WELDING

INTRODUCTION
Welding is a process of joining similar metals by application of heat with or without application
of pressure and addition of filler material. The result is continuity of the homogenous material of
the composition and the characteristics of two parts which are being joined together. The fusion
of metal takes places by means of heat. The heat may be obtained from electric arc, electric
resistance, chemical reaction.
Application
Welding has a vast application in industries of factories of any fields in case of joining two or
more metals. By the use of welding new type of instrument of anything made up of metal, the
welding application is very essential. Presently wielding is used extensively for fabrication of
vastly different components including critical structures like boilers, pressure vessels, shapes,
offshore structures, bridge, pipelines, railways, nuclear reactors, fertilizers and chemical plants,
automobile bodies and water turbines.
Important terms
a. Autogenous welding
The process of joining similar metals by melting the edges together, without the addition
of filler metal, is called autogenous welding.
b. Homogenous welding
The process of joining similar metals with the help of filler rod of the same metal.
c. Heterogeneous welding
The process of joining dissimilar metals using filler rod.
d. Weldability
The capacity of being welded into inseparable joints having specified properties as
definite weld strength, proper structure, etc. Weldability depends on one or more of the
five major factors:
a) melting point
b) thermal conductivity
c) thermal expansion
d) surface condition
e) change in micro structures
e. Base meta
The metal to be joined or cut is termed as the base metal.
f. Bead
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The metal added during welding.

g. Backing
The material support provided at the root side of a weld to aid in the control of
penetration.
h. Penetration
The depth upto which the weld metal combines with the base metal as measured from the
surface of the point.
i. Puddle
The portion of the weld joint that is melted by the heat of welding is called puddle.
j. Root
It is a point at which the pieces to be joined by welding are nearest to each other.
k. Toe of weld
It is the junction between the weld face and the base metal.
l. Weld metal
The metal that is solidified in the joint is called weld metal.
m. Deposition rate
The rate at which the weld metal is deposited per unit time.
Classification of wielding
In general, various welding and allied process are classified as follows:
1. Gas welding
a. Air acetylene welding
b. Oxy-acetylene welding
c. Oxy-hydrogen welding
d. Pressure gas welding
2. Arc welding
a. Carbon arc welding
b. Metal arc welding
c. Flux cored arc welding
d. Submerged arc welding
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e. Gas tungsten arc welding(TIG)

f. Gas metal arc welding(MIG)
g. Plasma arc welding
h. Electro slag arc welding
i. Electro gas arc welding
j. Stud arc welding
3. Resistance welding
a. Spot welding
b. Seam welding
c. Projection welding
d. Resistance butt welding
e. Flash butt welding
f. Percussion welding
g. High frequency resistance welding
4. Solid state welding
a. Cold welding
b. Diffusion welding
c. Explosive welding
d. Forge welding
e. Friction welding
f. Hot pressure welding
g. Roll welding
h. Ultra sonic welding
5. Thermo chemical welding process
a. Thermit welding
b. Atomic hydrogen welding
6. Radiant energy welding process
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a. Electron beam welding

b. Leaser beam welding
Arc Welding:
Arc wielding is widely used method of joining the metal parts. The source of heat is an electric
arc. Arc wielding is group of wielding processes where in heating os produced with an electric
arc or arcs. This process also use some shielding gas while other employ fluxes or coatings to
protect the wield pool from the ill effects of the surrounding atmosphere.
Principle
Arc is generated between the positive pole of D.C called anode and negative pole of D.C called
cathode. When these two poles are brought together, and separated for a small distance (1.5 to
3mm) such that the current continues to flow through a path of joinzed particles, called plasma,
an electric arc is formed. Heat is generated as the ions strike the cathode.

Types of Arc Welding

Carbon Arc Welding
In this process a pure graphite or baked carbon rod of 4-19mm diameter and 300-450mm long is
used as a non-consumable electrode to create an arc between it and the work piece by holding it
in an electrode holder with an electrode extension of 75-125mm. The weld can be made by the
application of heat with or without the addition of filler material. The carbon electrode is usually
ground over a length of 20-25mm to provide a pointed end with a diameter of about 1.5mm. This
provides a stable arc.
Shielded Metal Arc Welding
This process is also known as stick electrode welding or coated electrode welding which uses
coated electrodes of 2.5-6.35mm diameter and 300-450mm length held in an electrode holder.
The power source used is of the constant current type and both AC and DC supply. This process
is very versatile and is used for welding in all positions and all metals for which electrodes have
been developed.
Submerged Arc Welding
This process employs granular flux and a copper coated wire in spooled form which makes it
possible to deposit long weld runs without interruption. Both AC and DC power sources are used
though DC with electrode positive is preferred choice. This process is mainly used in the down
hand welding position in automatic and semi-automatic mode. The metal most widely welded by
this process includes low carbon, low alloy, stainless steels and high alloy steels.
Gas Metal Arc Welding (MIG)
In this process, welding heat is produced from an electric arc is established between the
continuously fed metal electrode and the job. Argon, helium, carbon dioxide or a gas mixture
shields the arc and molten metal from atmospheric contamination.
Tungsten Inert Gas welding (TIG)

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In this process, welding heat is produced from an electric arc established between the nonconsumable tungsten electrode and the job. A shielding gas (argon, helium, nitrogen etc.) is used
to avoid oxidation. Arc is struck either by touching the electrode with a scrap tungsten or by
using high frequency unit. Both AC and DC power source can be used.
Fluxed cored metal arc welding
In this process, flux coated consumable electrodes produces the heat by electric arc (750 Am.)
where both AC and DC supplies may be used. The temperature is in range of 2400C-2700C.
Electro slag welding
In electro-slag welding process, heat is produced by the molten slag, which melts the filler metal
and welding surface where the temperature range is 1650C-1950C. Arc initiated between
electrode and the work is extinguished after flux is melted and the molten conditions maintained
by the resistance to current flow between electrode and work.
Plasma arc welding
Plasma is used in this welding process which is formed when inert gas get ionized after passing
through arc and nozzle. Welding heat is obtained from a constricted arc set up between a
tungsten electrode and water cooled nozzle or between the electrode and job. The temperature is
in the order of 11000 C.
Arc Welding Equipment:
The most commonly used equipment for arc welding consists of the following1. AC or DC machine
2. electrode holder
3. cables, cables connectors
4. cables lug
5. chipping hammer
6. earthing clamps
7. wire brush
8. helmet
9. safety goggles
10. hand gloves
11. aprons, sleeves
12. electrode

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Types of Welding Joints

The following are the some basic type of joints commonly used in fusion welding:
1. Lap Joint: The lap joint is by overlapping the plates and then welding the edges of the plates.
2. Butt joint: the butt joint is obtained by welding the edges or ends of the two plates whose
surfaces are approximately in same plane. The butt joint may be
a. Square butt joint
b. Single V- butt joint
c. Double V- butt joint
d. Single U- butt joint
e. Double U- butt joint
3. Corner Joint: the corner joint is obtained by joining the edges of the two plates whose surfaces
are at an angle of approx 90 degrees to each other.
4. Edge Joint: The edge joint is obtained by joining two parallel plates. It is economical for plates
having thickness less than 6 mm.
5. T joint: The t joint is obtained by joining two plates whose surfaces are approximately at right
angle to each other. These joints are suitable up to 3 mm thickness.
Safety Precautions in wielding
1 Cotton and leather aprons, helmet, gloves, goggles should be wear while working.
2. Red hot metal should be carefully taken out with the aid of tong.
3. Brushing should be done carefully.
Material description
Two rectangular flat plates of cast iron were provided as a work piece. Since welding done was
carbon arc welding, filler rod was of carbon rod which was externally covered with the flux.
SEQUENCE OF OPERATIONS
In the welding practice, we performed three practices. At first the given dimensions were noted
and with the help of cutting machines, the job piece was cut. Then taking different precaution
measures, welding was performed in the job piece.
Job 1:
Lining the sheet with weld:
GIVEN:
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80*40 mm of mild steel.

Job 2:
Lap joint by welding:
GIVEN:
Two pieces of mild steel of dimensions (40*5)*60 mm.
Procedure
1. The ac machine was connected to the mains.
2. The welding rod was trapped by the electrode holder and the work piece was placed in
touch with the positive electrode.
3. The two rectangular job pieces were brought closer and arrange linearly in order to make
a lap joint by welding.
4. At the two ends, slightly small welding was done for linearity.
5. The two pieces were joined together by welding to make a lap joint.
6. The unnecessary chips that stacked at the job piece were removed by using chipping
hammer and the job piece was finally cleaned with the help of metal brush.
Job 3:
Butt joint by welding
GIVEN:
Two pieces of mild steel of dimensions (40*5)*60 mm.
Procedure
1. The ac machine was connected to the mains.
2. The welding rod was trapped by the electrode holder and the work piece was placed in
touch with the positive electrode.
3. The two rectangular job pieces were brought closer and arrange linearly in order to make
a butt joint by welding.
4. The two pieces were joined together by welding to make a butt joint.
5. The unnecessary chips that stacked at the job piece were removed by using chipping
hammer and the job piece was finally cleaned with the help of metal brush.
Job 4:
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Tee-joint by welding
GIVEN:
Two pieces of mild steel of dimensions (40*5)*60 and (40*5)*40 mm.

Procedure
1. The ac machine was connected to the mains.
2. The welding rod was trapped by the electrode holder and the work piece was placed in
touch with the positive electrode.
3. The two rectangular job pieces were brought closer and arrange them in tee shape in
order to make a Tee joint by welding.
4. The two pieces were joined together by welding to make a Tee joint.
5. The unnecessary chips that stacked at the job piece were removed by using chipping
hammer and the job piece was finally cleaned with the help of metal brush.
Quality Control
Job No

Nature Of work
01

Welding Practice

02

Butt Joint

03

Lap Joint

04

T Joint

Weld obtained
Non uniform bead ,
Not parallel lines
Uniform bead
Not so much
penetrated
Uniform Bead
T- is not exactly
perpendicular to
each other

Remarks
Satisfactory
Good
Good
Good

Conclusion
As a mechanical student, we learnt maximum knowledge about welding as well we learnt to use
welding tools practically. Now, I think well be able to perform welding in our future and will be
helpful for our career.

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