UNIT: V
Advanced Welding Processes
1.Submerged Arc Welding (SAW)
Submerged arc welding (SAW) is a welding process that uses a blanket of powdered flux to create
a protective layer around the arc and weld zone. The flux generates a slag and protects the weld
from atmospheric contamination. SAW is commonly used for welding carbon or carbon-
manganese steelwork, and is often automated.
Working principle
The flux starts depositing on the joint to be welded. Since the flux is not electrically conductive
when cold, the arc may be struck either by touching the electrode with the work piece or by placing
steel wool between electrode and job before switching on the welding current or by using a high
frequency unit. In all cases the arc is struck under a cover of flux. Flux otherwise is an insulator
but once it melts due to heat of the arc, it becomes highly conductive and hence the current flow
is maintained between the electrode and the workpiece through the molten flux. The upper portion
of the flux, in contact with atmosphere, which is visible remains granular (unchanged) and can be
reused. The lower, melted flux becomes slag, which is waste material and must be removed after
welding.
The electrode is continuously fed to the joint to be welded at a predetermined speed. In semi-
automatic welding sets, the welding head is moved manually along the joint. In automatic welding
a separate drive moves either the welding head over the stationary job or the job moves/rotates
under the stationary welding head.
The arc length is kept constant by using the principle of a self-adjusting arc. If the arc length
decreases, arc voltage will increase, arc current and therefore burn-off rate will increase thereby
causing the arc to lengthen. The reverse occurs if the arc length increases more than the normal.A
backing plate of steel or copper may be used to control penetration and to support large amounts
of molten metal associated with the process.
Advantages
1.High deposition rates
2.High operating factors in mechanized applications.
3.Deep weld penetration.
4.Sound welds are readily made (with good process design and control).
5.High speed welding of thin sheet steels up to 5 m/min (16 ft/min) is possible.
6.Practically no edge preparation is necessary depending on joint configuration and required
penetration.
Limitations
1.Limited to ferrous (steel or stainless steels) and some nickel-based alloys.
2.Normally limited to the 1F, 1G, and 2F positions.
3.Normally limited to long straight seams or rotated pipes or vessels.
4.Requires relatively troublesome flux handling systems.
5.Flux and slag residue can present a health and safety concern.
6.Requires inter-pass and post weld slag removal.
7.Requires backing strips for proper root penetration.
Applications
Structural Welding: Common in heavy-duty structures like bridges, ships, pressure vessels, and
pipelines.
Automotive and Aerospace Industries: Used for welding large sections that need consistent and
deep weld penetration.
Pipe and Tube Mills: Extensively used for joining large-diameter pipes due to high deposition
efficiency.
2.Resistance Welding Process
Resistance welding is a group of welding processes that generate heat through the resistance to
electrical current at the point of contact between two or more metal surfaces. The heat produced
by this resistance, combined with the application of pressure, causes the metals to fuse together
without the need for additional filler materials. Resistance welding is widely used in industries that
require rapid, consistent, and high-strength welds, such as automotive manufacturing.
The working principle of resistance welding is to heat the interface between two metal
components until they melt and join together:
Clamp the components: The components are placed between two electrode tips and clamped in
place.
Apply current: An electric current is passed through the components, which causes resistance at
the interface.
Generate heat: The resistance produces a large amount of heat through a process called Joule
heating.
Melt the metal: The heat melts the metal at the interface.
Solidify: The electrode extracts heat from the molten metal, which solidifies to form a weld nugget.
Types of Resistance Welding Processes
Spot Welding: Joins overlapping metal sheets by welding at specific points or "spots." It’s
commonly used in car body assembly.
Seam Welding: Similar to spot welding but produces a continuous, leak-tight seam, ideal for liquid
or gas containers.
Projection Welding: Involves raised projections on one or both pieces to concentrate the current,
suitable for parts with complex geometries.
Flash Welding: Parts are brought together and subjected to electric current until flashing occurs,
then pressure is applied to complete the weld.
Butt Welding: Used to join ends of bars or tubes, where both pieces are butted against each other
and then welded.
Advantages of Resistance Welding
High Efficiency: Fast, requires less energy compared to many other welding methods.
Minimal Deformation: Localized heating limits thermal distortion.
Automation-Friendly: Easily automated, making it suitable for high-production environments.
No Filler Required: Reduces material costs and simplifies the process.
Applications
Resistance welding is extensively used in:
Automotive Industry: Spot and projection welding for body panels, seat frames, exhaust systems.
Manufacturing of Containers: Seam welding for drums, cans, and tanks.
Electrical Industry: Welding of conductive materials like copper for busbars and connectors.
3. Electron Beam Welding Process
Electron-beam welding (EBW) is a fusion welding process in which a beam of high-velocity
electrons is applied to two materials to be joined. The workpieces melt and flow together as the
kinetic energy of the electrons is transformed into heat upon impact. EBW is often performed
under vacuum conditions to prevent dissipation of the electron beam.
The working principle of electron beam welding revolves around the conversion of electrical
energy into kinetic energy and then into heat energy.
Initially, the workpieces are securely clamped inside a vacuum chamber on a CNC worktable. The
chamber is evacuated using mechanical or electrical pumps.
The workpiece is positioned accurately using CNC, and upon reaching the correct position, the
power supply is activated.
A high voltage is applied between the anode and cathode, resulting in the release of an electron
beam generated by heating the filaments. The electron beam is accelerated by the electromotive
force (EMF) at the anode.
The converging coils then focus the high-velocity electron beam, which is further directed by the
deflection plate to the desired location on the workpiece.
As the electron beam strikes the workpiece, its kinetic energy is converted to heat energy, melting
the workpieces and creating a weld.
CNC controls the welding process, and once completed, the power supply and vacuum pumps are
deactivated. Finally, the operator manually unclamps the welded joints.
Advantages of EBW
High precision and weld quality, Deep penetration with a small heat-affected zone, Minimal
distortion due to localized heating, Ability to weld hard-to-reach areas and complex geometries,
Works with reactive and refractory materials (e.g., titanium, tungsten).
Limitations of EBW
Requires a vacuum environment (though non-vacuum systems exist but are less efficient),High
initial cost due to complex equipment, Not ideal for large-scale or field applications due to vacuum
chamber constraints.
Applications of EBW
Aerospace: Welding of turbine blades, fuel tanks, and structural components.
Automotive: Manufacturing of precision parts, such as transmission gears and engine components.
Electronics: Joining of small components in devices.
Medical: Fabrication of implants and surgical instruments.
Nuclear: Welding of high-integrity components
4.Plasma Welding Process
Plasma Arc Welding (PAW) is an advanced welding process that uses a constricted arc to melt
and join metals. It is similar to Tungsten Inert Gas (TIG) welding but utilizes a more focused and
intense plasma arc, making it highly precise and suitable for critical applications.
Plasma arc welding is an advanced form of tungsten inert gas (TIG) welding. In the case of TIG,
it is an open arc shielded by argon or helium, whereas plasma uses a special torch where the nozzle
is used to constrict the arc while the shielding gas is separately supplied by the torch. The arc is
constricted with the help of a water-cooled small diameter nozzle which squeezes the arc, increases
its pressure, temperature and heat intensely and thus improves arc stability, arc shape and heat
transfer characteristics.
Plasma arcs are formed using gas in two forms; laminar (low pressure and low flow) and turbulent
(high pressure and high flow).
The gases used are argon, helium, hydrogen or a mixture of these. In the case of plasma welding,
laminar flow (low pressure and low flow of plasma gas) is employed to ensure that the molten
metal is not blown out of the weld zone.
The non-transferred arc (pilot arc) is employed during plasma-welding to initiate the welding
process. The arc is formed between the electrode(-) and the water-cooled constricting nozzle (+).
A non-transferred arc is initiated by using a high-frequency unit in the circuit. After the initial
high-frequency start, the pilot arc (low current) is formed between the elect by employing a low
current. After the main arc is struck, the nozzle is neutral or in case of welding-mesh using micro
plasma, there can be an option given to have a continuous pilot arc. A transferred arc possesses
high energy density and plasma jet velocity. Depending on the current used and flow of gas, it can
be employed to cut and melt metals.
Advantages of Plasma Welding
Precision and Control, High Energy Density, Versatility, Low Heat-Affected Zone (HAZ), High
Welding Speed
Applications of Plasma Welding
Aerospace: Welding of jet engine components and turbine blades.
Automotive: Manufacturing exhaust systems and fuel tanks.
Electronics: Micro-welding of electrical components.
Medical: Production of surgical tools and implants.
Energy Sector: Fabrication of components for nuclear and power generation industries.
5.Rapid Prototyping Technology (RPT)
Rapid Prototyping Technology (RPT) refers to a group of advanced manufacturing techniques that
quickly fabricate physical models, prototypes, or parts directly from digital 3D designs. These
technologies play a crucial role in product development, allowing for fast iteration, testing, and
validation of design concepts before mass production.
Common RPT Techniques:
3D Printing (Additive Manufacturing):
Builds objects layer by layer using materials like plastics, metals, and resins.
Examples: Fused Deposition Modeling (FDM), Stereolithography (SLA), and Selective Laser
Sintering (SLS).
CNC Machining:
Subtractive manufacturing process that removes material from a solid block using computer-
controlled tools.
Selective Laser Melting (SLM) and Direct Metal Laser Sintering (DMLS):
Used for metal prototypes, creating highly durable and functional parts.
Vacuum Casting:
A technique to create multiple prototypes by pouring liquid materials into silicone molds.
Sheet Lamination:
Involves stacking and bonding thin layers of material that are cut to shape.
Applications of RPT:
Product Development: Testing form, fit, and function of new designs.
Aerospace and Automotive: Producing lightweight, custom components.
Medical: Creating patient-specific implants, surgical guides, and prosthetics.
Consumer Goods: Prototyping and testing ergonomic designs for everyday products.
Advantages of RPT:
Speeds up the design-to-market process.
Encourages innovation by allowing multiple design iterations.
Enhances collaboration among teams by offering tangible models for review.
