Introduction to Manufacturing

Processes IME 211

Lecture (11) – Week (12)
Welding Technology and Weldment
Couse Instructor

Mohamed Nassef, PhD

Associate Professor
IME Department

©INDUSTRIAL AND MANUFACTURING ENGINEERING

1
DEPARTMENT, MOHAMED G NASSEF
Definition
❑ Welding is a materials joining process which produces
coalescence (mixing) of materials by heating them to
suitable temperatures with or without the application of
pressure or by the application of pressure alone, and with
or without the use of filler material.

Pipe A

Pipe B

Welding
Joint
Welding
▪ there are two groups of welding processes:

- a) Fusion welding,

- b) Solid state welding (the joining occurs without

melting).
Classification of Welding Processes
❑ AWS distinguishes the welding processes according to the Mode of
energy transfer

Gas welding
(Oxy-acetylene
welding)

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Fusion Welding
▪ Welding processes involve the partial melting and
fusion between two members to be joined.

▪ Fusion welding is defined as melting together and

coalescing materials by means of heat.

▪ Filler metals are metals added to the weld area

during welding.

▪ Fusion welds made without the use of filler metals

are known as autogenous welds.

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Classification of Fusion Welding

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 1. Gas Welding
(Oxy-fuel Welding)
Types of Fusion
Welding Processes 2. Electric Arc
Welding

3. Resistance
Welding
7
1. Gas Welding (Oxy-acetylene Welding)
Oxyfuel–gas Welding (OFW)
▪ Oxyfuel–gas welding (OFW) is a general term used to
describe any welding process that uses a fuel gas
combined with oxygen to produce a flame.
▪ The most common gas-welding process is oxyacetylene
gas welding (OAW).
▪ OAW is typically used for structural metal
fabrication and repair.

▪ The primary combustion process involves:

C2 H2 + O2 → 2CO + H2 + Heat
▪ The secondary combustion process is:
2CO + H2 + 1.5O2 → 2CO2 + H2O + Heat
Gas Welding (Oxy-acetylene welding)
The oxy-acetylene welding is a fusion welding process.
- In this case, the heat required for welding is obtained from the combustion
of acetylene and oxygen.
-A filler rod is generally added to build up the seam for greater strength.
Oxy-fuel gas welding equipment
1.Oxygen gas cylinder:
Oxygen cylinders are painted
black or white and valve outlets
are screwed right handed.

2.Acetylene gas cylinder:

1

It is painted maroon or yellow

and the valves are screwed left 2
handed.

3
3. Welding Torch
❑ Oxygen and the fuel gas of low (regulated) pressure are fed
through suitable hoses to a welding torch which mixes and control
the flow of gases to the welding nozzle or tip where the gas mixture
is burnt to produce a flame.
Types of Flames: 1. Neutral flame
❑ It is produced when oxygen to acetylene ratio is 1 to 1.
❑ The temperature is 1260 C at the tip of the flame envelope.
❑ The flame has nicely defined inner cone (light blue in color) and is
surrounded by outer envelope which is dark blue in color than the
inner cone.
❑ It has no chemical reaction with the metals. It is used for welding
mild steel, stainless steel, cast iron.
 2. Oxidizing Flame
❑ 1.2 vol. oxygen + 1 vol. acetylene.
❑ -Its inner cone is more pointy, outer flame envelope is much shorter.
❑ -Temperature in the inner cone is (3482ºC) (because of excess
oxygen so complete combustion takes place).
❑ -This flame is harmful for steels, because it oxidize the steels.
❑ -It is desirable only in the welding of copper and copper based alloys.
 3. Reducing Flame
▪ 1 vol. oxygen + 1.2 vol. acetylene.
▪ Acetylene feather (whitish zone) exists between the inner cone and
outer envelope. A Temperature in the inner cone is about 2800C.
▪ carburizing flame will produce iron carbide, causing a chemical
change in steel and iron.
▪ Used in welding lead and Aluminum alloys.
Filler Metals
▪ Used to supply additional metal
to the weld zone during welding

▪ Available as filler rods or wire

and may be bare or coated with
flux

▪ Purpose of the flux is to retard

oxidation of the surfaces of
the parts being welded by
generating a gaseous shield
around the weld zone

Copyright © 2010 Pearson Education South Asia Pte Ltd

 Advantages & Limitations
Advantages Limitations
1. It can be applied to a 1. Flame temperature is
wide variety of less than the
manufacturing and temperature of the
metals. arc.
2. No electric current is 2. Gas flame takes a
required. long time to heat up
3. Cost and maintenance of the metal than an arc.
the welding equipment is 3. Heat affected zone is
low. wider.
4. Storage of gases is
not be safe. More
safety is needed.
2. Electric Arc Welding
Arc Welding
▪ It is a metal welding in which an
electric arc is produced between the
workpiece and an electrode.
▪ This arc is of intense heat that
melts part of the base metal and the
consumable electrode or filler metal.
▪ The arc is generated between two
conductors of electricity, upon
application of voltage and separated
by a small distance.
▪ Sustained electric discharge is
obtained through ionized gas column
between the two electrodes
Power Source
▪ The arc can be generated using DC power source or AC
power source.
Metal Transfer Modes
❑ Globule Transfer
1. Droplets close to or larger than diameter of electrode
2. Reach base metal by gravity action
3. Leads to spatter

❑ Spray Transfer
1. Fine droplets
2. Reach base material by electromagnetic force

❑ Short circuit transfer

❑ Small (incomplete) and fast solidifying weld pools
Types of Electric Arc Welding
A. Gas metal arc welding (GMAW) or (MIG)

B. Gas tungsten arc welding (GTAW) (TIG)

C. Shielded metal arc welding (SMAW)

D. Submerged arc welding (SAW)

E. Plasma arc welding (PAW)

F. Flux-cored arc welding (FCAW)

 A. Gas Metal Arc Welding (GMAW)
▪ It is a fusion welding process.
▪ In this process, the electrode is consumable.
▪ It is a semiautomatic arc welding process.
▪ The heat required for welding is obtained by generating an electrical
arc between the electrode and workpiece.
▪ A shielding gas is used to protect the molten pool of metal during
welding.
Role of Gas in GMAW
▪ The supplied gas an be Inert/ active
▪ provides Shielding effect from oxidation, contamination,
and chemical reactions.
▪ provides Stability of arc
Gas Ionization Potential
CO2 14.4 eV
O2 13.2 eV
N2 14.5 eV
H2 13.5 eV
Ar 15.7 eV
He 24.5 eV
Semi Automatic Welding Machine
 ❑ Advantages:
1. Welding can be done in all
positions
2. High Weld Quality
3. No slag formation
Advantages
and
Disadvantages ❑ Disadvantages
of GMAW 1. Excessive gas coverage will
lead to porosities.
2. Insufficient gas coverage may
lead to oxidation
B. Gas Tungsten Arc Welding (TIG)
| No.29
 ❑Advantages
1. Superior quality welds
2. Weld almost all metals
3. Easily automated
4. Used in all positions

Advantages ❑Disadvantages
and 1. Lowest deposition rate (speed)
Disadvantages 2. Tungsten impurities in welding
joint
3. Excessive gas will lead to
porosity and lack of sufficient
gas will lead to oxidation.
 C. Shielded Metal Arc Welding (SMAW)
▪ It is a fusion welding process.
▪ In this process, the electrode is consumable.
▪ It is a manual arc welding process.
▪ The equipments are portable and their cost is low. Therefore, this process
is versatile.
▪ In this case, the heat required for welding is obtained by generating an
electrical arc between the electrode and workpiece.
▪ The heat melts portions of the electrode tip, its coating, and the base metal.
| No.32
A Schematic Drawing of SMAW process

33
Role of Flux
❑ Role of a Flux : Protection from contamination,
oxidation reduction, Arc Stabilization

| No.34
 ❑ Advantages:
1. Welding can be carried out in any
position
2. highest weld qualities.
3. For large thickness (greater than gas
Advantages welding).
and
Disadvantages
❑Disadvantages
of SMAW
❑Slag formation that must be removed.
❑Applications
❑ It is used in ship buildings, pipe lines,
bridges construction, tanks, boilers.
SMAW in Shipyards
3.
Resistance
Welding
Resistance Welding
▪ Welding heat is obtained from resistance of the
work to the flow of electric current and by the
application of pressure. No filler metal or flux is
added.

H = I R.T
2

Resistance
of joint Time of which electric current is
passing through the joint

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Spot Welding

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Spot Resistance Welding
Demo

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 ❑ Advantages:
▪ No filler metal required
▪ High production rates
possible
Advantages and
Disadvantages ▪ Lower operator skill level
than for arc welding
of Resistance
Welding
❑ Disadvantages:
▪ High initial equipment cost
▪ Limited to lap joints
 ❑ Spot Welding
❑ Widely used in mass production
of automobiles, metal
furniture, appliances, and
other sheet metal products
➢Typical car body has ~ 10,000 spot
welds
Applications

❑ Seam Welding
➢Gasoline tanks
➢Automobile mufflers
➢Various sheet metal containers
Resistance Seam Welding
Principle of Work

Show video

Show
| No.43 video
Seam Resistance Welding Demo
Seam Welding Machine
Automated Spot Welding
❑ If individual spot welds are obtained by constant and
regularly timed interruption of the welding current, the
process is called roll (spot ) welding.
Welding Positions
Length of Arc
❑ The arc length does not exceed the diameter of the
metal portion (core) of the electrode.

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Weld Quality - Review

Undercut

Porosity
Poor Fitup

Lack of Penetration
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Welding Joint Design & Welding Symbols – Chapter #5
Other typical faults in single-pass horizontal fillet welds:

Porosity:

Lack of shielding gas

Wet electrode
Greasy material

Welding Joint Design & Welding Symbols – Chapter #5

Other typical faults in single-pass horizontal fillet welds:

Slag Inclusion: Improper cleaning / removal of slag

Welding Joint Design & Welding Symbols – Chapter #5

Types of Welding Joints
Types of Joints
Butt Joint
Lap Joint
Corner Joint
Tee Joint
Edge Joint
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Corner Joints and Edge Joints

Open Corner Closed Corner

FIGURE 5-2 Two ways of fitting up an outside corner joint.

© Cengage Learning 2012
Welding Joints can be classified into two main types:

▪ Groove weld: is a primary weld used in construction sites,

bridges, and buildings.

▪ Fillet weld: is a secondary weld used in machinery

Fillet Weld

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Groove Weld

Bevel Groove Vee Groove

J Groove

Square Groove U Groove

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