Welding Processes (Compatibility Mode)

Basics of
W ld Processes
Welding
Welding Definition
• Welding is a metal joining process used

to make welds
&
• weld
ld is
i a llocalised
li d ffusion
i off metals
t l
produced either by heating the materials to
suitable temperature, with or without
application of pressure, or by the
application of pressure alone, with or with
out the use of filler metal
metal.
2
Welding processes
Pressure welding Fusion welding
Cold pressure Hot pressure Chemical reaction

t i l LBW EBW
Electrical
El
welding welding resistance
Gas
Thermit
welding
welding Resistance
R i t Electroslag
El t l
Diffusion Explosive Ultrasonic
welding welding
welding
bonding welding
Electric arc
Friction welding
Flux-shielded Gas shielded
SAW GTAW PAW

SMAW
GMAW
Including
FCAW
Butt joint, butt weld T - Joint, fillet weld
Lap joint, fillet weld
Types of joints and welds

• Basically there are three inclinations
involved.
• Flat, which includes from 0 to 15 degrees
i li ti
inclination
• 15 - 80 degrees
g inclination
• Vertical, 80 - 90 degrees
• For
F each h off these
th inclinations
i li ti th
the weld
ld can
be rotated from the flat position to
Horizontal to overhead.
5
Welding Positions For Groove welds:-
Welding Position Test Position
Flat 1G
Horizontal 2G
Vertical Upwards Progression 3G
Vertical Downwards Progression 3G
Overhead 4G
Pipe Fixed Horizontal 5G
Pipe Fixed @ 45 degrees Upwards 6G
Pipe Fixed @ 45 degrees Downwards 6G
6
Welding Positions For Fillet welds:-
Welding Position Test Position
Flat (Weld flat joint at 45 degrees) 1F
Horizontal 2F
Horizontal Rotated 2FR
Vertical Upwards Progression 3F
Vertical Downwards Progression 3F
Overhead 4F
7
• Fusion and pressure welding
• Heat sources
Arc gas
Arc, gas, power beam
beam,
electrical resistance
• Shielding
g
Flux (MMAW, SAW)
Gas (GTAW
(GTAW, GMAW)
Vacuum (EBW)
Edge preparation
Filler material and weld metal
Weld metal (fusion zone)

Heat-affected zone (HAZ)
Unaffected parent material
Manual semi
Manual, semi-automatic
automatic and automatic welding
Welding positions: Flat

Flat, horizontal
horizontal, vertical
vertical,
overhead
Heat-affected zone Weld metal
(HAZ) (Fusion zone)
Unaffected
parent material
F i
Fusion and
d heat-affected
h t ff t d zones
Manual metal arc welding
(Shielded metal arc welding)
• Flux-coated electrode
• Consumable electrode process
• Why flux? – arc stabilization and shielding
• Manual mode
Metal transfer
Manual metal-arc welding (MMAW)

• Different types of MMAW electrodes
Cellulosic, rutile, basic coatings
• Iron-powder electrodes
Increase in productivity
• Low-hydrogen electrodes
Need for baking electrodes
• Ad
Advantages
t off MMAW
Cheap
Flexible
Versatile
• Di
Disadvantages
d t
Slow (current limitation)
Discontinuous
• Ways of making process continuous

From reel
Wire - feed rolls
From power source
Arc
Work
Mechanized wire
wire-feed
feed system
Submerged arc welding (SAW)
Submerged-arc
¾ Need for continuous welding
gpprocess
¾ Separation of wire and flux
¾ Wire-feed motor to deliver bare wire
¾ No current limitation – no spatter
no air entrainment
¾ High currents, high current densities
Suited to thick sections (mostly steel)
¾ Automatic welding
Submerged-arc welding (SAW)
Submerged-arc welding (SAW)
Ad
Advantages
t
g deposition
High p rate
Deep penetration
Hi h th
High thermall efficiency
ffi i
No need for operator protection
Smooth, ripple-free bead
Disadvantages
Limited to flat position

No visibility of weld pool
High dilution
High heat input Reduced toughness
Gas tungsten
tungsten-arc
arc welding (GTAW)
• Why
Wh gas shield?
hi ld?
• Aluminium,
Aluminium other non-ferrous
non ferrous alloys,
alloys
alloy steels
• Non-consumable electrode
• Shielding
Shi ldi gas only
l iinertt (A
(Ar or H
He))
• Electrode polarity (DCEN or AC)
• Advantages, applications, disadvantages
Gas tungsten-arc welding (GTAW)
GAS TUNGSTEN ARC WELDING
Special Features
Pulsed TIG
• The pulsed current TIG welding the melting of the metal
is controlled by pulsing the current at a higher value and
at regular intervals
intervals.
Advantages:
• Welding of thin plates and foils
• Less heat input to work
23
GAS TUNGSTEN ARC WELDING
24
Gas metal-arc
metal arc welding (GMAW)
• Consumable electrode process
Wire-feed drive
• Electrode polarity (always DCEP)
• Shielding gas - Inert ( Ar / He) or

active ((CO2)
Gas metal-arc
metal arc welding (GMAW)
(GMAW)……
• Suited to thick sections, thin sizes also

weldable
• Metal transfer problems

p
spray transfer, dip transfer
• Flux-cored arc welding (FCAW)
• Advantages, applications
Gas metal-arc welding (GMAW)
GAS METAL ARC WELDING
Types of Metal Transfer
1. Dip/Short Circuit
2. Globular
3. Spray
28
FLUX CORED ARC WELDING
Principle Features
• The productivity of continuous wire welding (GMAW)

• The metallurgical
g features that can be derived from a
flux (SMAW)
• A slag that supports and shapes the weld bead(SAW)
29
Flux cored arc welding (FCAW)
Flux-cored
• Variant of MMAW, for continuous welding
• Also variant of GMAW, with flux addition
Weld metal protected by slag (from flux)

and by gas (from flux or separate gas shield)
Self-shielded and gas-shielded types,

Gas shield usually CO2
Flux cored arc welding (FCAW)
Flux-cored (FCAW)……..
• In relation to MMAW: Higher deposition rate and
productivity
• In relation to SAW: Better arc visibility and

maneuverability
• In relation to solid
solid-wire
wire GMAW: Better arc
behaviour and metal transfer
Plasma arc welding (PAW)
Constricted arc: Many advantages
9 High power concentration

9 Remarkable arc stability even at
low currents (microplasma)
9 Stiff arc - directional control
9 Strong thrust in plasma jet
plasma cutting, spraying
9 Flexibility
Plasma arc welding
g (PAW)……..
( )
Need
eed for
o ppilot
o aarc
c – transferred
a s e ed aand
d
non-transferred
arcs
Electrode polarity – always DCEN
Need for two separate gas streams –
orifice (or plasma) & shielding gases,
usually argon for both
Applications
GTAW PAW
welding process selection in four easy steps:
1.) The joint to be welded is analyzed in terms of its requirements.
2.) The joint requirements are matched with the capabilities of available processes. One or
more of the processes are selected for further examination.
3.) A checklist of variables is used to determine the ability of the selected processes(s) to
meet the particular application.
4.) Finally, the proposed process or processes deemed most efficient

ff are reviewed with an
informed representative of the equipment manufacturer for verification of suitability and for
more information
35
The check List:
• The volume of production
• Weld Specifications
• Operator Skill
• Equipment Requirements
• Base Metal Condition
• Arc Visibility
• Fixturingg Requirements
q
• Set Up Time Requirements
• Cl
Cleanliness
li R
Requirements
i t
36

Welding Processes (Compatibility Mode)

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Basics of

• Welding is a metal joining process used

Pressure welding Fusion welding

Cold pressure Hot pressure Chemical reaction

Flux-shielded Gas shielded

SAW GTAW PAW

Lap joint, fillet weld

Types of joints and welds

Welding Position Test Position

Vertical Upwards Progression 3G

Vertical Downwards Progression 3G

Pipe Fixed Horizontal 5G

Pipe Fixed @ 45 degrees Upwards 6G

Pipe Fixed @ 45 degrees Downwards 6G

Welding Position Test Position

Flat (Weld flat joint at 45 degrees) 1F

Horizontal Rotated 2FR

Vertical Upwards Progression 3F

Vertical Downwards Progression 3F

Filler material and weld metal

Weld metal (fusion zone)

Welding positions: Flat

• Consumable electrode process

• Why flux? – arc stabilization and shielding

Manual metal-arc welding (MMAW)

• Ways of making process continuous

Wire - feed rolls

From power source

 Limited to flat position

• Electrode polarity (always DCEP)

• Shielding gas - Inert ( Ar / He) or

• Suited to thick sections, thin sizes also

• Metal transfer problems

• Flux-cored arc welding (FCAW)

Types of Metal Transfer

• The productivity of continuous wire welding (GMAW)

Weld metal protected by slag (from flux)

Self-shielded and gas-shielded types,

• In relation to SAW: Better arc visibility and

Constricted arc: Many advantages

9 High power concentration

1.) The joint to be welded is analyzed in terms of its requirements.

4.) Finally, the proposed process or processes deemed most efficient

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Limited to flat position