1585680360EEE 552 Slides-Pt3

LECTURE NOTES
ON
UTILASATION OF ELECTRICAL
ENERGY
UNIT II: ELECTRIC HEATING
ELECTRIC WELDING
Welding is the process of joining two pieces

of metal or non-metal together by heating
them to their melting point.
The physical and mechanical properties of a

Welding
material to be welded such as melting
temperature, density, thermal conductivity,
and tensile strength take an important role in
welding. Depending upon how the heat
applied is created; we get different types of
welding such as thermal welding, gas
welding, and electric welding.
Electric welding
Here in this chapter, we will discuss only about the electric welding, It is defined as
the process of joining two metal pieces, in which the electrical energy is used to
generate heat at the point of welding in order to melt the joint.
Welding is nowadays extensively used in automobile industry, pipe-line fabrication in
thermal power plants, machine repair work, machine frames, etc.
The classification of electric welding
ADVANTAGES OF WELDING
•Welding is the most economical method to permanently join two metal parts.
•It provides design flexibility.
•Welding equipment is not so costly.
•It joins all the commercial metals.
•Both similar and dissimilar metals can be joined by welding.
•Portable welding equipment are available.
DISADVANTAGES OF WELDING
•Welding gives out harmful radiations and fumes.
•Welding needs internal inspection.
•If welding is not done carefully, it may result in the distortion of workpiece.
•Skilled welding is necessary to produce good welding.
The selection of proper welding process depends on the following factors.
•The type of metal to be joined.
•The techniques of welding adopted.
•The cost of equipment used.
•The nature of products to be fabricated.
RESISTANCE WELDING
Resistance welding is the process of joining two metals together by the heat
produced due to the resistance offered to the flow of electric current at the
junctions of two metals. The heat produced by the resistance to the flow of current
is given by:
where I is the current through the electrodes, R is the contact resistance of the
interface, and t is the time for which current flows.
Here, the total resistance offered to the

flow of current is made up of:
1.The resistance of current path in the

work.
2.The resistance between the contact
surfaces of the parts being welded.
3.The resistance between electrodes and
the surface of parts being welded.
Electric circuit for resistance welding

In this process of welding, the heat developed at the contact area between the pieces to
be welded reduces the metal to plastic state or liquid state, then the pieces are pressed
under high mechanical pressure to complete the weld. The electrical voltage input to
the welding varies in between 4 and 12 V depending upon area, thickness, composition,
etc. and usually power ranges from about 60 to 180 W for each sq. mm of area. Any
desired combination of voltage and current can be obtained by means of a suitable
transformer in AC; hence, AC is found to be most suitable for the resistance welding.
The magnitude of current is controlled by changing the primary voltage of the welding
transformer, which can be done by using an auto-transformer or a tap-changing
transformer. Automatic arrangements are provided to switch off the supply after a pre-
determined time from applying the pressure, why because the duration of the current
flow through the work is very important in the resistance welding. The electrical circuit
diagram for the resistance welding is shown in Figure above. This method of welding
consists of a tap-changing transformer, a clamping device for holding the metal pieces,
and some sort of mechanical arrangement for forcing the pieces to form a complete
weld.
Advantages
•Welding process is rapid and simple.
•Localized heating is possible, if required.
•No need of using filler metal.
•Both similar and dissimilar metals can be welded.
•Comparatively lesser skill is required.
•Maintenance cost is less.
•It can be employed for mass production.
Drawback
•Initial cost is very high.
•High maintenance cost.
•The workpiece with heavier thickness cannot be welded, since it requires high input
current.
Applications
•It is used by many industries manufacturing products made up of thinner gauge

metals.
•It is used for the manufacturing of tubes and smaller structural sections.
ELECTRIC ARC WELDING
Electric arc welding is the process of joining two metallic pieces or melting of metal is
obtained due to the heat developed by an arc struck between an electrode and the metal to
be welded or between the two electrodes as shown in Figure below:
Arrangement of electric welding equipment

In this process, an electric arc is produced by bringing two conductors (electrode and
metal piece) connected to a suitable source of electric current, momentarily in contact and
then separated by a small gap, arc blows due to the ionization and give intense heat. The
heat so developed is utilized to melt the part of workpiece and filler metal and thus forms
the weld. In this method of welding, no mechanical pressure is employed; therefore, this
type of welding is also known as 'non-pressure welding’.
The length of the arc required for welding depends upon the following factors:
•The surface coating and the type of electrodes used.

•The position of welding.
•The amount of current used
COMPARISON BETWEEN RESISTANCE AND ARC WELDING
1.The source of supply is AC only, while the source of supply is either AC (1-φ
or 3-φ) or DC
2.The head developed is mainly due to the flow of contact resistance for
resistance welding. The heat developed is mainly due to the striking of arc
between electrodes or an electrode and the workpiece.
3.The temperature attained by the workpiece is not so high. The temperature of
the arc is so high, so proper care should be taken during the welding.
4.External pressure is required. No external pressure is required hence the
welding equipment is more simple and easy to control.
5.Filler metal is not required to join two metal pieces. Suitable filler electrodes
are necessary to get proper welding strength.
6.The power consumption is low. The power consumption is high.
7.The operating power factor is low. The operating power factor is high.
ELECTRIC WELDING EEQUIPMENT
Electric welding accessories required to carry out proper welding operation are:
•Electric welding power sets.
•Electrode holder to hold the electrodes.
•Welding cable for connecting electrode and workpiece to the supply.
•Face screen with colored glass.
•Chipping hammers to remove slag from molten weld.
•Wire brush to clean the weld.
•Earth clamp and protective clothing.
THAN
K
YOU!!

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LECTURE NOTES

Welding is the process of joining two pieces

The physical and mechanical properties of a

Here, the total resistance offered to the

1.The resistance of current path in the

Electric circuit for resistance welding

•It is used by many industries manufacturing products made up of thinner gauge

Arrangement of electric welding equipment

•The surface coating and the type of electrodes used.

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