WELDING WORKSHOP

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. The application of welding is so
varied and extensive that it would be no exaggeration to say that there is no
metal industry and no branch of engineering that doesn't make use of welding
in one form or another.
Welding:
It is a process of joining similar metals by application of heat with or without
application of pressure and addition of filler material.
Resistance Welding:
Metal parts to be joined can also be heated by developing the contact
resistance to the flow of electric current. It is based on the well-known and
very well documented principle that when the electric current experiences
resistance, the heat is generated.
Principle and Working of Resistance Welding:
The amount of heat (H) generated is related to magnitude of electric current
(I), the resistance (R) to the electric current, and the time for which the
current is allowed to flow, i.e.
Where
 H = Heat generated in watt hours,
 T = Time in hours,
 R = resistance in sums, and
 I = Current in amperes.
This process utilizes the contact resistance between the two metallic surfaces.
When two metallic surfaces are brought into contact, only a small fraction of
the apparent area is in actual metal to metal contact. When a current is passed
through such an interface, all of it is carried by these tiny metallic bridges and
the oxide layer in contact does not canny any current. As a result, the current
flow is restricted thus resistance to flow is experienced. The resistance to
current flow can be calculated with the following assumptions:
 All bridges are of uniform size having spherical shape of radius (rl).
 All the bridges are uniform spaced (Zr2 apart).

Types of Welding’s:
 TIG – Gas Tungsten Arc Welding (GTAW)
 Flux-Cored Arc Welding (FCAW)
 Stick – Shielded-Metal Arc Welding (SMAW)
 MIG – Gas Metal Arc Welding (GMAW)
 Laser Beam Welding
 Electron-Beam Welding
 Plasma Arc Welding
 Atomic Hydrogen Welding
  Electro slag
TIG Welding:
TIG welding also goes by the names of Heli arc and gas tungsten arc welding
(GTAW). With this type of welding, the electrode is non-consumable and
made of tungsten. It is one of the few types of welding that can be done with
no filler metal, using only the two metals being welded together. You can add
a filler metal if you desire, but you will have to feed it by hand. A gas tank is
necessary with TIG welding to provide the constant flow of gas needed to
protect the weld. This means it’s generally better performed indoors and
away from the elements.
TIG welding is a precise form of welding that creates visually appealing
welds and doesn’t require cleanup, as there is no spatter. Due to these traits, it
is a difficult type of welding that is best reserved for experienced welders.
Flux-Cored Arc Welding (FCAW):
Arc Welding This type of welding is similar to MIG welding. In fact, MIG
welders can often perform double duty as a FCAW welder as well. Just like
in MIG welding, a wire that serves as the electrode and the filler metal is fed
through your wand. This is where things begin to differ. For FCAW, the wire
has a core of flux that creates a gas shield around the weld. This eliminates
the need for an external gas supply.
FCAW is better suited for thicker, heavier metals, since it is a high-heat
welding method. It’s often used for heavy equipment repairs for this reason.
It is an efficient process that doesn’t create much waste. Since there’s no
need for external gas, it’s also low cost. There will be a bit of slag left over,
though, and it will need a bit of cleanup to make a beautifully finished weld.

Stick – Shielded-Metal Arc Welding (SMAW):

This process of welding started in the 1930s but continues to be updated and
improved today. It has remained a popular form of welding because it is
simple and easy to learn, as well as low cost to operate. However, it doesn’t
create the neatest welds, since it splatters easily. Cleanup is usually
necessary.
A replaceable electrode “stick” also serves the role of filler metal. An arc is
created that connects from the end of the stick to the base metals, melting the
electrode into filler metal and creating the weld. The stick is coated in flux
that creates a gas cloud when heated up and protects the metal from
oxidation. As it cools, the gas settles on the metal and becomes slag.

Since it doesn’t require gas, this process can be used outdoors, even in
adverse weather such as rain and wind. It also works well on rusted, painted,
and dirty surfaces, making it great for equipment repairs. Different types of
electrodes are available and easy to swap, making it simple to weld metals of
many different kinds, though it’s not great for thin metals. Stick welding is a
highly skilled process with a long learning curve.

MIG – Gas Metal Arc Welding (GMAW):

MIG welding is a simple form of welding that can easily be performed by
new welders. MIG stands for metal inert gas, though it is sometimes called
gas metal arc welding (GMAW). It is a quick process that involves the filler
metal being fed through the wand, while gas is expelled around it to shield it
from outside elements. This means it’s not great for outdoor use. Still, it’s a
versatile process and can be used to weld many different types of metal at
different thicknesses.

The filler metal is a consumable wire fed from a spool, and it acts as the
electrode as well. When the arc is created from the tip of the wire to the base
metal, the wire melts, becoming filler metal and creating the weld. The wire
is continuously fed through the wand, allowing you to dial in your preferred
speed. Done correctly, MIG welding produces a smooth and tight weld that is
visually appealing.

Laser Beam Welding

This type of welding can be used on metals or thermoplastics. As the name
implies, it involves the use of a laser as a heat source to create the welds. It
can be used on carbon steels, stainless steel, HSLA steels, titanium, and
aluminum. It is easily automated with robotics and is therefore used often in
manufacturing, such as in the automotive industry.
Electron-Beam Welding:
Electron-Beam Welding This is a type of welding where a high-velocity
beam of electrons creates heat through kinetic energy, welding two materials
together. This is a highly sophisticated form of welding that is performed by
machine, generally in a vacuum.

Plasma Arc Welding:

Plasma arc welding is similar to GTAW, but it uses a smaller arc, increasing
the precision of the weld. It also uses a different torch, achieving much higher
temperatures. Gas is pressurized inside the wand, creating plasma. The
plasma is then ionized, making it electrically conductive.
This allows the arc to be created, producing incredibly high temperatures that
can melt the base metals. This allows plasma arc welding to be performed
with no filler metal, another similarity to TIG welding.This type of welding
allows deep weld penetration with narrow welds, producing aesthetically
pleasing welds, as well as a high level of strength. On top of this, high
welding speeds are also possible.

Atomic Hydrogen Welding:

Atomic hydrogen welding is an extremely high-heat form of welding that
used to be known as arc-atom welding. This type of welding involves using
hydrogen gas to shield two electrodes made of tungsten. It can reach
temperatures above those of an acetylene torch and can be performed with or
without a filler metal. This is an older form of welding that has been replaced
by MIG welding in recent years.

Electro slag:
This is an advanced process of welding that is used to join the thin edge of
two metal plates together vertically. Instead of the weld being applied to the
outside of a joint, it will take place in between the edges of the two plates.
A copper electrode wire is fed through a consumable metal guide tube that
will act as filler metal. When electricity is introduced, the arc is created, and a
weld begins at the bottom of the seam and is slowly moved up, creating the
weld in place of the seam as it goes.
This is an automated process and performed by machine.

SEAM WELDING ELECTRODES:

Seam welding electrodes are generally in the form of wheels and are
sometimes referred to a seam welding wheels. An exception to this is when a
flat anvil or mandrel is used on one side with a wheel on the other. In either
case however the actual application is essential the same as spot welding and
the electrode materials are generally the same.
Seam welding wheels are at two types one for knurl or friction roll driven
machines and other for gear or idling .The essential difference between the
two types is their thickness and welding face contour or shape. Knurl or
friction roll driven wheel must fit the knurl contour or shape knurl driven
wheels are used principally on coated stock, because during the welding
operation, the coating sticks or alloys to the roll breaks up this coating. The
friction drive rolls are the same as the knurled roll hot with the
Knurling omitted. Both however are so constructed as to continually dress the
sides of the wheel thus preventing mushrooming and maintaining uniform
face width. Gear driven or idling wheels are sometimes provided with an
idling knurling tool to perform this same function.

Conclusion:
In above the welding types we see that in world we use different types of
welding but the point is that why Pakistan do not use the different types why
they use only two types of traditional welding.