Welding

Welding has evolved from an art in the late 19th century to a science today. There are several types of welding processes that involve melting metals with or without added filler material. Key processes include shielded metal arc welding, gas metal arc welding (MIG), and gas tungsten arc welding (TIG). Proper technique and joint design are needed to minimize welding defects and residual stresses. Weld symbols are used as guides for welding installation and specification.

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Welding

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hodmech scenashik

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Welding Processes

EN358 – Ship Structures

A Brief History of Welding
• Late 19th Century
• Scientists/engineers apply advances in electricity to heat
and/or join metals (Le Chatelier, Joule, etc.)
• Early 20th Century
• Prior to WWI welding was not trusted as a method to join
two metals due to crack issues
• 1930’s and 40’s
• Industrial welding gains acceptance and is used extensively
in the war effort to build tanks, aircraft, ships, etc.
• Modern Welding
• the nuclear/space age helps bring welding from an art to a
science
Types of Welding

Fusion Welding Pressure Welding

Homogeneous Heterogeneous Friction Welding

Gas Welding Brazing Soldering

Electroslag MIG

High Energy Beam TIG

Shielded Metal Arc – “Stick”
Electric Arc
Weldability of a Metal
• Metallurgical Capacity
• Parent metal will join with the weld metal without
formation of deleterious constituents or alloys
• Mechanical Soundness
• Joint will be free from discontinuities, gas porosity,
shrinkage, slag, or cracks
• Serviceability
• Weld is able to perform under varying conditions
or service (e.g., extreme temperatures, corrosive
environments, fatigue, high pressures, etc.)
Fusion Welding Principles
• Base metal is melted
• Filler metal may be added
• Heat is supplied by various means
• Oxyacetylene gas
• Electric Arc
• Plasma Arc
• Laser
Fusion Welding

ELECTRODE COATING

CORE WIRE

WELDING ATMOSPHERE
ARC STREAM
ARC POOL
SOLIDIFIED SLAG
PENETRATION
DEPTH

WELD

BASE METAL
Weld Metal Protection
• During fusion welding, the molten metal in the
weld “puddle” is susceptible to oxidation
• Must protect weld puddle (arc pool) from the
atmosphere
• Methods
• Weld Fluxes
• Inert Gases
• Vacuum
Weld Fluxes
• Typical fluxes
• SiO2, TiO2, FeO, MgO, Al2O3
• Produces a gaseous shield to prevent
contamination
• Act as scavengers to reduce oxides
• Add alloying elements to the weld
• Influence shape of weld bead during
solidification
Inert Gases
• Argon, helium, nitrogen, and carbon
dioxide
• Form a protective envelope around the
weld area
• Used in
• MIG
• TIG
• Shield Metal Arc
Vacuum
• Produce high-quality welds
• Used in electron beam welding
• Nuclear/special metal applications
• Zr, Hf, Ti
• Reduces impurities by a factor of 20
versus other methods
• Expensive and time-consuming
Types of Fusion Welding
• Oxyacetylene Cutting/Welding
• Shielded Metal Arc (“Stick”)
• Metal Inert Gas (MIG)
• Tungsten Inert Gas (TIG)
Oxyacetylene Welding
• Flame formed by burning a mix of acetylene
(C2H2) and oxygen

TORCH TIP 2300 deg F

Inner Cone: 5000-6300 deg F Combustion Envelope 3800 deg F

• Fusion of metal is achieved by passing the

inner cone of the flame over the metal
• Oxyacetylene can also be used for cutting
metals
Shielded Metal Arc (Stick)
• An electric arc is generated between a coated
electrode and the parent metal
• The coated electrode carries the electric
current to form the arc, produces a gas to
control the atmosphere and provides filler
metal for the weld bead
• Electric current may be AC or DC. If the
current is DC, the polarity will affect the weld
size and application
Shielded Metal Arc (con’t)
• Process:
• Intense heat at the arc melts the tip of the
electrode
• Tiny drops of metal enter the arc stream and are
deposited on the parent metal
• As molten metal is deposited, a slag forms over
the bead which serves as an insulation against air
contaminants during cooling
• After a weld ‘pass’ is allowed the cool, the oxide
layer is removed by a chipping hammer and then
cleaned with a wirebrush before the next pass.
Inert Gas Welding
• For materials such as Al or Ti which
quickly form oxide layers, a method to
place an inert atmosphere around the
weld puddle had to be developed
Metal Inert Gas (MIG)
• Uses a consumable electrode (filler wire made of the
base metal)
• Inert gas is typically Argon
DRIVE WHEELS
CONSUMABLE
ELECTRODE

POWER
SOURCE

SHIELDING GAS ARC COLUMN

BASE METAL PUDDLE

Tungsten Inert Gas (MIG)
• Tungsten electrode acts as a cathode
• A plasma is produced between the tungsten cathode and the
base metal which heats the base metal to its melting point
• Filler metal can be added to the weld pool
TUNGSTEN
ELECTRODE
POWER (CATHODE)
TUNGSTEN
SOURCE
ELECTRODE

++ ++
SHIELDING GAS ARC COLUMN ---

BASE METAL PUDDLE BASE METAL (ANODE)

Welding Positions
INCREASING DIFFICULTY

FLAT

HORIZONTAL
OVERHEAD

VERTICAL
Weld Defects
• Undercuts/Overlaps

• Grain Growth
• A wide T will exist between base metal and HAZ.
Preheating and cooling methods will affect the brittleness of
the metal in this region
• Blowholes
• Are cavities caused by gas entrapment during the
solidification of the weld puddle. Prevented by proper weld
technique (even temperature and speed)
Weld Defects
• Inclusions
• Impurities or foreign substances which are forced into the weld
puddle during the welding process. Has the same effect as a
crack. Prevented by proper technique/cleanliness.
• Segregation
• Condition where some regions of the metal are enriched with an
alloy ingredient and others aren’t. Can be prevented by proper heat
treatment and cooling.
• Porosity
• The formation of tiny pinholes generated by atmospheric
contamination. Prevented by keeping a protective shield over the
molten weld puddle.
Residual Stresses
• Rapid heating and cooling results in thermal stresses
detrimental to joint strength.
• Prevention
• Edge Preparation/Alignment – beveled edges and space
between components to allow movement
• Control of heat input – skip or intermittent weld technique
• Preheating – reduces expansion/contraction forces (alloys)
and removes moisture from the surface
• Peening – help metal stretch as it cools by hitting with a
hammer. Use with care since it may work harden the metal
• Heat Treatment – “soak” the metal at a high temperature to
relieve stresses
• Jigs and Fixtures – prevent distortion by holding metal fixed
• Number of Passes – the fewer the better.
Joint Design