Welding: Welding is a process of joining two metal pieces by the application of heat.

Welding is the least

expensive process and widely used now a days in fabrication. Welding joints different metals with the help
of a number of processes in which heat is supplied either electrically or by mean of a gas torch.

Classification of welding processes:

There are about 35 different welding and brazing process and several soldering methods, in use by the
industry today. There are various ways of classifying the factors of welding processes are classified

as given below:
1.
2.
3.
4.
5.

Chemical welding (Oxygen+combustible fuel)

chemico-mechanical(pressure gas welding)
Electro- chemical (Atomic hydrogen welding)
Electro Mechanical (Electric resistance welding)
Electric Arc welding.

Types of Welding:
Forge welding:
It is a solid state welding process. In this process the two metal surfaces to be joined are bought in
contact and then metals are joined by heating them to a high temperature and hammering them together.

Termite Pressure welding:

Pressure termite welding is a process in which the heat produced by the thermit reaction is utilized only
for heating the ends of the pieces to be joined, while the actual joint formation occurs by solid pressure
welding.

Pressure Gas welding:

It does not require filler material. Pressure Gas welding is used for joining pipes, rods, railroad rails.
In this process a weld is made simultaneously over the entire area of butting surfaces with gas flames
obtained from the combustion of a fuel gas with oxygen and the application of pressure. Pressure gas
welding has limited uses because of its low flame temperature, but is extensively used for welding lead.

Electric Resistance welding:

In this process two metals are joined by passing a low voltage and very high current through the joints
which melts the joint due to their contact resistance. External pressure is used to complete the weld. No
fillers are used in Electric Resistance welding.

Gas welding:
It is a fusion welding process where two metals are joined by burning a combustible gas with air or
oxygen in a concentrated flame of high temperature. Filler rod may be used to fill up the cavity during
welding process.

Electric Arc welding:

Arc welding process in which two metals are joined by heating with an electric arc to the melting
temperature and then allowed to solidify. Depending upon the thickness of the base plate, Filler metals
may be used.

Radiant Energy welding:

It this type of welding a beam of electron strikes the surfaces to be joined and produces heat which
causes the metal to melt and fuse.

GTAW or Tungsten Inert Gas: TIG welding is comparable to oxy acetylene gas welding and needs a
lot more expertise from the operator. Employed for carrying out high-quality work when a superior
standard of finish is needed without making use of excessive clean up by sanding or grinding.

GMAW or Gas Metal Arc Welding: More commonly called MIG welding this welding type is the most
widely used and perhaps the most easily mastered type of welding for industry and home use. The
GMAW process is suitable for fusing mild steel, stainless-steel as well as aluminum.

Arc Welding or SMAW: Generally known as stick or arc welding. Arc welding is the most basic of all
welding types, is easy to master in a home welding situation. Stick welding can be used for
manufacturing, construction and repairs, very much well suited for heavy metal size 4 millimeters
upwards. Thinner sheet metals and alloys are usually more suited to the MIG welding types.

Gas or Oxy Acetylene Welding: Not used as widely for general welding of mild steel. Consists of
mixing oxygen and acetylene gas to greater a flame capable of melting steels. Mostly used today for
maintenance work and gas metal cutting. Also common for brazing softer metals such as copper and
bronze. Can also be used for welding delicate aluminum parts such as refrigeration pipes. Gas Cutting
equipment for metal construction and maintenance. The most accessible of thermal cutting gear is by
oxy-acetylene gas cutting and plasma cutting machines. Other methods include the use of a thermal
cutting electrode for use with the arc welder machine.

Flux-cored Arc Welding: Flux-cored Arc Welding is a welding process similar to GMAW, in that it uses
a continuously fed electrode, but uses a tubular wire filled with flux instead of a solid wire. There are two
types of flux-cored wire, self-shielded and dual shield. Self-shielded is used without the aid of an external
gas shield and uses the flux to shield the molten weld puddle. Dual shield uses the flux and an external
shielding gas to protect the molten weld puddle. Typical shielding gases are carbon dioxide and
argon/carbon dioxide mixes. Self-shielded wires are optimal for outdoor use, even in windy situations.
Both wires produce a slag covering on the finished weld.