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Chapter 30
Fusion Welding Processes
Figure 30.1 Three basic types of oxyacetylene flames used in oxyfuel-gas welding and cutting
operations: (a) neutral flame; (b) oxidizing flame; (c) carburizing, or reducing, flame. The gas
mixture in (a) is basically equal volumes of oxygen and acetylene. (d) The principle of the oxyfuelgas welding operation.
Oxyacetylene Torch
Figure 30.2 (a) General view of and (b) cross-section of a torch used in oxyacetylene welding. The
acetylene valve is opened first; the gas is lit with a spark lighter or a pilot light; then the oxygen
valve is opened and the flame adjusted. (c) Basic equipment used in oxyfuel-gas welding. To
ensure correct connections, all threads on acetylene fittings are left-handed, whereas those for
oxygen are right-handed. Oxygen regulators are usually painted green, and acetylene regulators
red.
Figure 30.3 Schematic illustration of the pressure-gas welding process; (a) before, and (b) after.
Note the formation of a flash at the joint, which can later be trimmed off.
Arc-welding Processes
The process involves:
A consumable electrode.
A non consumable electrode.
An AC or a DC power supply produces an arc between
the tip of the electrode and the workpiece to be welded.
The arc generates temperatures of about 30,000C,
Non consumable-electrode
Non consumable-electrode
the electrode is typically a tungsten electrode.
An externally supplied shielding gas is
necessary to prevent oxidation of the weld zone.
Typically, direct current is used.
Its polarity (the direction of current flow) is
important.
polarity
Straight polarity:
Also known as direct-current electrode negative (DCEN).
The workpiece is positive (anode), and the electrode is
negative (cathode).
DCEN generally produces welds that are narrow and deep.
Reverse polarity:
Also known as direct-current electrode positive (DCEP).
The workpiece is negative and the electrode is positive.
Weld penetration is less, and the weld zone is shallower
and wider.
The heat input given by Eq. (30.3) melts a certain volume of material, usually the
electrode or filler metal, and can also be expressed as
Electrode Designations
Welded Joints
Weld Symbols
Weld Design
Figure 30.29 Some design guidelines for welds. Source: After J.G. Bralla.
Weld Quality
Cold Welding
In cold welding (CW), pressure is applied to the
workpieces through dies or rolls.
During the joining of two dissimilar metals that are
mutually soluble.
Brittle intermetallic compounds may form (Section 4.2.2);
these will produce a weak and brittle joint.
Friction Welding
Figure 31.3 (a) Sequence of operations in
the friction welding process: (1) Left-hand
component is rotated at high speed. (2) Righthand component is brought into contact under
an axial force. (3) Axial force is increased;
flash begins to form. (4) Left-hand component
stops rotating; weld is completed. The flash
can subsequently be removed by machining
or grinding.
Figure 31.4 The principle of the friction stir welding process. Alluminum-alloy plates
up to 75 mm (3 in.) thick have been welded by this process.
Spot Welding