Report for MTE521

Metallurgy in Welding
By ndrilon 2009
What is WELDING

 in engineering, any process in which

two or more pieces of metal are
joined together by the application of
heat, pressure, or a combination of
both.
Master chart of Arc Welding and Related Methods
Types of welds
 Bead
 Groove
 Fillet
 Surfacing
 Tack
 Plug
 Slot
 Resistance
Bead weld
 Produced by a
single pass
 Stinger Bead-
which is made
without weaving
motion.
 Weave Bead-
made by side-side
oscillation
Groove weld
 Groove welds are
simply welds made
in the groove
between two
members to be
joined.
Surfacing welds
 a  surfacing  weld  is
 composed  of  one  or
 more stringer  or  weave
 beads.  Surfacing,
 sometimes  known as
hardfacing or wearfacing.
 is often used to build up
worn shafts, gears, or
cutting edges.
Fillet weld
 This weld is used
to join two sur-
faces that are at
approximately
right angles to
each other in a
lap, tee, or comer
joint
Plug and Slot weld
 are welds made
through holes or
slots in one
member of a lap
joint.
Tack weld
  is a weld made to hold
parts of an assembly in
proper alignment
temporarily until the final
welds are made.
 they are normally between
1/2 inch to 3/4 inch in
length, but never more
than 1 inch in length.
Basic Welding Positions
Common Welding Types
 Arc Welding (AW)

 Oxyfuel Gas Welding(OFW)

 Resistance Welding
Types of ARC Welding
 Shielded Metal Arc Welding (SMAW)
 Submerged Arc Welding (SAW)
 Flux Cored Arc Welding (FCAW)

 Gas Tungsten Arc Welding (GTAW or TIG)

 Gas Metal Arc Welding (GMAW or MIG)

SMAW
 is performed by striking an arc
between a coated-metal electrode
and the base metal.
 Flux- the coating of the metal
electrode will form as shield to the
molten metal.
Shielded Metal Arc Welding
SMAW OPERATION
Arc Welding MAchines
Electrode and Holder
Advantages of SMAW
 High quality welds are made rapidly
at a low cost.
 Can be used easily even to thick and
wide work piece to be joined.
 Can be used from thinner to thicker
materials.
Disadvantages SMAW

 Consumes bigger electric current

 Dirty work finish
 Root pass is lower than TIG and MIG
 Prone to slag inclusions
 Weld deposits is prone to blue holes
SUBMERGED ARC WELDING
(SAW)
 Is a process in which is done by an
automatic electrode feeding machine
wherein the tip of the electrode is
submerged into a granular flux
which shields the arc and the molten
metal.
SAW operations
SAW Welding Machine
SAW block diagram
SAW APPLICATIONS
 widely used in heavy steel plate
fabrication work.
 welding of structural shapes.
 longitudinal seam of larger diameter pipe.
 manufacture of machine components for
all types of heavy industry.
 manufacture of vessels.
 pressure and storage tanks.
Advantages of SAW
 high quality of the weld metal.
 extremely high deposition rate and speed.
 smooth, uniform finished weld with no spatter.
 little or no smoke.
 no arc flash, thus minimal need for protective
clothing.
 high utilization of electrode wire.
 easy automation for high-operator factor.
 normally, no involvement of manipulative skills.
Disadvantages of SAW
 used only to weld mild and low-alloy
high-strength steels.
 Unseen arc and puddle can cause poor
penetration.
 high-heat input, slow-cooling cycle can be
a problem when welding quenched and
tempered steels.
 limited-position welding process only flat
and horizontal
GTAW or TIG
 Gas Tungsten Arc Welding or Tungsten Inert Gas or HELIARC
Welding

 is a process in which the joining of metals is produced by heating

therewith an arc between a tungsten (non consumable) electrode
and the work.

 A shielding gas is used, normally Argon.

 normally done with a pure tungsten or tungsten alloy rod, but

multiple electrodes are sometimes used.

 Filler metals are used such as stainless steel, Aluminum and

Bronze.
 Flux Cored Arc Welding
(FCAW)
 is an automatic or semi-automatic
electric arc welding process that
uses an arc between a continuously
fed flux-filled electrode and the weld
pool. The process is used with
shielded gas from a flux contained
within the tubular electrode with or
without additional shielding from an
externally supplied gas.
FCAW flux filled electrode
and torch
No shielding gas (FCAW)
With Shielding Gas (FCAW)
Two Types of FCAW

 no shielding gas
- using flux core in the tubular consumable
electrode
 uses a shielding gas
- gas that must be supplied by an external
supply. This is known informally as "dual shield"
welding.
Uses of FCAW
 Mild and low alloy steels
 Stainless steels
 Some high nickel alloys
 Some wear facing/surfacing
alloys
Advantages of FCAW
 FCAW may be an "all-position" process with the right filler
metals (the consumable electrode)
 No shielding gas needed making it suitable for outdoor
welding and/or windy conditions
 A high-deposition rate process (speed at which the filler
metal is applied) in the 1G/1F/2F
 Some "high-speed" (e.g., automotive applications)
 Less pre cleaning of metal required
 Metallurgical benefits from the flux such as the weld metal
being protected initially from external factors until the flux
is chipped away
Disadvantages of FCAW
 Melted Contact Tip – happens when the electrode actually
contacts the base metal, thereby fusing the two
 Irregular wire feed – typically a mechanical problem
 Porosity – the gases (specifically those from the flux-core)
don’t escape the welded area before the metal hardens,
leaving holes in the welded metal
 More costly filler material/wire as compared to GMAW
 Less suitable for applications that require painting, such as
automotive body works.
 Cannot be used in a rugged environment limited to shop
use only.
FCAW Equipment set up
TIG WELDING
GTAW or TIG process
GTAW Welding Equipment
TIG Welding Machine
TIG Torch
 ADVANTAGES of GTAW
 most popular method for welding aluminum stainless
steels, and nickel-base alloys.
 Produces top quality welds.
 No smoke or fumes
 clean – no slag and spatter to be clean during
welding
 reduced distortion in the weld joint because of the
concentrated heat source.
 is very good for joining thin base metals because of
excellent control of heat input.
 
ADVANTAGES of GTAW
especially useful for joining aluminum and magnesium
which form refractory oxides,
 excellent to use for the reactive metals like titanium
and zirconium, which dissolve oxygen and nitrogen and
become brittle if exposed to air while melting.
welding process by fusion alone without the addition
of filler metal.( non-consumable electrode)
 Used in very critical service application and on very
expensive metal or parts.
Disadvantages of GTAW
 EXPENSIVE
a. Arc travel speed and weld metal deposition
rates are lower.
b. high price of Inert gases for shielding such as
Argon and Helium.
c. price of Tungsten electrode is high.
d. Equipment costs are greater than that for
other processes, such as SMAW, which require less
precise controls.
 MANY LIMITATIONS and cannot be used in
full welding operations
 Limitations of GTAW
 SLOWER WELDING PROCESS
slower than consumable electrode arc welding.
 FAST CONTAMINATION
1. During transfer of molten tungsten from the
electrode to the weld.
2. tungsten inclusion(unbalance gas shielding the
inclusion is hard & brittle)
3. During exposure of the hot filler rod to air.
4. When there is improper welding techniques along
the line
GMAW or MIG
 is an electric arc welding process which joins
metals by heating them with an arc established
between a continuous filler metal (consumable)
electrode and the work.

 Shielding of the arc and molten weld pool is

obtained entirely from an externally supplied
gas or gas mixture both inert and reactive
gases.
GMAW Welding Operations
MIG Machine with Spool
feeder
GUN used in GMAW
MIG Torch
GMAW Weld Diagram
 Advantages of GMAW
 Produced High quality welds & much faster than with
SMAW and TIG welding.

 No flux is used no slag entrapment in the weld metal.

 Very little loss of alloying elements as the metal

transfers across the arc.

 Minor weld spatter is produced, and it is easily removed.

Advantages of GMAW

 Versatile and can be used with a wide variety of metals

and alloys, such as Aluminum, Copper, Magnesium,
Nickel, Iron and many of their alloys.
 The process can be operated in several ways, including
semi- and fully automatic.

MIG welding is widely used by many industries for
welding a broad variety of materials, parts, and structures.
Disadvantages of GMAW

 IT cannot be used in the vertical or overhead welding

positions due to the high heat input and the fluidity of
the weld puddle.

 Has complex equipment compared to equipment used

for the shielded metal-arc welding process.
Oxygen Fuel Gas Welding
(OFW)

is a group of welding processes

which join metals by heating with
a fuel gas flame or flares with or
without the application of
pressure and with or without the
use of filler metal.
Types of Oxy-fuel Gas Welding
 Oxy-Acetylene or Oxygen- Acetylene Gas
Welding
 Oxy-Hydrogen or Oxygen- Hydrogen Gas
Welding
 Methylacetone-Propadiene Gas Welding
 Pressure Gas Welding.
 Advantages of Oxy-fuel
Gas Welding
 Easy to use both welding and cutting

 Controlled heat input

 Controlled bead size

 Convenient to use in welding thin sheets, tubes

and small diameter pipes
 Disadvantages of Oxy-Fuel
Gas Welding

 Cannot be use to weld on thick work

piece.

 Expensive gas
Oxy-Acetylene Diagram

Welding Equipment
Complete Oxy-Acetylene
Welding Equipment
Resistance Welding
  is a process in which the fusing temperature is
generated at the joint by the resistance to the flow of an
electrical current.

 is  accomplished  by  clamping  two  or  more  sheets  of

metal  between  copper  electrodes  and  then  passing  an
electrical  current  through  them.  When  the  metals  are
heated to a melting temperature, forging pressure is
applied through either a manual or automatic means to
weld  the  pieces  together.
 Two common types are Spot  and Seam  welding
 2 Types of Resistance
Welding

SPOT WELDING

SEAM WELDING
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.
SEAM Welding

is
like spot welding
except that the
spots overlap each
other, making a
continuous weld
seam.