TWO WELDING CATEGORIES Fusion welding - accomplished by melting the two parts to be joined, in some cases adding filler

metal to the joint Examples: arc welding, resistance spot welding, oxyfuel gas welding Solid state welding - heat and/or pressure are used to achieve joining, but no melting of base metals occurs and no filler metal is added Examples: forge welding, diffusion welding, friction welding ARC WELDING Joining by an arc between electrode and parts being joined Heat from electric energy at 10,000 F (5500 C), Process usually adds filler metal for added strength ELECTRIC ARC The discharge of current across a gap making a circuit Molten metal solidifies in the wake of electrode making the weld Basic types of electrodes Consumable-filler metal Weld rods, welding wire Non-consumable-filler metal added separately Made of melt resistant material (tungsten) FLUX Coating on weld wire, core inside the weld wire or pouring flux onto weld operation Shields weld from air Reduces spatter AC or DC power supply AC restricted to ferrous CONSUMABLE WELDING PROCESSES (SMAW)Shielded Metal Arc Welding (stick welding) -filler rod with flux core -Used for steels, stainless steels, cast irons, and certain nonferrous alloys (GMAW)Gas Metal Arc Welding -bare wire fed from spool through gun -shielding provided by gas directed onto weld -argon and helium for aluminum CO2 for steel Flux-Cored Arc Welding -electrode contains flux in its core -self shielded-core includes material that produces gas -gas shielded-gas is supplied externally

Electrogas Welding -continuous wire supply, bare or flux coated Submerged Arc Welding -continuous wire supply -shielded by blanket of flux from a hopper NONCONSUMABLE Gas Tungsten Arc Welding -tungsten electrode -used with or without filler metal Plasma Arc Welding -form of GTAW Resistance Welding -used mostly on thin metal sheets -electrodes touched linearly to opposite sides of parts to be joined -used widely in automobiles, appliances, products made of sheet metal Laser beam welding -fusion created by heat from intense light beam -filler metal not usually added

SOLID STATE WELDING -joining is achieved by pressure alone -heat and pressure -no filler metal Forge welding -metal heated and then forged by hammering Cold welding -high pressure between surfaces at room temperature Roll welding -pressure applied by rolling metals together causing cohesion Diffusion welding -uses heat and pressure

Explosion welding -joining caused by energy from detonation Friction welding -heat from friction between two surfaces to cause weld Ultrasonic welding -ultrasonic frequency applied to cause cohesion

WELD QUALITY Welding defects