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

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
1. Carbon arc
2. Metal arc
3. Metal inert gas
4. Tungsten inert gas
5. Plasma arc
6. Submerged arc
7. Electro-slag
(ii). Gas Welding
1. Oxy-acetylene
2. Air-acetylene
3. Oxy-hydrogen
(iii). Resistance Welding
1. Butt
2. Spot
3. Seam
4. Projection
5. Percussion

(iv)

Thermit Welding

(v)

Solid State Welding

1. Friction
2. Ultrasonic
3. Diffusion
4. Explosive

(vi)

Newer Welding
1. Electron-beam
2. Laser

(vii)

Related Process
1. Oxy-acetylene cutting
2. Arc cutting
3. Hard facing
4. Brazing
5. Soldering

Arc welding methods

1. Metal arc welding
It is a process of joining two metal pieces by melting the edges by an electric arc. The electric
arc is produced between two conductors. The electrode is one conductor and the work piece is another
conductor. The electrode and the work piece are brought nearer with small air gap. (3mm app.)
When current is passed an electric arc is produced between the electrode and the work piece.
The work piece and the electrode are melted by the arc. Both molten piece of metal become one.
Temperature of arc is about 4000c Electrodes used in arc welding are coated with a flux. This flux
produces a gaseous shield around the molten metal. It prevents the reaction of the molten metal with
oxygen and nitrogen in the atmosphere. The flux removes the impurities from the molten metal and
form a slag. This slag gets deposited over the weld metal. This protects the weld seam from rapid
cooling. Fig.1 shows arc welding process.
Equipments:(Refer Fig 2)

A welding generator (D.C.) or Transformer (A.C.)

Two cables- one for work and one for electrode

Electrode holder

Electrode

Protective shield

Gloves

Wire brush

Chipping hammer

Goggles

Fig. 1 Arc Welding

Fig 2 Electric Arc Welding Equipments

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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
1. Manually applied, therefore high labor cost.
2. Need high energy causing danger
3. Not convenient for disassembly.
4. Defects are hard to detect at joints.
2. Carbon arc welding
In carbon arc welding, the intense of heat of an electric arc between a carbon electrode and
work piece metal is used for welding. DC power supply is used. The carbon electrode is connected to
negative terminal and work piece is connected to positive terminal, because positive terminal is hotter
(4000c) than the negative terminal (3000c) when an arc is produced. So carbon from the electrode
will not fuse and mix up with the metal weld. If carbon mixes with the weld, the weld will become
weak and brittle. To protect the molten metal from the atmosphere the welding is done with a long arc.
In this case, a carbon monoxide gas is produced, which surrounds the molten metal and protects it.
Carbon arc welding is used to weld both ferrous and non ferrous metals. Sheets of steel, copper
alloys, brass and aluminium can be welded in this method.( Refer Fig 3)

Fig 3 Carbon Arc Welding

Comparison of A.C. and D.C. arc welding

Alternating Current (from

Direct Current (from Generator)

1
2
3
4
5

Transformer)
More efficiency
Power consumption less
Cost of equipment is less
Higher voltage hence not safe
Not suitable for welding non ferrous

Less efficiency
Power consumption more
Cost of equipment is more
Low voltage safer operation
suitable for both ferrous non ferrous metals

6
7

metals
Not preferred for welding thin sections
Any terminal can be connected to the

preferred for welding thin sections

Positive terminal connected to the work

work or electrode

Negative terminal connected to the electrode

GAS WELDING
Oxy-Acetylene welding
In gas welding, a gas flame is used to melt the edges of metals to be joined. The flame is
produced at the tip of welding torch. Oxygen and Acetylene are the gases used to produce the
welding flame. The flame will only melt the metal. A flux is used during welting to prevent
oxidations and to remove impurities. Metals 2mm to 50mm thick are welded by gas welding. The
temperature of oxyacetylene flame is about 3200c. Fig 3 shows Gas welding equipments.
Gas Welding Equipment
1. Gas Cylinders
Pressure
Oxygen 125 kg/cm2
Acetylene 16 kg/cm2
2. Regulators
Working pressure of oxygen 1 kg/cm2
Working pressure of acetylene 0.15 kg/cm2
Working pressure varies depends upon the thickness of the work pieces welded.
3. Pressure Gauges
4. Hoses
5. Welding torch
6. Check valve
7. Non return valve

Fig- 4 Gas Welding Equipment

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TYPES OF FLAMES

When acetylene is burned in air, it produces a yellow sooty flame, which is not enough for
welding applications

Oxygen is turned on, flame immediately changes into a long white inner area (Feather)
surrounded by a transparent blue envelope is called Carburizing flame (30000c)

This flames are used for hardening the surfaces

Addition of little more oxygen give a bright whitish cone surrounded by the transparent blue
envelope is called Neutral flame (It has a balance of fuel gas and oxygen)

Most commonly used flame because it has temperature about 32000c

Used for welding steels, aluminium, copper and cast iron

If more oxygen is added, the cone becomes darker and more pointed, while the envelope
becomes shorter and more fierce is called Oxidizing flame

Has the highest temperature about 34000c

Used for welding brass and brazing operation

Fig 4 shows the types of flames.

Fig 5 Types of Gas Flames

Advantages
1. Equipment has versatile
2. Same equipment can be used for oxy acetylene cutting and brazing by varying the torch size
3. Heat can controlled easily
Disadvantages
1. Slower process
2. Risk is involved in handling gas cylinders

GAS CUTTING

Ferrous metal is heated in to red hot condition and a jet of pure oxygen is projected onto the
surface, which rapidly oxidizes

Oxides having lower melting point than the metal, melt and are blown away by the force of the
jet, to make a cut

Fast and efficient method of cutting steel to a high degree of accuracy

Torch is different from welding

Cutting torch has preheat orifice and one central orifice for oxygen jet

PIERCING and GOUGING are two important operations

Piercing, used to cut a hole at the centre of the plate or away from the edge of the plate

Gouging, to cut a groove into the steel surface

Fig 6 Automatic Gas Cutting

Fig 7 Manual Gas Cutting

Weld joint
There are 5 basic joint types in welding

Butt joint: Two materials are in the same plane, joined from the edges.

Corner joint:The corners of two materials form a right angle and joined.

Lap joint: Two parts overlaps.

Tee joint: One part is perpendicular to the other, making a T shape.

Edge joint: Edges of the two materials joined.

Types of weld
1. Fillet weld: Used in T joints,corner joints, lap joints.
2. Groove weld:Used in butt joints.
3. Plug weld: Used in lap joints.
4. Slot weld: Used in lap joints.
5. Spot weld: Used in lap joints.
6. Seam weld: Used in lap joints.
7. Flange weld:Used in edge joints.
8. Surfacing weld:Not a joining process, it is used to increase the thickness of the plate, or
provide a protective coating on the surface.

Fig 8 Types of Weld Joints

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Weldability is the ease of a material or a combination of materials to be welded under

fabrication conditions into a specific, suitably designed structure, and to perform satisfactorily in
the intended service

Brazing and Soldering

Brazing
It is a low temperature joining process. It is performed at temperatures above 840 F and it
generally affords strengths comparable to those of the metal which it joins. It is low temperature in
that it is done below the melting point of the base metal. It is achieved by diffusion without fusion
(melting) of the base
Depending upon the method of heating, brazing can be classified as
1. Torch brazing
2. Dip brazing
3. Furnace brazing
4. Induction brazing

Fig 9 Brazing

Advantages
Dissimilar metals which canot be welded can be joined by brazing
Very thin metals can be joined
Metals with different thickness can be joined easily
In brazing thermal stresses are not produced in the work piece. Hence there is no
distortion
Using this process, carbides tips are brazed on the steel tool holders
Disadvantages
Brazed joints have lesser strength compared to welding
Joint preparation cost is more
Can be used for thin sheet metal sections

Soldering
It is a low temperature joining process. It is performed at temperatures below 840F for
joining.
Soldering is used for,

Fig 9 Soldering

Sealing, as in automotive radiators or tin cans

Electrical Connections

Joining thermally sensitive components

Joining dissimilar metals

Questions:
PART A Short Questions
1. Define the term welding.
2. What is plastic welding? Give some examples.
3. What is fusion welding? Give some examples.
4.

Name few gases used in welding.

5. What is the function of regulator in gas welding?

6. What is carburizing flame?
7. What is neutral flame? Write down its temperature.
8. List out the advantages of gas welding.
9.

List the different equipments and accessories used in electric arc welding.

10. What is torch brazing?

PART B - Essay Type Questions

1. Classify the welding process.
2. Explain the principle of arc welding process.
3. Compare the use of A.C and D.C. in welding.
4. What are the equipments used in gas welding? State their functions.
5. What is brazing? Describe briefly two methods of brazing.
6. Write short notes on the following:
a. Gas cutting
b. Soldering
7. With a neat sketch, explain metal arc welding process.
8. With a neat sketch, explain different types of flames used in gas welding process. Also list
out their uses.

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