Rutash Mittal

M.E(CIM), B.Tech (M.E)

Assistant Professor

Mechanical Engineering Department,

MIMIT, MALOUT

Presented By:

Welding is a process of joining two or more pieces of the same or

dissimilar materials to achieve complete coalescence.

Welding is accomplished by the use of heat and pressure. Welding is the only method of developing monolithic structure.

Ω A large number of metals/alloys which are similar or dissimilar can be joined by welding.

Ω Welding permits considerable freedom in design.

Welding Processes

Arc, Beam & Flame Welding Process

Resistance Welding ProcessSolid State Welding Process

Seam Spot Seam Spot Zonal

High Heat Input

Low Heat Input

•Carbon Arc

•Shielded Metal Arc

•Submerged Arc

•Fusion Arc

•Gas Tungsten Arc

•Plasma Arc

•Plasma MIG

•Electro gas Welding

•Oxy-Acetylene

•Electron Beam

•Laser Welding

•GTAW

•GMAW

•Stud

•Seam

•Electric Resistance

•H.F Resistance Welding

•H.F Induction Welding

•Spot

•Projection

•Resistance Butt

•Flash Butt

•Percussion•Ultrasonic

•Explosion

•Cold Pressure

•Thermo Compression

•Friction

•Forge

•Fusion

Cast Weld Process

•Thermit Welding

•Electroslag Welding

• Cast weld process involves large amount of molten metal resulting in properties close to that of casting.

• Thermit Welding

• Electroslag Welding

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Thermit welding is a mixture of aluminium powder and metal oxide which when ignited results in a non explosive exothermic reaction. The heat so generated melts and reduces the metal oxide to metallic form at high temperature. This molten metal is used for joining metal parts by pouring it between them resulting in cast weld joint.

Return to Cast Weld Process

Electroslag welding is a fusion welding process for joining thick work pieces in a single run. This is not an arc welding process though most of the setup is similar to arc welding. An essential feature of ESW process is that welding is done with weld join in vertical position. Due to high heat input the weld pool in ESW is usually quite voluminous.

In this processes those welding processes are involved which make the use of electric arc or flame obtained by burning an oxy fuel gas mixture. Size of weld pool evolved depends upon the energy input per unit time.

• Carbon Arc Welding• Shielded Metal Arc Welding• Submerged Arc Welding (SAW)• Oxy-acetylene Welding• Gas Tungsten Arc Welding (GTAW)• Gas Metal Arc Welding(GMAW)

Click here• Laser Welding• Electron Beam Welding

In carbon arc welding heat is produced with an arc between carbon electrode and work piece. The heat from the arc melts the work piece and filler rod if required. The weld pool produced in this process is very small therefore it can be used in all position welding process.

Return to Arc Weld Process

In this process coated or covered electrode are used for producing an arc as heat source. Covering on burning provides the necessary shield to protect the molten metal from the ill effects of oxygen, nitrogen and from the surroundings. This process more popularly known as “STICK ELECTRODE WELDING” or “MANUAL METAL ARC WELDING.

Return to Arc Weld Process

Submerged arc welding is a process in which continuous copper coated spooled wire is used in conjunction with loose granulated flux poured ahead of the arc so as to provide a protective media to ward off the atmospheric gases from reacting with the molten metal pool. The weld joint produced by this process is of very high quality.

Return to Arc Weld Process

In this process acetylene gas is mixed with oxygen in the welding torch and is then burnt at the torch tip to give a flame with a temperatur of about 3300°C which can melt most of the ferrous and non ferrous metals in common use.

Return to Arc Weld Process

GTAW employs a non consumable tungsten electrode with an envelope of inert shielding gas (argon, helium etc.) to protect both the electrode and the weld pool from the effects of surrounding atmospheric gases. GTAW is all position welding process and gives highest quality of welds amongst the commonly employed welding processes

Return to Arc Weld Process

In GMAW, consumable wire bound in a spool form is fed at a preset speed through a welding torch where it is provided the electrical connection and shielding gas. The arc which is struck by the direct contact between the wire electrode and work piece is maintained at constant length by interaction of electrical parameters.

Return to Arc Weld Process

In EBW a beam of electron is used to melt the metal for welding. The electron beam, emitted from a heated filament is focused on to the desired spot on the work piece surface with the help of focusing coil. The work piece which is placed in a vacuum chamber can be moved to create the necessary welding speed.

Return to Arc Weld Process

In laser beam welding a monochromatic coherent light beam is used as a heat source. Laser light can be easily focused without any decrease in intensity to a very small spot giving a very high energy density. Thus a laser beam like an electron beam, can weld any known material.

In solid state welding processes the material to be welded is heated to a temperature below or just up to the solidus. The coalescence between the parts is achieved under pressure and forging plays an important role in all the processes.

• Friction Welding

• Forge Welding

• Ultrasonic Welding

• Explosion Welding

• Cold pressure Welding

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In friction welding one piece is held stationary and the other is rotated in the chuck of a friction welding machine. As they are brought to rub against each other under pressure, they get heated due to friction. When desired forging temperature is reached throughout the rubbing cross-section o f the work pieces, the rotation is stopped suddenly and axial pressure is increased to cause a forging action and hence welding.

Return to Solid State Welding Process

Forge welding is the oldest known welding process. By this process the pieces to be welded are heated to above 1000°C and then placed together and given impact glows by hammering .Fluxes commonly used for forge welding low carbon steels are sand and boarx. They helps in melting the oxide, if form.

Return to Solid State Welding Process

In ultrasonic welding a metallic tip vibrating at ultrasonic frequency is made to join a thin piece to a thicker piece supported on anvil. Frequency used is from 20khz to 60khz. Ultrasonic welding equipment consists of mainly two parts, one is power source and other is transducer.

Return to Solid State Welding Process

In explosion welding process the weld is achieved by making one part strike against the others at very high but subsonic velocity. This is achieved by the use of explosive usually of the ammonium nitrate base. The process is completed in microseconds. The plated to be welded are placed at inclination to each other angle varies from 1° to 10°.

Return to Solid State Welding Process

Cold pressure welding or cold welding is a solid state welding process in which a weld joint is produced soloely by the application of pressure at room temperature.no heat is involved in this process.the main requiremen of the process is that atleast one of the componenet shoukd be a ductile metal.this type of welding is mainly used for making lap and butt joint types.

In all resistance welding processes the heat is generated at the interface of contacting workpiece due to the resistance offered to the flow of electric current and is expressed by Joule`s law.

•Seam welding

•Spot welding

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In these processes the weld is established along a seam so as to make a leak proof joint. The seam weld may be produced by making partially overlapping spot welds. This process further divided into :

• Resistance Seam Welding

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In resistance seam welding wheel electrodes are used to produce spot welds due to shunting of current through already made weld the current required is higher than normal spot welds. Pressure is applied to fuse the metal properly.

In this process materials are joined at a spot the size of which depends upon the design specifications and is controlled by electrode size and the magnitude of the welding current.

• Resistance Spot Welding

• Projection Spot Welding

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In this spot welding process overlapping sheets are welded by flow of current between two cylindrical electrodes. The main equipment for spot welding is spot welding machine which consist of step down transformer, time control unit and pair of copper alloy electrode.

Return to Spot Welding Process

Projection welding is a joining of two sheets to big bodies like automobile chasis by making raised portions or projections on one of the components. The projections are made by intersection. There are several type of projections: Round Button or Dome Type, Ring type, Elongated Projection, Shoulder Projection and Radius Projection.