SURYA PANDEY

2K20/A6/15
WELDING SHOP

SURYA PANDEY 2K20/A6/15 1

Welding is a process of joining similar metals by application of heat with or without
application of pressure and addition of filler material. The result is a continuity of
homogeneous material, of the composition and characteristics of two parts which are being
joined together. Welding is extensively used in the fabrication work in which metal plates,
rolled steel sections, castings of ferrous materials are joined together it is also used for
repairing broken, worn-out or defective metal parts.

Types of welding
There are two main types of welding they are:

1. Plastic (Pressure) welding

2. Fusion (Non-Pressure) welding

In the plastic welding or pressure welding, the pieces of metal to be joined are heated
to a plastic state and then forced together by external pressure. This procedure is used
in forging welding, resistance welding, “thermit” welding, and gas welding, in which
pressure is required.

In the fusion welding or no pressure welding, the material at the joint is heated to a
molten state and allowed to solidify. This includes gas welding, arc welding, “thermit”
welding etc.
Arc welding

Fig: Arc welding

Arc welding is a metal joining process, where the joint is produced by heating the work
piece with an electric arc set up between an electrode and the work piece. The electrical
energy is converted into heat in the arc, which attains a temperature around 5500 degrees.
The electrode itself melts and supplies the necessary filler material.

Principle of arc welding

As shown in fig, in arc welding metal rod is used as one electrode, while the work being
welded is used as another electrode during welding operation, this metal electrode is
melted by the heat of the arc and is fused with the base metal, thus forming a solid uniform
weld, after the metal has been cooled. Both AC and DC may be used for this welding
process.

Electric arc welding

The process is illustrated by means of a schematic diagram the metal of the work piece to
be joined is called base metal or parent metal and that provided by the electrode as filler
metal. Arc welding is the most extensively employed method of joining metal pats. The
source of heat is electric arc.

The arc column is generated between an anode, which is positive pole of DC power supply,
and the cathode, the negative pole. When these two conductors of an electric circuit are
brought together and separated for small distance (2 to 4 mm) such that the current
continues to flow through a patch of ionized particles (gaseous medium) called plasma, an
electric arc is formed. Heat is generated as the ions strike the cathode. However, electrical
energy is converted to heat energy. Approximately 1 kWh of electricity will create the
temperature at the center of the arc being 6,000 to 7,000 degrees, the temperature of an
electric arc depends upon the type of electrodes between which it is stuck.

The heat of the arc raises the temperature of the parent metal which is melted forming a
pool of molten metal. The electrode metal (in metal arc welding) or welding rod (in carbon-
arc welding) is also melted and is transferred into the metal in the form of globules of
molten metal. The deposited metal serves to fill and bond the joint or to fuse and build up
the parent metal surface.

Arc welding electrodes

The 2 types of electrodes used in Arc welding are:

1. Consumable electrode
2. Non-consumable electrode

Consumable electrode melts along with the work piece and fills in the joint. When non-
consumable joints are used, an additional filer material is used, the advantage using non-
consumable electrode is the metal deposited by a filler rod can be controlled which is
into possible in consumable electrode.

Fluxes
An electrode has metal core surrounded by flux coating. Flux coating is made up of ferrous
alloys. The functions of flux coating are:

1. It produces a gas which provides a shield around the arc to protect it from
atmosphere.
2. It forms slag by mixing with impurities of the molten metal and thus refines the
metal.
3. The slag being lighter floats over the surface of the molten metal and on
solidification forms a thin layer over the weldment, which helps in gradual and
uniform cooling of weld and prevents its oxidation during cooling.
4. In some cases, it also carried necessary alloying elements which are added to the
molten metal.
5. It promotes conduction of electric current across the arc and helps in stabilizing the
arc.
6. It also helps in controlling the bead shape by providing necessary materials for this
purpose.

Equipment used in Arc welding

The most commonly used equipment for arc welding consists of:

1. AC or DC machine
2. Electrode
3. Electrode holder
4. Cables, cable connectors
 5. Earthing clamps
6. Safety goggles
7. Welding helmet
8. Hand gloves
9. Aprons
10. Chipping hammer
11. Wire bush etc.

Transformer

Fig: Transformer

The function of a transformer is to generate a low voltage (10 to 50 V) and high amperage
(50 A to 300 A) electric current. The current may be alternating current or direct current.
Transformer converts electrical energy into heat energy which is required for the welding
process.
Electrode holder

The electrode holder is connected to the end of the welding cable and holds the electrode.
It should be light strong and easy to handle and should not become hot while in operation.
The jaws of holder are insulated, providing protection from electric shock.
Electrode

Welding rod or electric rod acts as filler material i.e., when the arc produced at the tip of
electrode during the welding process, the electrode itself melts and fills the gap between
two base metals.

Electrodes commonly used are of two types

1) Coated electrodes
2) Bare electrodes

Coated electrodes carry a core of bare metallic coated wire provided with a flux coating wire
provide with a flux coating or covering on the outside surface.

Mild steel is the most commonly used for material for core wire.

The common ingredients of a flux which help in slag formation and metal refining are
asbestos, mica, silica, fluorspar, steatite etc.

Bare electrodes are one which does not have any coating. Bare electrodes are cheaper, but
welds produced through these are of poor quality. It is used in inert gas metal arc welding
(MIG).

Ground (earthing) clamp

It is connected to the end of the ground cable and is clamped to the work or welding table
to complete the electric circuit. It should be strong and durable, and give low resistance
connection.
Face or head shields

A face or head shield provides better protection and allow the welder the free use of both
hands. It is mainly used to protect the eyes and face from the spotter or flying particles of
hot metal. It is available either in hand or helmet type. The hand type is convenient when
the work can be done by one hand.

Goggles

Fig: Goggles

Goggles with coloured glasses are used to protect the eyes from glare and flying bits of hot
metal.

Chipping hammer

Chipping hammer is used for removing or chipping off the slag that forms on welded
surface. A chipping hammer has two striking ends, one end of the head is sharpened like a
cold chisel and the other flat and that turns parallel to handle.
Wire bush

Wire bush is used after chipping, for further cleaning of the welded surface. Bristles are
made from steel or stainless steel.

Aprons and hand gloves

Aprons and hand gloves are flame retardant outfits worn by a welder to protect the under
clothing and the body from the sparks the molten metal and the hot metal being welded.

Types of welded joints

The relative positions of the two work pieces being joined determine the type of joint. The
following are the give basic types of joints commonly used in fusion welding are:

1. Lap joint
2. Butt joint
3. Corner joint
4. T-joint
5. Edge joint

Lap joint
The lap joints are obtained by over lapping the plates and then welding the edges of the
plates. These joints are employed on plates having thickness less than 3 mm. The lap joints
may be

1. Single transverse
2. Double transverse
3. Parallel lap joint

Butt joint
The butt joint is obtained by welding the ends or edges of the two plates which are
approximately in the same plane with each other. In butt welds, the plate edges do not
require bevelling if the thickness of the plates is less than 5 mm, on the other hand, if the
plate thickness is 5 mm to 12.5 mm, the edges should be bevelled to V or U-groove and the
plates having thickness above 12.5 mm should have a V or U-groove on both sides.

The butt joints maybe:

1. Square butt joint

2. Single V-butt joint
3. Double V-butt joint
4. Single U-butt joint
5. Double U-butt joint

Corner joint
The corner joint is obtained by joining the edges of two plates whose surfaces are at right
angle to each other. It is used for both light and heavy gauge sheet metal. In some cases
corner joint can be welded; without any filler material, by melting of the edges of the parent
metal.

Edge joint
The edge joint is obtained by joining two parallel plates. It is economical for plates having
thickness less than 6 mm, this joint is unsuitable for members subjected to direct tension or
bending.

T-Joint
The T-joint is obtained by joining two plates whose surfaces are approximately at right
angles to each other. It is widely used to weld siffeners in aircraft and other tin structures.
These joints are suitable upto 3 mm thickness.

Preparation of the work before welding:

Before welding, the work pieces must be thoroughly cleaned of rust, scale and other foreign
materials. Thin pieces of metal are generally weld without bevelling the edges. However
thick work pieces should be bevelled to ensure adequate penetration and fusion of all parts
of the weld. But, in either case, the parts to be welded must be separated slightly to allow
better penetration of the weld.

Advantages of the welding

1) A properly made weld can be stronger than the part of which it is used.
2) It is a permanent joint.
3) The equipment is inexpensive.
4) The joint produced by welding is as strong as base metal.
5) No patters are used as in castings.
6) The equipment can be portable.
7) The process allows considerable freedom in design.
 Disadvantages of welding:
1) A good job requires a skilled worker.
2) Fixtures are often needed to hold parts in position for welding.
3) Each part of weldment must be cut to size and shape before it can be welded.
4) Presence of residual stresses and distortion in the welded joints.

Common defects in welding

The common defects of welded joints are as follows:

1) Cracks: Cracks may be microscopic scale or macroscopic scale depending upon their
size. Cracks in the welded joint may arise from localized stresses set up by uneven
heating and cooling, presence of high percentage of sulphur and carbon in the base
metal.
2) Porosity: Porosity is a group of small voids, whereas blow holes or gas packet is a
comparatively bigger isolated hole or cavity. They occur mainly due to entrapped
gases.
3) Poor fusion: it is lack of thorough and complete union between the metal deposited
by the electrodes and parent metal.
4) Inclusions: The presence of non-metallic substances in the metal is called inclusion.
Inclusion lowers the strength of the joint.
5) Undercut: In undercut, a groove gets formed in the base metal along the sides of the
welded joint. The reasons for under cutting are non-uniform feed of the welding rod,
improper off the electrode or excessive heating.

Safe welding practices

1) Never look at the arc with naked eye. The arc can burn your eyes severely.
Therefore, always use a face or head shield or goggles, while welding.
2) Always wear the safety hand gloves apron and shoes.
3) Ensure proper insulation of the cables and check for openings.

Gas welding
Gas welding is done by burning a combustible gas with air or oxygen in a concentrated flame
of high temperature. As with other welding methods, the purpose of the flame is to heat
and melt the parent metal and filler rod of a joint. It can weld most common materials.
Equipment is inexpensive, versatile, and serves adequately in many job and general repair
shops.

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 Fig: Oxy-acetylene welding (Example of gas welding)

Advantages:
i) The equipment is portable & is comparatively inexpensive & requires little
maintenance.
ii) Practically all metals may be welded and the equipment can be used for cutting.

Disadvantages:
1) Gas welding is slower than electric arc welding.
2) Not suitable for heavy section.
3) Gas cylinders should be handled carefully since they are highly explosive.

SURYA PANDEY 2K20/A6/15 11

 Job
Aim:
To weld two pieces of metal (100mmx50mmx6mm each) in a single V butt joint by
Shielded Metal Arc Welding.
Procedure:
1. A butt joint consists of placing the edges of two pieces of metal together.
2. In a v butt joint, the edges of both the pieces are prepared in such a manner
that a v- groove is formed between them when they are placed next to each
other.
3. The angle contained by the v- groove must be between 60 to 70 degrees.
4. After preparation and placement of the two workpieces (next to each other),
two tack welds are made at both ends.
5. Once it has been ascertained that the tack welds are made appropriately, an
arc should be struck and moved along the joint in a single pass.
6. The joint is then allowed to cool slightly after which slag deposits are removed
from its surface.
7. It is then allowed to cool.
Precautions:
i) Always use face and hand shields during welding.
ii) Distance between the two metal pieces should be the same throughout
the length of joint.