Fusion Welding Processes2011

Fusion Welding
• Joining of materials by the application of heat with

out pressure.
• Heating by oxy fuel flame or electric Arc.
• Invariably filler metal added to molten pool.
• On cooling, molten puddle solidifies to permanent

homogeneous joint.
Types of Fusion Welding Processes
• Shielded Metal Arc Welding- SMAW
• Gas Tungsten Arc Welding - GTAW
• Gas Metal Arc Welding - MIG / MAG
• Submerged Arc Welding – SAW
• Gas welding – Oxy Fuel Gas
• Electron Beam Welding - EBW
• Thermit Welding
Arc Welding
• Autogenous – without filler metal
• Homogenous – filler metal same as base metal
• Heterogenous – filler metal is different from
the base metal
Electric Arc welding
Shielded Metal Arc Welding Process
(SMAW)
• Stick Welding/ Manual Metal Arc welding/Electric
arc welding
• An electric Arc struck between electrode and
base metal joint
• Base metal melts under arc
• Electrode tip melts in drops and transfers to
molten pool of base metal
• Electrode with Arc moves along the joint keeping
constant arc length
• On cooling molten pool solidifies leaves a joint
SMAW
Electrode
• Bare electrode
• Flux coated electrode
• Coating Factor
• = diameter of coating/diameter
of corewire
Coating Factor of Electrodes

Light Coated 1.2 to 1.35
Medium Coated 1.4 to 1.7
Heavy Coated 1.8 to 2.2
Welding Power source: AC/DC
• Electrode selection
• Metal thickness
• Distance from work
• Welding Positions
• Arc blow
Arc Blow
• Deflection of welding arc from its intended
path
• Reduces the control of welding to apply the
molten metal at right place
• Increases spattering-less deposition
Heat Input In Welding
• The extent of heat energy generated in Joules
per unit length while making each weld bead.
• “Heat In Put” is the Function of Welding
Current, Arc Voltage, And the Welding Speed
• It is measured in Joules
Heat InPut In Joules / mm
= (I x V x 60)/ Travel Speed in mm / min
Heat input
• Controls the grain size of weld metal.

• Lower the Heat input finer the grain size.
• Finer the Grain size Better the impact properties
• Controls Dilution, HAZ & Geometry of Bead size
Good Engineering Practices for SMAW
• Do Welding with properly baked electrodes
• Basic coated electrodes to be baked to 250°C to 300°C for
two hours
• Unused balance electrodes shall be returned to baking oven
• Do not use electrodes with damaged coating
• Do not bend the electrodes after holding it in the holder
• All connections with earthing and welding cables shall be tight
fitted
• Tacks for set up shall be minimum 5 times the electrode
diameter
• Weaving shall be limited to 2D- 3D
GMAW/MIG
• GMAW stands for Gas Metal Arc
Welding
• A solid metal wire is fed through
a welding gun and becomes the
filler material
• Shielding gas is used to protect
the molten puddle from the
atmosphere which results in a
weld without slag
• (Ar/He/Co2)
GMAW is the most widely used arc welding process
15
Working Principle
An arc is struck between a continuously fed filler wire and the work.
The arc is protected from oxidation by a shielding gas over the weld
pool.
GMAW electrodes are commonly
packaged on spools, reels and Electric arcs can generate
coils ranging from 1lb to 1000lbs temperatures up to 10,000°F
.045” ER70S-6 at 400 ipm wire feed

speed and 28.5 Volts with a 90%
Argon/ 10% CO2 shielding gas
17
Laying a Bead
• Maintain a Contact Tip to Work Distance (CTWD) of 3/8” to

1/2”
• Use a uniform travel speed
• Most Importantly – Watch the Puddle!
The appearance of the weld bead

where molten metal solidifies
indicates correct travel speed.
18
Advantages
• Welds most metals
• Little or no slag
• Easiest to learn
• Greater speed and efficiency
• Fewer Weld Defects
• Welds in most positions
Disadvantages
• Welding outside can be difficult
• Not ideal for thick material or deep
penetrating welds
Submerged Arc Welding (SAW)
• Submerged arc welding is a method in which the heat
required to fuse the metal is generated by an arc formed by
an electric current passing between the electrode and the
work piece.
•Flux feeds through the hopper tube and continuously

distributes itself over the seam a short distance ahead of
the welding zone.
•The wire feed mechanism begins to feed the welding into

the joint at a controlled rate.
• There is no visible arc and no sparks, spatter or fume.

• The electrode may be a solid or cored wire or a strip.
• SAW is normally a mechanized process.

Submerged Arc welding process (SAW)
Electrical characteristics
• Current: 100 and 3600 amps.
• Wires in one molten pool: from 1 to 6.
• Voltage: 20-50 volts.
• Speed: 30-350 cm/min.
• Deposition rate: 2-100 kg/hr.

Advantages of SAW
• High quality
• Little risk of undercut and porosity
• No spatter
• Very little risk of lack of fusion due to deep and safe

penetration
• High deposition rate
•High thermal efficiency
• No radiation
• High welding speeds are possible

Limitations of SAW
 Precise joint preparation required
 No observation of arc during welding is possible
 High operational effort
 It can not be used for plates less than 5mm thickness
 Flux is subjected to contamination and adsorption of moisture.
 Solidification cracking.
 Irregular wire feed.

Gas tungsten arc welding process
(GTAW)/ TIG
Tungsten Electrodes
2% Thoriated Tungsten – RED
• DC negative or straight polarity applications

• Provides excellent resistance from weld pool
contamination
• easier arc starting capabilities and a more
stable arc. Contains 2% weight of thorium oxide
(ThO2).
• Carbon and Stainless Steel, Nickel Alloys, and
Titanium.
Pure Tungsten - GREEN
• AC welding applications.
• provide good arc stability.
• least expensive tungsten
• Contains a minimum of 99.5% weight tungsten with
no other alloys.
• Aluminum and Magnesium Alloys.
2% Ceriated Tungsten - Orange

• AC or DC welding applications.
• low amperage welding.
• Takes approximately 10% less current to initiate arc and
has a very stable arc.
• Carbon and Stainless Steels, Nickel Alloys and Titanium.
• TorchTorch and
and Filler FillerinPositioning
Positions TIG welding
Shielding gases
• Argon and Helium
ARGON HELIUM
Heavier lighter
Less arc voltage High arc voltage
Light sections Heavy sections
Gas flow rate is minimum 2 to 3 times the flow rate of

argon
Advantages
• Superior quality welds, generally free from spatter,
porosity, or other defects
• Precise control of arc and fusion characteristics
• Weld almost all metals
• Used with or without filler wire
• Easily automated
• Used in all positions
• Intricate geometries weldable
Disadvantages
• Less economical than consumable electrode processes

for sections thicker than 3/8 inch
• Lowest deposition rate
• Higher operator skill Required
• Tungsten inclusions

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Fusion Welding

• Joining of materials by the application of heat with

• Heating by oxy fuel flame or electric Arc.

• Invariably filler metal added to molten pool.

• On cooling, molten puddle solidifies to permanent

Coating Factor of Electrodes

• Controls the grain size of weld metal.

GMAW is the most widely used arc welding process

.045” ER70S-6 at 400 ipm wire feed

• Maintain a Contact Tip to Work Distance (CTWD) of 3/8” to

The appearance of the weld bead

•Flux feeds through the hopper tube and continuously

•The wire feed mechanism begins to feed the welding into

• There is no visible arc and no sparks, spatter or fume.

• SAW is normally a mechanized process.

• Current: 100 and 3600 amps.

• Wires in one molten pool: from 1 to 6.

• Voltage: 20-50 volts.

• Speed: 30-350 cm/min.

• Deposition rate: 2-100 kg/hr.

• Little risk of undercut and porosity

• Very little risk of lack of fusion due to deep and safe

• High deposition rate

•High thermal efficiency

• High welding speeds are possible

 No observation of arc during welding is possible

 High operational effort

 It can not be used for plates less than 5mm thickness

 Flux is subjected to contamination and adsorption of moisture.

 Irregular wire feed.

• DC negative or straight polarity applications

2% Ceriated Tungsten - Orange

Less arc voltage High arc voltage

Light sections Heavy sections

Gas flow rate is minimum 2 to 3 times the flow rate of

• Less economical than consumable electrode processes

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