Manufacturing Technology-I

Subject Code : ME3C04

Lectures per week : 3 No.s
Dr. Abhinaba Roy
Assistant Professor
Mechanical Engineering Department
National Institute of Engineering
Mysore, Karnataka
 Welding Process : Introduction
• Welding is a joining process
• Joining process can be of various types. Such as : welding,
brazing, soldering, adhesive bonding and mechanical fastening
• Welding is the most popular method
• Welding is useful when two components (having different
dimensions/different processing methods) has to be joined to
obtain the final product – such components are difficult and in
some cases impossible to manufacture from one piece
• Similar and dissimilar metals can be joined together using
welding process
Deep Space Telescopes Wind Turbines

Space Launch Systems Submarines

 Arc Welding Process
• Electric Arc Welding/Shielded Metal Arc Welding is most popular
• In arc welding, heat required to join two metallic parts is obtained
from electrical energy
• Electric arc is generated by touching the tips of a coated electrode
against the workpiece and then withdrawing it quickly to a
distance sufficient to maintain the arc
• Electrodes are in the shape of a thin, long stick which is coated by
a flux material (that forms vapors which act as a shielding gas and
produces a layer of slag which protects the weldment)
 Arc Welding : Classifications
• Shielded metal arc welding (SMAW) – Electric arc welding
• Submerged arc welding (SAW)
• Gas metal arc welding (GMAW) – MIG(metal inert gas)
• Flux core arc welding (FCAW)
• Gas tungsten arc welding (GTAW) – TIG(tungsten inert gas)
• Plasma arc welding (PW)
• Oxyfuel arc welding (OW) – Gas welding
• Electro slag welding (ESW)
• Electro gas welding (EGW)
• Electron beam welding (EBW)
• Laser beam welding (LBW)
Shielded Metal Arc Welding
Shielded Metal Arc Welding
Arc Welding : Role of Electrode Coating
The functions of the Electrode coating are :
• Shielding – The coating decomposes to form a gaseous shield
for the molten metal
• Deoxidation – The coating provides a fluxing action to remove
oxygen and other atmospheric gases
• Alloying – Provides additional alloying elements for the weld
deposit
• Ionizing – Improves electrical characteristics to increase arc
stability
• Insulation – Solidified slag provides an insulating blanket to
slow down the weld metal cooling rate
 Arc Welding : Advantages
• Relatively simple and inexpensive
• Quite portable
• Shielding provided by decomposition of flux covering
• It can be accomplished in remote locations
• Equipment required can be carried easily
• Resulting weld quality can be consistently higher
• Variety of electrodes are available depending upon the type of
base metal/plates to be joined
 Arc Welding : Disadvantages
• Low speed and slow production rate
• Layer of solidified slag must be removed after each pass
• High material and labor cost
• Higher chances of incomplete fusion
• Incomplete joint penetration
• Slag inclusion, cracking and undercut is common
• Improper weld profile and incorrect weld size is common
 Gas Welding
• Also known as Oxyfuel Gas Welding/Oxyfuel Gas Arc Welding
• This process employs use of a fuel gas combined with oxygen to
produce a flame which is the source of heat used to fuse metal
joints
C2H2 + O2  2CO + H2 + HEAT
2CO + H2 + 1.5O2  2CO2 + H2O + HEAT

• Most common gas welding process uses acetylene (C2H2) as

fuel and hence also known as oxyacetylene welding
• Typically used for structural sheets, metal fabrication,
automotive bodies and various other repair works
 Arc Welding : Applications
• Used for fabrication work and maintenance work
• All commonly employed metals and alloys can be welded
• The process finds application in :
 Ship building
 Pipes and penstock joining
 Building and bridges construction
 Automotive and Aircraft industries
 Gas Welding : Applications
• Used for joining thin materials
• It can be used to join most ferrous and non-ferrous metals
• It is used extensively in automotive and aircraft industries
• It is used to fabricate pipelines, pond liners and a wide variety
of vessels
• This process can also be used to join broken plastics easily
 MIG Welding – Metal Inert Gas
• In MIG welding, the weld area is shielded by an effectively inert
atmosphere of argon, helium, carbon dioxide or other gas mixtures
• The consumable bare wire is automatically fed to the weld area through a
nozzle
• Metal weld can be transferred by three methods in MIG welding process:
the spray, the globular and the short-circuiting
 MIG Welding – Metal Inert Gas
• In spray transfer process, small droplets of molten metal from the
electrode are transferred to the weld area at a rate of several hundred
droplets per second. The transfer is spatter free and very stable
• High DC current and voltages and large-diameter electrodes are used
with argon or an argon-rich gas mixture used as shielding gas.
• This process can be used in all welding positions
• Pulsed arc can be used to minimize average current requirement and is
becoming more and more popular
 MIG Welding – Metal Inert Gas
• In globular transfer process, carbon-dioxide rich gases are utilized and
globules propelled by the forces of the electric arc transfer the metal,
with considerable spatter.
• High welding currents are used; they make possible greater weld
penetration and welding speed than can be achieved in spray transfer.
• Heavier sections are commonly joined by this method
 MIG Welding – Metal Inert Gas
• In short-circuiting process, the metal is transferred in individual droplets,
more than 50 per second, as the electrode tip touches the molten weld
metal and short-circuits
• Low current and voltage is utilized with carbon dioxide rich gases and
with electrodes made of small diameter wire
• Power requirement is around 2 kW
 TIG Welding – Tungsten Inert Gas
• In TIG welding, the filler metal is supplied from a filler wire and the
tungsten electrode is not consumed. Since it is not consumed, a constant
and stable arc is maintained at a constant current level
• The shielding gas is usually argon or helium or a mixture of the two
• Under certain cases, filler material may not be used (in case of close fit
joints)
• Depending on the metal to be welded, the power supply can be either DC
at 200 A or AC at 500 A. Power requirement range from 8 kW to 20 kW
• This process is used for a wide variety of metals and applications,
particularly aluminium, magnesium, titanium and refractory metals.
• It is especially suitable for thin metals. It is more expensive than SMAW
but provides welds with high quality and surface finish
 TIG Welding – Tungsten Inert Gas
• In TIG welding, the filler metal is supplied from a filler wire and the
tungsten electrode is not consumed. Since it is not consumed, a constant
and stable arc is maintained at a constant current level
• The shielding gas is usually argon or helium or a mixture of the two
• Under certain cases, filler material may not be used (in case of close fit
joints)
• Depending on the metal to be welded, the power supply can be either DC
at 200 A or AC at 500 A. Power requirement range from 8 kW to 20 kW
• This process is used for a wide variety of metals and applications,
particularly aluminium, magnesium, titanium and refractory metals.
• It is especially suitable for thin metals. It is more expensive than SMAW
but provides welds with high quality and surface finish
 MIG Welding TIG Welding

Metal inert gas welding utilizes a consumable electrode that is Tungsten inert gas welding utilizes a non-consumable
continuously fed into the welding zone from a wire spool electrode, so it remains static and intact during welding

If required filler metal is supplied additionally by feeding a

The electrode itself melts down to supply necessary filler metal
small diameter filler rod into the arc, so filler metal is supplied
required to fill the root gap between base metals
separately

Composition of electrode metal is selected based on parent Electrode is always made of tungsten with other alloying
metal elements (like thorium, zirconium etc.)

The electrode cum filler comes in the form of small diameter The electrode filler comes in the form of small diameter (1-
(0.5-2mm) and a very long wire wound in a spool 3mm) and short length (60-180mm rod)

MIG welding is commonly carried out in AC/DCEP polarity to TIG welding is commonly carried out either in AC or DCEN
increase filler deposition rate polarity to increase polarity life
 Resistance Welding
In Resistance Welding, heat required for welding is produced by
means of electrical resistance across the two components to be
joined.
Major advantage of this process is that consumables like electrode
and shielding gases, fluxes are not required.

Heat generated in Resistance Welding is given by the expression :

𝐻 = 𝐼2 𝑅𝑡
Where, H = heat generated (in joules or in watt-seconds)
I = current (in amperes)
R = resistance (in ohms)
t = time of current flow (in seconds)
 Resistance Welding
The total resistance in this process is the sum of the following
properties :
a. The resistance of the electrodes
b. The electrode-workpiece contact resistance
c. The resistance of the individual parts to be welded
d. The workpiece-workpiece contact resistance

The actual temperature rise at the joint depends on the specific heat
and on the thermal conductivity of the metals to be joined.
For example, metals such as aluminium and copper have high thermal conductivity
and so they require high heat concentrations.
Resistance Welding

Magnitude of current in Resistance Welding operations may be

as high as 100,000 Amperes !!
 Resistance Spot Welding
• In Resistance Spot Welding, the tips of two opposing solid cylindrical
electrodes touch a lap joint of two sheet metals and resistance heating
produces a spot weld.
• In order to obtain a strong bond in the weld nugget, pressure is applied
until the current is turned off. Accurate control and timing of the electric
current and of the pressure are essential in resistance welding.
• The strength of the bond depends on surface roughness and on the
cleanness of the mating surfaces. Oil, paint and thick oxide layers should
therefore be removed before welding.
• The weld nugget is generally 6 to 10 mm in diameter. The surface of the
weld spot has a slightly discolored indentation. Currents range from 3000
A to 40000 A: which depends on the material type and thickness.
 Resistance Spot Welding
• Spot Welding is the simplest and most commonly used resistance-
welding process
• Welding may be performed by means of single or multiple pairs of
electrodes and the required pressure is supplied through mechanical or
pneumatic means
• Rocker arm type spot welding machines are used for smaller parts,
whereas Press type machines are used for larger workpieces
• Variety of electrode shapes are available and are used to spot-weld areas
that are difficult to reach
• It is widely used for fabrication of sheet metal parts
Example : Attaching handles to stainless steel cookwares
 Resistance Spot Welding
• Spot Welding is the simplest and most commonly used resistance-
welding process
• Welding may be performed by means of single or multiple pairs of
electrodes and the required pressure is supplied through mechanical or
pneumatic means
• Rocker arm type spot welding machines are used for smaller parts,
whereas Press type machines are used for larger workpieces
• Variety of electrode shapes are available and are used to spot-weld areas
that are difficult to reach
• It is widely used for fabrication of sheet metal parts
Example : Attaching handles to stainless steel cookwares
 Resistance Spot Welding
• Spot Welding is the simplest and most commonly used resistance-
welding process
• Welding may be performed by means of single or multiple pairs of
electrodes and the required pressure is supplied through mechanical or
pneumatic means
• Rocker arm type spot welding machines are used for smaller parts,
whereas Press type machines are used for larger workpieces
• Variety of electrode shapes are available and are used to spot-weld areas
that are difficult to reach
• It is widely used for fabrication of sheet metal parts
Example : Attaching handles to stainless steel cookwares
 Thermit Welding
• Thermit welding got its name from the compounds names Thermite
• This process involves exothermic reaction between metal oxides and
metallic reducing agents. The heat of the reaction is used to perform
welding on steel and cast iron
• Finely divided particles of iron oxide, aluminium oxide, iron and
aluminium is used along with a magnesium fuse and other special
compounds like peroxides, chlorates or chromates which are oxidizing
agents at an ignition temperature of about 1200°C. Temperature of the
reaction reaches 2200-2400 °C, enough to melt steels and iron alloys.
• Thermit welding is suitable for welding and repairing large forging and
castings and can also be used to weld thick steel structural sections, rail
roads and pipes.
Thermit Welding
1. Mold
2. Container
3. Thermite
Thermit Welding
1. Mold
2. Container
3. Thermite
Thermit Welding
1. Mold
2. Container
3. Thermite
Thermit Welding
1. Mold
2. Container
3. Thermite
 Plasma Arc Welding
• In Plasma Arc Welding, a concentrated plasma arc is produced and aimed
at the weld area
• The arc is stable and reaches temperature as high as 33000°C.
• A plasma is ionized hot gas, composed of nearly equal numbers of
electrons and ions. The plasma is initiated between the tungsten
electrode and the orifice by a low current pilot arc
• Unlike other processes, the plasma arc is concentrated because it is
forced through a relatively small orifice. Operating currents are usually
below 100 A but they can be higher for special applications.
 Plasma Arc Welding
• In Plasma Arc Welding, a concentrated plasma arc is produced and aimed
at the weld area
• The arc is stable and reaches temperature as high as 33000°C.
• A plasma is ionized hot gas, composed of nearly equal numbers of
electrons and ions. The plasma is initiated between the tungsten
electrode and the orifice by a low current pilot arc
• Unlike other processes, the plasma arc is concentrated because it is
forced through a relatively small orifice. Operating currents are usually
below 100 A but they can be higher for special applications.
 Plasma Arc Welding
• In Plasma Arc Welding, there are two methods of welding :
1. Transferred arc method 2. Non-transferred arc method
• In transferred arc method, the workpiece being welded is part of the
electrical circuit - the arc transfers from the electrode to the workpiece
• In non-transferred arc method, the arc occurs between the electrode
and the nozzle, and the heat is carried to the workpiece by the plasma
gas. (This thermal transfer mechanism is similar to gas welding)
• Plasma arc welding has higher energy concentration and hence permits
deeper and narrower welds, better arc stability, less thermal distortion
and higher welding speeds (120-1000mm/min)
 Plasma Arc Welding
Base metals welded by plasma arc welding are :
Stainless steels, Titanium alloys, Carbon and low alloy steels, Copper alloys,
Aluminium alloys and Nickel alloys

Applications of Plasma Arc Welding are :

• It is used in Aerospace applications
• It is used for melting high melting point metals
• It is used for welding titanium plates
• It is used for welding nickel alloys
• It is used for tube mill applications
 Laser Beam Welding
• Laser Beam Welding utilizes a high-power laser beam as the source of
heat to produce a fusion weld
• Laser beam can be focused onto a very small area and therefore it has
high energy density and therefore, deep penetrating capabilities. The
beam can be directed, shaped and focused precisely on the workpiece.
Therefore, deep and narrow joints can be welded with ease
• The laser beam may be pulsed (in milliseconds) for spot welding of thin
materials, with power levels up to 100 kW. Continuous multi-kW laser
systems are used for deep welds on thick sections
• LBW produces welds of good quality with minimum shrinkage and
distortion. Laser welds have good strength and are generally ductile and
free of porosity. This process can be automated and particularly effective
on thin workpieces
 Laser Beam Welding
• Welding speeds range from 2.5 m/min to as high as 80 m/min for thin
metals
• Because of the nature of the process, the welding can be done in
otherwise inaccessible location with high accuracy
• Safety is particularly important in LBW as the beam has extreme hazards
to the eye and as well as to the skin

Major advantages of this process are :

1. High precision
LASER welds can be done to smallest parts without causing any damage
to by
Light Amplification them
Stimulated Emission of Radiation
2. This process is capable of creating complicated joints
3. This process can be automated and hence repeatable and consistent weld jobs
can be done with high efficiency
Laser Beam Welding
 Laser Beam Welding
• Welding speeds range from 2.5 m/min to as high as 80 m/min for thin
metals
• Because of the nature of the process, the welding can be done in
otherwise inaccessible location with high accuracy
• Safety is particularly important in LBW as the beam has extreme hazards
to the eye and as well as to the skin

Major advantages of this process are :

1. High precision
LASER welds can be done to smallest parts without causing any damage
to by
Light Amplification them
Stimulated Emission of Radiation
2. This process is capable of creating complicated joints
3. This process can be automated and hence repeatable and consistent weld jobs
can be done with high efficiency
 Explosion Welding
• In explosion welding, pressure is applied by detonating a layer of
explosive that has been placed over one of the components being joined
(called the flyer plate)
• The contact pressure developed are extremely high and the kinetic
energy of the plate striking the mating component causes a wavy
interface
• This impact mechanically interlocks the two surfaces. Cold pressure
welding by plastic deformation also takes place. The flyer plate is placed
at an angle and any oxide films present at the interface are broken up and
propelled out of the interface. As a result, the bond strength from
explosion welding is very high
 Explosion Welding
• Detonation speed is usually in the range of 2400-3600 m/s; it depends on
the type of explosive, the thickness of the explosive layer and its packing
density
• For each process and materials, a certain detonation speed is necessary
for a superior weld quality
• It is particularly suitable for cladding a plate or a slab with a dissimilar
metal. Plates as large as 6m x 2m can be cladded using explosive welding
• This process is quite dangerous and must be handled by well trained and
experienced personnel
 Explosion Welding
Advantages Disadvantages
Metals must have high enough impact resistance and
Very large workpiece can be welded
ductility

Aluminium and Steel materials can be welded Weld geometry must be simple-flat, cylindrical or conical

Dissimilar and un-weldable metals can be bonded

The cladding plate can not be too large
through this process

Material melting temperature and coefficient of thermal Noise and blast require worker protection, vacuum
expansion do not affect the final product chambers or must be buried in sand/water

This process require license holders and area should be

Process is compact, portable and easy to maintain
cleared for explosion
 Explosion Welding
Advantages Disadvantages
Metals must have high enough impact resistance and
Very large workpiece can be welded
ductility

Aluminium and Steel materials can be welded Weld geometry must be simple-flat, cylindrical or conical

Dissimilar and un-weldable metals can be bonded

The cladding plate can not be too large
through this process

Material melting temperature and coefficient of thermal Noise and blast require worker protection, vacuum
expansion do not affect the final product chambers or must be buried in sand/water

This process require license holders and area should be

Process is compact, portable and easy to maintain
cleared for explosion
 Explosion Welding
Advantages Disadvantages
Metals must have high enough impact resistance and
Very large workpiece can be welded
ductility

Aluminium and Steel materials can be welded Weld geometry must be simple-flat, cylindrical or conical

Dissimilar and un-weldable metals can be bonded

The cladding plate can not be too large
through this process

Material melting temperature and coefficient of thermal Noise and blast require worker protection, vacuum
expansion do not affect the final product chambers or must be buried in sand/water

This process require license holders and area should be

Process is compact, portable and easy to maintain
cleared for explosion