Fundamentals of Welding
D.SELVAKUMARAN
Course Director/AWTI
Types of metal joining
Riveted joints
Bolted joints
Welded joints
RIVETED JOINTS
BOLTED JOINTS
Welded joint
Welded joint
Limitations of riveted
and
bolted joints
Load bearing
Difficult for higher thickness
Bolts can be unscrewed
Rivets and bolts are protruding
Fillet joints, butt joints curved joints,
are difficult. Additional flanges are
necessary
Limitations of riveted
and
bolted joints
Rivets and bolts are protruding
Fillet joints, butt joints curved joints,
are difficult. Additional flanges are
necessary
Advantages of welding
Permanent joint
Withstands high pressure or force or load
Occupies less space
Has less weight
Withstands high temperature
Quick process
Any profile can be welded. Different joint
types i.e. Butt, fillet, lap, corner joint
possible
Basic Joint Types
but
t
la
p
tee
edge
corn
er
Applicable Welds for Butt joint
Square Groove
weld
Single V weld
Single Bevel weld
Single U
weld
Single J weld
Applicable Welds for Butt joint
Double V weld
Double U weld
Double Bevel weld
Double J weld
Applicable Welds for Tee joint
Applicable Welds for Lap joint
Fillet
weld
Plug / slot
weld
Spot / seam
weld
Applicable Welds for Corner Joint
Applicable Welds for Edge Joint
Edge weld
Edge Preparation - Need
Poor
penetration
Poor strength
Good
penetration
Good strength
(100% joint
efficiency)
Edge Preparation
Factors which influence choice of edge
preparation
- Thickness
- Material
- Welding process
- Extent of penetration required
- Welding distortion
- Cost
Butt joint
Square Groove
weld
Root
Butt joint
Single V Groove
weld
Groove angle
Root face
Root
gap
Parts of welding joint
Root, root face, root gap
Groove
Weldment
Fusion zone
Heat affected zone
Bead width
Throat
Penetration
Fusion
Depth of fusion
Leg
Reinforcement
Quality of welding joint
Welding dimensions
Throat
Leg length
Bead width
Leg
Leg
Quality of welding joint
Fusion
Penetration
Quality of welding joint
Nice ripples
Quality of welding joint
Clean joint
Less defects
Testing of welding joint
Fracture test
tensile test
Quality of welding joint
Summary
Welding dimensions
Throat
Leg length
Bead width
Fusion
Penetration
Nice ripples
Clean joint
Less defects
Types of welding
Fusion welding
Pressure welding
Non fusion welding
Fusion welding
Manual metal
Arc welding
Gas metal arc
welding
Gas welding
Pressure welding
Forge welding
Resistance
welding
Friction stir
welding
Non fusion welding
No fusion
Brazing
Soldering
Fusion welding
Types of fusion welding
MMAW : Manual Metal Arc Welding
GMAW : Gas Metal Arc Welding
MIG/MAG welding
MIG : Metal Inert Gas welding
MAG : Metal Active Gas welding
GTAW : Gas Tungsten Arc Welding
TIG : Tungsten Inert Gas welding
SAW : Submerged Arc Welding
Plasma arc welding
Carbon arc welding
Gas welding
Laser welding
BASICS OF WELDING
WELDING PARAMETERS
POLARITY
CONSTANT CURRENT Vs CONSTAN
VOLTAGE
WELDING PARAMETERS
CURRENT
VOLTAGE
ELCTRODE TYPE
SHIELDING GAS FLOW RATE
POLARITY
Straight polarity : DCEN
Electrode ve
less fusion (suitable for thin section)
More penetration
suitable for TIG (avoids burning of tungsten)
Reverse polarity : DCEP
Electrode +ve
more common
more deposition
less penetration
arc is more stable
Constant current Vs constant
voltage
Constant Current characteristics
Manual Metal Arc Welding (MMAW)
Tungsten Inert Gas Welding (TIG)
Constant Voltage Constant Current
Gas Metal Arc Welding (GMAW)
Metal Inert Gas (MIG)/ Metal Active Gas
(MAG)
Submerged Arc Welding (SAW)
MMAW : Manual Metal Arc
Welding
SMAW : Shielded Metal Arc Welding
MMAW : Manual Metal Arc
Welding
SMAW : Shielded Metal Arc Welding
Electrode
Travel direction
4
6
6
Shielding Gas
Slag
Slag
Weld Puddle 3
Weld Puddle
3
5
5
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Solidified Weld Metal
Solidified Weld Metal
2
2
Arc
Arc
GMAW : Gas Metal Arc Welding
MIG : Metal Inert Gas welding
MAG : Metal Active Gas welding
Basic welding parameters in
GMAW
The basic parameters which require to
be set in GMAW process are
Current ( amps )
Voltage ( volts )
Shielding gas flow rate. ( litres / min )
Stick out
Torch angle
Welding speed
TIG WELDING
GTAW PROCESS
GTAW PROCESS
Fig 1a. TIG Arc
SAW : Submerged Arc Welding
Queries &
discussions.....
Thank you
SMAW
OBJECTIVES
The process
Process variables
Selection of consumables
SMAW
Current flows through the electrode
cable, to the electrode holder,
through the electrode, and across the
arc
On the work side of the arc, the
current flows through the base
material to the work clamp and back
to the welding machine
EQUIPMENT AND ACCESSORIES USED IN THE PROCESS
>> Power source
>> Electrode holder
>> Ground cable
>> Welding cable
>> Lugs
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SMAW Process
Lets take a little closer look at the
Electrode
SMAW process
1
Travel direction
4
6
6
Shielding Gas
Slag
Slag
Weld Puddle 3
Weld Puddle
3
5
5
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Solidified Weld Metal
Solidified Weld Metal
2
2
Arc
Arc
EQUIPMENT AND ACCESSORIES
USED IN THE PROCESS
>> Power source
>> Electrode holder
>> Ground cable
>> Welding cable
>> Lugs
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Shielded Metal Arc
Welding
Process Capabilities:
Versatile process
Indoor & Outdoor welding
Multi-position welding
Equipment is simple & portable
Universal process for repair welding
Limitations:
Productivity is less
> Fixed length of electrode
> Deslaging
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LIMITATIONS OF SMAW PROCESS
>> Less metal deposition Cannot be
used for heavy fabrication welding
>> Requires more number of welders
>> Control of distortion is difficult
>> Continuous & automatic Welding
is not possible
>> More strain to the welders
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POWER SOURCE
Either AC or DC may be used for SMAW process.
Factors to be considered for SMAW:
>>
Type of current---- AC or DC
>>
Current requirement
>>
Positon of welding
>> Primary power available at the work
station
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SELECTION OF ELECTRODES
>> Composition or Strength of BM.
>> Penetration requirement
>> Position of welding
>> Fit-Up condition
>> Skill of the welding personnel
>> Cost of the welding operation
>> Service requirement of weld joint.
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Welding electrodes
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The Electrode
Is a consumable - it
gets melted during the
welding process
Is composed of two
parts
Core Rod (Metal Filler)
Carries welding current
Becomes part of the weld
Flux Coating
Produces a shielding gas
Can provide additional
filler
Forms a slag
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CLASSIFICATION OF ELECTRODES (AWS 5.1)
E6010
Electrode
60 Psi
70
80
90
100
110
120
Welding
position
Coating and
current conditions
TYPES OF COVERING
Based of covering:
> Rutile electrodes
> Basic coated electrodes
> Cellulose coated electrode
>Iron powder,iron oxide electrodes
Based on application:
> carbon-manganese steel electrodes AWS A5.1
> Stainless steel electrodes A5.4
> Low alloy steel electrodes A5.5
> Copper & Copper alloy electrodes A5.6
> Aluminium & Aluminium alloy electrodes A5.10
> Nickel & Nickel alloy covered electrodes A5.11
> Hardfacing electrodes A5.13
> Covered electrodes for cast iron A5.15
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CHARACTERISTICS OF ELECTRODES
Rutile Electrodes:
Cellulose Electrode:
> Quite & smooth arc
>
>
>
>
>
> Forceful & noisy arc
Excellent slag removal
> Friable slag
Fine ripples
> Coarse ripples
Medium penetration
> Deep penetration
Thick slag
> Thin slag cover
Good running
> More gas shield
> vertical down
Basic Electrodes:
> Adequate penetration
> Slag removal is good
> Contains more iron powder
> Good mechanical Properties
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PURPOSE OF FLUX COATING
>> Gas shielding of arc
>> Stabilizes the arc
>> Provides slag blanket
>> Alloying element will improve the
mechanical
properties
>> Gives good appearance & penetration
>> Welding in all position is easy
>> Compensates for oxidation loss
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COMPOSITION OF FLUX IN THE ELECTRODE COATING
1. Organic substance or Cellulose material:
Wood, Flour & Cellulose
High arc force
Large volume of gas mostly hydrogen
2.
Rutile:
Found in sand
Arc stabilizer
Good slag former
3. Ball Clay:
Compound of silica & alumina
Slag former & Gives plasticity in the wet paste
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COMPOSITION OF FLUX IN THE ELECTRODE COATING
4.Iron powder:
Gives good operating characteristics
Improves arc stability
Makes the coating electrically conducting
5.Oxidizing Substance:
Makes the weld metal flow freely
Oxidizing substance are: iron oxide, Lamitite, Magnetite
6.Reducing Substances:
They compensate for manganese Ferro Silicon
Substances: Ferro Manganese, Ferro Silicon, Ferro Titanium
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COMPOSITION OF FLUX IN THE ELECTRODE COATING
7. Ionizing Substances:
Used for stabilizing the arc
Substances : Chalk, Marble
8.Binding substance:
Help the coating to grip firmly around the core wire
Substances: Sodium Silicate, Potassium Silicate
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Metal Transfer
Factors influencing metal transfer:
> Surface tension
> Force of gravity
> Magnetic forces
> Metallurgical factors
Surface tension forces:
> Holds the liquid metal droplet to the tip.
Force to be overcom
Force of gravity:
> Position of welding
Flat --- Helps in metal transfer
Overhead--Negative influence oppose metal transfe
Magnetic forces:
>Lorentz & Pinch forces.
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Metallurgical factors:
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RECOMMENDED SHADE NUMBER OF THE COLOURED
GLASSES
Shade No.
Range of welding
current(Amps)
8--9
Upto 100 Amps
10--11
100300 Amps
12--14
Above 300 Amps
EWG
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Welding Positions
GROOVE WELD
Flat position(1G)
Horizontal position(2G)
Vertical position(3G)
Overhead position(4G)
FILLET WELD
Flat position(1F)
Horizontal position(2F)
Vertical position(3F)
Overhead position(4F)
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EFFECT OF VARIATION OF
PARAMETERS
1.CURRENT TOO LOW:
Uneven bead height
Poor penetration
Slag inclusion
Irregular ripples
2.CURRENT TOO HIGH:
Wide & flat beads in uneven shape
Excessive penetration parent metal
More spatter
Poor ripple appearance
Porosity
Undercut
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EFFECT OF VARIATION OF
PARAMETERS
3.ARC TOO SHORT:
Irregular ripple
Burn through
Unequal width & height of bead
Electrode freezing the job
4. ARC TOO LONG:
Unequal height of bead
Wide ripple
Crater with blow holes
More spatters
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EFFECT OF VARIATION OF
PARAMETERS
5 . TRAVEL TOO LOW:
More width & height of the bead
Slag inclusion
6. TRAVEL TOO FAST:
Narrow width of the bead
Porosity
Elongated ripples
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ADVANTAGES OF SMAW PROCESS
>> Light & heavy gauge metals can be
>> Fabrication welding, Construction
Maintenance welding
>> All types of metals ( Ferrous, Noncan be welded
welded.
welding &
ferrous & alloys)
>> Welding operation is quick & easy
>> More suitable for short length welds
>> Less expensive
>> Less sensitive
>> It is portable
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APPLICATIONS OF SMAW PROCESS
>> Used for welding thin & thick gauge metals
>> Used in welding bridges, bus bodies,domestic
like grills for gates, windows, chairs,
doors .
items
>> Used in welding roof structure for workshop,
& cracked castings
broken
>> Whenever welding is done in outdoor work, this
process is very useful as a diesel generator
welding set can be used.
>> Used for hardfacing & repair welding
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Thank you
