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Welding is a materials joining process which produces coalescence of materials by heating them to suitable temperatures with or without the application of pressure or by the application of pressure alone, and with or without the use of filler material.
Welding is used for making permanent joints. It is used in the manufacture of automobile bodies, aircraft frames, railway wagons, machine frames, structural works, tanks, furniture, boilers, general repair work and ship building.
WELDING PROCESSES
1. 2. 3. 4. 5. 6. 7. 8. Arc Welding Resistance Welding Oxyfuel Gas Welding Other Fusion Welding Processes Solid State Welding Weld Quality Weldability Design Considerations in Welding
Arc Shielding
At high temperatures in AW, metals are chemically reactive to oxygen, nitrogen, and hydrogen in air Mechanical properties of joint can be degraded by these reactions To protect operation, arc must be shielded from surrounding air in AW processes Arc shielding is accomplished by: Shielding gases, e.g., argon, helium, CO2 Flux
Fillet Weld
Used to fill in the edges of plates created by corner, lap, and tee joints Filler metal used to provide cross section in approximate shape of a right triangle Most common weld type in arc and oxyfuel welding Requires minimum edge preparation
(a) Inside single fillet corner joint; (b) outside single fillet corner joint; (c) double fillet lap joint; (d) double fillet tee joint (dashed lines show the original part edges)
TYPE OF JOINT
APPLICABLE WELDS FILLET PLUG SLOT SQUARE GROOVE BEVEL GROOVE J-GROOVE FLARE BEVEL GROOVE SPOT PROJECTION SEAM
TYPE OF JOINT
APPLICABLE WELDS SQUARE GROOVE V-GROOVE BEVEL GROOVE U-GROOVE J-GROOVE FLARE V-GROOVE FLARE BEVEL GROOVE EDGE FLANGE
TYPE OF JOINT
APPLICABLE WELDS
FLARE V-GROOVE FLARE BEVEL GROOVE EDGE FLANGE CORNER FLANGE SPOT PROJECTION SEAM
TYPE OF JOINT
APPLICABLE WELDS
FILLET PLUG SLOT BEVEL GROOVE J-GROOVE FLARE BEVEL GROOVE SPOT PROJECTION SEAM
TYPE OF JOINT
APPLICABLE WELDS PLUG SLOT SQUARE GROOVE BEVEL GROOVE V-GROOVE U-GROOVE J-GROOVE EDGE FLANGE CORNER FLANGE SPOT PROJECTION SEAM EDGE
Arc Welding A pool of molten metal is formed near electrode tip, and as electrode is moved along joint, molten weld pool solidifies in its wake
Flux
A substance that prevents formation of oxides and other contaminants in welding, or dissolves them and facilitates removal Provides protective atmosphere for welding Stabilizes arc Reduces spattering
Square-groove welds are the most economical to use, but are limited by thickness of the members Welds for one side are normally limited to a 1/4 inch or less
With thicker materials joint accessibility must be provided for welding to ensure weld soundness and strength
Bevel- and J- groove welds are more difficult to weld than V- or U- groove welds Bevel welds are easier in horizontal
Leg Face Throat Groove radius Root opening (groove weld) is the space between the pieces before welding* Root face Groove angle
Incomplete Fusion
A weld bead in which fusion has not occurred throughout entire cross section of joint Several forms of incomplete fusion are shown below
(a) Desired profile for single V-groove weld joint, (b) undercut - portion of base metal melted away, (c) underfill - depression in weld below adjacent base metal surface, and (d) overlap - weld metal spills beyond joint onto part surface but no fusion occurs
WELDED CONNECTIONS