INTRODUCTION TO WELDING

Introduction to welding

OVERVIEW OF JOINING METHODS

Mechanical methods
Screwed fasteners, rivets,
Adhesive bonding
Brazing and Soldering
Base metal does not fuse.
Molten filler drawn into close-fit joints by capillary
action (surface tension forces).
Brazing filler melts >450 C, solder <450 C
Welding

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WELD

A joint produced by heat or pressure or both

So there is continuity of material.

Filler (if used) has a melting temperature

close to the base material

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WELDING PROCESSES
Fusion welding
Welding in the liquid state with no pressure
Union is by molten metal bridging
Solid phase welding
Carried out below the melting point without filler
additions
Pressure often used
Union is often by plastic flow

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Basic Requirements of Welding Process

Source of Heat
Chemical Reaction
Electrical - Arc, Resistance, Induction
Mechanical

Protection from Atmosphere

Gas Shielding
Flux
Mechanical Expulsion
Vacuum

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FUSION WELDING HEAT SOURCES

Electric resistance Chemical reaction Electric arc Power beams

Spot, seam and Oxyfuel gas MMAW Laser

projection welding welding GMAW Electron beam
GTAW
FCAW
Electroslag Thermit welding SAW

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SOLID PHASE WELDING

Hot processes
Forge welding
Friction welding
Diffusion bonding
Cold processes
Ultrasonic welding
Explosive welding

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SOME ARC WELDING PROCESSES

MMAW - manual metal arc welding

SAW - submerged arc welding
GTAW - gas tungsten arc welding (TIG)
GMAW - gas-metal arc welding (MIG, MAG)
FCAW - flux cored arc welding

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THE ELECTRIC ARC

Electric discharge between

2 electrodes through
Peak - ionised gas
Cathode
temperatures 10 to 2000 amps at 10 to
drop zone
18,000 K 500 V arc voltage
Column of ionised gas at
high temperature
Forces stiffen the arc
Anode column
drop zone Transfer of molten metal
+ from electrode to workpiece
Can have a cleaning action,
breaking up oxides on
workpiece
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ARC ENERGY
Q = arc energy in kJ/mm
ExI E = current in amps
Q= I = arc voltage
V V = travel speed in mm/min

Low arc energy High arc energy

Small weld pool size Large weld pool size
Incomplete fusion Low cooling rate
High cooling rate Increased solidification cracking risk
Unwanted phase transformations Low ductility and strength
Hydrogen cracking Precipitation of unwanted phases
(corrosion and ductility)

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103 Watts/cm2 melts most metals

106 -107 Watts/cm2 vaporizes most metals
103 to 106 Watts/cm2 typical for fusion welding 11
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MANUAL METAL ARC WELDING

MMAW,
SMAW,
Stick electrode welding
Manual welding

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Manual Metal Arc Welding

Heat source - arc between metal and a flux coated electrode (1.6- 8
mm diameter)
Current 30-400A (depends on electrode size)
AC or DC operation
Power 1 to 12 kW

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Manual Metal Arc Welding

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MANUAL METAL ARC WELDING

MINIMUM EQUIPMENT

Power source (ac or dc, engine driven or mains

transformer)
Electrode holder and leads
May carry up to 300 amps
Head shield with lens protects face & eyes
Chipping hammer to remove slag
Welding gloves protect hands from arc radiation,
hot material and electric shock

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MANUAL METAL ARC WELDING
PROCESS FEATURES

Simple portable equipment

Widely practiced skills
Applicable to wide range of materials, joints,
positions
About 1kg weld deposited per arc-hour
Portable and versatile
Properties can be excellent
Benchmark process

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MANUAL METAL ARC WELDING
COVERED ELECTRODES
Core wire
Solid or tubular
2mm to 8mm diameter,
250 to 450mm long
Coating
Extruded as paste, dried
to strengthen
Dipped into slurry and
dried (rare)
Wound with paper or
chord (obsolete)

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MANUAL METAL ARC WELDING
FUNCTIONS OF COATING

Slag protects weld pool from oxidation

Gas shielding also protects weld pool
Surface tension (fluxing)
Arc stabilising (ionising)
Alloying and deoxidation
Some ingredients aid manufacture (binder and
extrusion aids)

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MANUAL METAL ARC WELDING
AWS A5.1 CLASSIFICATION

E XXXX - H
Tensile Strength Hydrogen level (HmR)
in KPSI H = 5 ml / 100g of WM
R = low moisture pick-up

Useable positions Flux type

1=all positions 20 = Acidic (iron oxide)
2=flat + horizontal 10, 11 = Cellulosic
4=vertical down 12, 13 = Rutile
24 = Rutile + iron powder
27 = Acidic + iron powder
16 = basic
18, 28 = basic + iron powder
 Introduction to welding
MANUAL METAL ARC WELDING
APPLICATIONS
Wide range of welded products:
light structure & Heavy steel structures
Workshop and site
High integrity (nuclear reactors, pressure
equipment)
Ideal where access is difficult - construction
site, inside vessels, underwater
Joins a wide range of materials

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MANUAL METAL ARC WELDING

LIMITATIONS

Low productivity
Low power
Low duty cycle (frequent electrode changes)
Hydrogen from flux coatings
Electrode live all the time
Arc strike, stray current and electric shock risks

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SUBMERGED ARC
WELDING
SAW,
Sub-arc

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Submerged arc welding

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Submerged arc welding

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SUBMERGED ARC WELDING -
FEATURES
High productivity
2 to 10 kg/hour
Up to 2m/min
Bulky, expensive and
heavy equipment
Flat and horizontal
positions only
Thicker sections
(3mm and above)
Mostly ferrous
materials (also Ni
alloys)
 Introduction to welding
SUBMERGED ARC WELDING -
EQUIPMENT
Power source
Welding head and
control box
Welding head travel
Flux recovery
system (optional)
Positioners and
Fixtures

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SUBMERGED ARC WELDING -
CONSUMABLES
Solid or cored wires
Granular fluxes
Agglomerated, fused or sintered
Alloying activity
Contribution to weld metal chemistry from flux
Basicity
Acid fluxes made from manganese oxide, silica, rutile are
easy to use
Basic fluxes (MgO, CaO, CaF2, Al2O3) provide excellent
toughness welds

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SUBMERGED ARC WELDING -
APPLICATIONS

Long straight welds in heavier material

Vessel longitudinal and circumferential welds
Flange to web joints of I beams
Flat or horizontal position
Flux has to be supported
Access has to be good

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SUBMERGED ARC WELDING
PROCESS VARIATIONS

Surfacing and hardfacing

Wire and strip electrodes
Semi-automatic
Multiple electrodes
2 (and more) electrode wires
From one or more power sources
Iron powder additions to groove

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Submerged arc welding Tandem arc

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GAS SHIELDED ARC PROCESS

Tungsten Inert Gas welding (TIG)

Gas tungsten arc welding (GTAW)

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GAS TUNGSTEN ARC WELDING

Alternative names -
GTAW,TIG (Tungsten Inert
Gas), Argonarc

Heat source is an electric

arc between a non-
consumable electrode and
the workpiece

Filler metal is not added or

is added independently

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Gas Tungsten arc welding

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Gas Tungsten Arc Welding

Heat source - arc between a tungsten tip and the parent metal
30-400A, AC or DC
10-20V
0.3-8kW
Inert gas shielding
Consumable filler rod can be used (1 to 4mm diameter)

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GAS TUNGSTEN ARC WELDING - PROCESS
FEATURES
Excellent control
Stable arc at low power (80A at 11V)
Independently added filler
Ideal for intricate welds eg root runs in pipe or thin
sheet
Low productivity 0.5kg/h manual

High quality
Clean process, no slag
Low oxygen and nitrogen weld metal
Defect free, excellent profile even for single sided
welds

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GAS TUNGSTEN ARC WELDING -
EQUIPMENT
Welding power source with constant current
characteristic
DC for most metals, AC for Al
Arc starting by high frequency (5000V, 0.05A)
Sequence timers for arc starting, arc finishing & gas
control
Water- or gas-cooled torch with tungsten
electrode
Electrode may contain thoria or zirconia, etc
 Introduction to welding
GAS TUNGSTEN ARC WELDING - SHIELDING
GASES
Torch is fed with an inert or reducing gas
Pure argon - widespread applications
Argon-helium - Higher arc voltage, inert
Argon-2% hydrogen - Cu alloys & austenitic steel
Torch gas must not contain oxygen or CO 2
Backing (or purge) gas
Used for all single-sided welds except in carbon steel
Argon, nitrogen, formier gas (N2 + H2)
Supplementary shielding
Reactive metals: Ti, etc
Gas filled chambers or additional gas supply devices

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GAS TUNGSTEN ARC WELDING - FILLER
METALS

Autogenous welding (no filler)

Filler wire or rod of matching composition
C-Mn & low alloy steel
Stainless Steel
Al, Mg, Ti
Cu & Ni
Consumable inserts - filler preplaced in joint

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GAS TUNGSTEN ARC WELDING - AUTOMATION

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Gas Tungsten Arc Welding A TIG

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GMAW AND FCAW

Gas metal arc welding

(MIG, MAG, CO2 welding)
Flux cored arc welding

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GAS METAL ARC WELDING

A continuous solid wire, small

diameter
GMAW uses solid wire, no flux
FCAW uses flux-filled wire
Fed through the gun to the arc
by wire feeder.
The weld pool may be protected
from oxidation by shielding gas.
High productivity 3 kg/h or more
Direct current (DCEP mostly)

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Gas metal arc welding

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Gas metal arc welding
MIG Welding
Heat source - arc between parent metal and consumable
electrode wire (0.6 to 1.6mm diameter)
60-500A, DC only
16-40V
1 to 20kW

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Gas metal arc welding

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GAS METAL ARC WELDING - EQUIPMENT

Welding power source

Wire feeder mechanism
May be in power source cabinet

Gun with gas supply &

trigger switch
Manual (semiautomatic) guns
Automatic torches available
Can be fitted to robot etc

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GAS METAL ARC WELDING METAL

TRANSFER
Spray
Higher current & voltage, argon-rich gas
Short circuiting (dip)
Low current and voltage, CO2
Globular
Intermediate current
Pulsed current power sources
Adjustable frequency
One droplet per current pulse.
 Introduction to welding
GAS METAL ARC WELDING METAL TRANSFER

Burn-back
and unstable arc
Spray
Voltage

Globular

Short
circuiting
No arc (birds-nesting)

Current
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GAS METAL ARC WELDING -
CONSUMABLES
Solid Wires (GMAW)
A wide variety of alloys are available
Flux cored arc welding (FCAW)
Gas shielded flux cored wires
Self-shielded flux cored wires
Used outdoors
Metal cored wires
Light flux cover

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Gas metal arc welding Wire size

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GAS METAL ARC WELDING - GAS
MIXTURES
Inert gases (MIG)
Argon or helium or mixtures of these
Active base metals, Al, Mg, Ti

Active gases (MAG and FCAW)

Carbon dioxide
Argon plus oxygen and/or carbon dioxide
Nitrogen, hydrogen

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Gas metal arc welding - Developments

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Gas metal arc welding - Developments

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Gas metal arc welding - Developments

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Gas metal arc welding - Developments

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Plasma Cutting, Welding & Surfacing

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Oxidising Flame
Oxy-Acetylene Welding

Carburising Flame

Neutral Flame

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Thermit welding

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Laser Welding

Photons transmit energy and heat

Energy intensity up to 109 Watts/cm2
Depth to width of hole up to 50x
Automatic controllers needed
90% efficiency
Reflectors dont weld easily

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Laser welding

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Electron Beam Welding

Electrons strike surface and generate heat

Best performed in a vacuum
Workpiece must be a conductor
Magnetic fields affect beam
Current to 1/2 A
Power to 100 kW
X-rays produced

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Electron Beam Welding

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Size of weld beads in

(a) electron-beam or laser-beam welding
(b) conventional arc welding.

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Solid-State Welding

Heat
Pressure
Time
NO Melting
NO Filler Material
Intimate Contact
Usually Requires Deformation
Works with Dissimilar Metals

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Resistance Welding

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Resistance spot welding Robots

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Flash Butt Welding

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Friction Welding

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Friction Stir Welding

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Friction Stir Welding

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Explosive Welding

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ANY QUESTIONS

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