ARC WELDING

By
- Ahmed Abdul Rahman Siddiqui 13081A0305
- Altaf Hussain Khan 13081A0306

WELDING
Welding is a materials joining process which produces
coalescence of materials by heating them to suitable
temperatures with or without the application of pressure or
by the application of pressure alone, and with or without the
use of filler material.
Welding is used for making permanent joints.
It is used in the manufacture of automobile bodies, aircraft
frames, railway wagons, machine frames, structural works,
tanks, furniture, boilers, general repair work and ship
building.

TYPES OF WELDING
Plastic Welding or Pressure Welding
The piece of metal to be joined are heated to a plastic state and forced
together
by external pressure
(Ex) Resistance welding
Fusion Welding or Non-Pressure Welding
The material at the joint is heated to a molten state and allowed to solidify
(Ex) Gas welding, Arc welding

CLASSIFICATION OF WELDING PROCESSES

(i). Arc welding

Carbon arc

Metal arc

Metal inert gas

Tungsten inert gas

Plasma arc

Submerged arc

Electro-slag

(ii). Gas Welding

Oxy-acetylene

Air-acetylene

Oxy-hydrogen

(iii). Resistance Welding

Butt

Spot

Seam

Projection

(iv)Thermit Welding
(v)Solid State Welding

Friction
Ultrasonic
Diffusion
Explosive
(vi)Newer Welding
Electron-beam
Laser
(vii)Related Process
Oxy-acetylene cutting
Arc cutting
Hard facing
Brazing
Soldering

ARC WELDING
It is a fusion welding processes which uses an
electric arc to produce the heat required for
melting the 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

ARC WELDING

CARBON ARC WELDING

Carbon Arc Welding (CAW)is aweldingprocess, in which heat is generated by
anelectric arcstruck between ancarbonelectrode and the work piece. The arc heats
and melts the work pieces edges, forming a joint.
Carbon arc welding is the oldest welding process.
If required, filler rod may be used in Carbon Arc Welding. End of the rod is held in the arc
zone. The molten rod material is supplied to the weld pool.
Shields(neutral gas, flux) may be used for weld pool protection depending on type of
welded metal.
Carbon Arc Welding has been replaced byTungsten Inert Gas Arc Welding (TIG, GTAW)in
many applications.

Advantages of Carbon Arc Welding:

Low cost of equipment and welding
operation;
High level of operator skill is not
required;
The process is easily automated;
Low distortion of work piece.
Disadvantages of Carbon Arc
Welding:
Unstable quality of the weld
(porosity);
Carbon of electrode contaminates
weld material with carbides.

METAL ARC WELDING

Shielded metal arc welding (Stick welding, Manual metal arc welding)uses a metallic
consumable electrode of a proper composition for generatingarcbetween itself and the
parent work piece. The molten electrode metal fills the weld gap and joins the work pieces.
This is the most popularwelding processcapable to produce a great variety of welds.
The electrodes are coated with ashielding fluxof a suitable composition. The flux melts
together with the electrode metallic core, forming a gas and a slag, shielding the arc and the
weld pool. The flux cleans the metal surface, supplies somealloying elements to the weld,
protects the molten metal from oxidation and stabilizes the arc.
The slag is removed afterSolidification.

Advantages of Shielded Metal Arc

Welding (SMAW):

Simple, portable and inexpensive

equipment;
Wide variety of metals, welding positions
and electrodes are applicable;
Suitable for outdoor applications.

Disadvantages of Shielded Metal Arc

Welding (SMAW):

The process is discontinuous due to limited

length of the electrodes;
Weld may contain slag inclusions;
Fumes make difficult the process control.

METAL INERT GAS WELDING (MIG, GMAW)

Metal Inert Gas Welding (Gas Metal Arc Welding)is aarc welding process, in which the
weld isshieldedby an external gas (Argon, helium, CO 2, argon +Oxygenor other gas
mixtures).
Consumable electrode wire, having chemical composition similar to that of the parent
material, is continuously fed from a spool to thearczone. The arc heats and melts both the
work pieces edges and the electrode wire. The fused electrode material is supplied to the
surfaces of the work pieces, fills the weld pool and forms joint.
Due to automatic feeding of the filling wire (electrode) the process is referred to as a semiautomatic. The operator controls only the torch positioning and speed.

Advantages of Metal Inert Gas

Welding (MIG, GMAW):
Continuous weld may be produced
(no interruptions);
High level of operators skill is not
required;
Slag removal is not required (no
slag);
Disadvantages of Metal Inert Gas
Welding (MIG, GMAW):
Expensive and non-portable
equipment is required;
Outdoor application are limited
because of effect of wind,
dispersing the shielding gas.

TUNGSTEN INERT GAS ARC WELDING (TIG, GTAW)

Tungsten Inert Gas Arc Welding (Gas Tungsten Arc Welding)is awelding
process, in which heat is generated by anelectric arc struck between a tungsten nonconsumable electrode and the work piece.
The weld pool isshieldedby an inert gas (Argon, helium,Nitrogen) protecting the
molten metal from atmospheric contamination.
The heat produced by the arc melts the work pieces edges and joins them.Filler
rodmay be used, if required.
Tungsten Inert Gas Arc Welding produces a high quality weld of most of metals. Flux is
not used in the process.

Advantages of Tungsten Inert Gas

Arc Welding (TIG, GTAW):
Weld composition is close to that of the
parent metal;
High quality weld structure
Slag removal is not required (no slag);
Thermal distortions of work pieces are
minimal due to concentration of heat in
small zone.
Disadvantages of Tungsten Inert Gas
Arc Welding (TIG, GTAW):
Low welding rate;
Relatively expensive;
Requres high level of operators skill.

PLASMA ARC WELDING (PAW)

Plasma Arc Weldingis thewelding processutilizing heat generated by a constrictedarcstruck
between a tungsten non-consumable electrode and either the work piece (transferred arc
process) or water cooled constricting nozzle (non-transferred arc process).
Plasmais a gaseous mixture of positive ions, electrons and neutral gas molecules.
Transferred arc processproduces plasma jet of high energy density and may be used for high
speed welding and cutting ofCeramics,steels,Aluminum alloys,Copper alloys,Titanium
alloys,Nickel alloys.
Non-transferred arc processproduces plasma of relatively low energy density. It is used for
welding of various metals and forplasma spraying(coating). Since the work piece in nontransferred plasma arc welding is not a part of electric circuit, the plasma arc torch may move
from one work piece to other without extinguishing the arc.

Advantages of Plasma Arc Welding

(PAW):
Requires less operator skill due to
good tolerance of arc to
misalignments;
High welding rate;
High penetrating capability (keyhole
effect);
Disadvantages of Plasma Arc
Welding (PAW):
Expensive equipment;
High distortions and wide welds as
a result of high heat input (in

SUBMERGED ARC WELDING (SAW)

Submerged Arc Weldingis awelding process, which utilizes a bare consumable metallic
electrode producing anarcbetween itself and the work piece within a granularshielding
fluxapplied around the weld.
The arc heats and melts both the work pieces edges and the electrode wire. The molten
electrode material is supplied to the surfaces of the welded pieces, fills the weld pool and
joins the work pieces.
Since the electrode is submerged into the flux, the arc is invisible. The flux is partially melts
and forms a slag protecting the weld pool from oxidation and other atmospheric
contaminations.

Advantages of Submerged Arc

Welding (SAW):
Very high welding rate;
The process is suitable for
automation;
High quality weld structure.
Disadvantages of Submerged Arc
Welding (SAW):
Weld may contain slag inclusions;
Limited applications of the process mostly for welding horizontally
located plates.

ELECTROSLAG WELDING (ESW)

Electroslag Weldingis awelding process, in which the heat is generated by an electric current
passing between the consumable electrode (filler metal) and the work piece through a molten
slag covering the weld surface.
Prior to welding the gap between the two work pieces is filled with a welding flux. Electroslag
Welding is initiated by anarc between the electrode and the work piece (or starting plate). Heat,
generated by the arc, melts the fluxing powder and forms molten slag. The slag, having low
electric conductivity, is maintained in liquid state due to heat produced by the electric current.
The slag reaches a temperature of about 3500F (1930C). This temperature is sufficient for
melting the consumable electrode and work piece edges. Metal droplets fall to the weld pool and
join the work pieces.
Electroslag Welding is used mainly for steels.

Advantages of Electroslag
Welding:
High deposition rate - up to 45
lbs/h (20 kg/h);
Low slag consumption (about
5% of the deposited metal
weight);
Low distortion;
Unlimited thickness of work
piece.
Disadvantages of Electroslag
welding:
Coarse grain structure of the

COMPARISON OF A.C. AND D.C. ARC

WELDING
Direct Current (from Generator)

Alternating Current (from Transformer)

1. Less efficiency
2. Power consumption more

1. More efficiency

3. Cost of equipment is more

2. Power consumption less

4. Low voltage safer operation

3. Cost of equipment is less

5. Suitable for both ferrous non ferrous

metals

4. Higher voltage hence not safe

7. Positive terminal connected to the work

6. Not preferred for welding thin sections

8. Negative terminal connected to the

electrode

7. Any terminal can be connected to the work or

5. Not suitable for welding non ferrous metals

electrode

TYPES OF ELECTRODES
Electrodes can be divided into three groups
1. Fast-fill electrodes,
Fast-fill electrodes are designed to melt quickly so that the
welding speed can be maximized
2. Fast-freeze electrodes,
fast-freeze electrodes supply filler metal that solidifies quickly,
making welding in a variety of positions possible by preventing the
weld pool from shifting significantly before solidifying. and
3. Intermediate electrodes go by the name "fill-freeze" or "fastfollow" electrodes.

ARC WELDING
Advantages
Most efficient way to join
metals
Lowest-cost joining
method
Affords lighter weight
through better utilization
of materials
Joins all commercial
metals
Provides design flexibility

Limitations
Manually applied, therefore high
labor cost.
Need high energy causing
danger
Not convenient for disassembly.
Defects are hard to detect at
joints.