Welding

Fabrication Processes
➢ Joining two or more elements to make a single part is
termed as a fabrication process. Large no. of industrial
components are made by fabrication processes.
➢ Ex:- Aircraft & ship bodies, bridges, building trusses,
machine frames, sheet metal parts etc.

➢ It is also known as secondary manufacturing process.

➢ Most economical method.

 Classification of fabrication methods
• Mechanical joining by means of bolts, screws &
rivets.
• Adhesive bonding by employing synthetic glues
such as epoxy resins
• Welding, brazing & soldering
 Various factors affect during selection of
fabrication method
• Type of assembly : permanent, semi permanent &
temporary
• Materials being joined : steels, cast irons, similar or
dissimilar metals
• Economy achieved
• Types of service required : such as assembly
subjected to heavy loading, impact loading, high
temp. etc.
 Welding (Fabrication method)
❑ Welding is a materials joining process which produces
coalescence of materials by heating them to suitable
temperatures with or without the application of pressure
or by the application of pressure alone, and with or
without the use of filler material.

❑ Welding is used for making permanent joints.

❑ It is used in the manufacture of automobile bodies,

aircraft frames, railway wagons, machine frames,
structural works, tanks, furniture, boilers, general repair
work and ship building.
 Classification of welding process

There are various ways of classifying the welding

processes. for example, they may be classified on the
basis of state of the weld metal during welding,
source of heat (flames , arc) etc.
 Classification of welding process
Welding processes are classified into two major groups:

1. Fusion welding: In this process, base metal is melted by

means of heat. Often, in fusion welding operations, a filler
metal is added to the molten pool to facilitate the process
and provide bulk and strength to the joint. Commonly used
fusion welding processes are: arc welding, resistance welding,
oxy-fuel welding, electron beam welding and laser beam
welding.

2. Solid-state welding: In this process, joining of parts takes

place by application of pressure alone or a combination of
heat and pressure. No filler metal is used. Commonly used
solid-state welding processes are: diffusion welding, friction
welding, ultrasonic welding.
Classification of welding process
Classification of welding process
 Classification of welding process

2. Arc welding:
1. Gas welding:
I. Shielded metal arc welding
➢ Oxy-acetylene welding
II. Submerged arc welding
➢ Oxy-hydrogen
welding III. Gas tungsten arc welding
➢ Air acetylene welding IV. Gas metal arc welding
V. Carbon arc welding
VI. Plasma arc welding
VII.Atomic Hydrogen welding
 Classification of welding process

3. Resistance welding: 4. Other welding and related

I. Resistance spot processes :
welding ➢ Thermit welding
II. Resistance seam ➢ Electro slag welding
welding ➢ Electron beam welding
III. Projection welding ➢ Laser beam welding
IV. Percussion welding ➢ Forge welding
V. Flash welding ➢ Friction welding
VI. Upset welding ➢ Diffusion welding
➢ Explosion welding
➢ Brazing
➢ Braze welding
➢ soldering
 Types of welding joints

1. Butt Joint

2. Corner Joint

3. Fillet Joint (T)

4. Lap Joint

5. Edge Joint
Types of welding joints
 Butt Joints
❑ In Butt welded type, the parts lie in the same plane and
are joined at their edges.
❑ Universally accepted method for attaching a pipe to
itself, it’s also used for valves, flanges, fittings and other
equipment.

Butt Joint
Different Edge Shapes and Symbols for Butt-
Joints
Different Edge Shapes and Symbols for Butt-
Joints
 Corner Joints
▪ The parts in a corner joint form a right angle and are joined at the
center of the angle.

▪ These are common in the construction of boxes, box frames and

similar fabrications.

Corner Joint
Corner Joints
Corner Joints
 Lap joint
• Lap Joint- a joint between two overlapping members.
• The weld can be made on one or both sides.
• Used most often to joint two pieces with differing thicknesses
together.

Lap Joint
Different Edge Shapes and Symbols for Lap-
Joints
Different Edge Shapes and Symbols for Lap-
Joints
 Fillet-Joint (T)
❑ Fillet or Tee welding joints are formed when two members intersect at a 90°
angle which makes the edges come together in the center of a plate or
component.
❑ Tee Joints are considered a type of fillet weld, and can also be made when a
pipe or tube is welded onto a base plate.
❑ Extra care is required to ensure effective penetration into the roof of the weld.
❑ Can be used to weld pipe or tube onto a base plate.

Tee Joint
Different Edge Shapes and Symbols for Fillet-
Joint (T)
Different Edge Shapes and Symbols for Fillet-
Joint (T)
 Edge joints
❑ Edge welding Joints are often applied to sheet metal parts that have flanging
edges or are placed at a location where a weld must be made to attach to
adjacent pieces.

❑ Being a groove type weld, Edge Joints, the pieces are set side by side and
welded on the same edge.

❑ Edge joint- a joint between the edges of two or more parallel or nearly
parallel members.

❑ For heavier applications filler metal is added to melt or fuse the edge
completely and to reinforce the plate.
Different Edge Shapes and Symbols for Edge-
Joints
Edge joints
 Types of welding joints

Butt Joint
Lap Joint
Corner Joint

Tee Joint

Edge Joint
Types of welding joints
 Types of welds
Mainly Four types.

❖Bead Weld

❖Groove Weld

❖Fillet weld

❖Plug or Slot weld

 Types of welds
1. Bead Weld:
❑ A weld bead is a weld deposit produced by a single pass.
❑ A weld bead may be either narrow or wide, depending on
the amount of transverse oscillation (side-to-side
movement) used by the welder.
❑ When there is a great deal of oscillation, the bead is wide;
when there is little or no oscillation, the bead is narrow.
 Types of welds
2. Groove Weld
➢ A weld groove is defined as “A channel in the surface of a
work piece or an opening between two joint members
providing space to contain weld metal.”

➢ Groove welds fill the space made between sections of the

work piece.
 Types of welds
3. Fillet weld
❑ Process of joining two pieces together whether they be
perpendicular or at an angle.

❑ Commonly referred to as Tee joints or Lap joints.

❑ The weld is triangular in shape and may have a concave,

flat or convex surface depending on the welder’s technique.

❑ Fillet welds are used when connecting flanges to pipes,

welding cross sections of infrastructure.
 Types of welds

Fillet weld
 Types of welds
4. Plug Or Slot weld
❑ A plug weld is used to fasten two pieces of metal together.

❑ When joining the pieces, a hole is drilled into the top piece
and it is laid over the bottom one.

❑ A weld is then made by running a bead inside of the drilled

hole, thereby holding the two pieces together.
 Types Of Welding Positions
❑ The welding position refers to the position of the welding operator
towards the workpiece to be welded.

❑ Because of gravity, the welding position affects the flow of molten

filler metal.

❑ It’s important to understand the types of welding positions as

different welding processes require to be performed at a certain
position of the welder.
 Types Of Welding Positions
1. Flat Position

2. Horizontal Position

3. Vertical Position

4. Overhead Position
 Flat Positions
➢ The easiest type to perform is the flat position, which is also
sometimes called the down hand position.
➢ It involves welding on the top side of the joint. In this position, the
molten metal is drawn downward into the joint.
➢ The result is a faster and easier weld.
 Horizontal Positions
❑This is an out of position welding position. It requires more skill from
the welding operator to do them well.
❑Involves placing the weld axis in a horizontal plane or approximately
horizontal. As for the face of the weld, it should lie in an
approximately vertical plane.
 Vertical Positions
• In this position, both the plate and the weld lie vertically or almost
vertically.

• When welding vertically, the force of gravity pushes the molten

metal downward and so it has the tendency to pile up.

• To counteract this, you can use either an upward or downhill vertical

position.
 Overhead Position
▪ In this position, welding is carried from the underside of the joint. It’s
the most complicated and difficult position to work in.

▪ In the overhead position, the metal deposited to the joint tends to sag
on the plate, resulting in a bead with a higher crown. To prevent this,
keep the molten puddle small.
Welded Joints and Positions
 Welding positions

Increasing Difficulty

FLAT

HORIZONTAL
OVERHEAD

VERTICAL
Weld joints edge preparation methods
Welding Terms (Terminology)
Welding Terms (Terminology)
 Welding Terms (Terminology)
Backing: It is the material support provided at the root
side of a weld to aid in the control of penetration.
Base metal: The metal to be joined or cut is termed the
base metal.
Bead or weld bead: Bead is the metal added during a
single pass of welding. The bead appears as a separate
material from the base metal.
Crater: In arc welding , a crater is the depression in the
weld metal pool at the point where the arc strikes the
base metal.
Deposition rate: The rate at which the weld metal is
deposited per unit time is the deposition rate is normally
expressed as kg/h
Welding Terms (Terminology)
 Welding Terms

Fillet weld: The metal fused into the corner of a joint

made by two pieces placed at approximately 90 0 to each
other is termed fillet weld.
Penetration: It is the depth up to which the weld metal
combines with the base metal as measured from the top
surface of the joint.
Puddle: The portion of the weld joint that is melted by the
heat of welding.
Root: It is the point at which the two pieces to be joined
by welding.
Tack weld: A small weld , generally used to temporarily
hold the two pieces together during actual welding .
 Welding Terms
Toe of weld: It is the junction between the weld face & base
metal.

Weld face: It is the exposed surface of the weld.

Weld metal: The metal that is solidified in the joint is called

weld metal. It may be only a base metal or a mixture of
base metal & filler metal.

Weld pass: A single movement of the welding torch or

electrode along the length of the joint which results in a
bead is a weld pass.