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Welding

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73 views31 pages

Welding

Uploaded by

dmeist2022
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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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.

Video Link: https://www.youtube.com/watch?v=TeBX6cKKHWY


Gas Metal Arc Welding (GMAW)
• GMAW a.k.a Metal Inert Gas (MIG) Welding.
• It uses a consumable electrode in the form of a bare metal wire.
• Shielding is provided by a flood of gaseous mixture that covers the
arc.
• Inert Gases: Argon, Helium
• Active Gases: Carbon Dioxide
• Versatile in terms of base metals,
thickness, weld positioning.
• Ferrous/Non-Ferrous Alloys.

Video Link: https://www.youtube.com/watch?v=MRIGks3gxG0


Gas Tungsten Arc Welding (GTAW)
• GMAW a.k.a Tungsten Inert Gas (TIG) Welding.
• It uses a non-consumable electrode made of Tungsten.
• Filler, if used, must be fed independently.
• Shielding is provided by a flood of gaseous mixture that covers the arc.
• Inert Gases: Argon, Helium
• Versatile in terms of base metals,
thickness, weld positioning.
• Fine weld beads, suitable for thin sheets.
• No splatter/splashes.
• Aluminum/Copper Alloys + SS.

Video Link: https://www.youtube.com/watch?v=6LSLV8QRgMA


Resistance Welding
• RW uses a combination of heat and pressure to achieve welding.
• The heat is provided by electrical resistance of the base metals.
• AC-charged electrodes are used for both
the electrical connection and as
a source of pressure.
• RW almost always melts the parts,
creating a weld nugget.
• No filler, highly productive/repeatable.
• Costly setup and limited application
(joint types and part shapes).
Video Link: https://www.youtube.com/watch?v=Y0xRhn4UKzk
Resistance Spot Welding
• Spot Welding is the most common type of resistance welding technique.
• Suitable for sheets of <3mm.
• Electrode tips of various sizes and shapes are used.
Oxyacetylene Welding
• Oxyacetylene Welding is a type of Oxyfuel Gas Welding.
• OAW primarily uses heat and rarely pressure as well for welding.
• Filler can be used if required.
• The heat is provided by a high-temperature flame of Acetylene (C2H2) combusted
with Oxygen that burns at about 3000 Celsius.
• The flame is directed by a torch.
• Inexpensive and portable.
• Preferred for low-intensity jobs and
thin plates/sheets.
Weld Joints
Weld Types
• A fillet weld is used on surfaces approximately perpendicular to each
other. Consequently, the weld cross section is usually a right-angle
triangle.

• (a) inside single fillet corner joint


• (b) outside single fillet corner joint
• (c) double fillet lap joint
• (d) double fillet tee joint.
Weld Types
• A groove weld is performed on parts where specially shaped grooves
are precut into the edges to facilitate weld penetration.
Weld Types
• Plug welds and slot welds are used for joining plates. A hole/slot is cut
into one plate in which the weldment is created by filling it with the
filler metal.
Weld Types
• Spot welds and seam welds are used for lap joints. A weldment is
created, towards the inside, between the two joining surfaces. These
are most commonly associated with resistance welding.

Video Link: https://www.youtube.com/watch?v=YhWpub7NDss


Seam
Weldin
g
Related Technologies
Cutting Technologies
• Several welding setups are utilized for cutting operations as well.

• 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.

Video Link: https://www.youtube.com/watch?v=lrAiqhr9oD4


Underwater Welding
• Hyperbaric Welding is performed while submerged in water.
• Dry Welding: A water-tight chamber, known as a hyperbaric chamber, is
created around the part and filled with high-pressure inert gases and welding
is performed as normal.
• Wet Welding: Welding may be performed directly in water. However, it is not
accurate, weaker, and difficult.

• Most common technique: Arc Welding.


• Risks: Electrocution, drowning, explosions, etc.…
• Applications: Marine repair, oil rigs, pipes….

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