Methods of Welding Part 2

1. Thermite welding.
This welding method is based on the metal

thermia (recovery of metal from oxide using another metal), from
covered by Russian chemist N.N. Beketov in 1865. The best known is aluminum
nium thermite from aluminum metal powder and iron scale
FeO. If this mixture is set on fire, it burns out, giving metallic iron and oxide
aluminum. The reaction is accompanied by a large release of heat, which
melts reduced iron. Thermite welding is used for welding
rail, during repair work.
2. Gas welding. This welding method is based on the use of heat,
released during the combustion of combustible gases in special burners. As
combustible gases are acetylene, hydrogen, natural gas and propane-butane.
In order to increase the temperature of the flame, as an oxidizing agent,
oxygen. In shipbuilding and ship repair, gas welding is used
when welding joints of pipes of small diameter at installation, during manufacture
details from copper and its alloys, and also repair of details from cast iron, silumin.
3. Electric arc welding. The electric arc is the most
universal and widespread source of heat used for
fusion welding. Fusion welding methods using electric
arc, are diverse:
3.1. Welding with non-consumable carbon electrode. Welding by method
N.N. Benardos is not currently used in shipbuilding. This
the method is used on small shipyards when welding defects in cast iron
products, brass propellers.
3.2. consumable electrode welding. The electrode is a
tall rod coated on it. Substances, input
coating, provide gas and slag protection of the metal from
air and physical and chemical processing of the weld metal. Electrodes for
Welds were invented in 1911 by the Swedish engineer Kelberg. IN
in shipbuilding, welding with electrodes is used less, so it is being replaced
more productive mechanized methods. Last

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time in shipbuilding is widely used gravity and air
current-contact welding using long coated electro
dov (installations like "Spark", etc.).

3.3. Submerged arc welding. This method is based on arc burning under
a layer of powdery fluxes melting during welding (Fig. 1.4).
Rice. 1.4 Scheme of automatic submerged arc welding
In shipbuilding, semi-automatic and automatic

submerged arc welding. Application of automatic submerged arc welding
reduced the complexity of manufacturing welded structures by 5-7 times, as well as
reduced the cost of welding consumables and electricity. This way of posing
Allows welding of steels, as well as copper and titanium alloys. in shipbuilding
this method and its modifications are used very widely.
4. Welding in shielding gases. The idea of protecting the weld metal with gas was
expressed and implemented by N.N. Benardos. Distinguish between the welding method
consumable electrode (carbon or tungsten) and consumable. Welding is not
consumable electrode in an argon or helium jet is widely used in ship
structure for welding non-ferrous metals and their alloys, as well as titanium alloys
wow and stainless steel. Welding steel consumable electrode (wire)

became possible after the invention in 1952 by K.V. Lyubavsky and N.M. Novozhi
fishing special alloyed wire for welding in carbon dioxide
gas. Welding is carried out by semi-automatic and automatic machines. This welding method
(semi-automatic version) allows you to weld structures in any

14
strange position. This method has found wide application in sudo
building.
5. Arc plasma jet welding. This method was developed in five

1900s of the last century in the USSR. Plasma heat is used for welding
arcs. Plasma is formed in plasma torches, where
argon, nitrogen, hydrogen and their various mixtures, as well as air and water
(Fig. 1.5).
Rice. 1.5 Scheme of arc plasma torch:

1 - rod (tungsten) electrode; 2 - burner body (shaped electrode); 3 – cooling water
tube; 4 - arc; 5 - plasma jet
Plasma is currently widely used in shipbuilding.

interchangeable surfacing of non-ferrous and wear-resistant materials, hybrid laser
arc welding and plasma cutting.
6. Electroslag welding. Electroslag welding (ESW) developed

in 1949 at the Institute of Electric Welding named after E.O. Paton as a professor, doctor
of technical sciences G.Z. Voloshkevich. This method is based on the use
for heating the parts to be welded, the heat generated during the flow of current
cutting molten flux-slag, which is a conductor of electric current
(Fig. 1.6).
15
Rice. 1.6 Scheme of electroslag welding:
a - general view; b - welding pool. 1
- welded parts; 2 - water-cooled sliders; 3 - molten slag; 4 - electrode; 5 - molten bath;
6 - crystallized seam; 7 - cooling water; 8 – drops of electrode material; 9 - drops of the base
metal
This method of welding has found wide application in shipbuilding when welding.
large-sized structures (stems, sternposts, rowing brackets
shafts), as well as ship hull structures with a thickness of more than 15 mm.
Let us dwell on the advantages of welded structures over riveted ones.
(Fig. 1.7):
Rice. 1.7 Attaching the frame to the bilge plate of the skin:
a - riveted (shelf to sheet); b - welded (wall to sheet)
1) simplification of the design and, accordingly, the technology of building the core
start of the ship and the equipment used;
2) reducing the weight of the structure by 15-25%;

16
3) improving the tightness of welded joints, especially when
receiving permanent deformations from impacts and explosions, it is important, since sudo
high structures operate under vibration conditions and with alternating
loads;
4) reducing the cost by reducing their weight and labor intensity from
cooking;
5) possibility of mechanization and automation of welding processes;
6) improvement of working conditions for assemblers and welders (noiselessness
cease);
7) increasing the strength properties of joints while simplifying the con
structures;
8) the possibility of using dissimilar metals in the same con
structure, while maintaining continuity (steel body + aluminum
superstructure, surfacing of wear-resistant and corrosion-resistant materials);
9) the possibility of manufacturing cast-welded and forged-welded products su
old mechanical engineering;
10) the possibility of building large blocks in the workshops, followed by
putting them on a slipway for assembling the hull as a whole, which drastically reduced the cost
ship building time.
Control questions
1. Definition of the welding process.
2. What is an interatomic bond?
3.What is the soldering process? Difference from the welding process.
4. Which of the outstanding Russian scientists stood at the origins of welding?
5. What are the main features of welding processes?
6.Three main groups of welding.
7. List the main welding methods used in shipbuilding.
8. Advantages of welded joints over riveted ones?
17

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1. Thermite welding.

This welding method is based on the metal

more productive mechanized methods. Last

current-contact welding using long coated electro

dov (installations like "Spark", etc.).

Rice. 1.4 Scheme of automatic submerged arc welding

In shipbuilding, semi-automatic and automatic

wow and stainless steel. Welding steel consumable electrode (wire)

(semi-automatic version) allows you to weld structures in any

5. Arc plasma jet welding. This method was developed in five

Rice. 1.5 Scheme of arc plasma torch:

Plasma is currently widely used in shipbuilding.

6. Electroslag welding. Electroslag welding (ESW) developed

large-sized structures (stems, sternposts, rowing brackets

Let us dwell on the advantages of welded structures over riveted ones.

start of the ship and the equipment used;

2) reducing the weight of the structure by 15-25%;

high structures operate under vibration conditions and with alternating

5) possibility of mechanization and automation of welding processes;

6) improvement of working conditions for assemblers and welders (noiselessness

7) increasing the strength properties of joints while simplifying the con

8) the possibility of using dissimilar metals in the same con

structure, while maintaining continuity (steel body + aluminum

superstructure, surfacing of wear-resistant and corrosion-resistant materials);

9) the possibility of manufacturing cast-welded and forged-welded products su

old mechanical engineering;

10) the possibility of building large blocks in the workshops, followed by

ship building time.

1. Definition of the welding process.

2. What is an interatomic bond?

3.What is the soldering process? Difference from the welding process.

4. Which of the outstanding Russian scientists stood at the origins of welding?

5. What are the main features of welding processes?

6.Three main groups of welding.

7. List the main welding methods used in shipbuilding.

8. Advantages of welded joints over riveted ones?

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