FMP 221 Lecture 10 and 11
FMP 221 Lecture 10 and 11
FMP 221 Lecture 10 and 11
Welding processes
Welding is a process of joining two similar or dissimilar
metals by application of heat with or without application of
pressure and addition of filler material.
The heat may be obtained from the blacksmiths fire,
electric arc, electric resistance or chemical reaction.
Modern methods of welding may be classified into two major types.
Advantages of welding:
1. Welding structures are normally lighter than riveted or
bolted structure.
2. Welded joints are strong, rigid and tight.
3. Alteration and additions can be easily made in the
existing structure.
4. Welding structure is smooth in appearance.
5. Welded joint has a great strength.
6. Cost effectiveness.
7. Simplicity of welded structures design.
8. Possiblity of welding at any part of a structure.
9. Consumes less time when compared to other type of
joints.
Disadvantages of welding:
Internal stresses, distortions and change of
micro-structure in the weld region;
Harmful effects: light, ultra violate radiation,
fumes, high temperature.
Requires highly skilled labour
Edge preparation is required before welding
Applications of welding
Pipe lines
Rail roads
Machinery elements
I.Arc welding
1. Carbon Arc Welding (CAW)
2. Shielded Metal Arc Welding (SMAW)
3. Submerged Arc Welding (SAW)
4. Metal Inert Gas Welding (MIG, GMAW)
5. Tungsten Inert Gas Arc Welding (TIG, GTAW)
6. Electroslag Welding (ESW)
7. Plasma Arc Welding (PAW)
Weldability
The property of a metal, which indicates the ease with
which two similar or dissimilar metals are joined by
fusion with or without the application of pressure.
Factors affecting the weldability of a metal:
1.
2.
3.
4.
5.
6.
Arc welding
The discharge of electric
Current across a gap of two
Electrodes.
ii.
Electrode
iv.
v. Cable lug
vi.
Chipping hammer
ix.
Wire brush
x. Helmet
xi.
Safety goggles
xiii.
AC or DC Machine
D.C.Welding
AC or DC machine
The transformer consists of a rectangular steel tank.
An oil cooled double wound step down transformer
reduces the supply main voltage to a welding voltage
of 80. All windings are totally enclosed in the steel
tank.
Rotating the hand wheel can vary the output of the
transformers and the weld current can be directly
read at the window on the tank cover. The set is
connected 400-440 volts 3 phase, 50 cycles ac supply.
Electrode
It is filler metal in the form of a wire or rod used
as a terminal in an electric current for the
purpose of producing an electric arc.
The electrodes are classified as consumable
electrode and non-consumable electrode.
A consumable electrode is similar in composition
to the metal being welded and it melts to become
a part of weld.
A non-consumable electrode may be made of
carbon, graphite or tungsten, which do not
consume during the welding operation.
Specification of electrode
The coding consists of a prefix letter, a code number of
digits in numerals and in some cases one or more suffix
letters, each indicating a specific property or
characteristic or both of electrode.
e-g. E 616 515
E - The prefix letter indicate the method of manufacturing
6 -The first digit indicate the type of covering
1 -The second digit indicates the welding position
6 -The third digit indicates the welding current
5 & 1-The fourth and fifth digit indicates the tensile
strength of the weld metal
5- The sixth digit indicates the percentage elongation of
deposited metal.
Angularity of electrode
The quality of weld is determined to a
Polarity
In DC welding machine, the heat generated by the
flow of current is split into two parts, in the ratio of
66% at the positive pole and 33 percent at the
negative pole.
In straight polarity the electrode is negative and the
work is positive.
In the reverse polarity the electrode is positive and
the work is negative.
Wire Brush
Wire brush is a cleaning tool.
It is used for removing loose
slag, spatter and oxides.
Chipping Hammer
Helmet
A helmet is used by the welder for
protection of his eyes, face and the
throat from harmful rays of electric arc
and from the hot flying particles or
spatter.
Hand Gloves
For protection of wrist and hands,
gloves and worn by the welders.
They are made of leather or asbestos.
They should be as flexible as possible.
Welding joints
i.
Lap joint
ii.
Butt joint
iii.
Corner joint
iv.
Edge joint
v.
T-joint
Lap joint
This used to joint two overlapping
plates so that the edge of each plate
is welded in the other.
These joints are employed on plates
having thickness less than 3 mm.
The lap joints may be single
transverse, double transverse and
parallel lap joints.
Butt joint
It is used to joints two ends or two edges or surfaces located
in the same plane with each other.
In butt welds, the plate edges do not require beveling if the
thickness of plate is less than 5 mm.
Corner joint
Edge joint
T-joint
Welding Positions
1. Flat position
2. Horizontal position
3. Vertical position
4. Overhead position
Flat position
Horizontal position
Vertical position
Overhead position
Welding Terminologies
Bead - It describes the neatness of
ripples formed by the metal while it
was in semi liquid state. It denotes the
appearance of the finished weld.
Face of the weld - The exposed surface
of the weld
Flux - A fusible material used to
prevent formation of oxides, nitrites
and promote fusion of metal.
Arc Crater
The blast of the arc forces the molten metal out of the
pool, thus forming a small depression in the parent metal
around which molten metal is piled up. This is known as
arc crater
Arc Length
The distance through the centre of the arc from the tip of
the electrode to the bottom of the arc crater is the arc
length. Arc length is vital variable and should be 3 to 4 mm
Arc Blow
A large current produces arc blow. The space around the
arc and on the adjacent metal is always influenced by
magnetic field, which tends to deflect the arc. This is
known as arc blow. It can be minimized by changing the
angle of electrode and direction of welding.