HANDOUT 8

MEC3459
Welding

Learning Objectives
Welding Processes
Metallurgical / Microstructural Changes
during Welding: HAZ
Defects Produced during Welding
Welding Safety

1
 Common Welding Process

Pieces to be
welded
An energy
source to
produce
molten mass
(generally)
A welder

2
 Welding
process to join metal pieces,
heating to temperature high enough to cause
softening or melting metallic bonding
with or without application of pressure
often filler material is added to form a pool of
molten material

Similar metals welding

Dissimilar metals welding

3
 Why is Welding Important?
Many things around us are welded
Pipelines that bring fresh water
Towers that carry electricity to houses
Cars and buses that take people where they need to go

Join inexpensive parts to form complex product

4
 Can All Metals be Welded?
Most metals can be welded, but not all
The three most common weldable metals
include:
Mild Steel - inexpensive and strong
Stainless Steel does not rust
Aluminum does not rust and is light weight

Mild steel Stainless Steel Aluminum

5
 Manual Metal Arc Welding
Also known as Shielded Metal Arc Welding

Heat Source is
an electric arc:
- high current,
~500A
- low voltage
discharge 10-
50V

Direction of Welding
6
 Manual Metal Arc Welding
Electrode:
core filler-wire (welding rod),

flux coating
protection between
molten layer and air,
creates reducing environment
to prevent moisture to get to molten pool

Gaseous shield:
cover on the immediately produced molten mass
 Manual Metal Arc Welding
The filler wire (welding rod) and the adjoining part
of work pieces are both heated to temperatures
above melting
Appropriate filler wire for similar and dissimilar
welding
Upon solidification, fusion joint forms between the
work pieces
Temperature in the area adjoining the molten is
high enough to cause change in microstructure:
heat affected zone (HAZ)

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 Manual Metal Arc Welding

Weld Pool,
Heat Affected Zone (HAZ),
Base Metal

Progress of Welding
Front
 Heat Affected Zone
Cross-section of
Weldment:
Weld Pool,
Heat Affected Zone (HAZ),
Base Metal

Section of
Weldment
10
Temperature
Profile and
Metallurgical
Changes
across
Weldment:
Fe-C Alloy

11
 Microstructure and Property of HAZ
The areas adjacent to weld pool where temperature is
high enough:
o transformation to austenite: austenite upon cooling
transforms to martensite (undesirable)
o recrystallization and grain growth: decrease in
strength and hardness
o undesirable formation/coarsening of other phases
(e.g., carbides, intermetallics): decrease in strength
and hardness
o residual stress: necessitates post-weld heat-
treatment (PWHT)
o some alloys (e.g. stainless steels) may undergo
sensitization: poor corrosion resistance
12
 Welding Stresses:
Problems and Mitigation
Formation of martensite (highly strained
and hard structure):
may result in deformation of weldment
pre-heating the work-piece to
temperatures > Ms may be necessary
Residual stresses may cause cracking
(particularly stress corrosion cracking):
PWHT for stress relieving

13
Martensite Transformation

M = Martensite, A = Austenite
Pre-heating of Welding Workpieces

Preheating to temperatures > Ms:

For avoiding martensite formation

Preheating to temperatures > 100oC:

For removing H2O:
- for avoiding hydrogen-assisted
cracking

15
Multiple Pass Welding

Structure of
Multiple Pass
Weldment
Multiple Pass Welding: Metallurgical Changes
 Common Weld Defects
Porosity
Porosity is gas-filled pores found in the solidified weld bead
Slag inclusion
Inclusion of solidified slag in weld bead

Deleterious microstructure
Formation of martensite, brittle carbides etc.

Deformation
Due to: (a) melt solidification shrinkage, (b) stresses
Hydrogen cracking
Cracking due to dissolved hydrogen in weld bead

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Welding Defects

19
 Welding Defects

Incomplete Penetration
(not enough heat input)

20
 Welding Techniques
Manual Metal Arc Welding (MMAW)
Submerged Arc Welding (SAW)
Gas Tungsten Arc Welding (GTAW) or Tungsten Inert gas
welding (TIG)
Gas Metal Arc Welding (GMAW) or Metal Inert Gas
Welding (MIG)
Plasma Arc Welding (PAW)
Thermit Welding
Laser Beam Welding
Electron Beam Welding
22
 Protective Clothing
Welders must wear protective
clothing for
Protection from sparks, spatter and UV
radiation
Insulation from electric shock

Protective clothing includes

Fire-proof clothing without rolled sleeves,
cuffs or frays
Work boots
Welding gloves, jackets, bibs, and fire-proof
pants
Welding cap, helmet and safety glasses
Ear protection ear plugs and muffs

23
 Welding Safety
Protect yourself and
others from potential
hazards including:
Fumes and Gases
Electric Shock
Arc Rays
Fire and Explosion
Hazards
Noise
Hot objects

24
 Fire & Explosion Hazards
Welding sparks can cause fires
and explosions
Sparks and spatter from the
welding arc can spray up to 35
feet from your work
Flammable materials should be
removed from the welding area
or shielded from sparks and
spatter
Have a fire extinguisher ready
Inspect area for fires 30
minutes after welding
25
 Arc Rays

Arc rays can injure eyes and

burn skin

The welding arc is brighter

than the sun

Precaution must be taken to

protect your eyes and skin
from UV radiation

Wear correct eye and body

protection

26
 Electric Shock
Electric shock can kill !!!
Do not touch live electrical
parts
Primary Voltage 230, 460
volt input power
Secondary Voltage 6 to
100 volts for welding
Insulate yourself from work
and ground
Do not make repairs
Follow all warnings on yourself, alert your
welding equipment instructor immediately!

27
 Fumes & Gases
Fumes and gases can be
hazardous to your health
Keep your head out of the
fumes
Use enough ventilation,
exhaust at the arc, or both,
to keep fumes and gases
from your breathing zone
and the general area
See product labeling and
MSDS for ventilation and
respirator requirements

28
 Welding Safety
A welder MUST always follow safe work practices
Welding can be safe when sufficient measures are taken
to protect yourself and others from potential hazards
Students should read and understand the following
before welding:
Warning Labels
Material Safety Data Sheets (MSDS)
Students should also be familiar with the following
information
Safety in Welding, Cutting, and Allied Processes (ANSI Z49.1)
Lincoln Electrics Arc Welding Safety (E205)
https://www.youtube.com/watch?v=yI4bGRqG4F4
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 Time To Practice
Go out to the lab
Demonstrate the use of
proper safety
precautions such as:
Reading warnings
Using proper
protective clothing
Equipment inspection
Keeping your head
out of the fume
Proper ventilation

30
Thank You

31
Submerged Arc Welding (SAW)

Consumable wire electrode

Shielding provided by flux granules
Low UV radiation & fumes
Flux acts as thermal insulator

Automated process (limited to flats)

High speed & quality (4 10x SMAW)
Suitable for thick plates
32
Gas Tungsten Arc Welding (GTAW) or
Tungsten Inert Gas (TIG) Welding

33
Gas Metal Arc Welding (GMAW) or
Metal Inert Gas (MIG) Welding

34
Plasma Arc Welding (PAW)

35
 Solid State Welding Techniques
Welding processes carried out at
temperatures essentially below the melting
point of the base materials being joined
(welding without melting).
Forge Welding
Friction Welding
Flash Butt Welding
Explosive Bonding
Diffusion Bonding
Ultrasonic Welding
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 Modern Joining Techniques
Laser Welding
highly focused and intense laser beam in used as
heat source
laser beam melts the parent metal: solidification
results in fusion joint (no filler wire is required)
low heat in-put process: size of HAZ is less
non-contact process
rapid and easy to automate: precision welding
porosity/defect free welds
extensively used in automotive and electronic
industry: high quality welds
infrastructure is expensive
37
 Modern Joining Techniques
Electron-Beam Welding
Friction Stir Welding

Friction Stir Welding 38