Welding
Welding
Workshop Technology
Welding
• Welding is a materials joining process in which two or more parts, of
similar or dissimilar materials, are coalesced (kow·uh·lest) at their
contacting surfaces by a suitable application of heat and/or pressure.
• A welding operation may also use a filler material for better
coalescence/joining.
• The resulting assemblage is known as a weldment.
Welding
• Welding is one of the oldest fabrication techniques, originated from hot forging
around 1000 BCE.
• It has expanded rapidly to become one of the most commercially valuable fabrication
methods, recognized as a field in its own that attracts many researchers and
technicians.
• American Welding Society (AWS) is a significant regulatory authority internationally.
• Applications:
• Aerospace
• Automotive
• Oil & Gas
• Construction…..
Why Welding?
Advantages Disadvantages
• Provides a permanent joint that • Disassembly of welded joints is
may be stronger than the base not easy.
materials. • It is a high-skill labor and often
• Welding plants are portable. expensive in terms of wages.
• Time-saving and economical in • Numerous safety hazards.
terms of material and fabrication
costs as compared to some other
• Welding is susceptible to defects
joining methods. that are difficult to detect and
effect joint quality negatively.
• Final assembly is lightweight.
Safety Hazards & Precautions
• Welding is a high-energy process that can
be dangerous if not handled safely.
• Safety Hazards & Precautions
• Safety helmet is a MUST!!
• Use PPEs for hands, arms, neck, feet to
avoid getting burnt.
• Weld in open spaces or install
proper ventilation if in a closed space.
• Handle flammable/compressed gas cylinders
with care, keep them in an upright position.
• Have a fire extinguisher in reach.
Classification of Welding
Fusion vs. Solid State Welding
• Fusion-welding processes use • Solid-state welding refers to
heat to melt the base metals. joining processes in which
• In many fusion welding coalescence results from
operations, a filler metal is application of pressure alone or
added to the molten pool to a combination of heat and
facilitate the process and pressure.
provide bulk and strength to the • No filler metal is used.
welded joint.
Arc Welding
• Arc welding uses an electric arc to generate the heat required to melt
the base metals.
• The arc is a flow of electricity
through a gap in a circuit, supported
by ionized gas (plasma).
• The arc is created by bringing an
electrode near the charged work.
• Temperature: 6000-8000 Celsius.
Arc Welding Equipment
• Electrodes: The electrode is one end of the arc and is used to move the weld.
• Consumable: Made up of the filler material itself.
• Non-Consumable: Made of Tungsten/Carbon that do not melt easily.
• Arc Shielding: High temperatures make the metals reactive to air. The
resulting compounds are impurities that decrease weld strength and create
defects. The arc must be shielded from the air to avoid these reactions.
• Gas Shielding: Inert gas flooded around the arc.
• Flux: Substance fed into the weld to stop reactions or dissolve them; it forms a layer of
slag at the surface which can be easily removed.
• Power Supply: Produces the right Voltage and Current to maintain the arc.
Available in both AC and DC.
Arc Welding Schematic
Shielded Metal Arc Welding (SMAW)
• SMAW a.k.a Stick Welding.
• It uses a consumable electrode in the form of a stick.
• The electrode is coated with a layer of flux to provide shielding.
• Used for heavy-duty thick works owing to high power density.
• Easy, cheap, and portable.
• Used for steels, ferrous alloys,
cast iron.
• Gas Cutting
• Electron Beam Cutting
• Plasma Cutting
Welding vs. Brazing vs. Soldering
• All three are permanent joining processes that involve base metals,
heat, and filler materials.
• In welding, base metals are fused into each other along with the filler
metal.
• In brazing and soldering, base metals remain unchanged in terms of
geometry and microstructure, while the filler metal is melted and
spread over both to achieve joining.
Soldering vs. Brazing
Soldering vs. Brazing
Electron Beam Welding (EBM)
• EBM is a fusion welding process that
creates heat by firing high-speed electrons
through the workpiece, whose kinetic
energy is converted to heat.
Laser Beam Welding (EBM)
• Laser Beam Welding is a fusion welding process that
creates heat by directing a laser
at the workpiece.
Friction Stir Welding
• Friction Stir Welding is a solid-state
welding process that utilizes a
non-consumable tool.
• The tool is rubbed against the
workpiece to create friction, which
creates heat and softens the metals,
allowing them to fuse together.