RAILWAY COACH FACTORY, KAPURTHALA

TECHNICAL TRAINING CENTRE

A PROJECT REPORT ON

WELDING TECHNOLOGY

SUBMITTED BY:

JYOTIRAJ THAKURIA

B.TECH (2nd YEAR, MECH.)

IIT ROPAR

Welding is a fabrication or sculptural process that joins materials,

usually metals and thermoplastics, by causing coalescence. This is often

done by melting the workpiece and adding a filler material to form a

pool of molten material (the weld pool) that cools to become a strong

joint, with pressure sometimes used in conjugation with heat or by

itself to produce the weld.

Until the end of the 19th century, the only welding process was forge

welding, which blacksmith has used for centuries to join iron and steel

by heating and hammering them. Arc and Oxyfuel welding were among

the first processes to develop late in the century, and resistance

welding followed soon after. Welding technology advanced quickly

during the early 20th century as World War I and World War II drove the

demand for reliable and inexpensive joining methods. Following the

wars, several modern welding techniques were developed like Shielded

Metal Arc Welding (SMAW) as well as semi-automatic and automatic

processes such as Gas Metal Arc Welding (MIG or MAG), Tungsten

Inert Gas Shielded Arc Welding (TIG), Submerged Arc Welding (SAW),

Flux Cored Arc Welding, Electroslag Welding. Development continued

with the invention of Laser Beam Welding, Electron Beam Welding,

Electromagnetic Pulse Welding and Friction Stir Welding. Today, Robot

Welding is commonplace in industrial settings.

In most welding procedures metal is melted to bridge the parts to be

joined so that on solidification of the weld metal the parts become

united. The common processes of this type are grouped as fusion

welding. Heat must be supplied to cause the melting of the filler metal

and the way in which this is achieved is the major point of distinction

between the different processes. The method of protecting the hot metal

from the attack by the atmosphere and the cleaning or fluxing away of

contaminating surface films and oxides provide the second important

distinguishing feature. For example, welding can be carried out under a

shield comprising of a mixture of metal oxides and silicates which

produce a glass-like flux, or the whole weld area may be swept clear of

air by a stream of gas such as argon, helium or carbon dioxide which is

harmless to the hot metals. In the solid phase joining such melting does

not occur and hence the method can produce joints of high quality.

Leather Apron

It is used to protect the operator’s clothes from burning due to

spatter. It also act as a shield to the harmful UV rays.

Leather Hand Glove

It is used to protect the operator’s hand from burning due to spatter

and to handle hot job. It also acts as an insulator. It also act as a

shield to the harmful UV rays.

Arm Sleeve

It is used to protect the user’s clothes and arm from spatter.It also

act as a shield to the harmful UV rays.

Black Glass

It is used mainly in oxyfuel welding. It is a black glass which

absorbs the harmful UV rays and protects the user’s eyes from

exposure to those rays and spatter.

Fire Arrester

It is mainly used in Oxyfuel welding. It only allows outflow of

gases and prevents inflow, thus protects from explosion.

Chipping Goggle (white)

It is worn during removal of slag from the job, it protect our eyes

from small hot bits of slag during chipping.

Welding Goggle (black)

It is used during welding or cutting with Oxyfuel welding.

Wire Cutting

It is used to cut damaged, bent or accidently ejected wire feeded

during MIG welding.

Spark Lighter

It is used to initiate the combustion of acetylene with oxygen to

give the high temperature flame during Oxyfuel welding

Cylinder Key

It is used to tighten the contact tip holder in Oxyfuel welding.

Gas Nozzle

A gas nozzle is designed to control the direction and to increase its

velocity as it exits. It is used to converge (concentrate) the

outflowing gas so that the flame could be sharp enough.

Gas Diffuser

It is used to control the characteristics of a fluid at the entrance to a

thermodynamic open system. It is used to increase the pressure of

the gas.

Wire Brush

It is used to clean the job before welding otherwise there will be

more spatter (spatter is caused by dirty oily jobs) and also after

removing the slag.

Hose Clamp

It is used to clamp the hose of acetylene and oxygen pipes in

Oxyfuel welding.

Electrode Holder

It is used to hold the electrode during Arc welding. It handle is

insulated and protects the user from shocks.

Chipping Hammer

It is used to remove slag from the job after welding.

Tong

It is used to handle hot job during chipping, replace hot welded

jobs etc.

Gas Welding Blow Pipe

It is used to blow the gas mixture of acetylene and oxygen and to

regulate the gas flow according to requirement of the flame

depending on jobs.

Contact Tip Holder

It is part from where flame comes out in oxyfuel welding. It has 5

to 6 holes from which flames come out.

Welding Gauge

It is instrument to measure welding characteristics like undercut,

excess weld metal, fillet leg length, misalignment, angle of

preparation, fillet weld throat.

Screw Driver

It is used to tighten any nuts and bolts, etc.

The weld joint is where two or more metal parts are joined by welding.

The five basic types of weld joints are the butt, corner, tee, lap, and

edge, as shown in figure 3-6.

Distortion

Porosity & Blow Holes

Slag Inclusion

Under Cut

Incomplete Penetration

Excessive Penetration

Crater

Crack

Spatter

Lack Of Fusion

Arc strike cracking occurs when the

arc is struck but the spot is not

welded. This occurs because the spot

is heated above the materials upper

critical temperature and then

essentially quenched. This forms

martensite, which is brittle, and

micro-cracks. Usually the arc is

struck in the weld groove so this type

of crack does not occur, but if the arc

is struck outside of the weld groove then it must be welded over to

prevent the cracking.

Welding methods that involve the melting of metal at the site of the joint

necessarily are prone to shrinkage as the heated metal cools. Shrinkage

then introduces residual stresses and distortion. Distortion can pose a

major problem, since the final product is not the desired shape. To

alleviate certain types of distortion the workpieces can be offset so that

after welding the product is the correct shape. The following pictures

describe various types of welding distortion:

Transverse

shrinkage

Angular

distortion

Longitudinal

shrinkage

Fillet

distortion

Neutral axis

distortion

There are two types of inclusions: linear inclusions and isolated

inclusions. Linear inclusions occur when there is slag or flux in the

weld. Slag forms from the use of a flux, which is why this type of defect

usually occurs in welding processes that use flux, such as shielded metal

arc welding, flux-cored arc welding, and submerged arc welding, but it

can also occur in gas metal arc welding. This defect usually occurs in

welds that require multiple passes and there is poor overlap between the

welds. The poor overlap does not allow the slag from the previous weld

to melt out and rise to the top of the new weld bead. It can also occur if

the previous weld left and undercut or an uneven surface profile. To

prevent slag inclusions the slag should be cleaned from the weld bead

between passes via grinding, wire brushing, or chipping.

Lack of fusion is the poor adhesion of the weld bead to the base metal;

incomplete penetration is a weld bead that does not start at the root of

the weld groove. Incomplete penetration forms channels and crevices in

the root of the weld which can cause serious issues in pipes because

corrosive substances can settle in these areas. These types of defects

occur when the welding procedures are not adhered to; possible causes

include the current setting, arc length, electrode angle, and electrode

manipulation.

Undercutting is when

the weld reduces the cross-sectional thickness of the base metal, which

reduces the strength of the weld and workpieces. One reason for this

type of defect is excessive current, causing the edges of the joint to melt

and drain into the weld; this leaves a drain-like impression along the

length of the weld. Another reason is if a poor technique is used that

does not deposit enough filler metal along the edges of the weld. A third

reason is using an incorrect filler metal, because it will create greater

temperature gradients between the center of the weld and the edges.

Other causes include too small of an electrode angle, a dampened

electrode, excessive arc length, and slow speed.

Porosity is gas pores found in the solidified weld bead. As seen in Figure

10-4, these pores may vary in size and are generally distributed in a

random manner. However, it is possible that porosity can only be found

at the weld center. Pores can occur either under or on the weld surface.

The most common causes of porosity are atmosphere contamination,

excessively oxidized work piece surfaces, inadequate deoxidizing alloys

in the wire and the presence of foreign matter. Atmospheric

contamination can be caused by:

1) Inadequate shielding gas flow.

2) Excessive shielding gas flow. This can cause aspiration of air into

the gas stream.

3) Severely clogged gas nozzle or damaged gas supply system (leaking

hoses, fittings, etc.)

4) An excessive wind in the welding area. This can blow away the gas

shield.

CLASSIFICATION OF WELDING1. FUSION WELDING

i) RADATION

ii) THERMOCHEMICAL

iii) ELECTRICAL

a. ELECTRON BEAM

b. RESISTANCE

ELECTROSLAG

c. ARC

GAS SHIELDED

NON CONSUMABLE

o CARBON ARC

o ATOMIC HYDROGEN

o TIG

o PLASMA ARC

COMSUMABLE

FLUX SHIELDED

MANUAL METAL ARC

SUBMERGED ARC

CONTINUOUS COVERED ARC

FLUX CORED ELECTRODE

STUD WELDING

2. PRESSURE WELDING

i) HOT

a. ELECTRICAL RESISTANCE

LAP JOINT

SPOT

SEAM

PROJECTION

BUTT JOINT

UPSET

FLASH

b. FRICTION WELDING

c. GAS PRESSURE WELDING

d. ROLL WELDING

e. FORGE WELDING

f. DIFFUSION WELDING

ii) COLD

a. INDENTATION

b. ROLL BONDING

c. ULTRASONIC

d. EXPLOSIVE

GAS WELDING

Gas Welding is one of the most oldest, versatile and popular welding

methods used. In the oxyfuel gas welding process , heat is produced by

burning a combustible gas, most commonly acetylene, mixed with

oxygen to produce a welding flame temperature of about 3100oC.

Salient points about oxyacetylene welding: 1. The heat is obtained by combustion of acetylene and oxygen.

Here primary combustion occurring in the inner zone gives: C2 H2 + O2 → 2CO + H2 + Heat

And the second reaction in the outer zone gives: 2CO + H2 + 1.5O2 → 2CO2+ H2O + Heat

2. The maximum temperature at the tip of inner cone reaches up to 3000-3500°C. Therefore, most gas welding is performed by keeping this inner zone tip just above the metal to be welded so that maximum temperature is available for welding.

Filler materials are used to supply additional material to the weld zone. The flame, since it is less concentrated than an electric arc, causes slower weld cooling, which can lead to greater residual stresses and weld distortion, though it eases the welding of high alloy steels. Gas welding is widely used for welding pipes and in

maintenance and repair work because of the ease in transporting

oxygen and fuel cylinders. Once you learn the basics of gas welding,

you will find the oxyfuel process adaptable to brazing, cutting, and

heat treating all types of metals

Depending on the ratio of O2 to acetylene, three flame are obtained:

1. A neutral flame is obtained when the ratio of oxygen and acetylene is 1. Most gas welding operations are carried out by this flame.

2. An oxidizing flame is obtained when this ratio is more than 1. This type of flame is not suitable for welding of steels since excess oxygen present reacts with carbon in steel and is generally used for welding of copper and its alloys.

3. When the ratio in mixture is less than 1 a carburizing flame is obtained. In this type of flame acetylene decomposes into carbon and hydrogen and the flame temperature gets reduced. Joining operations such asbrazing and soldering which require

lower temperature generally use this flame.

Metal is merely melted by the flame of the oxyfuel gas torch and blown

away to form a gap or kerf.

When ferrous metal is cut, actually burning of oxygen takes place

according to one or more of the following reactions.

Fe + O→ Fe +Q

3Fe + 2O2→Fe3O4+ Q

4Fe+3 O2→2Fe2O 3+ Q

Because these reactions cannot take place below 815°C oxyfuel flame is first used to raise the metal temperature where burning can be initiated. Then a stream of pure oxygen is added to the torch (or the oxygen content of the oxyfuel mixture is increased) to oxidize the iron. The liquid iron and iron oxides are then expelled from the joint by the kinetic energy of the oxygen gas stream.

The process is suitable when edge finish or tolerance is not critical because low rate of heat input, and need of preheating ahead of the cut, oxyfuel produces a relatively large heat affected zone and thus associated distortion zone. Theoretically heat generated due to burning of Fe is sufficient to continue cutting however due to losses additional heat supply is needed. If the work is already hot due from the other processes, supply of oxygen through a small diameter pipe is needed to continue cut. This is called Oxygen Lance Cutting. A workpiece temperature of 1200°C is needed to sustain the cutting. Low carbon steel from 5 to 75 mm can be cut.

ARC WELDING

Arc welding is a process that uses an electric arc to join the metals being

welded. A distinct advantage of arc welding over gas welding is the

concentration of heat. In gas welding the flame spreads over a large area,

sometimes causing heat distortion. The concentration of heat,

characteristic of arc welding, is an advantage because less heat spread

reduces buckling and warping. This heat concentration also increases the

depth of penetration and speeds up the welding operation; therefore, you

will find that arc welding is often more practical and economical than

gas welding. All arc-welding processes have three things in common:

ma heat source, filler metal, and shielding. The source of heat in arc

welding is produced by the arcing of an electrical current between two

contacts.

Shielded metal arc welding (fig. 3-3) is performed by striking an arc

between a coated-metal electrode and the base metal. Once the arc has

been established, the molten metal from the tip of the electrode flows

together with the molten metal from the edges of the base metal to forma

sound joint. This process is known as fusion. The coating from the

electrode forms a covering over the m

weld deposit, shielding it from contamination; therefore the process is

called shielded metal arc welding. The main advantages of shielded

metal arcwelding are that high-quality welds are made rapidly at a

lowcost.

The primary difference between shielded metal arc welding and gas

shielded arc welding is the type of shielding used. In gas shielded arc

welding, both the arcand the molten puddle are covered by a shield of

inert gas.

The shield of inert gas prevents atmospheric contamination, thereby

producing a better weld. The primary gases used for this process are

helium, argon, or carbon dioxide. In some instances, a mixture of these

gases is used. The processes used in gas shielded arc welding are known

as gas tungsten arc welding(GTAW) (fig. 3-4) and gas metal arc

welding (GMAW). You will also hear these called “TIG” and “MIG.”

Gas shielded arc welding is extremely useful because it can be used to

weld all types of ferrous and nonferrous metals of all thicknesses. Now

that we have discussed a few of the welding processes available, which

one should you choose? There are no hard-and-fast rules. In general, the

controlling factors are the types of metal you are joining, cost involved,

nature of the products you are fabricating, and the techniques you use to

fabricate them. Because of its flexibility and mobility, gas welding is

widely used for maintenance and repair work in the field. On the other

hand, you should probably choose gas shielded metal arc welding to

repair a critical piece of equipment made from aluminum or stainless

steel. No matter what welding process you use, there some basic

information you need to know. The remainder of this chapter is devoted

to this type of information.

Study this information carefully because it allows you to follow welding

instructions, read welding symbols, and weld various types of joints

using the proper welding techniques.

Gas metal arc welding (GMAW), sometimes referred to by its

subtypes metal inert gas (MIG) welding or metal active gas (MAG)

welding, is a semi-automatic or automatic arc welding process in which

a continuous and consumable wire electrode and a shielding gas are fed

through a welding gun. A constant voltage, direct current power source

is most commonly used with GMAW, but constant current systems, as

well as alternating current, can be used. There are four primary methods

of metal transfer in GMAW, called globular, short-circuiting, spray, and

pulsed-spray, each of which has distinct properties and corresponding

advantages and limitations.

Originally developed for welding aluminum and other non-ferrous

materials in the 1940s, GMAW was soon applied to steels because it

allowed for lower welding time compared to other welding processes.

The cost of inert gas limited its use in steels until several years later,

when the use of semi-inert gases such as carbon dioxide became

common. Further developments during the 1950s and 1960s gave the

process more versatility and as a result, it became a highly used

industrial process. Today, GMAW is the most common industrial

welding process, preferred for its versatility, speed and the relative ease

of adapting the process to robotic automation. The automobile industry

in particular uses GMAW welding almost exclusively. Unlike welding

processes that do not employ a shielding gas, such as shielded metal arc

welding,

TIG Welding

Gas tungsten arc welding is also known as tungsten inert gas(tig)

welding, is an arc welding process that uses a nonconsumable tungsten

electrode to produce the weld. The weld area is protected from

atmosphere contamination by a shielding gas(usually an inert gas such

as argon), and a filler metal is normally used, though some welds

known as autogenous welds do not require it. A constant-current

welding power supply produces energy which is conducted across the

arc through a column of highly ionized gas and metal vapors known as

plasma.

GTAW is most commonly used to weld thin sections of stainless steel

and non-ferrous metals such as aluminum, magnesium, and copper

alloys. The process grants the operator control over the weld than

competing processes such as SMAW, GMAW, allowing for stronger,

high quality welds. However, GTAW is comparatively more complex

and difficult to master and it is significantly slower than other welding

processes

Resistance Welding involves the generation of heat by passing current

through the resistance caused by contact between two or more metal

surfaces . Small pools of molten metal are formed at the weld area as

high current (1,000A – 1,00,000 A) is passed through the metal. In

general, resistance welding are efficient and cause little pollution, but

their equipment are costly.

Spot Welding is a popular resistance welding used to join overlapping

metal sheets. Here, two opposing solid cylindrical electrodes are

pressed against the joint and two metallic sheets to be welded. At low

pressures, the resistance and heat are high and melted metal tend to

squeeze out of the weld. At high pressure, the resistance decreases and

heat is less and smaller weld formed provides lower weld strength.

Thus, for a given set of conditions, optimum electrode current and

electrode pressure are indicated.

The advantage of the method include effective energy use, limited

workpiece deformation, high production rate, easy automation and no

required filler materials. Weld strength is significantly lower than other

welding methods making the process suitable for only certain

application. It is extensively used in automobile industry with the help

of industrial robots.

Submerged Arc Welding(SAW)

SAW is a common arc welding process. It requires a continuously fed

consumable solid or tubular (flux cored) electrode. The molten weld

and the arc zone are protected from atmospheric contamination by

being “submerged” under a blanket of granular fusible flux consisting of

lime, silica, manganese oxide, calcium fluoride and other compounds.

When molten the flux becomes conductive and provides a current path

between the electrode and the work. this thick layer of flux completely

covers the molten metal thus preventing sparks and spatter as well as

suppressing the intense ultraviolet radiation and the fumes are part of

the shielded metal arc welding(SMAW) process.

Saw is normally operated in the automotive or mechanized mode,

however semi-automatic(handheld) saw guns with pressurized or

gravity flux feed delivery are available. The process is normally limited

to the flat or horizontal fillet welding position(although horizontal

groove position welds have been done with special arrangements to

support the flux).deposition rates approaching 100 lb./h(45 kg/hr.)

have been reported compared to 10 lb./hr.(5 kg /hr.) for shielded metal

arc welding. Although current ranging from 300 to 2000A are

commonly utilized. Currents up to 5000A have also been used.

Constant voltage welding power supplies are most commonly used,

however constant current systems in combination with a voltage

sensing wire feeder are available.

LASER BEAM WELDING

Laser Beam Welding is a technique used to join multiple pieces of metal

through the use of laser. The beam provides a concentrated heat

source, allowing for narrow deep welds and high welding rates. The

process is frequently used in high volume application with the help of

robots. Laser beam welding has a high power density (of the order of 1

MW/ cm^2).

MASTER TIG AC/DC-3500W

Make KEMPPI

Input 3ph 50/60 Hz 400V±10%

Output TIG DC- 3A/10V-350A/24V

TIG AC-10A/20V-350A/24V

Frequency 60Hz-200Hz

PROMIG-5200 WELDING SET

Make KEMPPI

Input 3ph-400±15%

Output @80% = 520A

@100% = 440A

O.C.V 65V

FAST MIG WELDING Set

Model MSF-57

Manufacture KEMPPI

Input 440v-AC

Load Capacity 440V@100% ED

Wire feed speed 0-25m/min

Degree protection IP-23

Feeding Mech. 4 roll feed

SIGMA-500c(Programmable)

Make MIGATRONIC(DENMARK)

Input 3ph±15%

Output 500A at 60%

Curent range 40A-500A

O.C.V 83V

Weight 71Kg

Submerged Arc Welding Power Source(DC)

Make ADOR FONTECH LTD.

Input 3ph-415 ±15%

Output 100A-800A

O.V.C 71V

O.V.R 20-25V

Submerged Arc Welding (Welding Tractor)

Input 110 V DC

Welding Wire 2.4mm-4mm

Wire feed rate 0.5-2.5mm/min

Welding speed 20-72m/min

Plasma Cutting Machine

Machine PLA-cut 50DP

Input power- 415v, 50Hz-3ph, 10kva

Output power 10amp-50amp

O.V.C 250V

Wt. 23kg

Size 490x270x37(mm)

Quality cut 8mm

Air pressure 3.5-4.0kg

MIG –MAG Welding Set

Make KEMPPI

Input 380-415V

50-60Hz, 3ph

Output 40amp/12V

Spot Welding Machine

Model BSW-30P

Input 415V,2ph,50Hz AC

Heating @5% duty cycle 30kva

@100% duty cycle 21kva

Cooling Transformer: natural

Air electrode

WELDING APPROVAL TEST

LOCATION TYPE OF JOINT

PROCESS WELDING POSITION

WIRE ᶲ mm

CURRENT AMPS.

VOLTAGE E V.

WIRE SPEED M/Min

A BUTT JOINT

MAG FLAT 1.2 100-120 15 3.9

B FILLET JOINT

MAG H & V 1.2 100-110 14 3.0

C CORNER JOINT

MAG H & V.D 1.2 100-120 15 4.0

WELDING APPROVAL TEST FIGURE

S.N

LOCATION

TYPE OF PROCESS

RANGE OF APPROVAL

SIZE OF ELECTRODE

WELDING POSITION

WELDING PARAMETERS FOR REFERENCE

CURRENT

VOLTAGE

SPEED

1. AB FILLET MAG 3 TO 16MM

1.2MM HORIZONTAL 220-240A

26-28

480

2. A*B* CORNER FILLET

MAG -DO- -DO- VERTICAL UPWARD

90-100A 20-22

-DO-

3. CD BUTT MAG -DO- -DO- DOWNHAND/FLAT

-DO- 20-22

-DO-

4. EF FILLET MMAW

2 TO 16MM

3.15MM OVERHEAD 80-90A 18-20

350

5. E*F* CORNER

MAG 3 TO 16MM

1.2MM VERTICAL DOWNWARD

100-120A

22-24

450

FILLET

6. GH BUTT MAG 2 TO 4 MM

1.0/1.2 MM

DOWNHAND/FLAT

-DO- 22-24

-DO-

VARIABLE FREQUENCY VARIATION

MATERIAL THICKNESS ELECTRODE DIAMETER

AVERAGE CURRENT

PEAK CURRENT

BACKGROUND CURRENT

ARC VOLTAGE (ELECTRODE)

GA IN. MM IN. MM (A) (A) (A) (POSITIVE)

22 0.031 0.8 0.035 0.9 50 150 20 16

20 0.037 0.9 0.9 60 160 20 17

18 0.050 1.3 0.9 70 180 20 18

16 0.063 1.6 1.2 80 200 25 19

14 0.078 2.0 1.2 90 250 35 21

11 0.126 3.2 1.2 120 250 150 22

3/16 0.188 4.8 1.2 150 250 200 23

1/4 0.250 6.4 1.3 120 275 90 24

3/8 0.275 9.5 1.3 200 350 150 26

MATERIAL THICKNESS WIRE FEED SPEED TRAVEL SPEED SHIELDING GAS

FLOW

GA. IN MM IN./MIN MM/MIN IN./MIN MM/MIN FT^3/MIN LITRES/MIN

22 0.031 0.8 75 1900 30 760 20 9

20 0.037 0.9 90 2300 30 760 20 9

18 0.050 1.3 115 2900 30 760 20 9

16 0.063 1.6 80 2000 20 500 25 12

14 0.078 2.0 120 3000 20 500 25 12

11 0.125 3.2 200 5000 15 375 25 12

3/16 0.188 4.8 240 6000 10 250 25 12

¼ 0.250 6.4 215 5500 9 225 25 12

3/8 0.375 9.5 300 7500 8 200 25 12

NOTE:

FOR SQUARE GROOVE OR FILLET, USE ROOT OPENING ½ MATERIAL THICKNESS, FILLET

EQUAL TO THICKNESS.

FOR MILD CARBON AND LOW ALLOY STEELS, SHIELDING GAS 95% + 5% OXYGEN

MIG/MAG WELDING VARIATION

MATERIAL THICKNESS

TYPE OF WELD

NO. OF PASS

ELECTRODE DIA

WELDING CURRENT

ARC VOLTAGE

WIRE FEED

TRAVEL SPEED

SHIELDING GAS

IN MM IN. MM AMPS-DC

ELEC. POS

IPM IPM FLOW CHF

1/8 3.2 FILLET OR SQUARE GROOVE

1 1/16 1.6 300 24 165 35 40-50

3/16 4.8 FILLET OR SQUARE GROOVE

1 1/16 1.6 350 325

25 24

230 210

32 40-50

1/4 6.4 VEE GROOVE

2 1/16 1.6 375 400

25 26

260 100

30 40-50

1/4 6.4 VEE GROOVE

2 3/32 2.4 450 29 120 35 40-50

1/4 6.4 FILLET 1 1/16 1.6 350 25 230 32 40-50

1/4 6.4 FILLET 1 3/32 2.4 400 325

26 24

100 210

32 40-50

3/8 9.5 VEE GROOVE

2 1/16 1.6 375 400

25 26

260 100

24 40-50

3/8 9.5 VEE GROOVE

2 3/32 2.4 450 29 120 28 40-50

3/8 9.5 FILLET 2 1/16 1.6 350 25 230 20 40-50

3/8 9.5 FILLET 1 3/32 2.4 425 325 375

27 24 26

110 210 269

20 40-50

1/2 12.7 VEE GROOVE

3 1/16 1.6 375 400 450

26 26 29

250 100 120

24 40-50

1/2 12.7 VEE GROOVE

3 3/32 2.4 425 27 110 30 40-50

1/2 12.7 FILLET 3 1/16 1.6 350 25 230 24 40-50

1/2 12.7 FILLET 3 3/32 2.4 425 325 375

27 24 26

105 110 210

26 40-50

3/4 19.1 DOUBLE VEE GROOVE

4 1/16 1.6 350 400 450

25 26 29

230 100 120

24 40-50

3/4 19.1 DOUBLE VEE GROOVE

4 3/32 2.4 425 27 110 24 40-50

3/4 19.1 FILLET 5 1/16 1.6 350 25 230 24 40-50

3/4 19.1 FILLET 4 3/32 2.4 425 27 110 26 40-50

1 24.1 FILLET 7 1/16 1.6 350 25 230 24 40-50

1 24.1 FILLET 6 3/32 2.4 425 27 110 26 40-50

NOTE :

USE ONLY IN FLAT AND HORIZONTAL FILLET POSITION.

1) FOR FILLET WELDS, MATERIAL THICKNESS INDICATES FILLET WELD SIZE.

2) SHIELDING GAS IS ARGON PLUS 1% TO 5% OXYGEN.

HANDLING STAINLESS STEEL WHILE WELDING

DO’S DON’Ts

1. Handle stainless steel with clean gloves to guard against finger marks.

2. Stack stainless steel on wood or non-metallic material.

3. Stack stainless steel and carbon steel separately.

4. Clean before welding to remove the effects of: a. Hydrocarbons: Grease,

oil, lubricants. b. Tools: hammers, backing

bars c. Shop dust, dirty gloves.

5. Always use the specified electrode & wire dia. for different welding.

6. Clean the sheet before doing any process with clean cloth.

7. Use only stainless steel wire brushes that never have been used on carbon steel.

8. Electrode should be dry when used.

9. Slag removal is important.

1. Avoid walking on stainless steel with dirty shoes or hob nail boots.

2. Avoid stacking of stainless steel with ferrous metal.

3. Avoid stacking of stainless steel with sheets/components directly on floor.

4. Protect the stainless steel from grinding sparks.

5. Avoid stainless steel’s contamination with grinding dust, welding spatter, rust or scale.

6. Avoid putting scratch, dent marks on stainless steel sheet.

7. Avoid use of only compressed air to blow away dirt and welding slag.

8. Avoid removing of the protective poly firm from the stainless steel sheets unnecessarily.

9. Rising temperature under

10. Clean the welding spatter after welding.

11. Use correct parameter for good welding.

12. Lifter’s that portion should be stainless steel or nylon which touches the SS.

13. Corrosion resistance improves when ground surface becomes smooth.

14. Protect the surface of stainless steel.

15. Clean oxides to avoid further progress of corrosion.

cut, lack of fusion, slag inclusion, and unfinished welding seam increase risk of pit and crevice corrosion.

10. Avoid scratching the electrode on stainless steel surface to start the arc.

11. Avoid number of beads as overheating of stainless steel causes rust.

12. Avoid putting ignition marks Avoid uneven/rough grinding.

13. Avoid using off-cuts of sheets for filling welding gaps.

14. Avoid leaving stainless steel sheets on the floor exposed to traffic.

15. Placing tack welds in an improper sequence can lead to distortion of sheets.

ASM International (2003). Trends in Welding Research. Materials

Park, Ohio: ASM International. ISBN 0-87170-780-2.

Blunt, Jane; Nigel C. Balchin (2002). Health and Safety in Welding

and Allied Processes. Cambridge: Woodhead. ISBN 1-85573-538-

5.

Cary, Howard B; Scott C. Helzer (2005). Modern Welding

Technology. Upper Saddle River, New Jersey: Pearson Education.

ISBN 0-13-113029-3.

Henderson, J.G. (1953). Metallurgical Dictionary. New York,

New York: Reinhold Publishing Corporation.

Hicks, John (1999). Welded Joint Design. New York: Industrial

Press. ISBN 0-8311-3130-6.

Kalpakjian, Serope; Steven R. Schmid (2001). Manufacturing

Engineering and Technology. Prentice Hall. ISBN 0-201-36131-0.

Lincoln Electric (1994). The Procedure Handbook of Arc Welding.

Cleveland: Lincoln Electric. ISBN 99949-25-82-2..

Workshop technology &manufacturing process bu S.K Garg.

TTC library

Rail Coach Factory, Kapurthala happens to be in the league of the best

production premises throughout Asia. It is a place where excellence has

not just been pursued but created too. For those engineering students

who wish to have good industrial exposure, this is the place to be.

Being here for training has been a great experience and I Believe that

whatever I got to learn here will surely help me in the future. I wish to

thank Mr. R.K Sharma(chief instructor TTC), R.C Nasa (chief

instructor of welding dept.) and Mr. Tarlok Singh Bhullar and Act

Apprentices for supporting me with their knowledge and expertise and

infusing with in attitude of a dedicated professional. I appreciate the

planned manner in which TTC is being run.

I am also grateful to the various experts who rendered typical and very

useful information on the various aspects of coach design &

manufacturing, basic manufacturing processes and the management

system implied here at RCF.