1 Introduction1 of Welding & Additive Manufacturing

Welding and Additive Manufacturing
(ME-512)
Course Instructor: Dr. Pankaj Biswas
INDIAN INSTITUTE OF TECHNOLOGY GUWAHATI

DEPARTMENT OF MECHANICAL ENGINEERING
Guwahati -781039, Assam, India
Broad area of work and research interest
Manufacturing and Design
 Computational Weld Mechanics
 Distortion & Residual stress analysis
 Distortion Control & Mitigation
 FEM
 Structural Analysis: Static, Dynamic, Transient, Fatigue etc.
 Metal forming Technique
 Line Heating
 Welding Techniques
 Friction stir welding
 Single side welding
Dr. Pankaj Biswas (Professor)

Syllabus of ME-512
 Introduction to welding processes; Classification of joining
processes;
 Type of welds and weld joints;
 Welding symbols and codes;
 Arc welding processes;
 Laser welding; Electron beam welding; Resistance spot welding;
Friction welding, and friction stir welding;
 Types of power sources; Current-voltage and arc power – arc
length characteristics;
 Synergic and pulsed welding;
 Forces on molten droplet, Mode of metal transfer in arc welding;
Cold metal transfer
Syllabus of ME-512
 Analysis of heat flow; Cooling rates;
 Models for welding heat sources; Analytical solution of temperature
distribution;
 Chemical reactions in welding;
 Solidification in welding and solidification cracking;
 Phase transformation in welded structure;
 Weld microstructure;
 Heat treatment of weld joint;
 Types of welding defects, their cause and remedies;
 Distortion and residual stress and their measurement;
 Weld testing methods: destructive and non-destructive;
 Analysis of welded structure for fatigue loading;
 Additive manufacturing: Introduction; Classification; Principle, Welding
technology based metal 3D printing; Solid state additive manufacturing,
Additive vs. subtractive manufacturing.
Reference/Text Books
 O’Brien, Welding Handbook: Welding Processes, Part 1, Vol. 2,
AWS, 2004
 J. F. Lancaster, The Physics of welding, Pergamon,1986
 R. W. Messler, Principles of Welding, John Wiley and Sons,1999
 Sindo Kou, Welding Metallurgy, 2nd Ed., Wiley Interscience, 2003
 V. M. Radhakrishnan, Welding technology and design, New Age
International Private Ltd., 2nd Ed., 2005
 R. S. Parmar, Welding Processes and Technology, Khanna
Publishers, 3rd Ed., 2015
 J. A. Goldak, Computational Welding Mechanics, Springer, 2005
 W Steen: Laser Material Processing, Springer-Verlag, 1991.
 Ian Gibson, David W. Rosen, Brent Stucke: Additive Manufacturing
Technologies, Springer, 2009.
INTRODUCTION
 Welding: In general, it is a process of joining two material plate and make

an integrated one where the entire structural continuity exist.
 The large bulk of materials that are welded are metals and their alloys. The welding
is also applied to the joining of other material such as thermoplastics.
 Welding joins different metals/alloys with the help of different welding processes
in which heat is supplied either electrically or by a gas torch.
 The most essential requirement is Heat but in some processes Pressure is also
employed.
The use of welding in today’s technology is extensive. It is a phenomenal rise since

about 1930; this growth is faster than the general industrial growth.
A Brief History of Welding
• Late 19th Century
– Scientists/engineers apply advances in electricity to heat and join
metals (Joule, Le Chatelier, etc.)
• Early 20th Century

– Prior to World War-I welding was not trusted as a method to join
two metals due to crack issues.
• 1930’s and 40’s

– Industrial welding gains acceptance and is used extensively in the
war effort to build tanks, aircraft, ships, etc.
• Modern Welding
– The use of welding in today’s technology is extensive.
History of Welding
 Middle Ages:
Blacksmiths of the Middle Ages welded various types of iron tools by hammering. The
welding methods remained more or less unchanged until the dawn of the 19th century.
 1800:
 In the 19th century, major welding were made. Englishman Edmund Davy discovered
acetylene in 1836 and acetylene was soon utilized by the welding industry.
1880:
In 1881, French scientist Auguste De Meritens succeeded in fusing lead plates by using.
the heat generated from an arc.
1890:
During the 1890's, one of the most popular welding methods was carbon arc welding.
 1900:
 Coated metal electrode was first introduced by Strohmenger. A coating helped the arc to be
much more stable.
 A number of other welding processes were developed during this period i.e. seam welding,
spot welding, flash butt welding and projection welding.
History of Welding (cont.)
1919: After the end of World War I, the American Welding Society was established by Comfort
Avery Adams. The aim of the society was the advancement of welding processes.
1920: Automatic welding was first introduced which was invented by P. O. Nobel.
1930: The New York Navy Yard developed stud welding. Stud welding was increasingly used for the
construction industry and also for shipbuilding.
1940: The gas shielded metal arc welding and GTAW was another significant milestone in the history
of welding which was developed in Battelle Memorial Institute, USA in 1948.
1949: Electron-beam welding was developed by the German physicist Karl-Heinz Steigerwald in
1949. Steigerwald conceived and developed the first practical electron-beam welding machine, which
began operation in 1958.
1960: There were several advancements in the welding industry during the 1960's. Electroslag
welding and Plasma arc welding was invented during this time.
1970: Laser welding of plastics was first reported in the early 1970s (Silvers and Wachtell, 1970),
when film materials were welded using a CO2 laser.
1991: Welding Institute invented FSW. It is a solid state joining process which utilizes frictional
heat of a rotating tool and stirring effect of the tool probe for solid state joining.
Common Welding Base Material
 Metals can be classified as:
1. Ferrous
2. Non-ferrous Material
1. Ferrous materials (Main composition is Iron) finding day-to-day welding application

are:
i) Wrought Iron (Less than 0.035% Carbon)
ii)Cast Iron [Carbon and Silicon % are: 2.3 to 4.5% and 0.5 to 3% respectively)
iii)
Carbon Steel [Low (0.05–0.3%), Medium (0.30–0.59%) and High (0.6–1.5%)]
iv)Cast Steels [Carbon content between 0.2 to 2.1% by weight, depending on the grade,
also other alloying elements manganese, chromium, vanadium, and tungsten]
v) Stainless steel [More than 11.5% chromium], etc.
2. Non-ferrous material are not Iron-based. Non-Ferrous materials finding day-to-day

welding application are:
i) Aluminium and its alloys
ii) Copper and its alloys
iii) Magnisium and its alloys
iv) Nickel and its alloys
v) Zinc and its alloys, etc
General Advantage of Welding
 Advantages:
• A good weld is as strong as the base metal.
• General welding equipment is not very costly.
• Portable welding equipments are available.
• Welding permits considerable freedom in design.
• A large number of metals/ alloys both similar and dissimilar can be joined by welding.
• Welding can join workpieces by spots, as continuous pressure tight seams, end-to-end
and in a number of other configurations.
• Welding can be mechanized.

General Disadvantage of Welding
 Disadvantages:
• Welding gives out harmful radiations (light), fumes and spatter.
• Welding results in residual stresses and distortion of the workpieces.
• Jigs and fixtures are generally required to hold and position the parts to be welded.
• A skilled welder is a must to produce a good welding job.
• Welding heat produces metallurgical changes. The structure of the welded joint is not
same as that of the parent metal.
• A welded joint, for many reasons, needs stress-relief heat-treatment.

Welding as compared to casting
 Machine tool beds which were earlier cast are fabricated using welding. In many fields
welding has replaced casting processes. Some of the reasons for the same as follow:
• Welding is more economical and is a much faster process as compared to casting.

• Fabricated mild steel structures are lighter as compared to (cast) cast iron ones.
• Fabricated mild steel structures have more tensile strength and rigidity as compared to
(cast)cast iron ones.
• Cost of pattern and storing is eliminated.
• As compared to casting and riveting fewer persons are involved in a welding fabrication.
• Structural shapes which are not easily obtainable with riveting or casting can be produced
by welding without much difficulty.
• Welding design involves low costs and it is very flexible also.
• Fabrication by welding saves machining cost involved in cast part.
Welding as compared to riveting
 Bridges, ships and boilers which were previously riveted are now welded.
• Welding is more economical and is a much faster process as compared to riveting.
• Welded pressure vessels are more (fluid and) pressure tight as compared to riveted ones.
• Ratio between weight of weld metal and the entire weight of structure is much lesser than the
ratio between the weight of rivets and entire weight of the structure.
• Cover plates, connecting angles, gusset plates, etc., needed in riveted construction are not
required when welding the structures.
• Members of such shape that present difficulty for riveting can be easily welded.
• Welding can be carried out at any point on a structure, but, riveting always requires enough
clearance to be done.
• A welded structure possesses a better finish and appearance than the corresponding riveted
structure.
• Layout for punching and drilling of holes is not required in welding.

Welding as compared to riveting
•Drilling holes in the plate in order to accommodate rivets, breaks material continuity and
weakens a riveted structure.
•Making changes in an already cast or riveted structure is extremely difficult, if not

impossible. On the other hand a welded structure can be repaired without much difficulty.
•Welding can produce a 100% efficient joint which is difficult to make by riveting.
•Riveting high strength steels presents the problems of acquiring high strength steels rivets.
Practical Applications of Welding
 Welding has been employed in industry as a tool for :

Regular fabrication of automobile cars, air-crafts, refrigerators, ships, offshore structure etc.
Repair and maintenance work, e.g., Joining broken parts, rebuilding worn out components, etc.
 A few important applications of welding are listed below:

1. Aircraft construction :
(a) Welded engine mounts.
(b) Turbine frame for jet engine.
(c) Rocket motor fuel thanks.
(d) Fittings, etc.
2. Automobile construction :
(a) Arc welded car wheels.
(b) Frame side rails.
(c) Automobile frame, brackets etc.
3. Bridges:
(a) Pier construction.
(b) Section lengths etc
Practical Applications of Welding (cont.)
4. Buildings:
(a) Column base plates.
(b) Trusses.
(c) Erection of structure, etc.
5.Pressure vessels and tanks:
(a) Clad and lined steel plates.
(b) Shell construction.
(c) Joining of nozzles to the shell, etc.
6. Storage tanks:
(a) Oil, gas and water storage tanks.
7. Rail road equipment:
(a) Rail
(b) Under frame
(c) Air receiver
(d) Engine etc.
8. Piping and pipelines:
(a) Rolled plate pipings.
(b) Open pipe joints.
(c) Oil, gas and gasoline pipe lines, etc.
Practical Applications of Welding (cont.)
9. Ships:
(a) Shell frames.
(b) Deck and bulkhead stiffeners.
(c) Girders to shells etc.
10.Trucks and trailers.
11. Machines tool frames, cutting tools and dies.
12. Household and office furniture.
 In addition, arc welding finds following applications in repair and maintenance work:
• Repair of broken and damaged components and machinery such as tools, punches, dies,
gears, press and machine tools frames.
•Fabrication of jigs, fixtures, clamps and other work holding devices.
•Being noiseless as compared to riveting, welding find extensive use, when making
modifications, addition or extension in hospital buildings.
Next Lecture Outline
• Classification of Welding and Joints

1 Introduction1 of Welding & Additive Manufacturing

Uploaded by

Copyright:

Available Formats

1 Introduction1 of Welding & Additive Manufacturing

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

1 Introduction1 of Welding & Additive Manufacturing

Uploaded by

Copyright:

Available Formats

Welding and Additive Manufacturing

INDIAN INSTITUTE OF TECHNOLOGY GUWAHATI

Dr. Pankaj Biswas (Professor)

 Welding: In general, it is a process of joining two material plate and make

The use of welding in today’s technology is extensive. It is a phenomenal rise since

• Early 20th Century

• 1930’s and 40’s

1. Ferrous materials (Main composition is Iron) finding day-to-day welding application

2. Non-ferrous material are not Iron-based. Non-Ferrous materials finding day-to-day

• A good weld is as strong as the base metal.

• General welding equipment is not very costly.

• Portable welding equipments are available.

• Welding permits considerable freedom in design.

• Welding can be mechanized.

• Welding gives out harmful radiations (light), fumes and spatter.

• Welding results in residual stresses and distortion of the workpieces.

• A skilled welder is a must to produce a good welding job.

• A welded joint, for many reasons, needs stress-relief heat-treatment.

• Welding is more economical and is a much faster process as compared to casting.

• Welding is more economical and is a much faster process as compared to riveting.

• Layout for punching and drilling of holes is not required in welding.

•Making changes in an already cast or riveted structure is extremely difficult, if not

 Welding has been employed in industry as a tool for :

 A few important applications of welding are listed below:

•Fabrication of jigs, fixtures, clamps and other work holding devices.

• Classification of Welding and Joints

You might also like