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    Welding: by Msc. Ahmed Taifor Azeez

    Uploaded by

    Shkar Galaly
    Welding involves heating metals to melting temperature to join them together. There are over 35 welding processes classified by heat source. Advantages include strong permanent joints, but disadvantages are need for edge preparation and risk of thermal stresses. The heat affected zone experiences microstructural changes from elevated temperatures during welding and can be the weakest part of the joint depending on properties like grain size. Butt and fillet welds are common joint types distinguished by their geometry. Heat input rate equations depend on parameters like thermal conductivity and diffusivity. Pre-heating and controlling energy input can affect the peak temperature and width of the heat affected zone.

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    Welding: by Msc. Ahmed Taifor Azeez

    Uploaded by

    Shkar Galaly
    22 views32 pages
    Welding involves heating metals to melting temperature to join them together. There are over 35 welding processes classified by heat source. Advantages include strong permanent joints, but disadvantages are need for edge preparation and risk of thermal stresses. The heat affected zone experiences microstructural changes from elevated temperatures during welding and can be the weakest part of the joint depending on properties like grain size. Butt and fillet welds are common joint types distinguished by their geometry. Heat input rate equations depend on parameters like thermal conductivity and diffusivity. Pre-heating and controlling energy input can affect the peak temperature and width of the heat affected zone.

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    1- welding (1)

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    Welding involves heating metals to melting temperature to join them together. There are over 35 welding processes classified by heat source. Advantages include strong permanent joints, but disadvantages are need for edge preparation and risk of thermal stresses. The heat affected zone experiences microstructural changes from elevated temperatures during welding and can be the weakest part of the joint depending on properties like grain size. Butt and fillet welds are common joint types distinguished by their geometry. Heat input rate equations depend on parameters like thermal conductivity and diffusivity. Pre-heating and controlling energy input can affect the peak temperature and width of the heat affected zone.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    22 views32 pages

    Welding: by Msc. Ahmed Taifor Azeez

    Uploaded by

    Shkar Galaly
    Welding involves heating metals to melting temperature to join them together. There are over 35 welding processes classified by heat source. Advantages include strong permanent joints, but disadvantages are need for edge preparation and risk of thermal stresses. The heat affected zone experiences microstructural changes from elevated temperatures during welding and can be the weakest part of the joint depending on properties like grain size. Butt and fillet welds are common joint types distinguished by their geometry. Heat input rate equations depend on parameters like thermal conductivity and diffusivity. Pre-heating and controlling energy input can affect the peak temperature and width of the heat affected zone.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 32

    WELDING

    By
    MSc. Ahmed Taifor Azeez
    2

    Welding
    • Is fabrication process to make high strength joint between two
    or more parts by heating to their melting temperature, with or
    without the application of pressure and with or without the use
    of filler metal. The filler metal has a melting point
    approximately same as the base metal.
    3

    History of Welding
    • By us asking ‘What is welding?’ we are often
    not aware of the fact that a lot of work and
    technological advances have made welding
    what it is today. Early examples of welding have
    been discovered which date back to thousands
    of years ago. These were known as forge
    welding which simply involved the heating of
    two metal surfaces and hammering them
    together. It was only during the 19th Century that
    welding became what we know it as today.
    When asking ‘What is welding?’ very few
    people realize that forge welding was done
    without the use of electricity. While this welding
    was very labor intensive, the industrial
    revolution gave rise to the better, improved
    methods of welding that we know today.
    4

    Classification of Welding
    • There are about 35 different welding and brazing process and several soldering methods, in use by the
    industry today. There are various ways of classifying the welding for example, they may be classified on the
    basis of source of heat(flames ,arc etc.)
    5

    Advantages of welding
     welding is permanent process.
    Efficiency of joint 100%.
    Welding produce equal strength as parent method
    Portable welding equipment is available.
    A lot of similar and dissimilar metal can be joint by welding.
    Welding joint as stronger as base metal.
    Welding joint are lighter in weight
    6

    Disadvantages of welding
    • Edge preparation is required
    before welding.
    • Ultraviolet and inferred rays
    produce during welding.
    • Thermal stresses are produced
    in the weld material.
    • Heat treatment process is
    required to remove these
    stress.
    • Skill operator is need to
    operate the welding machine.
    • HAZ produce.
    7

    Heat affected zone (HAZ)


    • The heat-affected zone (HAZ) is within the base metal
    itself. It has a microstructure different from that of the
    base metal prior to welding, because it has been
    temporarily subjected to elevated temperatures during
    welding. The portions of the base metal that are far
    enough away from the heat source do not undergo any
    microstructural changes during welding because of the
    far lower temperature to which they are subjected.
    8

    Properties of heat affected zone


    • The properties and microstructure of the HAZ depend on
    • (a) the rate of heat input and cooling.
    • (b) the temperature to which this zone was raised.
    • (c )original grain size. grains that are away from the weld metal
    will recrystallize into fine, equiaxed grains. On the other hand,
    grains close to the weld metal have been subjected to elevated
    temperatures for a longer time. Consequently, the grains will
    grow in size (grain growth), and this region will be softer and
    have lower strength. Such a joint will be weakest at its HAZ.
    9

    Effect of grain size


    10

    Heat effect zone


    11

    Welding joints and symbols


    12

    Types of connection
    13

    Butt and Fillet joint


    • Butt welds: originate in the joint gap of connected parts and are
    usually used as load-bearing, force welds. In order to achieve
    perfect workmanship of the welds, it is usually necessary to
    perform modification of the contact surfaces of the connected
    parts.
    14

    Butt and Fillet joint


    • Fillet welds are located along the wedge-shaped edge of connected parts and their
    basic cross-section includes an isosceles rectangular triangle. They are usually used
    for load-bearing, force welds in T-shape connections, cross-butt connections, angle
    connections and for lap joints. The welded parts do not need shape adjustment. For
    statically loaded connections, usually a flat weld is used, while a concave weld is
    more appropriate for dynamically loaded connections, as it has lower notch effects.
    15

    Heat input to the weld


    16

    Heat input to the weld


    17

    Melting efficiency
    • heat required for melting= melting heat x flow rate of melted
    metal
    18

    Relation between weld cross- section and energy input


    19

    Example

    v= 5mm/s
    20

    Heat input rate


    21

    Heat input rate


    •  The equations for heat input rate are
    • For two dimensional heat source (thin plate)
    • …….. 6.1
    • For three dimensional heat source (thick plate)
    • ……….. 6.2
    • K: thermal conductivity (W/m. )
    • : thermal diffusivity of the work (
    • : density , c: specific heat (
    • : Tm- R.T
    • Tm: melting point
    • R.T : room temperature
    22

    Two dimension Vs. three dimension heat source


    23

    Short circuit arc welding

    Time is critical in
    this short circuit
    arc welding
    24

    Lack of side diffusion


    25

    Example
    26

    Solution
    • 

      1 𝜔𝑣
    8 𝐾 ∆𝑇 h( + )
    5 4𝛼
    27

    Determination peak temperature and HAZ thickness


    28

    Importance of peak temperature equation


    29

    Example

     720 J/mm
    30

    Width of heat effected zone


    31

    Effect of pre-heating
    32

    Effect of energy increase

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