The energy for welding is supplied in the form

of heat.
So different welding types according to the
forms of heats are:
1- Pressure welding
2- friction welding
3- electric welding which are divided by:
A) Electric arc welding
a) Carbon arc welding
b) Flux Shielded Metal Arc Welding
b) Resistance are welding
a) Spot welding b) Seam welding
c) Butt welding
Electric Arc Welding
Arc welding is a type of welding that uses a welding power
supply to create an electric arc between an electrode and the
base material (workspace) to melt the metals at the welding
point. They can use either direct (DC) or alternating (AC)
current.
•In arc welding, the voltage is directly related to the length
of the arc, and the current is related to the amount of heat
input.
•The temperature of the arc is of order of 4000o c
•In case of a resistor the voltage drop increases with current
but an electric arc has a negative volt- ampere C\S i.e. the
voltage drop across the arc decreases as the current
increases.
A pool of molten metal is formed near electrode tip, and as
electrode is moved along joint, molten weld pool solidifies in
its wake
•The direction of current used in arc welding also plays an important
role in welding.

• The electrode can be charged either positively or negatively.

•In welding, the positively charged anode will have a greater heat
concentration (around 60%) and, as a result, changing the polarity
of the electrode has an impact on weld properties.
•If the electrode is positively charged, it will melt more quickly,
increasing weld penetration and welding speed.
•Alternatively, a negatively charged electrode results in more shallow
welds ‫ لحامات سطحية‬.
•Alternating current rapidly moves between these two,
resulting in medium-penetration welds. One disadvantage of
AC, the fact that the arc must be re-ignited after every zero
crossing, has been addressed with the invention of special
power units that produce a square wave pattern instead of the
normal sine wave, eliminating low-voltage time after the zero
crossings and minimizing the effects of the problem.[5]
1- Carbon arc welding (CAW)
is a process which produces coalescence ‫التحام‬of metals by heating
them with an arc between a nonconsumable carbon
(graphite) electrode and the work-piece.

• It was the first arc-welding process ever developed but is not used
for many applications today.
• In carbon-arc welding a carbon electrode is used to produce an
electric arc between the electrode and the materials being bonded.
This arc produces extreme temperatures in excess of 3,000 °C. At
this temperature the separate metals form a bond and become
welded together.
If the electrode is positive with respect to the work piece, electrons
will strike the electrode at a very high speed and cause very excessive
temperature at the tip. This will lead to rapid vaporization of the
carbon electrode and may also cause carbon particles to deposit in
the molten pool and cause brittleness. Hence such a process suited
with D.C. welding, the electrode being connected to the negative
terminal.
Flux Shielded Metal Arc Welding
is the most widely used of the various arc welding
processes. Welding is performed with the heat of an electric arc that
is maintained between the end of a coated metal electrode and the
work piece.
Advantage of coated flux:
1- the function of the coating are to stabilize the arc in case of A.C.
welding

2- They provide a layer of flux and gas which protect the arc and the
molten from contamination

3- They control weld- metal reaction and allows alloying elements to

be added to the weld metal

4- The slag left behind on the surface of the weld is allowed to

remain for some time (to avoid the welding to be brittle).
DC WELDING AC WELDING
An open circuit voltage of 60-80 volts is required
40-60 volts (safer)
The initial cost is greater The cost is half
(twice)
The overall efficiency is Is higher
lower
More popular for thin sheet The stability of AC welding
metalwork and requires is greater at high currents
lower currents because og greater energy
The magnetic field created The problem of arc below is
due to the current flowing less troublesome
through job (return current)
causes arc disturbance
known as arc blow
For good weld, the following points are to be considered:
1- The output current of the machine
2- The polarity , diameter and type of electrode
3- The arc and its adjustment
4- Base metal formation
5- Type of the base metal
Electric resistance welding (ERW)
•Resistance welding is the most commonly used method for joining steel
sheets. No filler metal is needed and the heat required for the weld pool
is created by means of resistance when a high welding current is directed
through the welded workpieces.
•heat to form the weld is generated by the electrical resistance of material
combined with the time and the force used to hold the materials together
during welding.
•Some factors influencing heat or welding temperatures are:
The proportions of the workpieces, the electrode materials, electrode
geometry, electrode pressing force, electrical current and length of
welding time.

In general, resistance welding methods are efficient and cause little

pollution, but their applications are limited to relatively thin materials
and the equipment cost can be high.
•Resistance welding is a highly efficient production method.
• The method is flexible, equipment simple and the welding
process is easy to control.

• In addition, an important advantage of the method is that it can

be used for joining a great number of metallic materials.
Resistance welding is also suitable or the welding of the most
common metal coated steel sheets.

• An electro-conductive contact surface is created between

the workpieces by pressing them together. Contact is made
using the shape of either the welded surfaces of the
workpieces or the shape of the electrodes.
Spot welding
• It is a resistance welding method used to join two or more
overlapping metal sheets, projections, electrical wiring hangers,
some heat exchanger fins, and some tubing.
• Usually power sources and welding equipment are sized to the
specific thickness and material being welded together. The
thickness is limited by the output of the welding power source
and thus the equipment range due to the current required for
each application.
• The maximum thickness of workpieces when producing lap
joints by means of resistance welding is approximately 6 mm for
uncoated steels and 4 mm for coated steels.
•Resistance spot welding typically employs electrical power in the
form of direct current,
alternating current, medium frequency,
half- wave dirct current, or high-frequency
half wave direct current.
Components in Resistance Spot Welding
• Parts to be welded (usually sheet metal)
• Two opposing electrodes
• Means of applying pressure to squeeze
parts between electrodes
• Power supply from which a controlled
current can be applied for a specified
time duration

• Resistance welding process in which fusion of faying surfaces of a lap

joint is achieved at one location by opposing electrodes
• Used to join sheet metal parts
• Widely used in mass production of automobiles, metal furniture,
appliances, and other sheet metal products
• When the current is passed through the
electrodes to the sheets, heat is generated
due to the higher electrical resistance
where the surfaces contact each other. As
the electrical resistance of the material
causes a heat buildup in the work pieces
between the copper electrodes, the rising
temperature causes a rising resistance,
and results in a molten pool contained
most of the time between the electrodes.
•When the current is stopped the copper tips cool the spot weld, causing the
metal to solidify under pressure. The water cooled copper electrodes remove
the surface heat quickly, accelerating the solidification of the metal, since
copper is an excellent conductor.
•Give reason the electrode used in spot welding are made of special copper alloy?
 Seam welding and Butt welding

Like spot welding, seam welding relies on two electrodes, usually made
from copper, to apply pressure and current. The electrodes are disc
shaped and rotate as the material passes between them. This allows the
electrodes to stay in constant contact with the material to make long
continuous welds. The electrodes may also move or assist the movement
of the material.
 A transformer supplies energy to the weld joint in the form of low voltage, high
current AC power. The joint of the work piece has high electrical resistance
relative to the rest of the circuit and is heated to its melting point by the
current. The semi-molten surfaces are pressed together by the welding pressure
that creates a fusion bond, resulting in a uniformly welded structure.

There are two modes for seam welding: Intermittent and continuous. In
intermittent seam welding, the wheels advance to the desired and stop to make
each weld. This process continues until the desired length of the weld is
reached. In continuous seam welding, the wheels continue to roll as each weld
is made.
• A common use of seam welding is during the manufacture of
round or rectangular steel tubing. Seam welding has been used to
manufacture steel beverage cans ‫علب المشروبات الصلب‬but is no longer
used for this as modern beverage cans are seamless aluminum.

The seam may be a butt joint or an overlap joint and is usually an automated process. It
differs from butt welding in that butt welding typically welds the entire joint at once and
seam welding forms the weld progressively, starting at one end.
Resistance welding equipment

The most common resistance welding machines

1- the electrical circuits ( transformer, electrodes, clamps..)
2- The mechanical system
3- The control equipment.

Some welding machines transform the supply frequency

of the welding current to be higher, which has several
advantages e.g. smaller transformers. Highfrequency
welding current is better focussed on the
connection point, which allows using significantly
lower welding currents.
1 - Pneumatic/hydraulic cylinder
2 - Push bar
3 - Electrodes and electrode holders
4 - T-plates for projection welding electrodes
5 - Throat area
6 - Control unit
7 - Transformer
8 - Transformation ratio selector
9 - Flexible conductor
Figure 6. Ordinary spot/projection welding
machine.