Topics covered

WELDING PROCESSES.
WELDING CONSUMABLES
WELDING EQUIPMENTS
WELDING PROCEDURE
WELDING DEFECTS ITS CAUSES
AND REMIDIES
SAFETY
WELDING PROCESS
 Types Of Welding

Welding

Gas Welding Arc Welding

 Normal practiced process
Manual Metal Arc Welding MMAW
Gas Tungsten Arc Welding GTAW
Gas Metal Arc Welding GMAW
Flux Cored Arc Welding FCAW
Sub Merged Arc Welding SAW
 WELDING PROCESS
The present process of welding used to
manufacture various components generally are as
follows
MMAW- Manual Metal Arc Welding Process
GMAW- Gas Metal Arc Welding process
GTAW - Gas Tungsten Arc Welding
FCAW- Flux Cored Arc Welding
SAW- Submerged Arc Welding
SMAW/MMAW
GTAW
GMAW(MIG/MAG)
FCAW
SAW
 Advanced process
Narrow Gap Welding
Laser Beam Welding
Electron Beam Welding
Friction Stir Welding
Plasma Welding
Plasma Transfer Arc Technique (PTA)
Robotic Welding
Orbital Welding
 Selection of Welding process
Type of Base Material
The Joint Design
The place of welding
Welding Position
Type of consumables availability
The skill availability of personnel
The types of equipment availability
WELDING CONSUMABLES
&
WELDING EQUIPMENTS.
 RECOMMEDATIONS
The selection of the correct welding consumables
depends on the following parameters
Base materials composition
The weld ability of the steel
Selection of the welding consumables as per
ASME section-II- C
Acceptance of AWS or any other standards
depends on the clients requirements.
 WELDING CONSUMABLES
The Welding consumables like the welding electrodes and
filler wires that are required and are recommended are as
follows

E-6013 Welding Electrodes for Welding in MMAW

process for Carbon steel, Mild steel, For the general
purpose welding applications up to thickness 18 mm or
3/4th inch.
For thickness over the above mentioned must be welded
with Low Hydrogen electrodes as per AWS E 7018 or
E7018-1 Type of welding consumables.
 Welding consumables for various
steels.

General Mild steel Up to 18mm

AWS 6013 class welding electrodes,
ER 70 SG Filler wires in case of GTAW &
ER 70 S-6 in case of GMAW process.
General Mild steel Above 18mm
AWS 7018class ER 70 S2 & ER 70 S-6
 Selection contd.
For Radiography joints
The following grades consumables are
mandatory.
AWS E6013 & E7018 classified Electrodes
ER 70 S2 TIG welding filler wires
ER 70 S-6 MIG Welding continuous filler
wires.
 Consumables- gases
ER 70 S-6 Solid wire for welding the
GMAW (MAG) welding process
ER 70-S-2 TIG filler applications incase of
carbon steel welding .
The use of 100 % CO2 gas for MAG
welding and 100 % pure Argon gas for TIG
welding applications are the main criteria.
 Alloy steels

AWS class of low alloy electrodes & wires

 Consumables- LAS

In the case of use of Low alloy steels where

C, Mo, Cr and other alloys are involved the
creep properties are important and hence the
matching composition of the weld metals
are mandatory
 Consumables S.S.
Welding of Stainless steels like commonly
used steels such as 304, 304L, 308L, 309,
316. and other categories such as 310, 321,
347, Duplex, Super Duplex Steels, the
respective grade of Electrodes and the Filler
wires to be used with proper shielding
gases.
 Stainless steel

301,304,308 Class
AWS E 308 & 308 L grades Electrodes
and ER 308 L TIG/ MIG welding wires.
316 and 316 L
-AWS E- 316 & 316 L
-ER 316 L TIG and MIG fillers
 SS Contd.
For 309 Grade steels
AWS E 309 Electrodes
ER 309 L Wires

Dissimilar metals of SS and SS-MS

AWS 309L and 309 MoL
ER 309L & ER 309 MoL
 SS Contd.
Stabilized steels of 321, 347
Namely Niobium/Columbium, Ti and Ta stabilized
steels the use of
AWS E- 347 electrodes and wires of
ER 347 grade is recommended.

For other grades like 310,312, 317 the respective

grades of consumables be used.
 Other metals
Cast Iron

Non-Ferrous Alloy:
Aluminium, Copper, Nickel, Magnesium
etc.
Welding Position










 

       

    

 
     

              
     
   

      
        
     
    

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 Proper Arc Length
Long arc results in:
Large globules melting
Wavering arc
Wide spatter and irregular bead
Short arc results in:
Electrode sticks
Poor penetration
Convex bead
Slag inclusions
Irregular bead
Use short length for vertical welds
 Speed of Travel
Travel speed influences:
Bead width
Penetration
General shape of the bead
Use a uniform speed
Both hands on the electrode holder
Operator comfort
Bead should be about twice the diameter of the
electrode wire
Read the Bead
WELDING EQUIPMENT
 TYPES OF EQUIPMENTS
Standard Type of welding Equipments
Arc Welding Transformers
D.C. Rectifiers
Thyristor controlled Welding Rectifiers
Welding Invertors
TIG Welding Equipments
MIG/MAG Welding machines
Sub Merged Arc Welding machines
 MMA Power sources

Welding generator
Transformer Rectifier
 category of MIG Welding

Pulsed MIG Welding Machines,

Inverter based MIG Welding Machines
Synergic Pulsed MIG Welding Machines
Surface Tension Transfer Machines (STT)
 Cont
Under TIG Welding category we can have
DC Pulsed welding machines
AC/ DC TIG welding machines
AC Square wave pulsing machines
 Advanced Welding Machines:

Electron Beam Welding machines

Narrow Gap welding machines
Laser cutting and welding
Plasma Welding
 Selection of the correct equipment
Selection of the right type of equipment is
important to get the desired welding properties.
The selection decides the feasibility of the use of
the process.
The selection should be based on the availability
of the equipment,
The acceptance of the process
The convenience of the operation.
Welding Defects
 TYPE OF DEFECTS
Lack of fusion
Lack of Penetration
Undercut
Crack
Porosity
Slag inclusion
Lack of Penetration
Lac of Fusion
Undercut
Porosity
Crack
 ITS CAUSES AND REMIDIES
Re-drying of Consumables/ Proper Storage
Base metal Cleaning.
Flow rate of Shielding GAS
Welding Parameter.
Use of correct welding consumables.
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