SUBMITTED BY: Name PUNEET Regd.

NO-10904420 Section: RM4901 Roll no: A21

SUBMITTED TO:Mr.HIMANSHU PAYAL

ACKNOWLEDGEMENT
I express my gratefulness to the department of MANUFACTURING SCIENCES for support. I further would like to sincerely and wholeheartedly thank Mr. HIMANSHU PAYAL ,faculty,MANUFACTURING SCIENCES ,Lovely Professional University, for his valuable guidance and for giving me a chance to undertake this term paper. A special word of thank should go to all the faculties of physics for providing the resources and guidance to execute the project work successfully. My family too has all my gratitude due for their ever required encouragement, support and valuable suggestions to improve my work. Last but not the least I thank all my friends and colleagues for helping me throughout the work directly or indirectly.

CONTENTS

ACKNOWLEDGEMENT INTROCUCTION HISTORY LITERARY SERVAE REVIEW AND DISCUSSION

INTRODUCTION
Welding, an integral part of fabrication process consists of merging of two or more metals by melting and subsequent cooling. One has to exercise proper safety norms while carrying out welding.Welding is a technique used in the fabrication process mostly. The method involves metals, materials etc. The act of welding relates to merging of two particles in to one, by the melting and cooling processes. The heating in the welding can be done by a gas flame, electric arc, laser, electron beam, friction and ultra sound. The actual procedure of welding can be carried out in open air, underwater and in space. But wherever it is done, welding remains to be more dangerous. Unless proper precautions are taken, the welding person may be exposed to burns, electric shock, deadly fumes and ultraviolet rays. Many different energy sources can be used for welding, including a gas flame, an electric arc, a laser, an electron beam, friction, and ultrasound. While often an industrial process, welding can be done in many different environments, including open air, under water and in outer space. Regardless of location, however, welding remains dangerous, and precautions are taken to avoid burns, electric shock, eye damage, poisonous fumes, and overexposure to ultraviolet light.

History

The iron pillar of Delhi

The history of joining metals goes back several millennia, with the earliest examples of welding from the Bronze Age and the Iron Age in Europe and the Middle East. Welding was used in the construction of the iron pillar in Delhi, India, erected about 310 AD and weighing 5.4 metric tons. The Middle Ages brought advances in forge welding, in which blacksmiths pounded heated metal repeatedly until bonding occurred. In 1540, Vannoccio Biringuccio published De la pirotechnia, which includes descriptions of the forging operation. Renaissance craftsmen were skilled in the process, and the industry continued to grow during the following centuries. Welding, however, was transformed during the 19th century. In 1802, Russian scientist Vasily Petrov discovered the electric arc and subsequently proposed its possible practical appplications, including welding. In 1881-82 a Russian inventor Nikolai Bernardos created the first electric arc welding method known as carbon arc welding, using carbon electrodes. The advances in arc welding continued with the invention of metal electrodes in the late 1800s by a Russian, Nikolai Slavyanov (1888), and an American, C. L. Coffin. Around 1900, A. P. Strohmenger released a coated metal electrode in Britain, which gave a more stable arc. In 1905 Russian scientist Vladimir Mitkevich proposed the usage of three-phase electric arc for welding. In

1919, alternating current welding was invented by C. J. Holslag but did not become popular for another decade. Resistance welding was also developed during the final decades of the 19th century, with the first patents going to Elihu Thomson in 1885, who produced further advances over the next 15 years. Thermite welding was invented in 1893, and around that time another process, oxyfuel welding, became well established. Acetylene was discovered in 1836 by Edmund Davy, but its use was not practical in welding until about 1900, when a suitable blowtorch was developed. At first, oxyfuel welding was one of the more popular welding methods due to its portability and relatively low cost. As the 20th century progressed, however, it fell out of favor for industrial applications. It was largely replaced with arc welding, as metal coverings (known as flux) for the electrode that stabilize the arc and shield the base material from impurities continued to be developed.

LITERARY SERVAE
WIKIPEDIA GOOGLE BOOK

REVIEW AND DISCUSSION

There are many different types of welding that you can use to join materials together. I'm going to be talking about the welding of metal to metal and steel to steel. The most common forms welding are:

Wire feed welding - which some people describe as mig, mag, gasless or flux cored. Arc welding - also known as stick welding Tig welding Gas welding Spot welding

MIG WELDING:
MIG (Metal Inert Gas) or as it even is called GMAW (Gas Metal Arc Welding) uses an aluminium alloy wire as a combined electrode and filler material. The filler metal is added continuously and welding without filler-material is therefore not possible. Since all welding parameters are controlled by the welding machine, the process is also called semi-automatic welding. The MIG-process uses a direct current power source, with the electrode positive (DC, EP). By using a positive electrode, the oxide layer is efficiently removed from the aluminium surface, which is essential for avoiding lack of fusion and

oxide inclusions. The metal is transferred from the filler wire to the weld bead by magnetic forces as small droplets spray transfer. This gives a deep penetration capability to the process and makes it possible to weld in all positions. It is important for the quality of the weld that the spray transfer is obtained. There are two different MIG-welding processes, conventional MIG and pulsed MIG: Conventional MIG uses a constant voltage DC power source. Since the spray transfer is limited to a certain range of arc current, the conventional MIG process has a lower limit of arc current (or heat input). This also limits the application of conventional MIG to weld material thicknesses above 4 mm. Below 6 mm it is recommended that backing is used to control the weld bead. Pulsed MIG uses a DC power source with superimposed periodic pulses of high current. During the low current level the arc is maintained without metal transfer. During the high current pulses the metal is transferred in the spray mode. In this way pulsed MIG is possible to operate with lower average current and heat input compared to conventional MIG. This makes it possible to weld thinner sections and weld much more easily in difficult welding positions.

ARC WELDING

Arc welding is a process utilizing the concentrated heat of an electric arc to join metal by fusion of the parent metal and the addition of metal to joint usually provided by a consumable electrode. Either direct or alternating current may be used for the arc, depending upon the material to be welded and the electrode used.

TYPES OF ARC WELDING:

1.Fluxed-Core Arc-Welding Fluxed-Core Arc-Welding uses a tubular electrode filled with flux that is much less brittle than the coatings on SMAW electrodes while preserving most of its potential alloying benefits.The emissive fluxes used shield the weld arc from surrounding air, or shielding gases are used and nonemissive fluxes are employed. The higher weld-metal deposition rate of FCAW over GMAW (Gas Metal Arc Welding) has led to its popularity in joining relatively heavy sections of 1" or thicker. Another major advantage of FCAW is the ease with which specific weld-metal alloy chemistries can be developed. The process is also easily automated, especially with the new robotic systems.

2. Gas Metal-Arc Welding Gas Metal-Arc Welding (GMAW), also called Metal Inert Gas (MIG) welding, shields the weld zone with an external gas such as argon, helium, carbon dioxide, or gas mixtures. Deoxidizers present in the electrode can completely prevent oxidation in the weld puddle, making multiple weld layers possible at the joint. GMAW is a relatively simple, versatile, and economical welding apparatus to use. This is due to the factor of 2 welding productivity over SMAW processes. In addition, the temperatures involved in GMAW are relatively low and are therefore suitable for thin sheet and sections less than inch.GMAW may be easily automated, and lends itself readily to robotic methods. It has virtually replaced SMAW in present-day welding operations in manufacturing plants.

3. Gas Tungsten-Arc Welding Gas Tungsten-Arc Welding (GTAW), also known as Tungsten Inert Gas or TIG welding, uses tungsten electrodes as one pole of the arc to generate the heat required. The gas is usually argon, helium, or a mixture of the two. A filler wire provides the molten material if necessary.

The GTAW process is especially suited to thin materials producing welds of excellent quality and surface finish. Filler wire is usually selected to be similar in composition to the materials being welded.Atomic Hydrogen Welding (AHW) is similar and uses an arc between two tungsten or carbon electrodes in a shielding atmosphere of hydrogen. Therefore, the work piece is not part of the electrical circuit.

4. Plasma Arc Welding Plasma Arc Welding (PAW) uses electrodes and ionized gases to generate an extremely hot plasma jet aimed at the weld area. The higher energy concentration is useful for deeper and narrower welds and increased welding speed.

TIG WELDING

TIG-welding (Tungsten Inert Gas) or GTAW-welding (Gas Tungsten Arc Welding) uses a permanent non-melting electrode made of tungsten. Filler metal is added separately, which makes the process very flexible. It is also possible to weld without filler material. The most used power source for TIG-welding generates alternating current (AC). Direct current can be used, but due to high heat generation on the tungsten electrode when DC-EP (electrode positive) welding, that particular polarity is not feasible. In some cases DC-EN (electrode negative) is used, however, this requires special attention before welding, due to the arc's poor oxide cleaning action. AC TIG-welding usually uses argon as a shielding gas. The process is a multi purpose process, which offers the user great flexibility. By changing the diameter of the tungsten electrode, welding may be performed with a wide range of heat

input at different thicknesses. AC TIG-welding is possible with thicknesses down to about 0,5 mm. For larger thicknesses, > 5 mm, AC TIG-welding is less economical compared to MIG-welding due to lower welding speed. DC TIG-welding with electrode negative is used for welding thicknesses above 4 mm. The negative electrode gives a poor oxide cleaning compared to AC-TIG and MIG, and special cleaning of joint surfaces is necessary. The process usually uses helium shielding gas. This gives a better penetration in thicker sections. DC TIGwelding is applicable for welding thicknesses in the range 0,3 - 12 mm. More and more popular is also pulsed DC TIG-welding, which makes it possible to weld uniform welds with deeper penetration at the same heat input. Pulse frequency is usually in the range 1 - 10 HZ

SPOT WELDING

Spot welding is a process in which contacting metal surfaces are joined by the heat obtained from resistance to electric current flow. Work-pieces are held together under pressure exerted by electrodes. Typically the sheets are in the 0.5-3.0 mm thickness range. The process uses two shaped copper alloy electrodes to concentrate welding current into a small "spot" and to simultaneously clamp the sheets together. Forcing a large current through the spot will melt the metal and form the weld. The attractive feature of spot welding is a lot of energy can be delivered to the spot in a very short time (ten to one hundred millisecond). That permits the welding to occur without excessive heating to the rest of the sheet. The amount of heat (energy) delivered to the spot is determined by the resistance between the electrodes and the amplitude and duration of the current. The amount of energy is chosen to match the sheet's material properties, its thickness, and type of electrodes. Applying too little energy won't melt the metal or will make a poor weld. Applying too much energy will melt too much metal and make a hole rather than a weld. Another attractive feature of spot welding is the energy delivered to the spot can be controlled to produce reliable welds.