Experiment No. 1: Introduction To Metal Joining Process 1. Welding

Experiment no.
1: Introduction to Metal Joining Process
1. Welding: -
It is a process of joining of two or, more than two similar or dissimilar materials with or,
without application of heat, with or, without application of pressure or, with or, without
application of filler material. Welding is broadly classified into two categories such as fusion
welding and non-fusion or, solid-state welding.
Joining of two metals by melting parent material with coalescing by means of heat,
usually supplied by electrical or high energy means is known as fusion welding. Fusion
welding consists of arc welding, gas welding and chemical welding.
By using electrical arc if the heat required for melting of plate is obtained then it is known
as arc welding shown in fig 1. The arc is produced between the tip and the electrode by
employing either a consumable electrode or non-consumable electrode (rod or wire) and the
part is welded using AC or DC power supply. There are several types of arc welding such
Shielded Metal Arc Welding (SMAW), Submerged Arc Welding (SAW), Metal Inert Gas
Welding (MIG), Tungsten Inert Gas Welding (TIG) etc.
Fig. 1. Basic ARC welding diagram
2. Brazing: -
Brazing, non-fusion joining process, a filler metal is placed at or between the faying
surface to be joined and the temperature is raised to melt the filler metal. In this process work
piece is not melted. The molten metal fills the closely fitting space by capillary action. The
strength of the joint depends upon the cooling and solidification of the filler metal. In braze
welding the filler metal is deposited at the joint. There are several brazing methods are
available such as torch brazing, furnace brazing, induction brazing, resistance brazing, dip
brazing, infrared brazing, diffusion brazing etc.
3. Soldering: -
Soldering, also a non-fusion joining process, the filler metal melts below 723 K and fills
the joint by capillary action between the closely fitting or closely fit components. Soldering
can be used to join various metals and part thickness and is used extensively in electronics
industry. The filler metal which is used for joining is known as Solder. Solders are generally
tin-lead alloy in typical composition such as 96.5% Sn-3.5% Ag. There are various types of
soldering methods are available such as reflow soldering, wave soldering, torch soldering,
furnace soldering, iron soldering, induction soldering, resistance soldering, dip soldering,
infrared soldering etc.
4. Difference between welding, brazing and soldering
Welding Brazing Soldering

Base metal fused Base metal doesn’t fuse Base metal doesn’t fuse
High temp, high power Low temp, low power Low temp, low power
High distortion Low distortion No distortion
High stress in joints Low stress in joints Low stress in joints
Microstructure of base Base metal microstructure Base metal microstructure
metal change no change no change
Difficult to join dissimilar Easy to join dissimilar Easy to join dissimilar
metals metals metals
Thin sheet difficult to join Thin sheets can be joined Thin sheets can be joined
Joints have high strength Low strength of joints Low strength of joints
5. Classification of Welding processes
Welding is mainly classified into two categories:
A) Fusion welding and B) Non-fusion welding.

A) Fusion welding is broadly classified into three types:
a) Gas welding.
b) Arc welding.
c) Chemical welding.
a) Gas welding are four types:
i) Oxy acetylene
ii) Air acetylene
iii) Oxy hydrozen.
iv) Atomic welding.
b) Arc welding are four types:
i) SMAW
ii) SAW
iii) TIG
iv) MIG
c) Chemical welding has one type:
i) Thermit welding.
B) Non-fusion welding are two types:
a) With heat and b) Without heat
a) Non-fusion welding with heat have four categories:
1) Resistance welding.
2) Soldering.
3) Brazing.
4) Braze weld.
1) Resistance welding have four types:
i) Spot welding
ii) Seam welding
iii) Projection welding
iv) Percusion welding.
b) Without heat non-fusion welding have two categories:
1) Cold pressure welding.
2) Cryogenic welding.
5) Safety precaution during welding:
a) Welding helmet with side shields: To protect from UV radiation, particles, debris,
hot slag and chemical slag.
b) Apron: To protect from heat, fire and radiation created during welding process and it
shields welder from burning.
c) Boots and gloves: Insulted, flame resistance gloves and rubber-soled, steel toe-
capped safety shoes shield welder from electric shocks, heat, fire, burns and falling
objects.

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Experiment no.

1: Introduction to Metal Joining Process

Fig. 1. Basic ARC welding diagram

4. Difference between welding, brazing and soldering

Welding Brazing Soldering

5. Classification of Welding processes

Welding is mainly classified into two categories:

A) Fusion welding and B) Non-fusion welding.

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