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Mod2 Welding

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Kushal Gayekwad
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11 views18 pages

Mod2 Welding

Uploaded by

Kushal Gayekwad
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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WELDING PROCESS

WELDING PROCESS
 Welding is a fabrication in which two or more work pieces,
usually metals are permanently joined to form a single
component.
 Welding is carried out by heating the edges of the work pieces
to a suitable temperature and then fused together with or
without application of pressure.
 Filler material is filled between the edges or gap between the
work piece.
 Definition: It is a process of joining of two materials (like or
unlike) by the application of heat or heat and pressure using a
filler material
Application of welding
• Fabrication: Fabrication of wide variety of components in
fields like aircraft, ship building, space, buildings, boilers,
pipes, bridges, automobile, power plants, pressure vessels,
machine tools, railway equipments etc.

• Repair and maintenance: to join structural parts that are worn


out
Advantages
 Any metal or alloy can be welded
 Any shape can be produced
 Strength of the joint is better.
 It is possible to build similar and dissimilar metals.
 Better corrosion resistance compared to bolts and rivets
 Welding equipments are portable hence parts can be fabricated at
relevant location.
 Complex shapes can be easily welded
 Parts can be fabricated at reasonable cost.
Limitations
 Radiation is a major problem during the process
 Residual Stresses produced will harm the metal
 Operation involves skilled labor
 Heat involved is very important during welding process which may
alter the structure of the metal by lowering its properties.
Arc Welding-principles
Arc Welding-principles
• Electric arc is generated between the work piece and the
electrode.
• Both work piece and electrode are connected to two different
poles of the circuit.
• Arc will be generated between the gap of the work piece when
the electrode tip is brought in contact.
• Electrical energy is converted into the heat energy.
• Temperature at the tip of the arc is around 5000-6000oC.
• Coalescence takes place where both work pieces get fused
• Electrode may be consumable or non consumable
• Non consumable electrodes are made of tungsten, graphite etc
• Consumable electrodes are same material as that of the work
piece
METAL ARC WELDING OR FLUX SHIELDED METAL ARC WELDING
METAL ARC WELDING
• Here consumable electrodes are used and AC or DC current can be
used for welding.
• Metallic wire is used as the electrode which has the composition of
the work piece.
• Metallic wire is coated with flux material like calcium fluoride,
cellulose, iron oxide etc which gives off gases as it decomposes.
• Distance between the electrode and the work piece is maintained as
2-4 mm.
• High heat at the tip of the arc melts the work piece metal forming a
small molten metal pool along with the melting of the electrode.
• The deposited metal fills the joint and bonds the joint to form a
single piece of metal.
• When molten metal is exposed to air forms oxides and nitrides due
to chemical reaction with oxygen and nitrogen respectively. This
weaken the joint.
• Hence the metal is shielded by using a coated electrode which has
flux coating, which will burn along with metal of electrode and
produces a dense smoke, which shields the weld pool. The flux
forms the slag after melting.
• Weld slag is formed when the flux used in the welding process
solidifies after the welding has been performed. The weld slag is a
combination of the flux and the impurities or atmospheric gases
that combined with the flux during welding.
• When manually done it will be called manual metal arc welding
(MMAW)
TUNGSTEN INERT GAS WELDING (TIG)
TUNGSTEN INERT GAS WELDING (TIG)
 Non consumable tungsten electrode is used in
presence of inert gas.
 Various alloys like zirconium, thorium, lanthanum etc
are alloyed with tungsten to improve the arc stability.
 Diameter of the electrode varies from 0.5-6 mm.
 Inert gas used as the shielding gas such as argon or
helium to protect the welding area from atmospheric
gases such as oxygen and nitrogen
 Pressure regulator and flow meters are used to
regulate the flow of gas from the cylinder
Advantages and limitations
 It welds more different types of metals and alloys
 Even unlike metals can also be welded like mild steel to stainless steel
or brass to copper.
 Heat affected zone will be less as the weld is free from spatter.
 Since the shielding gases are used no need of fluxes that avoid slag
formation and further cleaning.

The limitations are:

 TIG welding is confined to thin


metals (up to 7mm).

 Skilled labor is required to handle


the welding gun.
METAL INERT GAS WELDING (MIG)
METAL INERT GAS WELDING (MIG)
• Bare consumable electrode in the form of wire is guided by a
guide tube
• Electrode metal used is same as that of the work piece. Its
diameter varies from 0.7-2.4 mm.
• Electrode is fed continuously at constant rate.
• MIG uses shielding gas as argon and CO2 in the ratio of 75%
to 25%.
• DC current is most preferred.
• Control switch is provided in the welding torch to initiate the
electric power, shielding gas and wire feed.
Advantages and limitations
 Continuous welding with high penetration is possible.
 The operator skill is not necessary
 Can weld almost any metal
 Slag free welds can be obtained
 Cracking of weld is eliminated as atmospheric hydrogen is
shielded

The limitations are:


 The welding equipments are not portable and it is costly.
 Very difficult to reach places
 Since the cooling rate is high, the metallurgical properties can
be affected

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