Importance of Welding

 Limitaions
 Procedures must be provided for all metals and applications
 Manual welding depends on human factor
 Internal inspection is often required to assure quality
 Limitations can overcome by NDT, good supervision, qualified
procedures, qualified personnel and use mechanised welding

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Bride construction

Long span bridge done with welded construction

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Heavy engineering

Structures

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Off shore structures

Ship Industry

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Oil and gas

Automobile industry-Spot Welding

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ALMOST EVERY WHERE ?

AUTOMOBILES, RAILWAYS
SHIPPING
AEROSPACE
OFF SHORE STRUCTURES
CROSS CONTINENTAL PIPE LINES
BOILERS, POWER GENERATION EQUIPMENT
HEAT EXCHANGERS
DESALINATION PLANTS
ELECTRONICS
SMALL AND MINUTE COMPONENTS

History

Forge Welding was the first known welding

process in existence for several centuries..
About 3000years
Heated metals were pounded or rammed
together until they fused
By 15 th century it has developed into an
industry
Book Pyrotechnia by Vannoccio Biringuccio
in 1540 AD refers to many such techniques

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 Forge Welding
Forge welding is a process of joining
two metal pieces by heating them to a
high temperature in a forge or furnace
and then hammering or pressing them
together to create a solid bond.
Unlike other forms of welding that
involve melting the base metal, forge
welding relies on the plasticity (plastic
deformation) and malleability of the
heated metal to allow it to be
manipulated and fused together.
 It's an ancient technique that has
been used for centuries to create
various metalwork pieces such as
tools, weapons, and decorative items.

Forge welding ?
The Iron Pillar located in
Delhi, India, (7.6 m tall (25 ft)
with a dia of 12 inches at top
and 16 inches at bottom)
column in the Qutub complex,
notable for the rust-resistant
composition of the metals
used in its construction.
It was made from Iron billets
welded together

Total weight of pillar: 5443 Kgs

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 Welding

 Welding is used in the manufacture of automobile bodies,

aircraft frames, railway wagons, machine frames, structural
works, tanks, furniture, boilers, pressure vessels, bridges, pipe
lines, nuclear reactors, missile and rocket parts, earth moving
equipment, fertilizer and chemical plants, general repair work
and ship building.

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Welding
 Welding is a materials joining process which produces
coalescence (joining) 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.
 A weldment is an assembly whose component parts are
joined by welding
 Welding is carried out with out filler metal is called an
autogenous weld
 Filler metal is the metal or alloy to be added in making a
welded, brazed or soldered joint
 Base metal is the metal or alloy that is welded, brazed,
soldered joint
 Welding is used for making permanent joints.
 Welding is used throughout industry to join metals efficiently
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and economically

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Brazing and Soldering
 Brazing is a group of joining processes that produces coalescence
(joining) of materials by heating them to brazing temperatures in the
presence of filler metal having liquidus temperatures above 450°C and
below the solidus of the base metal. The filler metal is distributed
between the closely fitted faying surfaces of the joint by capillary action

 Soldering is a group of joining processes that produces coalescence

(joining) of materials by heating them to soldering temperatures in the
presence of filler metal having liquidus temperatures below 450°C and
below the solidus of the base metal. The filler metal is distributed
between the closely fitted faying surfaces of the joint by capillary action

 Additive manufacturing (AM) is: ‘’a process of joining materials to make

objects from 3D model data, usually layer upon layer, as opposed to
subtractive manufacturing methodologies.

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Weldability
 The capacity of a materials to be welded under the imposed
fabrication conditions into a specific, suitably designed
structure and to perform satisfactorily in the intended
service
 Weldability is a simply a measure of how easy it is to make a
weld in a particular material without cracks. If it is easy to
avoid cracking, the material is deemed weldable
 Good weldability characterized by:
 Ease with which welding process is accomplished
 Absence of weld defects
 Acceptable strength, ductility, and toughness in welded
joint
 Weld defects: degrades mechanical properties and corrosion
resistance

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 Welded joints
 To produce a usable structure or weldment there must be weld joints
between the various pieces that make the weldment.
 5 basic type of welded joints

1. Butt Joint: In Butt welded type, the

parts lie in the same plane and are
joined at their edges. When two
mating parts are beside each other
and joint is made.
2. Lap joint: Lap joint consists of two
overlapping parts. Two mating parts
kept on top of each other and joint
is made.

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 Welded joints

3. Tee-joint: In a Tee-joint, one joint is the

right angle to the other joint in the
approximate shape of the letter “T”. Two
mating parts are configured to look like a
T.
4. Corner joint: The parts in a corner joint
form a right angle and are joined at the
center of the angle. The mating surfaces
are kept at an angle to each other and
then at the edge are joined
5. Edge joint: The parts in edge joint are
parallel with at least one of their edges in
common and the joint is made at the
common edge(s). The two mating parts
are initially kept in the but geometry but
then are folded up so that they can be
joined along the edge

 Bead/Surface Weld: Where a plate is welded by making the welding

torch move along the surface. Used for low thickness. No joint
preparation required.
 Groove Weld: Thicker sections

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• Similar to Spot welds

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 Welding positions for groove welds

 Flat Position: plates and axis of the weld horizontal. Welding torch is kept vertically
up and moved horizontally on a plane
 Horizonal Position: plates vertical and axis of the weld horizontal. Torch moving
horizontally and welding torch is held not in the direction of gravity but at 90° to it.
 Vertical Position: plates vertical and axis of the weld vertical. Welding torch is held
90° to the gravity direction but it is moved vertically up or down as opposed to
horizontal direction.
 Overhead Position: plates and axis of the weld horizontal. Torch is held anti parallel
to the gravity direction and it is moved along the horizontal direction. Arc is moving
opposite to the gravity direction.

Welded joints

A root opening must be prepared properly to prevent

excess welding. Weld reinforcement is the convex surface
of the weld. The joint may also require a root face to
prevent excess penetration.

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Welding Terms

Parts of a weld are identified for specifying weld

characteristics.

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 Diversity of welding processes
welding

Solid state welding Fusion welding Soldering and brazing

Resistance welding Soldering

Cold welding Brazing
Friction welding
Diffusion welding
Flash welding Electrical energy Chemical energy
Ultrasonic welding
Explosion welding Oxyacetylene welding
Oxyfuel gas welding

Consumable Non Other

electrode consumable processes
Gas metal arc welding electrode Laser beam welding
Shielded metal arc Gas tungsten arc Thermit welding
welding welding Electron beam welding
Submerged arc welding Atomic hydrogen
Flux cored arc welding welding
Electrogas welding Plasma arc welding
Electroslag welding

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Safety

Safety

Burn hazard Protection clothes and gloves

Eye protection against spatters and

Helmet or special glasses
ultraviolet and infrared rays

Toxic gases:
- carbon monoxide (CO)
- ozone (O2) Well ventilated area
- phosgene gases produced with
some metals when welded

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 Safety
 A ventilation system is required to remove toxic fumes, smoke, and dust
caused by welding
 The rays generated by welding are harmful to workers. A welder should
always wear suitable personal protective equipment to protect against the
ultraviolet and infrared rays generated during welding.
 A welding helmet protects the welder from infrared rays, ultraviolet rays,
and hot sparks.
 Safety glasses should always be worn under the helmet during arc welding
and cutting operations to prevent damage to the eyes resulting from
deflected slag or other debris. Safety goggles or a face shield should be
worn during oxyfuel welding or cutting.
 Gloves must be worn when welding and cutting to protect the hands from
arc radiation, intense heat, and spatter.
 Ear protection is required for tasks that expose workers to high noise
levels.
 Ear protection lowers the decibel level to which the eardrums are exposed,
reducing the risk of hearing loss.

Safety

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Welding Skill

 Welder must have a skill and ability to manipulate

equipment to produce welds
 Welders are certified by an employer, government
agency, or inspection authority to perform specific
welds.

Thank you for your attention

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