Welding:

Welding is a material joining process that joins two or more materials, typically
metals or thermoplastics, by applying heat, pressure, or both to melt the
workpieces and allow them to fuse as they cool. Filler materials are often used
to enhance the joint strength.

Classification of Welding:
1. Based on Composition of the Joint:
 Homogeneous Welding: Welding where the filler metal and the base
metal are of the same composition.
 Heterogeneous Welding: Welding where the filler metal is of a different
composition than the base metal.
 Autogenous Welding: Welding process where no filler metal is used, and
the joint is formed by melting the base metals together.
Process Types:

1. Friction Welding (FRW): Heat is generated by friction, and pressure is

applied to forge the joint.
2. Ultrasonic Welding (USW): High-frequency vibrations create localized
friction and pressure to join materials.
3. Cold Welding (CW): Materials are joined by applying pressure at room
temperature.
4. Explosion Welding (EXW): Materials are welded by applying high
pressure through controlled explosions.
5. Resistance Welding (RW): Heat and pressure are applied simultaneously
to join the metals.
2. Based on application of pressure:
 Forge or Pressure Welding (Non-Fusion Welding/Plastic Welding): In this
type of welding, pressure is applied to the joint, either with or without
the application of heat, to join the materials. The materials are joined
without melting, often just by plastic deformation. Heat may be applied,
but it is not enough to melt the base metals.
 Fusion or Non-Pressure Welding: In this type of welding, the materials
are joined by melting the base metals at the joint. No external pressure
is required to complete the weld. A filler material may or may not be
used.

Process Types:
1. Arc Welding:
 Shielded Metal Arc Welding (SMAW) (Stick Welding)
 Gas Metal Arc Welding (GMAW) (MIG Welding)
 Gas Tungsten Arc Welding (GTAW) (TIG Welding)
2. Gas Welding:
 Oxy-Acetylene Welding (OAW): Combines metal by melting it using a
gas flame.
3. Laser Beam Welding (LBW): Uses a laser to melt the base metals at the
joint.
4. Electron Beam Welding (EBW): Uses high-energy electrons to melt and
fuse the base metals.
5. Submerged Arc Welding (SAW): Uses an electric arc to melt the metal
under a layer of granular flux.
 Welding Process

Oxy-fuel gas Resistance

Arc Welding Laser welding
welding welding

Oxy-acetylene Metal arc Spot

Shielded metal
Oxy- Hydrogen arc (Stick Seam
welding)

Submerged arc Projection

Gas metal arc

Upset Butt
(MIG)

Gas tungsten arc

Flash Butt
(TIG)

Electroslag

Advantages of Welding:
 Strong and Permanent Joints: Welding produces robust and long-lasting
joints that are as strong as or stronger than the base material.
 Wide Range of Materials: Almost all metals, alloys, and thermoplastics
can be welded, offering great versatility.
 Design Flexibility: Complex shapes and structures can be formed with
welding, allowing for intricate designs and custom fabrication.
 Efficient for Large-Scale Production: Automated welding processes like
robotic or machine welding allow for fast, consistent production in
industries such as automotive and construction.
 Weight Reduction: Welded joints are often lighter than mechanical
fasteners, such as rivets or bolts, especially in industries like aerospace
where weight savings are critical.
 Cost-Effective: For many applications, welding is a relatively low-cost
process, especially for long-term, high-volume production.
Disadvantages of Welding:
 Skilled Labor Requirement: Welding often requires highly skilled labour,
and improper techniques can result in weak or defective joints.
 Risk of Defects: Welding defects such as cracks, porosity, or distortion
can occur due to improper technique or material incompatibility,
affecting the integrity of the joint.
 Limited Portability: Many welding processes require bulky equipment
and power sources, which can limit their use in remote or confined
spaces.
 Heat-Affected Zone (HAZ): Welding can alter the properties of the
material in the heat-affected zone, potentially weakening it or causing
residual stress and distortion.
 Safety Hazards: Welding processes involve high temperatures, sparks,
UV radiation, and toxic fumes, posing significant health and safety risks
to operators without proper precautions.
 Energy Consumption: Some welding processes, such as arc or laser
welding, can consume a lot of energy, adding to operational costs.

Types of Welding joints:

 Butt Joint: Two pieces of metal are placed end-to-end which are in
same plane and welded at their edges, commonly used in pipelines,
pressure vessels, and structural components.
  Lap Joint: One piece overlaps the other, and the edges of the
overlapping section are welded, often used in sheet metal work,
automotive bodies, and thin materials.
 Corner Joint: Two pieces form a 90-degree angle, and the welding is
done at the corner, typically used in box frames, sheet metal
products, and frames.
 Tee Joint: One piece is placed perpendicular to another, forming a "T"
shape, commonly used in structural frameworks, beams, and cross-
sections.
 Edge Joint: Two parallel pieces of metal are welded at the edges,
often used for thin materials or in cases where strength is not critical,
such as sheet metal fabrication and tanks.

Welding position:

 Flat Position: The workpiece is placed horizontally, and the welder welds
from above. This is the easiest and most common welding position,
offering good control over the weld pool.
 Vertical Position: Welding is done along a vertical surface, either upward
(vertical-up) or downward (vertical-down), commonly used in
construction and piping.
 Horizontal Position: The weld is made along a horizontal axis, with the
workpiece vertical. This position is more challenging than flat and
requires good skill to control the weld pool.
 Overhead Position: The welder works from beneath the joint, welding
overhead. It is one of the most difficult positions due to the risk of
molten metal falling, requiring high skill and precision.
Edge preparation:
To ensure complete penetration and sound weld, edge preparation is essential.

 Straight edge is used when thickness of metals to be welded are small (3

to 5mm)
 Single V -butt edge is used when thickness of metals to be welded are
thick (8-16mm)
 Double V-butt edge is used when thickness of metals to be welded are
thicker than 16mm.
 Single and Double U-butt edge is used when extra metal to be filled with
weld increases and thickness of work pieces are above 20mm.

Basic terms associated with welding:

Base metal: Metals to be joined or cut.
Weld or Weld bead: Metal added in welding. It looks separate from base
metal.
Puddle: Portion of base metal which got melted due to heat of welding.
Root: Nearest point between two metals to be joined.
Penetration: It is the dept till which base metal combines with weld metal.
Backing: Material support at root side of weld to aid in control of penetration.
Tack Weld: Temporary small weld, that is used to hold base metals together
while doing actual welding.
Weld face: It is the exposed part of weld.
Weld pass: Single movement of electrode or torch along length of joint along
which weld bead forms.