UNITUNIT-2

JOINONG PROCESSES

WELDING DEFINITION
The process of joining similar metals by means of heat is called WELDING. Welding can be obtained with or without application of pressure and without addition of filler metal, which is known as electrode.

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Classification of welding process

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 1.Fusion Welding or 2.Plastic Welding or Non-Pressure Pressure Welding Welding The material at the The piece of metal to be joint is heated to a joined are heated to a molten state and plastic state and forced allowed to solidify. together by external pressure. (Ex) Gas welding, Arc (Ex) Resistance welding welding
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1.1. THERMIT WELDING

y

Welding the parts using liquid thermit steel around the portions to be welded is called as THERMIT WELDING. Welding principle: The heat of the thermit reaction used for welding plastic state and mechanical pressure is applied to join the parts.

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Neither Arc is produced to heat parts nor the flames. Thermit weld reaction is 8Al + 3Fe3O4 = 4Al2O3 +9Fe Thermite = mixture of Al and Fe3O4 fine powders that produce an exothermic reaction when ignited.
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Filler metal obtained from liquid metal. y Process used for joining, but has more in common with casting than welding. y Two Types of TW are (a) Pressure welding process (b) Non- Pressure welding process
y

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Thermit Welding process

y

(1) Thermit ignited; (2) crucible tapped, superheated metal flows into mold; (3) metal solidifies to produce weld joint

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Thermit Welding process

Parts to be welded is butted and enclosed in mould. y Heated iron slag is poured to the mould. y Them aluminum oxide is poured on the parts to be welded. y This will create the hating of parts and then pressure is applied on the work piece to join.
y
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Applications of TW
Joining of railroad rails. y Repair of cracks in large steel castings and forgings. y Steel rolling mills y To weld non ferrous metals.
y

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1.2 Arc welding

y

Arc welding is the process of joining two metal pieces by melting their edges by an electric arc.

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Arc welding process

The electrode and work piece are brought nearer with a small air gap of 3mm approximately. y Then the current is passed through the work piece and the electrode to produce an electric arc. y Here electrical energy is converted into heat energy
y

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Arc welding process

y

The electrode is melted by arc and electrode is also melted hence the work pieces become a single piece without applying any external pressure. The temperature of arc produced is about5000o to 6000o Electrode supplies additional filler material in to the joints and deposited between the work pieces.
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Arc welding process

The depth to which the metal melted and deposited is called Depth of Fusion. y Electrode is coated with flux to prevent the reaction of molten metal with the atmospheric air. y Also removes the impurities from the molten metal and forms slag which deposit over the weld to protect it from rapid cooling.
y
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Arc welding process

The molten metal is forced out of the pool by the electric arc. Hence small depression is formed in the parent metal where the molten metal is piled up. This is known as Arc carter. y The distance between the tip of this electrode and the bottom of the arc crater is called Arc length
y
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ELECTRODE TYPES
1.Consumable Electrode (a)Bare Electrode (b)Light Coated Electrode (c)Heavily Coated Electrode 2.Non-Consumable Electrode

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Consumable consumed during welding process

Source of filler metal in arc welding

Non-consumable not consumed during welding process

Filler metal must be added separately if it is added

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Consumable Electrode
Bare Electrode y Dont have flux coating on its surface. y Rarely used to weld wrought and cast iron. y It is used in submerged arc welding and Inert gas welding processes.

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Consumable Electrode
Light Coated Electrode: y A coating layer of several tenths of a millimeter and is 1 to 5% of electrode weight. y The mail purpose of light coating is to increase arc stability called as INOZING COATING. y It is used to weld non ferrous metals
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Consumable Electrode
Heavily Coated Electrode: yA heavy coating layer of several tenths of a millimeter and is 1 to 3mm of thick.
y

The weight of coating is from 15 to 30 % of the electrode rod.

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NonNon-Consumable Electrode
Non consumable electrodes are made of carbon, graphite or tungsten which do not consume during the welding. y The arc length remains constant and hence it is stable. y It is used in Atomic hydrogen welding and TIG welding processes.
y

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Purpose of flux coating

To give stability to the arc. y To produce the gas shield around the arc and molten metal. y To provide the formation of slag so as to protect the welding seam from rapid cooling. y Increase the deposition efficiency.
y

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1.2.1 Submerged arc welding

y

Submerged arc welding is also called as sub arc welding or hidden arc welding. An electrode is produced between consumable bare electrode and the work piece but the arc is completely submerged(hidden under the flux).

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Submerged arc welding process

The metal electrode is fed continuously from the reel by moving head. y The flux power is fed in front of the moving head and it is fed from hopper. y When the arc is produced in the welding zone at the end of the electrode and the arc is completely covered by flux power.
y

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Submerged arc welding process

The flux power used here is made up of silica, metal oxide. y The flux not only protect the weld surface from atm. And also act as a deoxidizer and scavenger. y It is used specially for welding carbon steels and alloys
y

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Applications of SAW
Steel fabrication of structural shapes (e.g., I -beams) y Seams for large diameter pipes, tanks, and pressure vessels y Welded components for heavy machinery y Most steels (except hi C steel) y Not good for nonferrous metals
y
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1.2.3. Plasma Arc welding

y

Tungsten electrode is contained in a nozzle that focuses a high velocity stream of inert gas (argon) into arc region to form a high velocity, intensely hot plasma arc stream. Temperatures in PAW reach 28,000rC (50,000rF), due to constriction of arc, producing a plasma jet of small diameter and very high energy density
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Plasma Arc welding process

rinciple: y Plasma is high ionized gas. It is a mixture of neutral atoms, positively charged atoms and free elements.
y

When this high temperature plasma is passed through the orifice, the portion of the ionized gas increases and plasma arc is formed.
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Plasma Arc welding process

Working: y When the high heat content plasma gas is forced through the torch orifice surrounded by ve tungsten electrode in the form of jet.
y

The plasma cutting force imposes a swirl on the orifice gas flow.

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Plasma Arc welding process

The arc is initiated in the beginning by supplying electrical energy between nozzle and tungsten electrode. y This will release high energy and heat and is normally 10000oC to 30000oC y Two types of plasma arc welding are 1.Transfer type 2.Non-transfer type
y
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Applications of PAW
Aerospace y Welding titanium plates y Welding Nickel Alloys
y

Advantages:
Good arc stability and excellent weld quality Better penetration control than other AW processes High travel speeds Can be used to weld almost any metals Disadvantages: High equipment cost Larger torch size than other AW processes Tends to restrict access in some joints
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1.2.3.Atomic Hydrogen welding

Commonly used to bond two dissimilar metals, e.g., to clad one metal on top of a base metal over large areas (1) Setup in parallel configuration, and (2) during detonation of the explosive charge

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1.2.4.Metal Inert gas Welding

In this arc welding, the electric arc is produced between a consumable metal electrode and the work piece. y During welding the arc an welding zone are surrounded by an Inert gas(Argon or Helium). y The surrounding air protects the weld from atm.
y

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Metal Inert gas Welding

y

The electrode is fed continuously through welding head because at the time of welding the electrode is melted by the arc deposited over the work piece.

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Applications of MIG
y

To Weld thick plates of Aluminum, Stainless steel, Nickel and Magnesium metal parts are welded using MIG without weld defects. Advantages: No flux is required High welding Speed Greater efficiency

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1.2.5. Metal Arc Welding

Uses a consumable bare metal wire as electrode with shielding by flooding arc with a gas. y Wire is fed continuously and automatically from a spool through the welding gun.
y

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Metal Arc Welding

y

Shielding gases include argon and helium for aluminum welding, and CO2 for steel welding Bare electrode wire plus shielding gases eliminate slag on weld bead
No need for manual grinding and cleaning of slag

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Applications of MAW
Higher deposition rates y Eliminates problem of slag removal y Can be readily automated
y

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1.2.6. Electro slag welding

y

Principle Electro slag is a welding process in which the coalescence is formed by molten slag and molten pool remains shielded by the molten slag

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Electro slag welding

Working: y The electric arc is struck between the electrode and the work joined by use of steel.
y

Welding flux is added and the melted by use of heat flux added and further melted by use of heat from the arc.
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Electro slag welding

This action is stopped until the molten slag is formed and molten slag remains between the electrode and work. y The temperature of this slag remains 1600oC to 1900oC. y The electric current passes from electrode to the work piece through the slag.
y
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1.3 GAS WELDING

Types of Gas welding Oxy-Acetylene welding y Oxy-hydrogen welding y Air-hydrogen welding
y

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1.3.1Oxy-Acetylene welding 1.3.1OxyA welding process in which the edges of the metals to be welded are melted melted by gas flame. y No pressure is applied during welding except pressure gas welding. y Commonly used gases are Acetylene,Hydrogen,propane and Butane.
y
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OxyOxy-Acetylene welding
The flame is produced at the tip of a welding torch. The welding heat is obtained by burning a mixture of oxygen and consumable gas. The gases are mixed in the required proportion in a welding torch provides control for the welding flame.

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Types of Oxy-Acetylene welding Oxy1.High pressure System y Both 02 and C2H2 are supplied from High pressure cylinders. y O2 is compressed to 120atm gauge pressure. y But C2H2 cant be compressed more than 1.5atm in the from of dissolved Acetylene which dissolved in acetone under the pressure of 16 to 22atm gauge pressure
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Types of Oxy-Acetylene welding Oxy2. Low pressure System Acetylene y C2H2 is produced at the place of welding by interaction of calcium carbide and water in acetylene generator.
y

Chemical reaction is CaC2+2H2O Ca(OH)2+C2H2

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1.3.2 Oxy-hydrogen welding OxyThis is similar to that of welding process process. y O2 and H2 are mixed with the required proportion for producing heat. y It is used to weld low temperature metals such as Al,Pb,Mg.
y

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1.3.3 Air-Acetylene welding AirThis is similar to that of welding process process. y Atmospheric air and C2H2 are mixed with the required proportion for producing heat. y It is used to weld low melting temperature metals such as Pb and alloys.
y

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Flame Characteristics
Neutral flame y Carburising flame y Oxidising flame
y

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ELECTRODE MOVEMENT DIRECTION

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