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Indian Institute of Technology Patna: Bihta, Bihar - 801103

The document discusses various aspects of welding including: 1) Welding involves melting materials using heat and adding a filler material to form a strong joint. There are several welding processes that use heat sources like electric arcs or gas flames. 2) Arc welding is a common type that uses a power supply to create an electric arc between an electrode and base material to melt them. It can weld ferrous and some non-ferrous metals. 3) Key aspects of arc welding include the power supply, electrodes, and materials to be welded. Proper selection of parameters like current, voltage, electrode type and size depends on the material thickness.

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Jalsingh Mali
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43 views

Indian Institute of Technology Patna: Bihta, Bihar - 801103

The document discusses various aspects of welding including: 1) Welding involves melting materials using heat and adding a filler material to form a strong joint. There are several welding processes that use heat sources like electric arcs or gas flames. 2) Arc welding is a common type that uses a power supply to create an electric arc between an electrode and base material to melt them. It can weld ferrous and some non-ferrous metals. 3) Key aspects of arc welding include the power supply, electrodes, and materials to be welded. Proper selection of parameters like current, voltage, electrode type and size depends on the material thickness.

Uploaded by

Jalsingh Mali
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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INDIAN INSTITUTE OF TECHNOLOGY PATNA

Bihta , Bihar - 801103


Welding
Welding is a fabrication that joins materials, usually
metals or thermoplastics, by melting the workpiece
and adding a filler material to form a pool of molten
material (the weld pool) that cools to become a strong
joint, with pressure sometimes used in conjunction
with heat, or by itself, to produce the weld.
List of welding processes
 Arc welding
Electrogas welding
Electroslag welding
Flux cored arc welding
Gas metal arc welding
Gas tungsten arc welding
Plasma arc welding
Submerged arc welding
MIG,TIG welding
 Oxyfuel gas welding
Air acetylene welding
Oxyacetylene welding
Thermite welding
 Resistance welding
Flash welding
Pressure-controlled resistance welding

 Other welding
Electron beam welding
Electroslag welding
Flow welding Induction welding
Laser beam welding
Arc Welding
• Arc welding is a type of welding that uses a power
supply to create an electric arc between an electrode
and the base material to melt the metals at the
welding point.
• Limited to welding ferrous materials
• Special electrodes cast iron, nickel, aluminium,
copper and other metals can also be welded.
• Versatile ,Portability, cheap.
Essentials
 Power Supply
 Electrodes
 Metals to be Welded
Power Supply
 Constant current power supply
 Constant voltage power supply
• Voltage is directly related to the length of the arc,
• Current is related to the amount of heat input.
• Typical parameters 50 to 500 amps, depending on the
size of weld required; 100 amps is typical for manual
welders.
• Voltage 20 to 50 volts
• Energy consumption/Kg of metal deposited
AC- 3-4 Kwh DC- 6-10 Kwh
Power Supply (contd.)
• Constant current power supply- for manual welding
processes because they maintain a relatively constant
current even as the voltage varies. in manual welding, it can
be difficult to hold the electrode perfectly steady, and as a
result, the arc length and thus voltage tend to fluctuate.
• Constant voltage power supplies hold the voltage constant
and vary the current, automated welding processes . arc
length is kept constant, since any fluctuation in in the
distance between the wire and the base material is quickly
rectified by a large change in current.
Polarity Of Electrode
 Positively charged anode will have a greater heat concentration .
If the electrode is positively charged, it will melt more quickly,
increasing weld penetration and welding speed.
 negatively charged electrode results in more shallow welds.
 Non-consumable electrode processes, such as gas tungsten arc
welding, can use either type of direct current (DC), as well as
alternating current (AC).
 Alternating current rapidly moves between these two, resulting
in medium-penetration welds.
 Heat generated
66% anode
33% cathode
Polarity selection
o Thick and high conductivity materials – Anode

o Thin and low conductivity materials -- Cathode


Electrodes
 Compatible with the base material
 Covered with a flux that protects the weld area from
oxidation and contamination by producing CO2 gas
during the welding process. The electrode core itself
acts as filler material,
 Consumable electrode
 Non-consumable electrode (thin section, high
accuracy)
Composition of Electrode
Electrode comprising
• A metal to be deposited on a substrate
• Flux composition :
1. Magnesium-aluminium alloy having an aluminium content of 20
to 80 percent alloy present in said flux in the amount of 5 to 35
percent by weight
2. Calcium fluoride 30 to 80 percent based on the weight of said
flux;
3. Hematite 3 to 30 percent by weight;
4. Silica and/or manganese less than 10 percent based on the
weight of said flux;
5. Titanium less than 1.00 percent, based upon the weight of said
flux;
6. Zirconium from 0.005 to 0.200 weight percent, based on the
weight of said flux; and
7. Boron in an amount less than 0.060 weight percent, based upon
the weight of said flux.
Parameters
Thickness(mm) Elect. Dia I V

3-6 3.2 100-150 18-22

6 4 140-200 20-24

9 6 200-300 21-25

16 8 275-350 23-27

20-25 9 375-450 24-28


Characteristic curve

40

30
Volt V

20

10

50 100 150 200 250 300


Current I
Process
Electrode Angles
Electrode Holder
Different Electrodes
Welding Defects
Different Electrode Holders
Welding- An art
Robots in Welding
Safety issues
 Heat and Sparks (Burn)
 Eye Damage (UV Rays)
 Inhaled matter
 Protective clothing
 Leather Gloves
 Welding Goggles and Helmets
 Limiting the amount of oxygen in the air and keeping
combustible materials away from the workplace
Weld Joints

Common welding joint types – (1) Square butt


joint, (2) V butt joint, (3) Lap joint, (4) T-joint
Heat Input Calculations
Heat input for arc welding process

Q=(V x I x 60 x efficiency) /(S x 1000)

where Q = heat input (KJ/mm), V = voltage (V), I =


current (A), and S = welding speed (mm/min). The
efficiency is dependent on the welding process used,
with shielded metal arc welding having a value of 0.75,
gas metal arc welding and submerged arc welding, 0.9,
and gas tungsten arc welding, 0.8.
Thank you

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