Report for MTE521

Metallurgy in Welding
By ndrilon 2009

What is WELDING

in engineering, any process in which

two or more pieces of metal are
joined together by the application of
heat, pressure, or a combination of
both.

Master chart of Arc Welding and Related Methods

Types of welds

Bead
Groove
Fillet
Surfacing
Tack
Plug
Slot
Resistance

Bead weld

Produced by a
single pass
Stinger Beadwhich is made
without weaving
motion.
Weave Bead- made
by side-side
oscillation

Groove weld

Groove welds are

simply welds made
in the groove
between two
members to be
joined.

Surfacing welds

a surfacing weld is
composed of one or
more stringer or weave
beads. Surfacing,
sometimes known as
hardfacing or wearfacing.
is often used to build up
worn shafts, gears, or
cutting edges.

Fillet weld

This weld is used

to join two surfaces that are at
approximately
right angles to
each other in a
lap, tee, or comer
joint

Plug and Slot weld

are welds made

through holes or
slots in one
member of a lap
joint.

Tack weld

is a weld made to hold

parts of an assembly in
proper alignment
temporarily until the final
welds are made.
they are normally between
1/2 inch to 3/4 inch in
length, but never more
than 1 inch in length.

Basic Welding Positions

Common Welding Types

Arc

Welding (AW)

Oxyfuel

Gas Welding(OFW)

Resistance

Welding

Types of ARC Welding

Shielded Metal Arc Welding (SMAW)

Submerged Arc Welding (SAW)
Flux Cored Arc Welding (FCAW)

Gas Tungsten Arc Welding (GTAW or TIG)

Gas Metal Arc Welding (GMAW or MIG)

SMAW
is performed by striking an arc
between a coated-metal electrode
and the base metal.
Flux- the coating of the metal
electrode will form as shield to the
molten metal.

Shielded Metal Arc Welding

SMAW OPERATION

Arc Welding MAchines

Electrode and Holder

Advantages of SMAW
High quality welds are made rapidly
at a low cost.
Can be used easily even to thick and
wide work piece to be joined.
Can be used from thinner to thicker
materials.

Disadvantages SMAW
Consumes bigger electric current
Dirty work finish
Root pass is lower than TIG and MIG
Prone to slag inclusions
Weld deposits is prone to blue holes

SUBMERGED ARC WELDING

(SAW)

Is a process in which is done by an

automatic electrode feeding machine
wherein the tip of the electrode is
submerged into a granular flux
which shields the arc and the molten
metal.

SAW operations

SAW Welding Machine

SAW block diagram

SAW APPLICATIONS

widely used in heavy steel plate

fabrication work.
welding of structural shapes.
longitudinal seam of larger diameter pipe.
manufacture of machine components for
all types of heavy industry.
manufacture of vessels.
pressure and storage tanks.

Advantages of SAW

high quality of the weld metal.

extremely high deposition rate and speed.
smooth, uniform finished weld with no spatter.
little or no smoke.
no arc flash, thus minimal need for protective
clothing.
high utilization of electrode wire.
easy automation for high-operator factor.
normally, no involvement of manipulative skills.

Disadvantages of SAW

used only to weld mild and low-alloy highstrength steels.

Unseen arc and puddle can cause poor
penetration.
high-heat input, slow-cooling cycle can be
a problem when welding quenched and
tempered steels.
limited-position welding process only flat
and horizontal

GTAW or TIG

Gas Tungsten Arc Welding or Tungsten Inert Gas or

HELIARC Welding

is a process in which the joining of metals is produced by

heating therewith an arc between a tungsten (non
consumable) electrode and the work.

A shielding gas is used, normally Argon.

normally done with a pure tungsten or tungsten alloy rod,

but multiple electrodes are sometimes used.

Filler metals are used such as stainless steel, Aluminum

and Bronze.

Flux Cored Arc Welding

(FCAW)

is an automatic or semi-automatic
electric arc welding process that
uses an arc between a continuously
fed flux-filled electrode and the weld
pool. The process is used with
shielded gas from a flux contained
within the tubular electrode with or
without additional shielding from an
externally supplied gas.

FCAW flux filled electrode

and torch

No shielding gas (FCAW)

With Shielding Gas (FCAW)

Two Types of FCAW

no shielding gas
- using flux core in the tubular consumable
electrode

uses a shielding gas

- gas that must be supplied by an external

supply. This is known informally as "dual shield"

welding.

Uses of FCAW
Mild

and low alloy steels

Stainless steels
Some high nickel alloys
Some wear facing/surfacing
alloys

Advantages of FCAW

FCAW may be an "all-position" process with the right filler

metals (the consumable electrode)
No shielding gas needed making it suitable for outdoor
welding and/or windy conditions
A high-deposition rate process (speed at which the filler
metal is applied) in the 1G/1F/2F
Some "high-speed" (e.g., automotive applications)
Less pre cleaning of metal required
Metallurgical benefits from the flux such as the weld metal
being protected initially from external factors until the flux
is chipped away

Disadvantages of FCAW

Melted Contact Tip happens when the electrode actually

contacts the base metal, thereby fusing the two
Irregular wire feed typically a mechanical problem
Porosity the gases (specifically those from the flux-core)
dont escape the welded area before the metal hardens,
leaving holes in the welded metal
More costly filler material/wire as compared to GMAW
Less suitable for applications that require painting, such as
automotive body works.
Cannot be used in a rugged environment limited to shop
use only.

FCAW Equipment set up

TIG WELDING

GTAW or TIG process

GTAW Welding Equipment

TIG Welding Machine

TIG Torch

ADVANTAGES of GTAW

most popular method for welding aluminum

stainless steels, and nickel-base alloys.
Produces top quality welds.
No smoke or fumes
clean no slag and spatter to be clean during
welding
reduced distortion in the weld joint because of
the concentrated heat source.
is very good for joining thin base metals
because of excellent control of heat input.

ADVANTAGES of GTAW
especially useful for joining aluminum and
magnesium which form refractory oxides,
excellent to use for the reactive metals like
titanium and zirconium, which dissolve oxygen
and nitrogen and become brittle if exposed to air
while melting.
welding process by fusion alone without the
addition of filler metal.( non-consumable
electrode)
Used in very critical service application and on
very expensive metal or parts.

Disadvantages of GTAW

EXPENSIVE
a. Arc travel speed and weld metal
deposition rates are lower.
b. high price of Inert gases for shielding
such as Argon and Helium.
c. price of Tungsten electrode is high.
d. Equipment costs are greater than that
for other processes, such as SMAW, which
require less precise controls.

MANY LIMITATIONS and cannot be used

in full welding operations

Limitations of GTAW

SLOWER WELDING PROCESS

slower than consumable electrode arc welding.

FAST CONTAMINATION
1.

During transfer of molten tungsten from the

electrode to the weld.

2. tungsten inclusion(unbalance gas shielding

the inclusion is hard & brittle)
3.

During exposure of the hot filler rod to air.

4.

When there is improper welding techniques

GMAW

or

MIG

is an electric arc welding process which

joins metals by heating them with an arc
established between a continuous filler
metal (consumable) electrode and the work.

Shielding of the arc and molten weld pool is

obtained entirely from an externally
supplied gas or gas mixture both inert and
reactive gases.

GMAW Welding Operations

MIG Machine with Spool

feeder

GUN used in GMAW

MIG Torch

GMAW Weld Diagram

Advantages of GMAW

Produced High quality welds & much faster than

with SMAW and TIG welding.

No flux is used no slag entrapment in the weld

metal.

Very little loss of alloying elements as the metal

transfers across the arc.

Minor weld spatter is produced, and it is easily

removed.

Advantages of GMAW

Versatile and can be used with a wide variety of

metals and alloys, such as Aluminum, Copper,
Magnesium,
Nickel, Iron and many of their alloys.
The process can be operated in several ways,
including semi- and fully automatic.
MIG welding is widely used by many industries for
welding a broad variety of materials, parts, and
structures.

Disadvantages of GMAW

IT cannot be used in the vertical or overhead

welding positions due to the high heat input and
the fluidity of the weld puddle.

Has complex equipment compared to

equipment used for the shielded metal-arc
welding process.

Oxygen Fuel Gas Welding

(OFW)
is a group of welding
processes which join metals
by heating with a fuel gas
flame or flares with or without
the application of pressure
and with or without the use of
filler metal.

Types of Oxy-fuel Gas

Welding
Oxy-Acetylene or Oxygen- Acetylene
Gas Welding
Oxy-Hydrogen or Oxygen- Hydrogen
Gas Welding
Methylacetone-Propadiene Gas
Welding
Pressure Gas Welding.

Advantages of Oxy-fuel
Gas Welding

Easy to use both welding and cutting

Controlled heat input

Controlled bead size

Convenient to use in welding thin sheets,

tubes and small diameter pipes

Disadvantages of Oxy-Fuel
Gas Welding

Cannot be use to weld on thick work

piece.

Expensive gas

Oxy-Acetylene Diagram
Welding Equipment

Complete Oxy-Acetylene
Welding Equipment

Resistance Welding
is a process in which the fusing temperature is generated
at the joint by the resistance to the flow of an electrical
current.

is accomplished by clamping two or more sheets of

metal between copper electrodes and then passing an
electrical current through them. When the metals are
heated to a melting temperature, forging pressure is
applied through either a manual or automatic means to
weld the pieces together.
Two common types are Spot and Seam welding

2 Types of Resistance
Welding
SPOT WELDING
SEAM WELDING

SPOT WELDING
The metal to be joined is
placed between two
electrodes and
pressure is applied.
A charge of electricity is
sent from one
electrode through the
material to the other
electrode.

SEAM Welding

is
like spot welding
except that the
spots overlap each
other, making a
continuous weld
seam.