Addis Ababa Science and Technology University
College of Electrical & Mechanical Engineering
Mechanical Engineering Department
Gas & Arc Welding Equipment and Tools
Israel Z.
Manufacturing Engineering
Chapter 5:Metal Joining Processes May,2022
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
Electric Arc Shielded Metal Arc – “Stick”
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
TYPES OF FLAMES…
• Oxygen is turned on, flame immediately changes into a long
white inner area (Feather) surrounded by a transparent blue
envelope is called Carburizing flame (30000c)
• Addition of little more oxygen give a bright whitish cone
surrounded by the transparent blue envelope is called Neutral
flame (It has a balance of fuel gas and oxygen) (32000c)
• Used for welding steels, aluminum, copper and cast iron
• If more oxygen is added, the cone becomes darker and more
pointed, while the envelope becomes shorter and more fierce
is called Oxidizing flame has the highest temperature about
34000c.
• Used for welding brass and brazing operation
Two Basic Types of Arc Welding
(Based on Electrodes)
1. Consumable electrodes
consumed during welding process
added to weld joint as filler metal
in the form of rods or spools of wire
2. Non-consumable electrodes
not consumed during welding process but does get
gradually eroded
filler metal must be added separately if it is added
Consumable Electrode AW Processes
Shielded Metal Arc Welding (or Stick Welding)
Gas Metal Arc Welding (or Metal Inert Gas
Welding)
Submerged Arc Welding
Flux-Cored Arc Welding
Electro-gas Welding
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
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.
Metal Inert Gas (MIG)
Inert Gas Welding(MIG)
• 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
GMAW Advantages over
SMAW
1. Continuous welding because of continuous wire electrode.
Sticks must be periodically changed in SMAW.
2. Higher deposition rates.
3. Eliminates problem of slag removal.
4. Can be readily automated.
5. Has better control to make cleaner & narrower welds than
SMAW.
Non-consumable Electrode Processes
Gas Tungsten Arc Welding(TIG)
Plasma Arc Welding
Carbon Arc Welding
Stud Welding
Tungsten Inert Gas (TIG)
• 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)
Parameters for effective welding
Successful welding depends on the following
factors:
• Selection of the correct electrode
• Selection of the correct size of the electrode
for the job
• Correct welding current
• Correct arc length
• Correct angle of electrode to work
• Correct travel speed
• Correct preparation of work to be welded.
Welding Positions
INCREASING DIFFICULTY
FLAT
HORIZONTAL
OVERHEAD
VERTICAL
TYPES OF Weld Joint AND WELDS
• Types of Joints
– Butt joint
– Corner joint
– Lap joint
– Tee joint
– Edge joint
• Types of Welds
– Fillet weld
– Groove weld
– Plug and slot welds
– Spot and Seam welds
– Flange and Surfacing welds
-----T joint----
Butt welds : A butt weld is made between two pieces of metal usually in the
same plane, the weld metal maintaining continuity between the sections.
weld metal is generally contained within the profiles of the welded elements
Fillet welds : These welds are roughly triangular in cross section and
between two surfaces not in the same plane and the weld metal is
substantially placed alongside the components being joined. Deposited weld
metal is external to the profile of the welded elements
VARIOUS
PARTS
OF
WELDS
WELD JOINT PREPARATION.
Weld joint fit up before welding. The weld groove which is to
be filled by welding can be seen.
Weld joint fit up for a pipe to reducer joint, the root gap is clearly visible.
Double Vee Weld groove fit up for plates bend in to pipes
Welding sequence.
Welding sequence :
Welding sequence
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
BUTT JOINT
FILLET JOINT
STRAP JOINT
LAP JOINT CORNER JOINT
Generalized Welding Symbol
FAR SIDE DETAILS Field weld symbol
Weld Geometry
Electrode D L1-L2 Weld all-around for
pipes, etc.
Material D L1-L2
ARROW SIDE DETAILS D = Weld Depth (usually equal to plate thickness)
L1 = Weld Length
L2 = Distance between centers for stitched welds
The Field Weld Symbol is a guide for installation. Shipyards
normally do not use it, except in modular construction.
Example Welding Symbol
Geometry symbol for V-groove
One-sided welds are max 80% efficient
Two sided are 100% efficient
1/2
1/2
1/2” 1/2”
Weld Symbols (Butt Joints)
Backing
Weld Symbol (Fillet Joints)
Weld Symbol (Corner Joints)
• Brazing is a joining process in which a filler metal is melted
and distributed by capillary action between the faying
surfaces of the metal parts being joined.
• No melting of the base metals occurs in brazing; only the
filler melts.
As in brazing, no melting of the base metals occurs, but the filler metal wets and
combines with the base metal to form a metallurgical bond.
Mechanical Fastening Methods
• There are good reasons why mechanical assembly is often
preferred over other joining .
• Its because of ease of assembly and disassembly
Mechanical fastening methods
1. those that allow for disassembly, Threaded fasteners(e.g.,
screws, bolts, and nuts)
•
2. those that create a permanent joint. E.g. rivets.
Rivets are widely used for achieving a permanent mechanically
fastened joint.
Riveting is a fastening method that offers high production rates,
simplicity, dependability, and low
cost.
3. Seaming
where the edges of two separate sheet-metal parts or the opposite
edges of the same part are bent over to form the fastening seam.
the metal must be ductile in order for the bending to be feasible;
