IIW Welding Practitioner

Module 1 - Welding Processes and Equipment

General Introduction to Welding

1 Technology
Terminology & Definitions

AC or alternating current

Is that kind of electricity which reverses its direction periodically. For 60 cycle current.
the current goes in one direction and then in the other direction 60 times in the same
second, so that the current changes its direction 120 times in one second.
arc blow: The deflection of an electric arc from its normal path because of magnetic
forces.

Arc length

The distance from the end of the electrode to the point where the arc makes contact
with work surface.

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Arc voltage

The voltage across the welding arc.

As-welded

The condition of weld metal welded joints. and weldments after welding but prior to
any subsequent thermal, mechanical, or chemical treatments.

Automatic welding

Welding with equipment which performs the welding operation without adjustment of
the controls by a welding operator. The equipment may or may not perform the
loading and unloading of the work.

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Backing

A material or device placed against the back side of the joint, or at both sides of a
weld in electroslag and electrogas welding, to support and retain molten weld metal.

The material may be partially fused or remain unfused during welding and may be
either metal or non-metal.

Backstep Sequence

A longitudinal sequence in which weld passes are made in the direction opposite to
the progress of welding.

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Bare Electrode

A filler metal electrode consisting of a single metal or alloy that has been produced
into a wire. strip, or bar form and that has had no coating or covering applied to it
other than that which was incidental to Its manufacture or preservation.

Base Metal (Material)

The metal (material) to be welded, brazed, soldered, or cut.

Butt Joint

A joint between two members aligned approximately in the same plane.

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Concavity

The maximum distance from the face of a concave fillet weld perpendicular to a line
joining the weld toes.

Convexity

The maximum distance from the face of a convex fillet weld perpendicular to a line
joining the weld toes.

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Covered Electrode

A composite filler metal electrode consisting of a core of a bare electrode or metal

cored electrode to which a covering sufficient to provide a slag layer on the weld
metal has been applied.

The covering may contain materials providing such functions as shielding from the
atmosphere, deoxidation, and arc stabilization and can serve as a source of metallic
additions to the weld.

Crater

In arc welding. a depression at the termination of a weld bead or in the molten weld
pool.

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Depth of Fusion

The distance that fusion extends into the base metal or previous pass from the
surface melted during welding.

DC or Direct Current

Electric current which flows only in one direction. In welding, an arc welding process
wherein the power supply at the arc is direct current.

Fillet Weld

A weld of approximately triangular cross section joining two surfaces approximately at

right angles to each other in a lap joint. T-joint or corner joint.

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Fillet Weld Leg

The distance from the joint root to the toe of the fillet weld.

Flat Position

The welding position used to weld from the upper side of the joint; the face of the
weld is approximately horizontal

Flux

Material used to prevent, dissolve, or facilitate removal of oxides and other

undesirable surface substances.

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Flux Cored Arc Welding

(FCAW) An arc welding process that produces coalescence of metals by heating

them with an arc between a continuous filler metal (consumable) electrode and the
work.

Shielding is provided by a flux contained within the tubular electrode Additional

shielding may or may not be obtained from an externally supplied gas or gas mixture.

Gas Metal Arc Welding

(GMAW) An arc welding process that produces coalescence of metals by heating

them with an arc between a continuous filler metal (consumable) electrode and the
work. Shielding is obtained entirely from an externally supplied gas or gas mixture.

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Gas Tungsten Arc Welding

(GTAW) An arc welding process that produces coalescence of metals by heating

them with an arc between a tungsten (non-consumable) electrode and the work.
Shielding is obtained from a gas or gas mixture.

Pressure may or may not be used and filler metal may or may not be used. This
process has sometimes been called TIG welding.

Groove Weld

A weld made in the groove between the work pieces.

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Heat-affected Zone

That portion of the base metal that has not been melted, but whose mechanical
properties or microstructure have been altered by the heat or welding, brazing,
soldering, or cutting.

Horizontal Position

(a) fillet weld - The position in which welding is performed on the upper side of an
approximately horizontal surface and against an approximately vertical surface

(b) groove weld - The position of welding in which the weld axis lies in an
approximately horizontal plane and the weld face lies in an approximately vertical
plane

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Joint Penetration

The depth a weld extends from its face into a joint, exclusive of reinforcement.

Lap Joint

A joint between two overlapping members in parallel planes.

Machine Welding

Welding with equipment that performs the welding operation under the constant
observation and control of a welding operator The equipment may or may not load
and unload the work pieces

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Manual Welding

A welding operation performed and controlled completely by hand.

Melting Rate

The weight or length of electrode melted in a unit of time.

Open Circuit Voltage

The voltage between the Output terminals of the welding machine when no current is
flowing in the welding circuit.

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Overhead Position

The position in which welding is performed from the underside of the joint.

Overlap

The protrusion of weld metal beyond the weld toe or weld root.

Peening

The mechanical working of metals using Impact blows.

Porosity

Cavity type discontinuities formed by gas entrapment during solidification.

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Post Heating

The application of heat to an assembly after welding, brazing, soldering, thermal

spraying or cutting operation.

Pre Heating

The application of heat to the base metal immediately before welding, brazing,
soldering, thermal spraying, or cutting.

Radiography

The use of radiant energy in the form of X-rays or gamma rays for the non-destructive
examination of metals.

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Reverse Polarity

A non standard term for direct current electrode positive, root opening A separation at
the joint root between the work pieces.

Root Penetration

The depth that a weld extends into the joint root.

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Semiautomatic Arc Welding

Arc welding with equipment that controls only the filler metal feed. The advance of the
welding is manually controlled.

Shielded Metal Arc Welding

(SMAW) An arc welding process that produces coalescence of metals by heating

them with an arc between a covered metal electrode and the work pieces.

Shielding is obtained from decomposition of the electrode covering. Pressure is not

used and filler metal is obtained from the electrode.

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Slag Inclusion

Non metallic solid material entrapped in weld metal or between weld metal and base
metal

Spatter

The metal particles expelled during fusion welding which do not form a part of the
weld.

Straight Polarity

A term for direct current electrode negative.

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Stress Relief Heat Treatment

Uniform heating of a structure or a portion thereof to a sufficient temperature to

relieve the major portion of the residual stresses, followed by uniform cooling.

Stringer Bead

A type of weld bead made without appreciable weaving motion.

Tack Weld

A weld made to hold parts of a weldment in proper alignment until the final welds are
made.

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Throat Of A Fillet Weld:

(a) theoretical throat - The distance from the beginning of the joint root perpendicular
to the hypotenuse of the largest right triangle that can be inscribed within the cross
section of a fillet weld. This dimension is based on the assumption that the root
opening is equal to zero.

(b) actual throat - The shortest distance between the weld root and the face of a fillet
weld

(c) effective throat - The minimum distance minus any convexity between the weld
root and the face of a fillet weld.

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Underbead Crack

A crack in the heat-affected zone generally not extending to the surface of the base
metal undercut.

Weave Bead

A type of weld bead made with transverse oscillation.

Weld

A localized coalescence of metals or non-metals produced either by heating the

materials to welding temperature, with or without the application of pressure, or by the
application of pressure alone, and with or without the use of filler material.

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Weld Face

The exposed surface of a weld on the side from which welding was done.

Weld Pass

A single run of welding or surfacing along a joint.

Weld Pool

The localized volume of molten metal in a weld prior to its solidification as weld metal.

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Weld Root

The points, as shown in cross section, at which the back of the weld intersects the
base metal surfaces.

Weld Size

(a) groove weld size - The joint penetration of a groove weld.

(b) fillet weld size - For equal leg fillet welds, the leg lengths of the largest isosceles
right triangle which can be inscribed within the fillet weld cross section. For unequal
leg fillet welds, the leg lengths of the largest right triangle that can be inscribed within
the fillet weld cross section

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Weld Toe

The junction of the weld face and the base metal.

Welding Procedure

The detailed methods and practices involved in the production of a weldment.

Welding Rod

A form of welding filler metal. normally packaged in straight lengths, that does not
conduct electrical current.

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Weldment

An assembly whose component parts are joined by welding.

Definition Of Welding

Welding is joining of materials in the welding zone by the application of heat and/or
pressure, with or without the addition of filler material.

Auxiliary materials, e.g. shielding gases, flux or pastes may be used to render the
process possible or to facilitate it.

The energy required for welding is supplied by outside sources.

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Manual Arc Welding With Covered Electrode (MMA)
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Gas Shielded Metal Arc-Welding, MIG/MAG and Flux Cored Arc Welding (FCAW)
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Tungsten Inert Gas Welding (TIG)
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Gas Welding
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Submerged Arc Welding (SAW)
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Overview of the metal welding processes

Schematic presentation of some fusion welding processes.

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Overview of the metal welding processes

Schematic presentation of some fusion welding processes.

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Areas Of Welding Engineering
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Areas Of Welding Engineering
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