable and versatile
Properties can be excellent
Benchmark process
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Introduction to welding
Manual Metal Arc Welding
Covered electrodes
Core wire
Solid or tubular
2mm to 8mm diameter,
250 to 450mm long
Coating
Extruded as paste, dried
to strengthen
Dipped into slurry and
dried (rare)
Wound with paper or
chord (obsolete)
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Introduction to welding
Manual Metal Arc Welding
Functions of coating
Slag protects weld pool from oxidation
Gas shielding also protects weld pool
Surface tension (fluxing)
Arc stabilising (ionising)
Alloying and deoxidation
Some ingredients aid manufacture
(binder and extrusion aids)
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Introduction to welding
Manual Metal Arc Welding
AWS A5.1 classification
E XXXX - H
Tensile Strength
in KPSI
Useable positions
1=all positions
2=flat + horizontal
4=vertical down
Hydrogen level (HmR)
H = 5 ml / 100g of WM
R = low moisture pick-up
Flux type
20 = Acidic (iron oxide)
10, 11 = Cellulosic
12, 13 = Rutile
24 = Rutile + iron powder
27 = Acidic + iron powder
16 = basic
18, 28 = basic + iron powder
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Introduction to welding
Manual Metal Arc Welding
Applications
Wide range of welded products:
light structure & Heavy steel structures
Workshop and site
High integrity (nuclear reactors, pressure
equipment)
Ideal where access is difficult construction site, inside vessels,
underwater
Joins a wide range of materials
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Introduction to welding
Manual Metal Arc Welding
Limitations
Low productivity
Low power
Low duty cycle (frequent electrode
changes)
Hydrogen from flux coatings
Electrode live all the time
Arc strike, stray current and electric shock
risks
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Introduction to welding
Submerged arc welding
SAW,
Sub-arc
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Introduction to welding
Submerged arc welding
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Introduction to welding
Submerged arc welding
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Introduction to welding
Submerged arc welding - Features
High productivity
2 to 10 kg/hour
Up to 2m/min
Bulky, expensive and
heavy equipment
Flat and horizontal
positions only
Thicker sections (3mm
and above)
Mostly ferrous materials
(also Ni alloys)
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Introduction to welding
Submerged arc welding - Equipment
Power source
Welding head and
control box
Welding head travel
Flux recovery system
(optional)
Positioners and
Fixtures
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Introduction to welding
Submerged arc welding - Consumables
Solid or cored wires
Granular fluxes
Agglomerated, fused or sintered
Alloying activity
Contribution to weld metal chemistry from flux
Basicity
Acid fluxes made from manganese oxide, silica, rutile are
easy to use
Basic fluxes (MgO, CaO, CaF2, Al2O3) provide excellent
toughness welds
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Introduction to welding
Submerged arc welding - Applications
Long straight welds in heavier material
Vessel longitudinal and circumferential
welds
Flange to web joints of I beams
Flat or horizontal position
Flux has to be supported
Access has to be good
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Introduction to welding
Submerged arc welding
Process variations
Surfacing and hardfacing
Wire and strip electrodes
Semi-automatic
Multiple electrodes
2 (and more) electrode wires
From one or more power sources
Iron powder additions to groove
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Introduction to welding
Submerged arc welding Tandem arc
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Introduction to welding
Gas shielded arc process
Tungsten Inert Gas welding (TIG)
Gas tungsten arc welding (GTAW)
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Introduction to welding
Gas Tungsten Arc Welding
Alternative names GTAW,TIG (Tungsten Inert
Gas), Argonarc
Heat source is an electric
arc between a nonconsumable electrode and
the workpiece
Filler metal is not added or
is added independently
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Introduction to welding
Gas Tungsten arc welding
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Introduction to welding
Gas Tungsten Arc Welding
Heat source - arc between a tungsten tip and the parent
metal
30-400A, AC or DC
10-20V
0.3-8kW
Inert gas shielding
Consumable filler rod can be used (1 to 4mm diameter)
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Introduction to welding
Gas Tungsten Arc Welding - Process features
Excellent control
Stable arc at low power (80A at 11V)
Independently added filler
Ideal for intricate welds eg root runs in pipe or thin sheet
Low productivity 0.5kg/h manual
High quality
Clean process, no slag
Low oxygen and nitrogen weld metal
Defect free, excellent profile even for single sided welds
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Introduction to welding
Gas Tungsten Arc Welding - Equipment
Welding power source with constant
current characteristic
DC for most metals, AC for Al
Arc starting by high frequency (5000V, 0.05A)
Sequence timers for arc starting, arc finishing &
gas control
Water- or gas-cooled torch with tungsten
electrode
Electrode may contain thoria or zirconia, etc
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Introduction to welding
Gas Tungsten Arc Welding - Shielding gases
Torch is fed with an inert or reducing gas
Pure argon - widespread applications
Argon-helium - Higher arc voltage, inert
Argon-2% hydrogen - Cu alloys & austenitic steel
Torch gas must not contain oxygen or CO2
Backing (or purge) gas
Used for all single-sided welds except in carbon steel
Argon, nitrogen, formier gas (N2 + H2)
Supplementary shielding
Reactive metals: Ti, etc
Gas filled chambers or additional gas supply devices
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Introduction to welding
Gas Tungsten Arc Welding - Filler metals
Autogenous welding (no filler)
Filler wire or rod of matching composition
C-Mn & low alloy steel
Stainless Steel
Al, Mg, Ti
Cu & Ni
Consumable inserts - filler preplaced in joint
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Introduction to welding
Gas Tungsten Arc Welding - Automation
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Introduction to welding
Gas Tungsten Arc Welding A TIG
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Introduction to welding
GMAW and FCAW
Gas metal arc welding
(MIG, MAG, CO2 welding)
Flux cored arc welding
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Introduction to welding
Gas metal arc welding
A continuous solid wire, small
diameter
GMAW uses solid wire, no flux
FCAW uses flux-filled wire
Fed through the gun to the arc by
wire feeder.
The weld pool may be protected
from oxidation by shielding gas.
High productivity 3 kg/h or more
Direct current (DCEP mostly)
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Introduction to welding
Gas metal arc welding
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Introduction to welding
Gas metal arc welding
MIG Welding
Heat source - arc between parent metal
and consumable electrode wire (0.6 to
1.6mm diameter)
60-500A, DC only
16-40V
1 to 20kW
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Introduction to welding
Gas metal arc welding
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Introduction to welding
Gas metal arc welding - Equipment
Welding power source
Wire feeder mechanism
May be in power source cabinet
Gun with gas supply & trigger
switch
Manual (semi-automatic) guns
Automatic torches available
Can be fitted to robot etc.
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Introduction to welding
Gas metal arc welding Metal transfer
Spray
Higher current & voltage, argon-rich gas
Short circuiting (dip)
Low current and voltage, CO2
Globular
Intermediate current
Pulsed current power sources
Adjustable frequency
One droplet per current pulse.
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Introduction to welding
Gas metal arc welding Metal transfer
Burn-back
and unstable arc
Spray
Voltage
Globular
Short
circuiting
No arc (birds-nesting)
Current
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Introduction to welding
Gas metal arc welding - Consumables
Solid Wires (GMAW)
A wide variety of alloys are available
Flux cored arc welding (FCAW)
Gas shielded flux cored wires
Self-shielded flux cored wires
Used outdoors
Metal cored wires
Light flux cover
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Introduction to welding
Gas metal arc welding Wire size
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Introduction to welding
Gas metal arc welding - Gas mixtures
Inert gases (MIG)
Argon or helium or mixtures of these
Active base metals, Al, Mg, Ti
Active gases (MAG and FCAW)
Carbon dioxide
Argon plus oxygen and/or carbon dioxide
Nitrogen, hydrogen
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Introduction to welding
Gas metal arc welding - Developments
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Introduction to welding
Gas metal arc welding - Developments
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Introduction to welding
Gas metal arc welding - Developments
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Introduction to welding
Gas metal arc welding - Developments
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Introduction to welding
Plasma Cutting, Welding & Surfacing
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Introduction to welding
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Introduction to welding
Oxy-Acetylene Welding
Oxidising Flame
Carburising Flame
Neutral Flame
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Introduction to welding
Thermit welding
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Introduction to welding
Laser Welding
Photons transmit energy and heat
Energy intensity up to 109 Watts/cm2
Depth to width of hole up to 50x
Automatic controllers needed
90% efficiency
Reflectors dont weld easily
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Introduction to welding
Laser welding
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Introduction to welding
Electron Beam Welding
Electrons strike surface and generate heat
Best performed in a vacuum
Workpiece must be a conductor
Magnetic fields affect beam
Current to 1/2 A
Power to 100 kW
X-rays produced
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Introduction to welding
Electron Beam Welding
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Introduction to welding
Size of weld beads in
(a) electron-beam or laser-beam welding
(b) conventional arc welding.
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Introduction to welding
Solid-State Welding
Heat
Pressure
Time
NO Melting
NO Filler Material
Intimate Contact
Usually Requires Deformation
Works with Dissimilar Metals
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Introduction to welding
Resistance Welding
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Introduction to welding
Resistance spot welding Robots
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Introduction to welding
Flash Butt Welding
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Introduction to welding
Friction Welding
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Introduction to welding
Friction Stir Welding
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Introduction to welding
Friction Stir Welding
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Introduction to welding
Explosive Welding
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Introduction to welding
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Introduction to welding
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ANY QUESTIONS
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Introduction to welding
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Introduction to welding
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