DEPARTMENT OF TECHNICAL EDUCATION

ANDHRA PRADESH
Name
: V.Surya Pratap
Designation
: Lecturer
Branch
: Mechanical Engineering
Institute
: GMR Polytechnic, Paderu
Year/Semester
: III Semester
Subject
: Manufacturing Technology I
Subject Code
: M306
Topic
: Welding
Duration
: 50 min
Sub Topic
: Advantages and limitations of
Teaching Aids
Revised by

welding and principle of arc welding

: Visuals
: P.Jaganmohan Rao
9M306.48

Recap
In the previous class we have learnt about
The definition of welding
Classification of welding

9M306.48

Recap
Difference between pressure and fusion welding
Pressure welding
Requires heat and
pressure
Joint area is heated to
plastic state
Requires lower
temperature
Composition not much
affected
No need of filler metal

Fusion welding
Requires only heat
Joint area is heated to
molten state
Requires higher
temperature
Composition and
structure are affected
Filler metal is required
9M306.48

Objectives
On completion of this period you would be able to
understand

Advantages and limitations of welding

Principle of arc welding

9M306.48

Welding
Advantages
Welding joint is as strong as base metal
Equipment is portable
Equipment is not very costly
Welding permits freedom in design
Large variety metals and alloys can be welded
Suitable for both similar and dissimilar metals
9M306.48

Welding
Advantages
Welded products are heavier and stronger
compared to other types of metal joining methods
Inspection is easy
Time of construction can be reduced
Cost of construction is reduced
Chances of breakdown of equipment is less
Welding can be mechanized
9M306.48

Welding
Limitations
Requires skilled operator
Residual stresses are developed at the joint
Welding results in distortion of material
Requires edge preparation of work piece before
welding
Gives out harmful radiation, fumes and spatter

9M306.48

Welding (contd)
Limitations
Welding heat produces metallurgical changes
Grain structure of the joint alters from the base metal
Welding sometimes requires jigs and fixtures
Initial expenditure and time to train operator are more

9M306.48

Arc Welding
Principle
Heat required for welding is obtained from the arc
struck between an electrode and the work piece
Electric arc sustains when current flows across the air
gap between the electrode and the work piece
Temperature of this arc is about 3600c, which is
sufficient to melt the base metal

9M306.48

Arc Welding

Principle
Temperature of the arc at the center is around 6500c
Only 60-70% heat produced is utilized and remaining
is dissipated to surroundings
Due to the heat developed, both the electrode and the
base metal gets melted

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Arc Welding
Principle
Flux coated electrodes help in forming slag deposition
on the weld metal
Slag protects the weld pool from oxidation and heat
loss (slow cooling)
Slow cooling avoids distortion and brittleness of the
joint
Slag is removed by chipping after cooling
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Principle Of Operation

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Principle of arc welding

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13

Arc welding

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Summary
In this class we have learnt about
Advantages of welding
Limitations of welding
Principle of electric arc welding

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Quiz
1.

Weld joint strength is poor compared to base metal.

a) Yes
b) No

2.

Only similar metals can be joined together in welding.

a) Yes
b) No

3.

Skilled operator is required for welding.

a) Yes
b) No

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Quiz
4. Welding results distortion of work piece
a) Yes
b) No
5. What is the source of heat in arc welding
a) Chemical reaction
b) Application of pressure
c) AC / DC power supply
d) None of the above

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Frequently Asked Questions

1.

What are the advantages of welding?

2.

What are the limitations of welding?

3.

Explain the principle of arc welding.

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