CONTENTS

INTRODUCTION
ARC COLUMN
CONDITION FOR MAX.UTILISATION OF POWER
METAL INERT GAS WELDING (M.I.G)
TUNGSTEN INERT GAS WELDING (T.I.G)
RESISTANCE WELDING
STUD WELDING
SOLDERING & BRAZING



INTRODUCTION
Welding is the process of joining two
materials with or without application
of heat, pressure or filler material.
ARC WELDING EQUIPMENTS

AC or DC machine
Electrode
Electrode holder
Cables, cable connectors
Cable lug
Chipping hammer
Earthlings clamps
Wire brush
Helmet
Safety goggles
Hand gloves
Aprons, sleeves.



WELDING CLASSIFICATION
















































WELDING
FUSION WELDING
(WITHOUT PRESSURE)
NON-FUSION WELDING
(WITH PRESSURE)
ARC GAS
THERMIT
(CHEMICAL)
A.C.

D.C.

TIG

MIG

SAW
Oxy- C
2
H
2

Oxy-H2
Air-C
2
H
2

HEAT
BLACKSMITH FORGE
RESISTANCE
WELDING
COLD PRESSURE
WELDING
ELECTRODES FOR ARC WELDING
Basically electrodes are classified into

1. consumable electrode
a. Bare electrode
b. Coated electrode

2. Non-consumable electrode
Specification of electrode
TYPE OF COATING
WELDING POSITION
% ELONGATION
CURRENT CONDITIONS
STRENGTH OF ELECTRODE
ARC COLUMN
The arc column is generated between an anode, which is the
positive pole of D.C.power supply and the cathode.

ELECTRICAL THEORY OF ARC COLUMN

Approximately 1Kw-hr of electricity will create 3413 Btu,
i.e.3.6MJ of heat will be liberated.

Three areas of heat are liberated in the arc stream.
Cathode area
Plasma area
Anode area
Of the above anode area is the high heat area.
INITIATION OF ARC
TYPES OF WELDS
METAL INERT GAS WELDING
WORKING PRINCIPLE
Metal inert gas welding or Gas metal-arc
welding is a gas shielded metal-arc welding process,
which uses the high heat of an electric arc between a
continuously fed, consumable electrode wire and the
material to be welded in the presence of an inert gas.
CURRENT RANGE: 100 to 400A
Welding wire : citofil of diameter of 0.9 to 1.6mm
Block Diagram of MIG welding
Working Principle
MIG welding is done in combination of
For welding aluminium/copper, argon or
argon-helium mixtures are used.
For stainless steel, argon-oxygen or helium-
argon gas mixtures are used.
Titanium requires pure argon gas shielding.
Copper-nickel and high-nickel alloys use
argon-helium mixture.
ADVANTAGES OF MIG

No flux required.

High welding speed.

Increased corrosion resistance.

Easily automated welding.

Welds all metals including aluminium and stainless steel.

High economy.

Up to 25-30 mm plates can be welded in single pass.

TUNGSTEN INERT GAS WELDING
WORKING PRINCIPLE
This process uses the intense heat of an electric arc between a non-
consumable tungsten electrode and the material to be welded. The shielding
is obtained from an inert gas such as helium or argon or a mixture of two.
ELECTRODE: Tungsten
FLUX : Argon or Helium ( Inert gas)
The TIG process lends itself able to the fusion welding of aluminium and
it's alloys, stainless-steel, magnesium alloys, nickel base alloys, copper
base alloys, carbon steels. TIG welding can also be used for the combining
of dissimilar metals, hard facing, and the surfacing of metals. But this
process is not used, as often on plate over 6.4 mm thick, but it is easier than
MIG welding for thin plates and small parts.
In general, an AC power source is best for TIG welding non-ferrous alloys
except deoxidized copper. For ferrous alloys the DC power with straight
polarity is better.
ADVANTAGES OF TIG WELDING
It produces high quality welds in non-ferrous
metals.
Practically no weld cleaning is necessary.
The arc and weld pool are clearly visible to the
welder.
Developed for most reactive materials.
DISADVANTAGES OF TIG WELDING

DI SADVANTAGES
The flux needs preplanning of the same on the
joint that is not always possible.
The process is limited to welding in flat
position and on metal more than 4.8 mm thick.
Flux is subject to contamination that may
cause weld porosity.
Coated electrodes serve several purposes
To facilitate the establishment and maintenance of the
arc, coating of potassium compounds is provided.
To protect the molten metal from the oxygen and
nitrogen.
To provide the formation of slag so as to protect the
welding seam from rapid cooling. For this, rutile
coating is provided.
To provide a means of introducing alloying elements
not contained in the core wire.
Shielding gas protection, for this, cellulose coating
will be applied.
MERI TS
Because of high heat concentration, considerably
higher welding speeds can be used.
Because of high heat concentration and faster welding
speeds distortion is much less.
Welding is carried out without sparks, smoke, flash
and spatter.
Weld metal deposited possesses uniformity, good
ductility, corrosion resistance and good impact
strength.
SOLDERI NG
For soldering temperature should be either less than 427
o
C or
less than melting point of metals to be joined, whichever is
minimum.
Air-acetylene is used as heat source for soldering earlier but
now electrical resistance is used as heating source.
Filler material: Lead + Tin Soft solder
If percentage of tin increases weld ability and joint strength
but cost is high.
Lead + Tin + Silver Hard soldering
By using this joint is much more but cost is very high.
For space and aircraft industries it is used.
BRAZI NG
For Brazing, temperature should be either greater
than 427
o
C or less than melting point of
metals to be joined.
FI LLER MATERI AL: Copper + zinc
Due to capillary action, molten metal pass
through joint is known as Brazing.
Due to gravity action, molten metal pass
through joint is known as Braze welding.
WELDABI LI TY
Melting point of material.
Thermal conductivity.
Thermal expansion.
Electrical resistance.
Surface condition.
Reactiveness with Oxygen.

t
y
t
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 of 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 easily in difficult welding positions.