HMINE119 WORKSHOP

PRACTICE: WELDING PROCESS

By
LAURENCE MAREGEDZE +263773467505
maregedzel@staff.msu.ac.zw
 OBJECTIVES
• Define welding
• Identify types of welding techniques
• Explain the operation process of common types of
welding techniques
• Identify and explain welding defects
• Identify and explain welding positions and symbols
• Compare and contrast welding techniques
 INTRODUCTION AND PRINCIPLE
• Welding is the use of heat to melt two similar or dissimilar base metals in
order to join them into a single component during the cooling process.
• The molten metal of the workpieces and electrode combines to join the
two metals into a single component.
• The source of heat for arc welding process is an 'electric arc' generated
between two electrically conducting materials.
• The filler material called 'electrode' is connected to positive pole of the
electric circuit, while the other workpiece which forms the second
conducting material is connected to the negative pole of the circuit.
• When the tip of the electrode material is brought in contact with the
workpiece material and momentarily separated by small distance of 2 to 4
mm, an arc can be generated.
 INTRODUCTION AND PRINCIPLE
• The electrode material can be either a non-consumable material
or a consumable material.
• The non-consumable electrode made of tungsten, graphite etc.,
serve only to strike the arc and is not consumed during the
welding process.
• The consumable electrode is normally made of the same
material as that of the workpiece metal helps to strike the arc
and at the same time melt (gets consumed) and combines with
the molten metal of the workpiece to form a weld.
• The electrical energy is thus converted to heat energy.
• The high heat of the arc melts the edges of the workpieces.
DIAGRAM 1: WELDING TERMINOLOGY
 SAFETY RULE
• Ensure that all cable insulation is undamaged and all terminations are secure
and undamaged. If in doubt do not use the equipment until it has been
checked by a qualified electrician .
• Ensure that all welding equipment is adequately earthed
• Ensure that the current regulator has an ‘off ’ position so that in the event of
an accident the welding current can be stopped without having to trace the
primary cables back to the isolating switch.
• Ensure that all cables and fittings for the ‘ external welding circuit ’ are
adequate for the heavy currents involved.
• Electrode holders should be well connected to the welding cable and have
adequate rating for the maximum welding current in order to prevent heating
up and becoming to hot to handle
WELDING PERSONAL PROTECTIVE EQUIPMENT
 CLASSIFICATION OF WELDING
PROCESSES
Welding processes may be classified on the basis of:
• Source of heat, like flame, arc, radiant energy and others
• Type of interaction like liquid to liquid which is fusion welding or solid
to solid which is solid state welding.
• In general, various welding and allied processes are classified as
follows:
1. Gas Welding
• Air Acetylene Welding
• Oxy acetylene Welding
• Oxy hydrogen Welding
• Pressure gas Welding
 CLASSIFICATION CONTI……
2. Arc Welding 3. Resistance Welding
• Carbon Arc Welding • Spot Welding
• Shielded Metal Arc Welding • Seam Welding
• Flux Cored Arc Welding • Projection Welding
• Submerged Arc Welding • Resistance Butt Welding
• TIG (or GTAW) Welding • Flash Butt Welding
• MIG (or GMAW) Welding • Percussion Welding
• Plasma Arc Welding • High Frequency Resistance Welding.
• Electro slag Welding
• Electro gas Welding
• Stud Arc Welding.
 CLASSIFICATION CONTI……
5. Solid State Welding 5. Thermo-Chemical Welding
• Cold Welding Processes
• Diffusion Welding • Thermit Welding
• Explosive Welding • Atomic Hydrogen Welding.
• Forge Welding 6. Radiant Energy Welding
Processes
• Friction Welding
• Electron Beam Welding
• Hot Pressure Welding
• Laser Beam Welding.
• Roll Welding
• Ultrasonic Welding.
 PRACTICAL APPLICATION OF
WELDING
Welding has been employed in Industry• Rocket motor fuel and oxidizer
as a tool for: tanks.
• Regular fabrication of automobile cars, • Ducts, fittings, cowling
air-crafts, refrigerators, etc. components, etc.
• Repair and maintenance work, e.g.,
joining broken parts, rebuilding worn
out components, etc. 2. Automobile Construction
• Sone important applications of welding • Arc welded car wheels
are listed below:
• Steel rear axle housing.
1. Aircraft Construction
• Frame side rails.
• Welded engine mounts.
• Turbine frame for jet engine. • Automobile frame, brackets, etc.
 APPLICATION CONTI…..
3. Bridges • Joining of nozzles to the shell,
• Section lengths. etc.
• Shop and field assembly of 6. Storage Tanks
lengths, etc. • Oil, gas and water storage
4. Buildings tanks.
• Column base plates 7. Rail Road Equipment
• Trusses Locomotive
• formation of structure, etc. • Under frame
5. Pressure Vessels and Tanks • Air receiver
• Clad and lined steel plates • Engine
• Shell construction • Hoods, etc.
 APPLICATION CONTI…..
8. Pipings and Pipelines 12. Household and office furniture.
• Rolled plate piping 13. Earth moving machinery and cranes.
• Open pipe joints, • In addition, arc welding finds following applications in
• Oil gas and gasoline pipe lines, etc. repair and maintenance
9. Ships • work:
• Shell frames. 14. Repair of broken and damaged components and
machinery such as tools,
• Deck beams and bulkhead
stiffeners. • punches, dies, gears, shears, press and machine tools
frames.
• Girders to shells
15. Hard-facing and rebuilding of worn out or
• Bulkhead webs to plating, etc. undersized (costly) parts rejected
10. Trucks and trailers. • during inspection.
11. Machine tool frames, cutting 16. Fabrication of jigs, fixtures, clamps and other
tools and dies. work holding devices.
 ADVANTAGES OF WELDING
• A good weld is as strong as the base metal.
• General welding equipment is not very costly.
• Portable welding equipment is available.
• Welding permits considerable freedom in design.
• A large number of metals/alloys both similar and dissimilar can
be joined by welding.
• Welding can join workpieces through spots, as continuous
pressure tight seams, end-to-end and in a number of other
configurations.
• Welding can be mechanized.
 DISADVANTAGES OF WELDING
• Welding gives out harmful radiations (light), fumes and spatter.
• Welding results in residual stresses and distortion of the work-
pieces.
• Edge preparation of the workpieces is generally required before
welding them.
• A skilled welder is a must to produce a good welding job.
• Welding heat produces metallurgical changes. The structure of
the welded joint is not same as that of the parent metal.
• A welded joint, for many reasons, needs stress-relief heat-
treatment.
 ARC WELDING PROCESS
• Arc welding process
is fusion method of
welding that utilizes
the high intensity of
the arc generated by
the flow of current to
melt the workpieces
and join them.
• A solid continuous
joint is formed upon
cooling.
 1. METAL ARC WELDING (MAW)
• In metal arc welding an arc is established between work and the
filler metal electrode.
• The intense heat of the arc forms a molten pool in the metal being
welded, and at the same time melts the tip of the electrode.
• As the arc is maintained, molten filler metal from the electrode
tip is transferred across the arc, where it fuses with the molten
base metal.
• Arc may be formed with direct or alternating current.
• Petrol or diesel driven generators are widely used for welding in
open, where a normal electricity supply may not be available.
 METAL ARC WELDING (MAW) ( CONTI……)

• A simple transformer is employed for A.C. arc welding.

• The transformer sets are cheaper and simple having no maintenance cost
as there are no moving parts.
• With AC system, the covered or coated electrodes must be used, while
D.C. system are normally ideal for cast iron and non-ferrous metals and
bare electrodes can be used.
• In order to strike the arc an open circuit voltage of between 60 to 70
volts is required.
• For maintaining the short arc 17 to 25 volts are necessary.
• The current required for welding, however, varies from 10 A to 500 A,
depending upon the class of work to be welded.
METAL ARC WELDING DIAGRAM
 2. CARBON ARC WELDING
• The work is connected to negative and the carbon rod or electrode is
connected to the positive of the electric circuit.
• Arc is formed in the gap, filling metal is supplied by fusing a rod or wire
into the arc by allowing the current to jump over it and it produces a
porous and brittle weld because of inclusion of carbon particles in the
molten metal.
• The voltage required for striking an arc with carbon electrodes is about 30
volts (A.C.) and 40 volts (D.C).
• A disadvantage of carbon arc welding is that approximately twice the
current is required to raise the work to welding temperature as compared
with a metal electrode, while a carbon electrode can only be used
economically on D.C. supply.
DIAGRAM
 3. SHIELDED METAL ARC WELDING (SMAW OR
MMAW AND GMAW)
• It is an arc welding process where fusion Infuse alloys into the weld to
is produced by heating the workpiece with increase mechanical properties
an electric arc set up between a flux  Reduce the surface tension of the
coated electrode and the workpiece. molten pool
• The flux covering decomposes due to arc  Clean the metal surfaces and lift the
heat and performs many functions, like: impurities to the surface,
 arc stability, Help the filler metal deposition rates
 weld metal protection, • The electrode itself melts and
ensuring slow cooling of the weld, form a supplies the necessary filler metal.
layer of protective slag which also shapes
the weld
 A.C. WELDING

• At higher currents AC gives a • It occupies less space

smoother arc. • It is less costly to purchase and
• Once established the arc can be maintain.
easily maintained and controlled. • It possesses high efficiency (0.8).
• It is suitable for welding thicker • It consumes less energy per unit
sections. weight of deposited metal.
• AC is easily available. • Melting rate of electrode cannot
• AC welding power source has no be controlled in AC as equal heat
rotating parts. generates at electrode and job.
• It does not produce noise. • An AC welding power source is
Transformer
 D.C. WELDING
• DC arc is more stable. • A DC welding equipment
is a self contained unit. It
• DC is preferred for can be operated in fields
welding certain non- where power supply is not
ferrous metals and alloys. available
• It has lower open circuit • DC welding power source
voltage and therefore is is a transformer-rectifier
safer. unit or a DC generator
• ARC heat can be regulated (motor or engine driven)
DIAGRAMS
 SIMILARITIES BETWEEN SMAW AND GMAW
• Both SMAW and GMAW are fusion welding processes as the faying surfaces of
the base components are fused with the help of arc heat to form coalescence.
• Both the processes employ consumable electrode. A consumable electrode melts
down due to arc heat and successively deposits on the weld bead. So it provides
necessary filler to fill the root gap. Thus no filler is required to supply separately.
• Autogenous mode of welding is not possible by any of these two processes as
filler is applied inherently. An autogenous welding is carried out without the
application of any filler material.
• Both the processes are applicable to conductive base metals only like all arc
welding processes are applicable to conductive materials only as the base metals
are made one electrode for establishing the arc.
 DIFFERENCE BETWEEN SMAW OR MMAW AND
GMAW
SMAW or MMAW GMAW
A short and small diameter rod is used as electrode for Gas Metal Arc Welding (GMAW) employs a small
Shielded Metal Arc Welding (SMAW). Electrode diameter but long consumable electrode that comes in the
length is typically restricted to 60cm. form of a wire. This long wire is wound in a pool
Short consumable electrode is required to replace Because of very long consumable electrode, it is not
frequently. Thus welding cannot be carried out required to change frequently and thus welding can be
continuously for a longer duration carried out continuously for a longer duration.
This process is not very productive as filler deposition It can deposit filler metal at a very high rate, and hence it
rate is low. is highly productive.
A flux-coated electrode is utilized in SMAW process. Bare electrode is utilized in GMAW process. Sometimes a
The flux layer is thicker. thin anti-corrosive coating layer is deposited on the
electrode.
The flux coating of the electrode disintegrates during Here shielding gas is delivered additionally from a gas
welding and provides necessary shielding gas. cylinder to the welding torch via suitable pipeline.
The flux also produces a slag layer on the weld bead. Due to absence of flux, no slag layer forms on the weld
This slag layer protects hot weld metal pool from bead. So changes of slag inclusion defect is also nil.
oxidation, but can also lead to welding defects if get
embedded inside the weld bead.
 ADVANTAGES OF SHIELDED METAL ARC
WELDING
Advantages
• SMAW is the simplest of all the arc welding processes.
• The equipment can be portable and the cost is fairly low.
• This process finds innumerable applications, because of the
availability of a wide variety of electrodes.
• A big range of metals and their alloys can be welded.
• Welding can be carried out in any position with highest weld
quality.
 DISADVANTAGES OF SHIELDED METAL ARC
WELDING
Disadvantages
• Because of the limited length of each electrode and brittle flux coating
on it, mechanization is difficult.
• In welding long joints (e.g., in pressure vessels), as one electrode
finishes, the weld is to be progressed with the next electrode. Unless
properly cared, a defect (like slag inclusion or insufficient penetration)
may occur at the place where welding is restarted with new electrode.
• The process uses stick electrodes and thus it is slower as compared to
MIG welding.
• Because of flux coated electrodes, the chances of slag entrapment and
other related-defects are more as compared to MIG or TIG welding.
 APPLICATIONS
•Today, almost all the commonly employed metals and their alloys can be
welded by this process.
• Shielded metal arc welding is used both as a fabrication process and for
maintenance and repair jobs.
• The process finds applications in
Air receiver, tank, boiler and pressure vessel fabrications
Shipbuilding
Pipes and Penstock joining
Building structures and Bridge construction;
Automotive and Aircraft industry, etc.
 4. TUNGSTEN INERT GAS WELDING (TIG)
• It is a welding process in which the workpieces are joined by the heat obtained from
an electric arc struck between a non-consumable tungsten electrode and the
workpiece in the presence of an inert gas.
• A filler metal may be added if required, during the welding process.
• TIG equipment consists of a welding torch in which a non-consumable tungsten
alloy electrode is held rigidly in the collet.
• The diameter of the electrode varies from 0.5 - 6.4 mm using either AC or DC supply
current.
• TIG welding makes use of a shielding gas like argon or helium to protect the welding
area from atmospheric gases such as oxygen and nitrogen, otherwise which may
cause fusion defects and porosity in the weld metal.
• The shielding gas flow from the cylinder, through the passage in the electrode holder
and then impinges on the workpiece.
• Pressure regulator and flow meters are used to regulate the pressure and flow of gas
from the cylinder.
TIG DIAGRAM
 OPERATION
• The workpieces to be joined are cleaned to • Filler metal in the form of a rod is added
remove dirt, grease and other oxides manually to the front end of the weld pool.
chemically or mechanically to obtain a • The deposited filler metal fills and bonds
sound weld. the joint to form a single piece of metal
• The welding current and inert gas supply • The shielding gas is allowed to impinge
are turned ON. on the solidifying weld pool for a few
• An arc is struck by touching the tip of the seconds even after the arc is extinguished
tungsten electrode with the workpiece and (shut off)
instantaneously the electrode is separated • This will avoid atmospheric contamination
from the workpiece by a small distance of of the solidifying metal thereby increasing
1.5 - 3 mm such that the arc still remains the strength of the joint.
between the electrode and the workpiece.
• The high intensity of the arc melts the
workpiece metal forming a small molten
metal pool.
ADVANTAGES AND DISADVANTAGES OF
TIG
Advantages
• Suitable for thin metals.
• Clear visibility of the arc provides the operator to have a greater control over the
weld.
• Strong and high quality joints are obtained.
• No flux is used. Hence, no slag formation. This results in clean weld joints.
• Disadvantages
• TIG is the most difficult process compared to all the other welding processes. The
welder must maintain short arc length, avoid contact between electrode and the
workpiece and manually feed the filler metal with one hand while manipulating
the torch with the other hand.
 DISADVANTAGES CONTINUE

• Tungsten material when gets transferred into the molten metal contaminates the
same leading to a hard and brittle joint.
• Skilled operator is required.
• Process is slower.
• Not suitable for thick metals.
 5. METAL INERT GAS (MIG) WELDING
• Metal inert gas welding or gas metal arc welding (GMAW) is a group
of arc welding process in which the workpieces are joined by the heat
obtained from an electric arc struck between a bare (uncoated)
consumable electrode and the workpiece in the presence of an inert gas
atmosphere.
• The consumable electrode acts as a filler metal to fill the gap between
the two workpieces. The equipment consists of a welding torch in
which a bare consumable electrode in the form of a wire is held and
guided by a guide tube.
• The electrode material used in MIG welding is of the same material or
nearly the same chemical composition as that of the base metal with
diameter varying from 0.7 -2.4 mm.
 METAL INERT GAS (MIG) WELDING CONT……
• The electrode is fed continuously at a constant rate through feed rollers
driven by an electric motor.
• MIG makes use of shielding gas to prevent atmospheric contamination
of the molten weld pool.
• Mixture of argon and carbon dioxide in a order of 75% to 25% or 80%
to 20% is commonly used.
• The shielding gas flow from the cylinder, through the passage in the
electrode holder and then impinges on the workpiece.
• AC is rarely used with MIG welding; instead DC is employed and the
electrode is positively charged. This results in faster melting of the
electrode which increases weld penetration and welding speed.
MIG DIAGRAM
 OPERATION
• The workpieces to be joined are cleaned to remove dust, grease and other oxides
chemically or mechanically to obtain a sound weld. The tip of the electrode is also
cleaned with a wire brush.
• The control switch provided in the welding torch is switched ON to initiate the
electric power, shielding gas and the wire (electrode) feed.
• An arc is struck by touching the tip of the electrode with the workpiece and
instantaneously the electrode is separated from the workpiece by a small distance of
1.5-3 mm such that the arc still remains between the electrode and the workpiece.
• The high intensity of the arc melts the workpiece metal forming a small molten pool.
• At the same time, the tip of the electrode also melts and combines with the molten
metal of the workpieces thereby filling the gap between the two workpieces.
• The deposited metal upon solidification bonds the joint to form a single piece of
metal.
 ADVANTAGES AND DISADVANTAGES OF MIG
Advantages
• MIG welding is fast and economical.
• The electrode and inert gas are automatically fed, and this makes the
operator easy and to concentrate on the arc.
• Weld deposition rate is high due to the continuous wire feed
• No flux is used. Hence, no slag formation resulting in clean welds.
• Thin and thick metals can be welded and the process can be automated.
Disadvantages
• Equipment is costlier
• Porosity (gas entrapment in weld pool) is the most common quality problem
in this process. However, extensive edge preparation can eliminate this
defect.
 6. SUBMERGED ARC WELDING (SAW)

• It is an arc welding process in which the workpieces are joined by the

heat obtained from an electric arc struck between a bare consumable
electrode and workpiece.
• The arc is struck beneath a covering layer of granulated flux.
• The arc zone and the molten weld pool are protected from atmospheric
contamination by being 'submerged under a blanket of granular flux.
• This gives the name 'submerged arc welding' to the process. The
equipment consists of a welding head carrying a bare consumable
electrode and a flux tube.
• The flux tube remains ahead of the electrode, stores the granulated or
powdered flux, and drops the same on the joint to be welded.
 SUBMERGED ARC WELDING (SAW) CONTI…..

• The flux shields and protects the molten weld metal from atmospheric
contamination.
• The electrode which is bare (uncoated) and in the form of wire is fed
continuously through feed rollers.
• It is usually copper plated to prevent rusting and to increase its
electrical conductivity (since it is submerged under flux).
• The diameter of the electrode ranges from 1.6-8 mm and the electrode
material depends on the type of the work piece metal being welded.
• The process makes use of either AC or DC for supplying the required
current.
SAW DIAGRAM
 ADVANTAGES AND DISADVANTAGES OF SAW
• High productivity process, due to high heat concentration.
• Weld deposition rate is high due to continuous wire feed. Hence, single
pass welds can be made in thick plates.
• Deep weld penetration.
• Less smoke, as the flux hides the arc. Hence, improved working
conditions.
• Can be automated
• Process is best suitable for outdoor works and in areas with relatively
high winds.
• There is no chance of spatter of molten metal, as the arc is beneath the
flux.
 DISADVANTAGES OF SAW
• The invisible arc and the weld zone make the operator
difficult to judge the progress of welding.
• Use of powdered flux restricts the process to be carried
only in flat positions.
• Slow cooling rates may lead to hot cracking defects.
• Need for extensive flux handling.
 7. SPOT WELDING
• The metal to be joined is placed between two electrodes and pressure is applied.
• A charge of electricity is sent from one electrode through the material to the other
electrode.
SPOT WELDING MACHINE
WELDING JOINTS
 TYPES OF DEFECTS

• Slag Inclusion • Spatter

• Undercut • Excessive Convexity
• Porosity • Excessive Weld
Reinforcement
• Incomplete fusion
• Incomplete Penetration
• Overlap
• Excessive Penetration
• Underfill
 SLAG INCLUSION
• Causes: Low amperage, improper techniques, slow
travel rate
• Prevention: Increase amperage, increase travel rate
• Repair:- Remove by grinding or other mechanical
process
 UNDERCUT
• It is the burning away of the parent metal edges so as to reducethe joint thickness
where the weld bead joins the parent metal (toes of the weld) resulting in
weakening of the joint
• Causes:- High amperage, wrong electrode angle, long arc length, rust, excessive
weaving of the electrode.
• Prevention:- Set machine on scrap metal to correct parameters, clean metal before
welding
• Repair:- Weld with smaller electrode, sometimes must be low hydrogen with
preheat.
 POROSITY
• Causes:- Short arc, with the exception of low hydrogen and stainless,
insufficient puddling time, impaired base metal and poor electrodes
• Prevention: Clean impurities in base metal, allow sufficient puddling
time for gases to escape, use proper current, weave your weld to
eliminate, use proper electrodes for job and hold longer arc.
• Repair:- Remove and reweld, being careful to completely remove the
defective area.
 INCOMPLETE FUSION
• Cause:- Low amperage, steep electrode angle, fast travel speed, short
arc gap, lack of preheat, electrode too small, unclean base metal, arc off
seam
• Prevention:- Eliminate the potential causes
• Repair:- Remove and reweld, being careful to completely remove the
defective area.
 OVERLAP
• Cause:- Improper welding technique, steep electrode angle, fast
travel speed
• Prevention:- Overlap is a contour problem. Proper welding
technique will prevent this problem
 UNDERFILL
• Cause:- Improper welding techniques
• Prevention:- Apply proper welding techniques for the weld type
and position. Use stripper beads before the cover pass.
• Repair:- Simply weld to fill. May require preparation by
grinding.
 SPATTER
• Cause:- High arc power, magnetic arc blow, Damp electrodes
• Prevention:- Reduce arc power, reduce arc length, use dry
electrodes
• Repair:- Remove by mechanical process
 EXCESSIVE CONVEXITY
• Cause:- Low amperage slow travel speed
• Prevention:- Observe proper parameters and techniques
• Repair:- Must blend smoothly into the base metal
 GAS WELDING
• It is a fusion-welding metal joining process in which heat is generated from the combustion of
an oxygen/air and fuel gas such as acetylene, hydrogen, propane or butane.
• • The intense heat (flame) thus produced melts and fuses together the edges of the parts to be
welded, generally with the addition of a filler metal.
Principle of gas welding
• When the fuel gas and oxygen are mixed in suitable proportions in a welding torch and ignited
the flame resulting at the tip of the torch is sufficient enough to melt the edges of the workpiece
metals.
• A solid continuous joint is formed upon cooling.
• The two familiar fuel gases used in gas welding are:
Mixture of oxygen and acetylene gas -called oxy-acetylene welding process.
Mixture of oxygen and hydrogen gas - called oxy-hydrogen welding process.
• Oxy-acetylene welding is the most versatile and widely used gas welding process due to its
high flame temperature (up to 3500 degree celcius) as compared to that of oxy-hydrogen
process (up to 2500 degree celcius)
GAS WELDING EQUIPMENT
 CYLINDER STORAGE AND USE.
• Acetylene cylinders must always be stored and used upright.
• Cylinders must be kept cool. On no account should the welding fl ame, or any other naked light, be
allowed to play on the cylinders or regulators. Cylinders must be protected from direct sunlight, wet, and
frost on an open site.
• Cylinders must always be stored in well-ventilated surroundings to prevent the build-up of explosive
mixtures of gases should leaks occur.
• Keep cylinders free from contamination. Although oxygen is not flammable, an oxygen-rich atmosphere
in the event of leaks can cause the spontaneous combustion and violent burning of oils and greases
together with oily rags and overalls.
• Correct automatic pressure regulators must be fitted to all cylinders prior to use. The main cylinder valve
must always be kept closed when the cylinder is not in use or whilst changing cylinders or equipment.
• To reduce the risk of fire and explosions:
Do not position gas cylinders and hoses where sparks can fall on them.
Avoid the use of wooden structures and other combustible materials in the vicinity of welding
operations.
 GAS CYLINDER COLOUR
• Acetylene maroon
• Argon Peacock blue
• Carbon monoxide Signal red
• Helium Middle brown
• Hydrogen Signal red
• Methane Signal red
• Oxygen Black
 TESTING FOR LEAKS
• Never search for gas leaks with a flame. Oxygen is odourless and,
whilst it does not burn, it speeds up the combustion process
violently.
• Acetylene has an unmistakeable, strong, garlic-like smell and can be
readily ignited by a spark or even a piece of red-hot metal.
• The correct procedure for pressure testing is as follows:
1. Open the control valves on the torch.
2. Release the pressure-adjusting control on the regulators.
3. Open cylinder valves to turn on the gas.
4. Set the working pressure by adjusting the regulator controls.
5. Having established the correct pressure for each gas, close the
control valves on the torch and test using soapy water on possible
leak positions as shown
 ADVANTAGES OF GAS WELDING
• It is probably the most versatile process. It can be applied to a
wide variety of manufacturing and maintenance situations.
• Welder has considerable control over the temperature of the
metal in the weld zone.
• The rate of heating and cooling is relatively slow. In some cases,
this is an advantage.
• Since the sources of heat and of filler metal are separate, the
welder has control over filler-metal deposition rates.
• The equipment is versatile, low cost, and usually portable.
• The cost and maintenance of the gas welding equipment is low
when compared to that of some other welding processes.
 DISADVANTAGES OF GAS WELDING
• Heavy sections cannot be joined economically.
• Flame temperature is less than the temperature of the arc.
• Fluxes used in certain welding and brazing operations produce
fumes that are irritating to the eyes, nose, throat and lungs.
• Gas flame takes a long time to heat up the metal than an arc.
• More safety problems are associated with the handling and
storing of gases.
• Acetylene and oxygen gases are rather expensive.
• Flux shielding in gas welding is not so effective as an inert gas
shielding in TIG or MIG welding.
 TYPES OF FLAMES

(a) Neutral
Flame
(b)
Oxidizing
Flame
(c)
Carburizing
flame
 NEUTRAL FLAME
• A neutral flame is produced when approximately equal volumes of oxygen
and acetylene are mixed in the welding torch and burnt at the torch tip. The
temperature of the neutral flame is of the order of about 3260°C
• The flame has a nicely defined inner cone which is light blue in color. It is
surrounded by an outer flame envelope, produced by the combination of
oxygen in the air and superheated carbon monoxide and hydrogen gases
from the inner cone. This envelope is usually a much darker blue than the
inner cone.
• A neutral flame is named so because it affects no chemical change on the
molten metal and, therefore, will not oxidize or carburize the metal.
• The neutral flame is commonly used for the welding of: mild steel, stainless
steel, cast Iron, copper and aluminium
 OXIDIZING FLAME
• If, after the neutral flame has been established, the supply of oxygen is further increased, the
result will be an oxidizing flame.
• An oxidizing flame can be recognized by the small cone which is shorter, much bluer in color
and more pointed than that of the neutral flame.
• The outer flame envelope is much shorter and tends to fan out (disperse) at the end.
• An oxidizing flame tends to be hotter than the neutral flame. This is because of excess oxygen
and which causes the temperature to rise as high.
• The excess oxygen, tends to combine with many metals to form hard, brittle, low strength
oxides.
• Moreover, an excess of oxygen causes the weld bead and the surrounding area to have a
scummy or dirty appearance.
• For these reasons, an oxidizing flame is of limited use in welding. It is not used in the welding
of steel.
• A slightly oxidizing flame is helpful when welding most copper-base metals and zinc-base
metals
 CARBURIZING FLAME
• A reducing flame may be distinguished from carburizing flame
by the fact that a carburizing flame contains more acetylene
than a reducing flame.
• A carburizing flame is used in the welding of lead and for
carburizing (surface hardening) purposes.
• A reducing flame, on the other hand, does not carburize the
metal, rather it ensures the absence of the oxidizing condition. It
is used for welding with low alloy steel rods and for welding
those metals, (e.g. non-ferrous) that do not tend to absorb
carbon.
• This flame is very well used for welding high carbon steel.
 WELDING TECHNIQUES

• There are two usual techniques in gas welding, namely:

Leftward technique or Forehand welding method.
Rightward technique or Backhand welding method.
 Differences between forehand welding and
backhand welding conti…….
Forehand Welding Backhand Welding

Pre-heating offers a faster torch feeding rate, Torch feeding rate usually slow due to lack of
which helps in improving productivity. pre-heating.

It increases the filler deposition rate but cannot It assists in achieving deeper penetration,
fetch deeper penetration. though filler deposition rate is slow.

Tendency of spatter formation is more with Backhand welding technique creates

forehand technique. comparatively less spatter.

This technique offers good visibility to the The weld zone has poor visibility.
welder.

It is preferred for joining thin plates (usually up It is preferred for joining thicker plates.
to 3.0 mm without edge preparation).
 Differences between forehand welding and backhand welding
Forehand Welding Backhand Welding
In forward welding, the flame or electrode is In backwards welding, the flame or electrode is
pointed towards the direction of weld progression pointed away from the direction of weld
progression.
Here the torch is inclined at an obtuse angle Here the torch is inclined at an acute angle
(usually 135° – 150°) with the feed vector. (usually 30° – 45°) with the feed vector.
The torch is situated above the deposited weld The torch does not remain above the weld bead,
bead (puddle). rather it remains above the unfilled root gap
Filler metal is applied ahead of the torch. Filler metal is applied behind the torch.
Pre-heating of the base metals takes place No pre-heating occurs here.
automatically in forehand technique.
No post-heating occurs here. Backhand welding technique facilitates post-
heating of the deposited weld bead.
The weld joint is subjected to undesired residual Post-heating allows the joint to be continuously
stress. annealed that helps relieving the residual stress.
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