Welding types and

their applications

1. INDEX
Page
1.
2.
3.
4.
5.
6.
7.

Frontal page2
Index....3
Introduction.....4
Objectives..........................................................................................5
3.1 General objective.5
3.2 Specific objectives...5
Investigation....6-14
4.1 Welding......6-7
4.2 Types of welding and their applications ......7-14
Conclusions....15
Annexes......16-18
Bibliography....19

2. INTRODUCTION
WELDING TYPES AND THEIR APPLICATIONS

Welding is a fabrication or sculptural process that joins materials, usually metals or

thermoplastics, by causing fusion, which is distinct from lower temperature metaljoining techniques such as brazing and soldering, which do not melt the base
metal. In addition to melting the base metal, a filler material is often added to the
joint to form a pool of molten material (the weld pool) that cools to form a joint that
can be as strong, or even stronger, than the base material.
Some of the best known welding methods include: Shielded metal arc welding
(SMAW, Gas tungsten arc welding (GTAW), Gas metal arc welding (GMAW), Fluxcored arc welding (FCAW) , Submerged arc welding (SAW), Electro-slag welding
(ESW), although these are some of the processes most commonly used in
welding, in this project only developed some.
For example, the Shielded metal arc welding (SMAW) - also known as "stick
welding or electric welding", uses an electrode that has flux around it to protect the
weld puddle. The electrode holder holds the electrode as it slowly melts away. Slag
protects the weld puddle from atmospheric contamination.
Applications of welding processes are enough, since most of the things we do in
manufacturing and construction require these processes among which can be
added; Industrial applications; Shop work, Automotive repair shops, Plumbing
applications, Fabricating industry, Artisan welding.

WELDING TYPES AND THEIR APPLICATIONS

3. OBJECTIVES

GENERAL OBJECTIVE:

Analyze the concept of welding, which welding means and its operation in the
industry.

SPECIFIC OBJETIVES:
1. Investigate the types of welding that exist and which are most commonly
used in the industry.
2. Determine which applications are welding processes and what is the
proper use of them.
3. Analyze what are the advantages in using welding, type FCAW.

4. Investigation
4.1

Welding

Welding is as a process where two or more pieces of metal or thermoplastics are

fastened together by the use of heat and pressure. The process of applying heat

WELDING TYPES AND THEIR APPLICATIONS

softens the material and enables it to affix together as one in a joint area when an
adequate amount of pressure is applied.
The concept of welding was first developed in the Middle Ages, though it did not
form into the process of welding as it is today until the latest years of the 19th
century. Before this, a process known as forge welding was the only means of
joining two metal objects together. Forge welding consisted of using a flame to heat
metal to extremely high temperatures and then hammering each piece together
until they became one. This method was replaced around the time of the industrial
revolution. Electric and gas flame heating methods proved to be much safer and
faster for welders. Practically every material object that has made society what it is
today, was created by welded construction tools or has been welded itself.
Although less common, there are also solid state welding processes such as
friction welding or shielded active gas welding in which metal does not melt.
Some of the best known welding methods include:
Shielded metal arc welding (SMAW): also known as "stick welding or
electric welding", uses an electrode that has flux around it to protect the
weld puddle. The electrode holder holds the electrode as it slowly melts
away. Slag protects the weld puddle from atmospheric contamination.
Gas tungsten arc welding (GTAW): also known as TIG (tungsten, inert
gas), uses a non-consumable tungsten electrode to produce the weld. The
weld area is protected from atmospheric contamination by an inert shielding
gas such as argon or helium.
Gas metal arc welding (GMAW): commonly termed MIG (metal, inert gas),
uses a wire feeding gun that feeds wire at an adjustable speed and flows an
argon-based shielding gas or a mix of argon and carbon dioxide (CO2) over
the weld puddle to protect it from atmospheric contamination.
Flux-cored arc welding (FCAW): almost identical to MIG welding except it
uses a special tubular wire filled with flux; it can be used with or without
shielding gas, depending on the filler.
Submerged arc welding (SAW): uses an automatically fed consumable
electrode and a blanket of granular fusible flux. The molten weld and the arc
zone are protected from atmospheric contamination by being "submerged"
under the flux blanket.
Electroslag welding (ESW): a highly productive, single pass welding
process for thicker materials between 1 inch (25 mm) and 12 inches (300
mm) in a vertical or close to vertical position.
Many different energy sources can be used for welding, including a gas flame, an
electric arc, a laser, an electron beam, friction, and ultrasound. While often an
WELDING TYPES AND THEIR APPLICATIONS

industrial process, welding may be performed in many different environments,

including in open air, under water, and in outer space. Welding is a hazardous
undertaking and precautions are required to avoid burns, electric shock, vision
damage, inhalation of poisonous gases and fumes, and exposure to intense
ultraviolet radiation.

4.2

Types of welding and their applications

Shielded metal arc welding (SMAW)

Also known as manual metal arc welding, stick welding, orelectric arc welding and
is the most widely used of the various arc welding processes. Welding isperformed
with the heat of an electric arc that is maintained between the end of a coated
metal electrode and the work piece. The heat produced by the arc melts the base
metal, the electrode core rod, and the coating. As the molten metal droplets are
transferred across the arc and into the molten weld puddle, they are shielded from
the atmosphere by the gases produced from the decomposition of the flux coating.
The molten slag floats to the top of the weld puddle where it protects the weld
metal from the atmosphere during solidification. One reason for the wide
acceptance of the SMAW process is the simplicity of the necessary equipment.
The equipment consists of the following items.
1. Welding power source
2. Electrode holder
3. Ground clamp
4. Welding cables and connectors
5. Accessory equipment (chippinghammer, wire brush)
6. Protective equipment (helmet, gloves, etc.)

Applications
Is often used to weld carbon steel, low and high alloy steel, stainless steel, cast
iron, and ductile iron. While less popular for nonferrous materials, it can be used on
nickel and copper and their alloys and, in rare cases, on aluminium. The thickness
of the material being welded is bounded on the low end primarily by the skill of the
welder, but rarely does it drop below 1.5 mm (0.06 in). No upper bound exists: with
proper joint preparation and use of multiple passes, materials of virtually unlimited
WELDING TYPES AND THEIR APPLICATIONS

thicknesses can be joined. Furthermore, depending on the electrode used and the
skill of the welder, SMAW can be used in any position.
Gas tungsten arc welding (GTAW)
Is a welding process performed using the heat of an arc established between a
nonconsumable tungsten electrode and the work piece. The electrode, the arc, and
the area surrounding the molten weld puddle are protected from the atmosphere by
an inert gas shield. The electrode is not consumed in the weld puddle as
inshielded metal arc welding.
Gas tungsten arc welding produces exceptionally clean welds no slag is produced,
the chance inclusions in the weld metal is and the finished weld requires virtually
no cleaning. Argon and Helium, the primary shielding gases employed, are inert
gases. Inert gases do not chemically combine with other elements and therefore,
are used to exclude the reactive gases, such as oxygen and nitrogen, from forming
compounds that could be detrimental to the weld metal.
Gas tungsten arc welding may be used for welding almost all metals mild steel, low
alloys, stainless steel, copper and copper alloys, aluminum and aluminum alloys,
nickel and nickel alloys, magnesium and magnesium alloys, titanium, and others.
This process is most extensively used for welding aluminum and stainless steel
alloys where weld integrity is of the utmost importance. Another use is for the root
pass (initial pass) in pipe welding, which requires a weld of the highest quality. Full
penetration without an excessively high inside bead is important in the root pass,
and due to the ease of current control of this process, it lends itself to control of
back-bead size. For high quality welds, it is usually necessary to provide an inert
shielding gas inside the pipe to prevent oxidation of the inside weld bead.
Gas tungsten arc welding may be accomplished with relatively simple equipment,
or it may require some highly sophisticated components. Choice of equipment
depends upon the type of metal being joined, the position of the weld being made,
and the quality of the weld metal necessary for the application. The basic equipment consists of the following:
1. The power source
2. Electrode holder (torch)
3. Shielding gas
4. Tungsten electrode
5. Water supply when necessary
6. Ground cable
7. Protective equipment

WELDING TYPES AND THEIR APPLICATIONS

Applications
While the aerospace industry is one of the primary users of gas tungsten arc
welding, the process is used in a number of other areas. Many industries use
GTAW for welding thin workpieces, especially nonferrous metals. It is used
extensively in the manufacture of space vehicles, and is also frequently employed
to weld small-diameter, thin-wall tubing such as those used in the bicycle industry.
In addition, GTAW is often used to make root or first-pass welds for piping of
various sizes. In maintenance and repair work, the process is commonly used to
repair tools and dies, especially components made of aluminum and magnesium.
Because the weld metal is not transferred directly across the electric arc like most
open arc welding processes, a vast assortment of welding filler metal is available to
the welding engineer. In fact, no other welding process permits the welding of so
many alloys in so many product configurations. Filler metal alloys, such as
elemental aluminum and chromium, can be lost through the electric arc from
volatilization. This loss does not occur with the GTAW process. Because the
resulting welds have the same chemical integrity as the original base metal or
match the base metals more closely, GTAW welds are highly resistant to corrosion
and cracking over long time periods, making GTAW the welding procedure of
choice for critical operations like sealing spent nuclear fuel canisters before burial.
Gas metal arc welding (GMAW)
Sometimes referred to by its subtypes, metal inert gas (MIG) welding or metal
active gas (MAG) welding, is a semi-automatic or automatic arc welding process in
WELDING TYPES AND THEIR APPLICATIONS

which a continuous and consumable wire electrode and a shielding gas are fed
through a welding gun. A constant voltage, direct current power source is most
commonly used with GMAW, but constant current systems, as well as alternating
current, can be used.
There are four primary methods of metal transfer in GMAW, called globular, shortcircuiting, spray, and pulsed-spray, each of which has distinct properties and
corresponding advantages and limitations. Shielding is obtained from an externally
supplied gas or gas mixture.
Originally developed for welding aluminum and other non-ferrous materials in the
1940s, GMAW was soon applied to steels because it allowed for lower welding
time compared to other welding processes. The cost of inert gas limited its use in
steels until several years later, when the use of semi-inert gases such as carbon
dioxide became common.

Flux-cored arc welding (FCAW)

Flux Core Arc Welding (FCAW) uses a tubular wire that is filled with a flux. The arc
is initiated between the continuous wire electrode and the workpiece. The flux,
which is contained within the core of the tubular electrode, melts during welding
and shields the weld pool from the atmosphere. Direct current, electrode positive
(DCEP) is commonly employed as in the FCAW process.

WELDING TYPES AND THEIR APPLICATIONS

There are two basic process variants; self-shielded FCAW (without shielding gas)
and gas shielded FCAW (with shielding gas). The difference in the two is due to
different fluxing agents in the consumables, which provide different benefits to the
user. Usually, self-shielded FCAW is used in outdoor conditions where wind would
blow away a shielding gas. The fluxing agents in self-shielded FCAW are designed
to not only deoxidize the weld pool but also to allow for shielding of the weld pool
and metal droplets from the atmosphere.
The flux in gas-shielded FCAW provides for deoxidation of the weld pool and, to a
smaller degree than in self-shielded FCAW, provides secondary shielding from the
atmosphere. The flux is designed to support the weld pool for out-of position welds.
This variation of the process is used for increasing productivity of out-of-position
welds and for deeper penetration. Flux core arc welding for this reason is primarily
used in the ship building industry. Ships are made of heavy plate, and have
endless amounts of welding that needs to be done. Flux core welding produces
high quality welds, fast, and even when in windy conditions.

Process variables
Wire feed speed (and current)
Arc voltage
Electrode extension
Travel speed and angle
Electrode angles
Electrode wire type
Shielding gas composition (if required)

WELDING TYPES AND THEIR APPLICATIONS

10

Reverse polarity (Electrode Positive) is used for FCAW Gas-Shielded wire,

Straight polarity (Electrode Negative) is used for self shielded FCAW
Advantages and applications
FCAW may be an "all-position" process with the right filler metals (the
consumable electrode)
No shielding gas needed with some wires making it suitable for outdoor
welding and/or windy conditions
A high-deposition rate process (speed at which the filler metal is applied) in
the 1G/1F/2F
Some "high-speed" (e.g., automotive) applications
As compared to SMAW and GTAW, there is less skill required for operators.
Less precleaning of metal required
Metallurgical benefits from the flux such as the weld metal being protected
initially from external factors until the slag is chipped away
Porosity chances very low
Used on the following alloys:
Mild and low alloy steels
Stainless steels
Some high nickel alloys
Some wearfacing/surfacing alloys
Submerged arc welding (SAW)
Is a common arc welding process. The first patent on the submerged-arc welding
(SAW) process was taken out in 1935 and covered an electric arc beneath a bed of
granulated flux. Originally developed and patented by Jones, Kennedy and
Rothermund, the process requires a continuously fed consumable solid or tubular
(metal cored) electrode. The molten weld and the arc zone are protected from
atmospheric contamination by being "submerged" under a blanket of granular
fusible flux consisting of lime, silica, manganese oxide, calcium fluoride, and other
compounds. When molten, the flux becomes conductive, and provides a current
path between the electrode and the work. This thick layer of flux completely covers
the molten metal thus preventing spatter and sparks as well as suppressing the
intense ultraviolet radiation and fumes that are a part of the shielded metal arc
welding (SMAW) process.
SAW is normally operated in the automatic or mechanized mode, however, semiautomatic (hand-held) SAW guns with pressurized or gravity flux feed delivery are
available. The process is normally limited to the flat or horizontal-fillet welding
positions (although horizontal groove position welds have been done with a special
arrangement to support the flux). Deposition rates approaching 45 kg/h (100 lb/h)
WELDING TYPES AND THEIR APPLICATIONS

11

have been reported this compares to ~5 kg/h (10 lb/h) (max) for shielded metal
arc welding. Although currents ranging from 300 to 2000 A are commonly utilized,
[2] currents of up to 5000 A have also been used (multiple arcs).
Single or multiple (2 to 5) electrode wire variations of the process exist. SAW stripcladding utilizes a flat strip electrode (e.g. 60 mm wide x 0.5 mm thick). DC or AC
power can be used, and combinations of DC and AC are common on multiple
electrode systems. Constant voltage welding power supplies are most commonly
used; however, constant current systems in combination with a voltage sensing
wire-feeder are available.

Applications
Carbon steels (structural and vessel construction)
Low alloy steels
Stainless steels
Nickel-based alloys
Surfacing applications (wear-facing, build-up, and corrosion resistant
overlay of steels)
Advantages
High deposition rates (over 45 kg/h (100 lb/h) have been reported).
High operating factors in mechanized applications.
Deep weld penetration.
Sound welds are readily made (with good process design and control).
High speed welding of thin sheet steels up to 5 m/min (16 ft/min) is possible.
Minimal welding fume or arc light is emitted.
Practically no edge preparation is necessary depending on joint
configuration and required penetration.
The process is suitable for both indoor and outdoor works.
WELDING TYPES AND THEIR APPLICATIONS

12

Welds produced are sound, uniform, ductile, corrosion resistant and have
good impact value.
Single pass welds can be made in thick plates with normal equipment.
The arc is always covered under a blanket of flux, thus there is no chance of
spatter of weld.
50% to 90% of the flux is recoverable, recycled and reused.

Electroslag welding (ESW)

Is a process joining metals with heat generated by passage of electric current
through molten conductive slag which melts the filler and base metals. Due to
practically unlimited deposition rates ESW is considered the most productive of any
welding processes in joining very thick components.
The (ESW) process was developed at the Institute of Electric Welding named after
E.O. Paton (former USSR) in the late 40's. In the U.S., ESW came into practice in
the late 60's. In the mid 70's, ESW became a well established fabrication process
for joining thick wall components in bridge, building, shipbuilding, pressure vessel,
machine building and other industries.
Applications are similar to electrogas welding. The main difference is that the arc is
started between the electrode tip and the bottom of the part to be welded. Flux is
added, which then melts by the heat of the arc. After the molten slag reaches the
tip of the electrode, the arc is extinguished. Heat is produced continuously by the
electrical resistance of the molten slag. Because the arc is extinguished,
Electroslag welding is not strictly an arc-welding process. Single or multiple solid
as well as flux-cored electrodes may be used.
Electroslag welding is capable of welding plates with thicknesses ranging from 50
mm to more than 900 mm and welding is done in one pass. The current required is
about 600 A at 40 to 50 Volts although higher currents are used for thick plates.
The travel speed of the weld is in the range from 12 to 36 mm/min. Weld quality is
high.
The quality of weld in Electroslag welding depends on
The ratio of width of the weld pool and its maximum depth known as Form
Factor.
Weld current and voltage.
Slag depth.
Number of electrodes and their spacing etc.

WELDING TYPES AND THEIR APPLICATIONS

13

5. CONCLUSIONS

Welding is as a process where two or more pieces of metal or

thermoplastics are fastened together by the use of heat and pressure.
Some of the best known welding methods include: Shielded metal arc
welding (SMAW,. Gas tungsten arc welding (GTAW, Gas metal arc welding
(GMAW, Flux-cored arc welding (FCAW, Submerged arc welding (SAW),
Electroslag welding (ESW). Many different energy sources.
In the Welding SWAW, the applications is Application Is often used to weld
carbon steel, low and high alloy steel, stainless steel, cast iron, and ductile
iron, the application in the Gas tungsten arc welding, there is Mild and low
alloy steel, Stainless steel, Some high nickel alloy, some
wearfacing/surfacing alloys.
Some of the advantages in using welding type FCAW, are; FCAW may be
an "all-position" process with the right filler metals (the consumable
electrode), no shielding gas needed with some wires making it suitable for
outdoor welding and/or windy conditions, a high-deposition rate process
(speed at which the filler metal is applied) in the 1G/1F/2F.

WELDING TYPES AND THEIR APPLICATIONS

14

6. ANNEXES

Edgar doing Gas or Oxy Acetylene Welding

WELDING TYPES AND THEIR APPLICATIONS

15

Marisol doing Arc Welding

Lidia doing Gas Metal Arc Welding

WELDING TYPES AND THEIR APPLICATIONS

16

Carlos doing Gas or Oxy Acetylene Welding

7. BIBLIOGRAPHY

Title: Welding types; Author: Anonymous; Consulting date: April 22 nd, 2016;
Edition date: Anonymous; Link: http://www.weldingtypes.net/

Title: Types of welding; Author: Anonymous; Consulting date: April 22 nd,

2016;
Edition
date:
Anonymous;
Link:
http://www.gowelding.org/articles/types-welding/

Title: Welding; Author: Wikipedia; Consulting date: April 22 nd, 2016; Edition
date: April 20th, 2016; Link: https://en.wikipedia.org/wiki/Welding

WELDING TYPES AND THEIR APPLICATIONS

17

Title: Common electric arc welding processes; Author: The ESAB Group
Consulting date: April 22nd, 2016; Edition date: Anonymous; Link:
http://www.esabna.com/euweb/awtc/lesson2_5.htm

Title: Gas metal arc welding; Author: Lincoln Electric; Consulting date: April
22nd,
2016;
Edition
date:
Anonymous;
Link:
http://www.lincolnelectric.com/assets/global/Products/Consumable_MIGGM
AWWires-SuperArc-SuperArcL-56/c4200.pdf

WELDING TYPES AND THEIR APPLICATIONS

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