Welding PPMT

Introduction to Welding
Welding is a fabrication process that involves heating and fusing two or more pieces of
metal to join them together. There are several types of welding processes, including
electric arc welding, gas welding, resistance welding, and more. The choice of welding
process depends on the materials being joined, the desired quality of the weld, and the
production rate.
Welding is widely used in various industries such as construction, automotive,
aerospace, and manufacturing. It provides several benefits, including strong and
permanent joints, improved efficiency in the manufacturing process, and the ability to
join dissimilar metals.
Classification of Welding
Welding classification can be done based on the following aspect

• Depending upon the source of heat
• Depending upon the application of pressure
• Depending upon the different phases of base and filler material
• Depending upon the composition of the joint
• Depending upon the mechanism

2.Depending upon the application of pressure
3.Depending upon the different phases of base and filler material
4.Depending upon the composition of the joint
 Autogenous welding: No filler material is added during this joining. Ex.: All
type of solid phase welding, resistance welding and non-consumable welding.
 Homogeneous welding: The composition of filler material used during this
joining is same as the parent material. Ex.: Arc, Gas and Thermit welding.
 Heterogeneous welding: The composition of filler material used during this
joining is different as the parent material. Ex.: Soldering and Brazing.
5. Depending upon the mechanism
Manual Welding: In manual welding both feeding of filler material
and welding speed are controlled manually. Example: SMAW.
Semi-automatic: In this welding either feeding of filler material or
welding speed is controlled automatically. Example: MIG, TIG etc.
Fully automatic: In this welding both feeding of filler material and
welding speed is controlled automatically. Example: SAW, Laser, EB etc.
Arc Welding
Arc welding is a welding process where in coalescence is produced by heating with an
electric arc. Mostly arc welding is done without pressure and with or without filler
metal depending upon plate thickness. The electric arc heats the metal to its melting point,
and the molten metal fuses the base material together. The molten metal is then cooled and
solidified to form a weld joint.
Arc is generated by electrons flowing from negative (-ive) to positive (+ ve) terminal and
electrical energy is changed in the arc into heat and light approximately 2/3 of the heat is
generated near the positive (+ ive) terminal which burns into the form of a creater.
Temperature range form 2700 ° C to 5500 ° C. While remaining 1/3 is generated near
negative (-ive) terminal as electrode connected with positive (+ve) terminal.
Welding Stick in SMAW
• Composition of filler metal ( aluminium ,tin or lead)usually close to base

metal
• Coating: powdered cellulose mixed with oxides and carbonates, and held
together by a silicate binder
• Welding stick is clamped in electrode holder connected to power source
• Disadvantages of stick welding:
– Sticks must be periodically changed
– High current levels may melt coating prematurely

Some common terms used in EAW:
• Electrode - A metal rod or wire that serves as both the filler material and the electrode in
the welding process.
• Electrode Coatings - The material coating on the electrode that affects the type of weld and
the shielding from the environment.
• Filler Material - The material that is added to the weld pool to fill the gap between the base
materials.
• Weld Pool - The area where the melted metal is present during the welding process.
• Weld Bead - The finished weld that results from the welding process.
• Weld joint: the point at which two or more pieces of metal are joined together.
• Shielding Gas - A gas used to protect the weld pool from the air, which can cause oxidation
and porosity in the weld.
• Arc: the electrical discharge between the electrode and the workpiece that creates heat
and melts the metal.
• Arc Length - The distance between the electrode tip and the weld pool.
• Welding Voltage - The electrical potential difference between the electrode and the
workpiece.
• Welding Current - The electrical current that flows through the electrode and into the
weld pool, providing the heat to melt the metal.
• Weld penetration: the depth of the weld bead in relation to the base metal.
Two Basic Types of Arc Welding (Based on Electrodes)
1. Consumable electrodes
Consumed during welding process
Added to weld joint as filler metal in the form of rods or spools of wire
2. Non-consumable electrodes
Not consumed during welding process but does get gradually eroded
filler metal must be added separately if it is added
Basic Steps of Arc Welding
• Prepare the base materials: remove paint and rust.

• Choose the right welding process.
• Choose the right filler material.
• Assess and comply with safety requirements.
• Use proper welding techniques and be sure to protect the molten
puddle from contaminants in the air.
• Inspect the weld.
Polarity in Arc Welding
Difference Between AC and DC Welding
AC Welding DC Welding
• Striking of arc with electrode is • Developing an arc is easier
relatively difficult • Problem of arc blow in DC
• No problem of arc blow in AC welding
arc welding • Arc is more stable
• Arc is never stable. • Polarity (DCSP or DCRP) can be
changed
• No polarity change possible.
• Bare and coated electrode can be
• Bare electrode cannot be used. used
• Distribution of heat in arc is • Most of heat (up to 66.67 %) is
equal at electrode and job. liberated in the positive side of arc
Advantages of arc welding
1. Simple welding equipment
2. Portable
3. Inexpensive power source
4. Relatively inexpensive equipment
5. Welders use standard domestic current.
6. Process is fast and reliable
7. Equipment can be used for multiple functions
8. Used for maintenance, repair, and field construction
SMAW Applications
•Used for steels, stainless steels, cast irons, and certain

nonferrous alloys.
• Not used or rarely used aluminium and its alloys, copper alloys,
and titanium.
• Can be used in windy weather.
• Can be used on dirty metals (i.e. painted or rusted surfaces).
• Good for repair work.
• Makes thick welds.

Safety and environmental factors
Welding also has some associated hazards, such as the emission of harmful
fumes and ultraviolet radiation, and the risk of fire and explosion. It is
important to follow proper safety procedures and use the appropriate
personal protective equipment to minimize these risks.
The operator is normally protected by means of protective clothing, local
screening and ventilation whilst additional protection may be required to
protect other workers in adjacent areas. These measures may be costly in
themselves as well as having an effect on the overall efficiency of the
production operation.

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Introduction to Welding

Welding classification can be done based on the following aspect

• Depending upon the application of pressure

• Depending upon the different phases of base and filler material

• Depending upon the composition of the joint

• Depending upon the mechanism

• Composition of filler metal ( aluminium ,tin or lead)usually close to base

• Welding stick is clamped in electrode holder connected to power source

• Disadvantages of stick welding:

– Sticks must be periodically changed

– High current levels may melt coating prematurely

• Prepare the base materials: remove paint and rust.

•Used for steels, stainless steels, cast irons, and certain

• Can be used on dirty metals (i.e. painted or rusted surfaces).

• Good for repair work.

• Makes thick welds.

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