UNDERSTANDING

WELDING
Types of Joints

Butt
Tee
Corner
Lap
Butt Joint

Members to be joined are in

same plane
Tee Joint

Members to be joined form a tee

Corner Joint

Members to be joined form a

corner
Lap Joint

Members to be joined overlap

each other
Types of Joining
Processes

Fastening
Adhesive
Soldering
Brazing
Fusion Welding
Fastening

Joined members can be

separated easily

Joint is not permanent

The material property of the

joining members is not affected
Adhesive

Joined members can be separated, but not

easily

Joint is not permanent

The joint strength may be lower than that

of the members joined

The material property of the joining

members is not affected
Soldering

Joined members can be separated, but not easily

Joint is not permanent

The joint strength may be lower than that of the members

joined

The joining members are heated but they do not melt

The material property of the joining members is not

affected

The filler metal melts at temperature less than 420C

Fusion Welding

Joined members cannot be separated except by cutting,

grinding , chiseling

Joint is permanent

The joint strength can be same as that of the members joined

The joining members are heated and the joining faces are melted

The material property of the joining members is affected and a

heat affected zone forms in the joining member

The filler metal melts along with the faces of the joining member
and forms weld metal
Criteria for Fusion
Welding

Heat for fusion shall be provided

Base metal and filler metal shall melt

Molten metal shall be shielded from

Oxygen & Nitrogen of air

Fused weld metal shall be free from defects

Fused metal & HAZ shall have properties as good as base

metal
Fusion Arc Welding
Processes

SMAW Shielded Metal Arc Welding

GTAW - Gas Tungsten Arc Welding
GMAW Gas Metal Arc Welding
FCAW - Flux-cored Arc Welding
SAW- Submerged Arc Welding
Thermal Cycle during
arc welding
There is very fast heating

There is very fast cooling from

melting point to 500C

The cooling rate depends upon the

heat input in the arc

The cooling rate also depends on the

thickness of the joining members
SMAW

Heat is provided by arc between stick electrode and joining member

Shielding of the molten metal done by the flux which melts and produces
shielding gases and slag

Welding is manual

The welding operation is not continuous

The rate of deposition is low

The depth of fusion is less

Welding can be done in all positions

Welding power source is of constant current type

GTAW

Heat is provided by arc between non-consumable tungsten electrode and

joining member

Shielding of the molten metal done by the inert shielding gas

Welding is manual / machine / Automatic

The welding operation in manual mode is not continuous

The rate of deposition is low

The depth of fusion is less

Welding can be done in all positions

Welding power source is of constant current type

GMAW

Heat is provided by arc between filler wire electrode and joining member

Shielding of the molten metal done by the gas which is provided thru the
nozzle on the welding gun

Welding can be semi-auto, machine or auto

The welding operation can be continuous in machine or auto mode since

wire is fed by machine

The rate of deposition is more than SMAW

The depth of fusion is more than SMAW

Welding can be done in all positions

Welding power source is of constant voltage type

FCAW Gas Shielded

Heat is provided by arc between flux cored filler wire electrode and joining member

Shielding of the molten metal done by the gas which is provided thru the nozzle on the
welding gun

Welding can be semi-auto, machine or auto

The welding operation can be continuous in machine or auto mode since wire is fed by
machine

The rate of deposition is more than SMAW / GTAW

The depth of fusion is more than SMAW / GTAW

Welding can be done in all positions

Welding power source is of constant voltage type

SAW

Heat is provided by arc between filler wire electrode and joining member

Shielding of the molten metal done by the flux which is provided thru the
flux delivery chute on the welding head

Welding can be machine or auto

The welding operation is continuous

The rate of deposition is more than SMAW and GMAW

The depth of fusion is more than SMAW and GMAW

Welding can be done only in Flat and Horizontal positions

Welding power source is of constant voltage type or constant current

with feed back to wire feeder
Welding Variables for
SMAW
Power
Electrode Type
Electrode Polarity
Electrode diameter
Current
Arc length
Forehand or Back-hand technique
Welding weave
Welding Speed
Run Out Length
Heat Input
Welding Variables for
GTAW
Power
Tungsten Electrode Type
Electrode Polarity
Electrode diameter
Filler Wire type
Filler wire dia
Shielding Gas & Gas Flow
Purging Gas & Gas Flow
Gas Nozzle Type, shape & Dia
Current Type and level
Arc length
Welding weave
Filler wire Feed
Welding Speed
Heat Input
Welding Variables for
GMAW
Gas Type
Gas Pressure
Gas Flow
Shielding cup diameter
Power
Polarity
Wire Type
Wire Diameter
Arc Voltage
Current / Wire Feed
Forehand or Back-hand technique
Welding Weave / Oscillation
Welding Speed
Heat Input
Welding Variables for
FCAW
Gas Type
Gas Pressure
Gas Flow
Shielding cup diameter
Power
Polarity
Wire Type
Wire Diameter
Arc Voltage
Current / Wire Feed
Forehand or Back-hand technique
Welding Weave / Oscillation
Welding Speed
Heat Input
Welding Variables for
SAW
Power
Polarity
No. of electrodes
Diameter of electrodes
Type of electrodes
Inclination and Spacing of electrodes
Alignment of electrodes
Flux Type
Electrode Stick-out
Flux Burden
Arc Voltage
Current / Wire Feed Rate for each electrode
Welding Speed
Re-circulation of Flux
Effect of Variables on
various process outputs
Depth of Penetration
Deposition Rate
Fusion Profile
Weld Bead Width
Weld Bead Re-inforcement
Weld Finish
Depth of Penetration

Increased by

Higher Current
Higher current density
Back ward inclination of
electrode
DC electrode positive
Deposition Rate

Increased by

Higher Current
Higher current density
Fusion / Bead Profile

Is affected by

Shielding gas
Type of flux
Position of electrodes
Backward or forward inclination
of electrode
Bead Width

Is affected by

Welding Voltage
Welding Speed
Weaving width
Bead Re-inforcement

Is affected by

Welding Voltage
Welding Speed
Weaving width
Positioning of electrodes