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•The heat may be generated either from combustion of gases, electric arc,
electric resistance or by chemical reaction.
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• Welding is a permanent joining process in which two pieces of metal join
together to form one piece.
• Additional metal, also called filler metal, is added during the heating
process to help bond the two pieces together.
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• The welded joint can be stronger than the parent materials if a filler metal
is used that has;
Strength properties superior to those of the parents, and
• But, Most welding operations are performed manually and are expensive in
terms of labor cost.
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1.2. Terminological Elements Welding Process
• Fusion zone: the area where new metal is situated after welding.
• Weld face: the face of the weld looking from top side of the weld.
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• Filler rod/Electrode: commonly known as welding stick, consumable and many
more, it transmit electricity to heat up the tip of electrode which melts it along
with the base metal.
• Flux: provides the following to the weld process: shielding gas, inter pass
cooling temperature control by slag, reinforcement alloy to weld metal.
• Welding produces a solid connection between two pieces, called a weld joint.
• A weld joint is the junction of the edges or surfaces of parts that have been
joined by welding.
• There are five basic types of joints for bringing two parts together for joining.
The five
• joint types are not limited to welding; they apply to other joining and fastening
techniques as well.
• For welding the edges of joining surfaces of metals are prepared first.
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a) Butt joint: in this joint type, the parts lie in the same plane and are joined at
their edges.
b) Corner joint: the parts in a corner joint form a right angle and are joined at
the corner of the angle.
d) Tee joint: in a tee joint, one part is perpendicular to the other in the
approximate shape of the letter ‘‘T.’’
e) Edge joint: the parts in an edge joint are parallel with at least one of their
edges in common, and the joint is made at the common edge(s).
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• Different edge preparations may be used for welding butt joints,
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Generally, types of joints and welds based on joining systems,
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Advantages of Welding
• Large number of metals and alloys both similar and dissimilar can be
joined by welding.
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Cont..
• Welding can join welding jobs through spots, as continuous pressure tight
• Jigs, and fixtures may also be needed to hold and position the parts to be
welded
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• Edges preparation of the welding jobs are required before welding
welded
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Classification of Welding
1. Fusion/liquid welding
Fusion/liquid welding
pool to facilitate the process and provide bulk and strength to the welded
joint.
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• The weld may be formed entirely by melting parts of the base metal, and
1. Arc welding,
2. Resistance welding,
•Arc welding is a type of welding process using an electric arc to create heat to
melt and join metals.
•An electric arc from an AC or DC power supply creates an intense heat of around
5500 °C (10,000°F) or higher, sufficiently hot to melt any metal.
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Cont..
• Because the metals react chemically to oxygen and nitrogen in the air when
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• Arc welding process can be categorized into two different types;
Consumable and
Non-consumable electrode methods.
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Cont..
Stud welding
A consumable electrode acts as filler and thus it supplies necessary filler material intended to fill the root gap. Non-consumable electrode does not supply filler. Thus filler
material is required to supply separately.
After welding, a significant portion of the electrode becomes an integrated part of the weld bead. After welding, the electrode remains unaffected (except a
small erosion).
This type of electrode does not allow autogenous mode of welding as filler is applied inherently. It can be used It allows all three modes of welding – autogenous,
for either homogeneous or heterogeneous mode of welding. homogeneous and heterogeneous.
Electrode material must be chosen based on the parent materials in order to maintain chemical compatibility Since non-consumable electrode does not act as filler, so
between them. electrode material is independent of the parent materials to be
welded.
Since electrode material is consumed during welding, so frequent replacement of the electrode is usually A non-consumable electrode offers extended life as it is not
desired. However, the replacement frequency depends on electrode size and filler deposition rate. consumed during welding. Frequent replacement is also not
desired (it helps improving productivity).
Arc welding processes that employ a consumable electrode: Arc welding processes that employ a non-consumable
Shielded Metal Arc Welding (SMAW) electrode:
Gas Tungsten Arc Welding (GTAW) or Tungsten Inert Gas
Gas Metal Arc Welding (GMAW) (both MIG and MAG)
(TIG) welding
Flux-cored arc welding (FCAW)
Atomic Hydrogen Welding (AHW)
Submerged arc welding (SAW)
Carbon Arc Welding (CAW)
Electroslag welding (ESW)
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Electro-gas welding (EGW)
2. Non- fusion/solid-state welding
• If heat is used, the temperature in the process is below the melting point of
the metals being welded. No filler metal is utilized.
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Cont..
between the two parts and an oscillating motion at ultrasonic frequencies is used in
a direction parallel to the contacting surfaces.
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1. Gas Metal Arc/Metal inert gas (MIG) welding
• Metal Inert Gas (MIG) is also known as gas metal arc welding (GMAW).
• This type of welding is basically an arc welding process that joins two metals.
• Is an arc welding process in which the electrode is a consumable bare metal wire,
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• This arc is formed between the surface to be welled and a continuously
fed filler electrode.
• This type of welding uses a shielding gas to protect the molten pool of
weld metal from reacting with elements present in the atmosphere.
• Wire diameters ranging from 0.8 to 6.5mm are used in MIG welding.
• Gases used for shielding include inert gases such as argon and helium, and
active gases such as carbon dioxide.
• Inert gases are used for welding aluminum alloys and stainless steels, while
CO2 is commonly used for welding low and medium carbon steels. 26
MIG welding setup
• The first step before turning on the welder is to prepare your metal.
• Unlike stick and flux-cored electrodes, which have higher amounts of special
additives, the solid MIG wire does not combat rust, dirt, oil or other contaminants
very well.
• Use a metal brush or grinder and clean down to bare metal before striking an arc.
Make sure your work clamp connects to clean metal, too.
• Any electrical impedance will affect wire feeding performance. To produce strong
welds on thicker metal, bevel the joint to ensure the weld fully penetrates to the
base metal.
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Next, it's time to set up your machine:
•Check your cables: before striking an arc, check your welding equipment to
make sure all of the cable connections are tight and free of fraying or other
damage.
•Set gas flow: turn on the shielding gas and set the flow rate to 20 to 25 cubic
feet per hour. 26
• Check tension: too much or too little tension on either the drive rolls or the
wire spool hub can lead to poor wire feeding performance. Adjust according to
your owner's manual.
• Inspect consumables: remove excess spatter from contact tubes, replace worn
contact tips and liners and discard the wire if it appears rusty.
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Working principle of MIG welding
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Metal inert gas’s electrodes
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• The basic components in the MIG welding system.
The welding torch/gun
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Advantages and disadvantages of MIG Welding
•It is versatile and works with various alloys and metals, including aluminum,
mild steel, stainless steel, copper, magnesium, nickel, and iron.
•Cleanup is quick and easy since there isn’t any slag or spatter to remove after
each pass. It is a fast and efficient way to weld metal.
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• Ease of use
• MIG, uses consumable wire as both the electrode and filler material to
join large and thick materials
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Disadvantages of MIG welding
•MIG is perfect for thicker metals while thinner metals react better to TIG welding
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2. Tungsten inert gas (TIG) welding
• The weld area and electrode are protected from oxidation or other
atmospheric contamination by an inert shielding gas (argon or helium).
• The shielding gases generally used are argon, helium or their mixtures
• The shielding gas protects the tungsten electrode and the molten metal weld
• Its most common applications are for aluminum and stainless steel.
• Cast irons, wrought irons, and of course tungsten are difficult to weld by
GTAW
• For most uses any size between 1.6 to 3.2mm electrode diameter will do.
• Since Tungsten electrodes come in a rod form with a square cut end, an
electrode needs to be shaped.
• Some of the tip shapes used in these electrodes are pointed, rounded, and
tapered with a ball end. 30
Cont..
Tungsten electrode
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Working principle of TIG welding
• TIG welding elaborate as tungsten inert gas welding and its process works on the
basic principle.
• The basic principle leads to the joining of two base metals by providing electric arc.
• Some necessary types of equipment are essential for processing the TIG welding.
Gas cylinder
Regulator
Welding torch
Tungsten electrode
Additional Filler metal (if required)
DC electric supplier 30
Working principle of TIG welding
• TIG welding elaborate as tungsten inert gas welding and its process works on the
basic principle.
• The basic principle leads to the joining of two base metals by providing electric arc.
• Some necessary types of equipment are essential for processing the TIG welding.
Gas cylinder
Regulator
Welding torch
Tungsten electrode
Additional Filler metal (if required)
DC electric supplier 30
Cont..
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Cont..
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Advantages and disadvantages of TIG welding
• No weld spatter because no filler metal is transferred across the arc, and
• There are fewer fumes and less smoke when TIG welding.
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• The body or the frame of the welding machine shall be efficiently earthed.
• Welding arc in addition to being very is a source of infra-red and ultra-violet light
also; consequently the operator must use either helmet or a hand-shield fitted with a
special filter glass to protect eyes
• Excess ultra-violet light can cause an effect similar to sunburn on the skin of the
welder
• The welder’s body and clothing are protected from radiation and burns caused by
sparks and flying globules of molten metal
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Cont..
• Leather or asbestos apron is very useful to protect welder’s clothes and his
trunk and thighs while seated he is doing welding.
• For overhead welding, some form of protection for the head is required
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• Leather jackets and 1ather leggings are also available as clothes for
body protection.
• All parts of welding set shall be suitably enclosed and protected to meet
the usual service conditions.
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