welding

• welding is a joining process that uses

heat ,pressure, chemicals, to fuse two
material together
 • joining process

Mechanical Atomic bonding

bonding

Temporary Permanent, Solid state liquid

, screw semi
elements permanent

electric chemical

Rivets, stitches,
Arc, induction, resistance Gas, thermit
staples
Joint design

1-2mm

Root gap
TUNGSTEN INERT GAS WELDING
•In tungsten inert gas welding arc is maintained
between non consumable tungsten electrode and
work piece in a protective inert gas atmosphere

Any filler material needed is supplied externally.

 Tig welding
• Tig welding is arc welding process which
produces coalescence of metal by heating them
with an arc between tungsten electrode and
work.
• The arc develops intense heat which melts the
surface of base metal to form molten pool.
• Shielding of arc :argon gas
• The shielding gas displaces air so that 0 2 and N2
of air doesn’t contact with molten metal and hot
tungsten electrode.
• No spatter and no smoke.
• Resulting weld smooth and uniform and require
minimum finish
 SMAW(Shielded metal arc
welding)
1. SMAW consist of an arc between covered
electrode and base metal.
2. The arc is initiated by momentarily touching
the electrode
3. The heat of arc melts the surface of base
metal to form a molten pool at the end of
electrode
4. The melted electrode metal is transferred
across the arc into the molten pool and
become deposited metal.
 CORE WIRE

ARC
SLAG
WELD POOL

PARENT METAL
DEPOSITED
WELD METAL
 Flux coating for SMAW is to provide one or
more of following characteristic.
• Gas from decomposition of certain ingridient of coating
to shield arc from atmosphere.
• Deoxidiser for scavenging and purifying deposited metal
• Slag formers to protect deposited weld metal with slag
from atmospheric oxidation.
• Alloying element to provide special characteristic to the
deposited weld metal.
• Iron powder to improve the deposition rate or the
productivity of electrode
•
 Ingridient added in flux
• Iron powder : imparts a number of desirable
characteristic to the electrode
• It improves the stability
• It melts and remain unoxidised and joint
weld pool there by increasing deposition
efficiency.

• ALLOYING ELEMENT: mn, cr, ni, mo, v, co

are added in small quantity to flux coating
which melt and go into the weld metal to
enhance its properties
 Fusion
face
panetration

reinforce
men
t

gap
Fillet weld

th
ng
g le
Le
Throat
thickness
 Classification of welding electrode
• For classifying electrode AWS has adopted 4 or 5
digit no prefixed with E.
• The first two in five digit no indicate tensile
strength of weld metal in thousand of pound per
square inch.
• Third digit indicates the position in electrode can
be used
• Fourth digit indicates type of coating and weld
current for electrode, (1-8)
• E7018 70: seventy thousand pound per square
inch.
• 1: all position
• 8: iron powder low hydrogen AC/DC+
• WELDING PROCEDURE
• Joint design
• Base metal :grade ,thickness range- base metal
to groove,
• Filler material
• Electrode- flux size
• Welding progression
• Preheat : thickness of base metal, preheat
temp, interpass temp,
• Electrical characteristic
• Welding technique: string or weave bead,
multiple or single pass
 Base metal and filler material
Base metal root 1/2/3 pass
SA210C ER70S-2 E-7018-1
20G ER70S-2 E-7018-1

SA106-C ER70S-A1 E-7018-A1

12CR1MOVG ER90S-B3 E-9018-B3
15CRMOG ER80S-B2 E8018-B2
P22 ER90S-B3 E9018-B3
P91 ER90S-B9 E9018-B9
SA210C ER70S-2 ER7018-1
+15CRMOG
 Weld layers
Weld process class dia polarity Amp-
layer volt
range
Root GTAW 2.4 DCEN 70-130

1st SMAW 2.5 DCEP 70-100

2nd SMAW 3.1 DCEP 90-140

5
3/4th SMAW 4 DCEP 140-
190
 COMPOSITION OF ALLOY
ALLOY0.27 C% Cr Mo V

20G 0.17-0.24

SA 210C <0.27

SA106C <0.35

15NicuMoNb5 <0.17 .25-.50

15Cr1MoV 0.12-0.18 0.80-1.10 0.40-0.55

12Cr1MoV 0.08-0.15 0.90-1.20 0.25-0.35

T91 0.08-0.12 8-9.50 0.85-1.05 0.18-0.25

SA213TP347H 0.04-0.10 ,,
 Basic type of electrode
• These type of electrode are also called low
hydrogen electrode.
• Hydrogen has found to be harmful in welding of
medium carbon, low carbon , alloy and stainless
steel.
• Flux of these electrode have calcium and other
carbonate and fluoride.
• Co2 generated from carbonate give effective
shielding to weld metal.
• A thick slag is formed over weld metal which
doesn’t peel of easily . Due to this hard sticking
slag, weld metal is cooled slowly and exhibit good
mechanical properties.
• Weld metal susceptibility due to cracking is
reduced by these electrode
 PROPERTIES OF ALLOYING
ELEMENTS
• Cr: increases resistance to corrosion, abrasion,
and wear
• Increases high temp strength
• Increases harden ability
• 4-8% to increase harden ability

• MO: increases harden ability, significantly,

increases strength, toughness, red hardness,
and hot strength, when used with Cr, Mn, V,
increases corrosion, and abrasion resistance,
typical percentage 0.2-5
• Vanadium: 1. produces fine grain size
2. increases harden ability

3. impart hardness and wear resistance

4.typical percentage is 0.15
5. form stable carbide that persist at
quite high temp , normally used with combination
of chromium
 Nickel : increases toughness and impact strength
 WHY PRE HEATING
• There are four primary reasons to utilize
preheat
• It slows the cooling rate in the weld metal
and base metal producing more ductile
metallurgical structure with greater
resistance to cracking
• The slower cooling rate provides an
opportunity for hydrogen that may be
present to diffuse out harmlessly, reducing
potential for cracking
• It reduces the shrinkage forces in the weld
and adjacent base metal which is especially
important in highly restraint joint
• It raises some steel above the temperature at
which brittle fracture would occur in
fabrication
• Additionally preheat can be used to help
ensure specific mechanical properties such as
weld metal notch toughness
• In order to determine whether or not preheat
one should consider section thickness, base
metal chemistry, restraint, ambient
temperature, filler metal hydrogen content,
previous cracking problem
 Reasons for preheating
• To reduce the weld metal and base metal
cracking
• To improve general weld ability
• To retard the cooling rate in the weld metal, and
heat affected base metal
• To improve the ductility near the heat affected
zone, and reduce hardness
• To increase the weld speed and to keep the
moisture away from the weld zone.
• Bead deposited in preheated joint tend to be
more fluid and exhibit flatter or concave
surfaces than joint with out preheat.
 Post weld heat treatment
• Residual stresses resulting from welding are reduced
• Residual stresses remaining in material after thermal
stress relief depends on rate of cooling
• The heat affected zone in the vicinity of welding joint are
aided by PWHT
• HAZ properties are improved by reduction of residual
stresses and metallurgical changes brought about
• Necessity of post heating increases with higher carbon
content, increase in alloy content, and cross sectional
thickness of part
• Micro structure , tensile and impact strength are among
properties affected by pwht.
 Original
MELT work
BOUNDARY piece

HAZ
 Soaking temperature
• SA-106GC 620 deg Celsius
• P11 650-680
• P22 700-720
• P91 760+-10
thickness R/H R/C S. TIME S/TEMP

25mm 220/hr 220/hr 620 max T*2.5

25-50mm 110/hr 110/hr ‘’

50-70mm 75/hr 75/hr
71- 55/hr 75/hr
100mm
100- 35/hr 35/hr
150mm
• CLEANING: grinding, chipping, brushing
• Mode of metal transfer : spray arc, short circuit
• Post heating:
 Procedure for handling of welding
electrode
• While handling avoid contact of oil , grease,with
electrode.
• Identify and mark the drying, backing and
holding oven
• Dry oven: baking, 250-350 deg celcius, for 2-3hr
• Holding oven: 100 - 125 deg C
• Potable oven :above 70 deg
• Electrode shall not be subjected to 2 cycle of
drying
 Electrode Preservation &
Documentation
• Electrodes shall be kept in moisture free
HOT rooms having temperature at least 25
deg C higher than the room temp.
• Electrode backing register shall be
maintained to assure proper backing of the
electrodes.
• Electrodes shall be issued on request of
authorized person only.
 Forces responsible for metal
transfer across the arc
• Surface tension of metal droplet and weld
pool
• Gravitational force acting
• Electromagnetic force in plasma stream
 Importance of metal transfer
• Metal transfer dictate the usefulness of
welding process
• Effects the welding position that can be
used
• Depth of weld penetration
• Stability of weld pool
• Weld contour
• Metal transfer depends upon current
density, polarity of electrode, electrode
size
 Types of metal transfer
• Spray transfer
• Dip transfer
• Globular transfer
• Spray transfer: axial stream of fine
droplets, occur at high current density, max
deposition rate
• Spray transfer limited to down hand, or flat
position welding
 Short circuit transfer
• At the start electrode melts into small
globule of liquid metal
• Next molten globule advances towards
work piece creating short circuit
• At above stage metal transfer is by gravity
and surface tension and arc is
extinguished. Now current rises up and by
nature of magnetic impinch force , electric
contact is broken and arc is reignited.
Frequency of arc extincted and resignation
varies from 20-200 times per second
 Reason for thermal treatment of
weldament
• To restore properties affected by heating
of welding
• To improve properties for subsequent
operation or service condition
• To increase hardness and strength
• To remove internal stresses
• To increase ductility, toughness, and
softness
• To refine grain structure
 WELDING POSITIONS
• 1F, 1G, 1S -flat position
• 2F, 2G, 2S, - horizontal
• 3F, 3G, 3S, - vertical
• 4F, 4G, 4S, - over head