MECHANICALWORKSHOP

TRAINING MANUAL
COURSE: ME-1-03(PO)

Training Module: Introduction To Welding Processes.

CENTRAL WORKSHOP
INDIAN INSTITUTE OF TECHNOLOGY JAMMU
JAMMU– 181221, INDIA
 INTRODUCTION TO WELDING PROCESSES.
LEARNING OBJECTIVE
The learning objectives of the module are

 To understand the working principles of SMAW, and gas welding and MIG
welding processes.

 To familiarize students with the safe handling and operation of SMAW equipment by
performing basic welding beads and joints.

 To develop hands-on welding skills through practice of simple joints, focusing on

electrode angle, travel speed, and arc length.

 To identify and evaluate common welding defects (such as porosity, slag inclusion, and
undercut) and practice corrective measures to improve weld quality.

1. INTRODUCTION TO WELDING
Welding is a permanent joining process in which two or more similar or dissimilar materials,
usually metals or thermoplastics, are joined together by the application of heat, pressure, or a
combination of both, with or without the addition of a filler material, to produce a strong and
continuous joint. During welding, the surfaces of the base materials are brought into close contact
and fused together, resulting in a metallurgical bond that is often as strong as or stronger than the
parent material.
1.1 Importance of Welding

Welding has become indispensable in modern engineering because it offers numerous advantages
over other joining methods. Some of its key importance includes:

 Produces permanent and high-strength joints.

 Enables fabrication of complex structures.
 Provides leak-proof joints for pressure vessels and pipelines.
 Reduces the overall weight of fabricated structures.
 Allows joining of similar and dissimilar metals.
 Suitable for both mass production and repair work.
 Can be easily automated for high production rates.

1.2 Applications of Welding

Welding is extensively used in almost every engineering sector, including:
 Structural steel fabrication
 Building and bridge construction
 Automobile manufacturing
 Shipbuilding
 Aircraft and aerospace industries
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  Railway coaches and locomotives
 Oil and gas pipelines
 Power plants
 Pressure vessels and boilers
 Heavy machinery manufacturing
 Agricultural equipment
 Nuclear engineering
 Repair and maintenance industries

1.3 Classifications of Welding

Figure 1: Classification of Welding

2. ELECTRIC ARC WELDING

2.1 Introduction:
Electric Arc Welding, also known as Shielded Metal Arc Welding (SMAW) or Manual Metal Arc
(MMA) Welding, is one of the most widely used fusion welding processes in manufacturing and
fabrication industries. In this process, an electric arc is generated between a consumable coated
electrode and the workpiece. The intense heat produced by the arc melts both the base metal and
the electrode, forming a molten weld pool. Upon cooling and solidification, a strong and
permanent metallurgical joint is formed. SMAW is a versatile, economical, and portable welding
process that can be used for welding various ferrous and non-ferrous metals in different positions.
Due to its simplicity and low equipment cost, it is extensively used in construction, repair work,
shipbuilding, pipelines, pressure vessels, and structural fabrication.

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2.2 Principle of Electric Arc Welding:
Electric arc welding works on the principle of generating heat by an electric arc. When an electric
current flows through a small air gap between the electrode and the workpiece, the air becomes
ionized and forms an electric arc. This arc produces temperatures ranging from 5,000°C to
7,000°C, which is sufficient to melt most engineering metals.

The molten metal from both the electrode and the base metal combines to form a weld pool. As
the weld cools, the molten metal solidifies to produce a strong welded joint.

The flux coating on the electrode melts during welding and performs several important functions:

 Produces shielding gases that protect the molten metal from atmospheric contamination.
 Forms a slag layer that protects the weld during cooling.
 Stabilizes the electric arc.
 Improves the mechanical properties and appearance of the weld.

Figure 3: Layout of Electric arc welding setup

2.3 Working Principal:

The working of electric arc welding involves the following steps:

1. The workpiece is connected to one terminal of the welding machine through an earth
clamp.
2. The electrode is connected to the other terminal using an electrode holder.
3. When the electrode briefly touches the workpiece and is then withdrawn slightly (2–4
mm), an electric arc is established.
4. The heat generated by the arc melts the edges of the workpiece and the electrode tip.
5. The molten electrode metal acts as filler metal and mixes with the molten base metal.
6. The flux coating decomposes, producing shielding gases and slag that protect the molten
weld pool.
7. As the electrode moves along the joint, the molten metal solidifies, forming a continuous
weld bead.
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 8. After cooling, the slag is removed using a chipping hammer and wire brush.

2.4 Equipment Used in Electric Arc Welding

The basic equipment required for electric arc welding includes:

1. Welding Power Source
2. Electrode Holder
3. Welding Electrodes
4. Earth Clamp
5. Welding Cables
6. Chipping Hammer
7. Wire Brush
8. Welding Table
9. Personal Protective Equipment (PPE)

2.5 Types of Welding Power Sources

2.5.1 AC Welding Machine

 Uses alternating current.
 Lower equipment cost.
 Simple construction.
 Suitable for general-purpose welding.

2.5.2 DC Welding Machine

 Uses direct current.
 Provides a stable arc.
 Easier arc starting.
 Better control over weld quality.
 Suitable for thin materials and out-of-position welding.

2.6 Types of Electrodes

Electrodes used in SMAW are classified as:

2.6.1 Bare Electrodes
These electrodes have no coating and are rarely used because they provide little
protection against atmospheric contamination.

2.6.2 Flux-Coated Electrodes

These are the most commonly used electrodes. The flux coating provides shielding
gas, forms slag, stabilizes the arc, and improves weld quality.

2.7 Electrode Angle

Maintaining the correct electrode angle is essential for obtaining a sound weld.
 Travel Angle: Approximately 10°–15° in the direction of welding.

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  Work Angle: Usually 90° for butt joints and 45° for fillet welds.
Proper electrode angle ensures good penetration, uniform bead shape, and reduced spatter.

2.8 Welding Parameters

Parameter Typical Range

Arc Temperature 5,000–7,000°C
Arc Voltage 20–40 V
Welding Current 60–180 A
Arc Length 2–4 mm
Electrode Diameter 2.5–4.0 mm

2.9 Welding Procedure:

The following steps should be followed during electric arc welding:

1. Clean the workpiece thoroughly to remove rust, oil, paint, and dirt.
2. Prepare the joint if required.
3. Select the appropriate electrode.
4. Set the required welding current.
5. Connect the electrode holder and earth clamp.
6. Wear all required PPE.
7. Strike the arc by gently touching and lifting the electrode.
8. Maintain a constant arc length and electrode angle.
9. Deposit the weld bead at a uniform speed.
10. Allow the weld to cool.
11. Remove slag using a chipping hammer.
12. Clean the weld with a wire brush.
13. Inspect the weld visually for defects.

3. Exercise: Preparation of Single Butt Joint Using Shielded Metal Arc Welding (SMAW)
Aim: To prepare a single butt joint on two mild steel plates using the Shielded Metal Arc
Welding (SMAW) process and to study the welding procedure, machine settings, and weld
quality.
Arc
3.1 Apparatus and Equipment Required Welding MIG
 Arc welding machine (AC/DC)
 Electrode holder
 Earth clamp
 Welding cables
 Welding table
 Chipping hammer
 Wire brush
 Steel rule Exercise
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  Bench vice
 C-clamps
 Angle grinder (if required)
 Welding helmet
 Leather gloves
 Leather apron
 Safety shoes

3.2 Material Required

Material Specification Quantity
Mild Steel Flat 100 × 50 × 5 mm 2 Nos.
Welding Electrode E6013, Ø3.15 mm As required

3.4 Procedure
Step 1: Edge preparation on work pieces
 Clean the edges of the flat using a wire brush or grinder to remove rust, oil, paint, and dirt.
 Ensure that the edges are straight and free from burrs.
 Prepare the 450 angle on the edges of the flats (Manually as well as using power tools).
Step 2: Joint Assembly
 Place the two plates edge-to-edge on the welding table.
 Maintain a root gap of approximately 1–2 mm.
 Align the plates properly.
 Clamp the plates firmly to prevent movement.
Step 3: Tack Welding
 Apply tack welds at both ends of the joint.
 Re-check the alignment after tack welding.
Step 4: Machine Setup
 Connect the electrode holder and earth clamp.
 Select an E6013 electrode.
 Set the welding current to 90–110 A.
Step 5: Welding
 Wear all required PPE.
 Strike the arc at one end of the joint.
 Maintain an arc length of about 2–3 mm.
 Hold the electrode at a travel angle of 10–15°.
 Move the electrode uniformly along the joint while maintaining a constant travel speed.
Step 6: Cleaning
 Allow the weld to cool.
 Remove the slag using a chipping hammer.
 Clean the weld bead using a wire brush.
Step 7: Inspection
 Visually inspect the weld bead for:
o Uniform width

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 o Smooth appearance
o Proper fusion
o Adequate penetration
o Absence of cracks, porosity, undercut, and excessive spatter

3.5 Observation Table

Observation Student Record
Electrode Used
Electrode Diameter
Welding Current (A)
Arc Voltage (V)
Welding Position
Root Gap (mm)
Welding Time (min)

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4. GAS WELDING (OXY-ACETYLENE WELDING)

4.1 Introduction
Gas welding, commonly known as Oxy-Acetylene Welding (OAW), is one of the oldest fusion
welding processes used for joining metals. In this process, heat is produced by the combustion of
acetylene gas with oxygen, generating a high-temperature flame of approximately 3200°C. The
heat melts the edges of the workpieces and, when required, a filler rod is added to produce a
strong welded joint. Gas welding is widely used for welding thin metal sheets, repair and
maintenance work, pipe welding, and fabrication of light structures. It is particularly suitable for
welding mild steel, cast iron, aluminium, copper, and their alloys. Since it does not require
electricity, gas welding is highly portable and can be used in remote locations.

4.2 Principle of Gas Welding

Gas welding operates on the principle of combustion of a fuel gas (acetylene) with oxygen to
produce a high-temperature flame. The flame heats the base metal above its melting point, causing
the edges to fuse together. A filler rod may be added to fill the joint and increase its strength. The
type of flame used depends on the material being welded. A neutral flame, obtained by
maintaining equal proportions of oxygen and acetylene, is most commonly used for welding mild
steel. A basic setup for gas welding is shown in Figure 3.

Figure 3: Layout of Gas welding setup

4.3 Working Principle

The working of gas welding involves the following steps:
1. Connect the oxygen and acetylene cylinders with regulators and hoses.
2. Open the acetylene valve slightly and ignite the gas using a spark lighter.
3. Slowly open the oxygen valve and adjust the flame to obtain a neutral flame.
4. Hold the welding torch at an angle of approximately 45° to the workpiece.
5. Heat the joint uniformly until a molten weld pool is formed.
6. Introduce the filler rod into the molten pool if required.
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 7. Move the torch and filler rod simultaneously along the joint at a uniform speed.
8. Allow the welded joint to cool naturally.

4.4 Equipment Used in Gas Welding

The basic equipment required includes:
1. Oxygen Cylinder
2. Acetylene Cylinder
3. Pressure Regulators
4. Gas Hoses
5. Welding Torch (Blow Pipe)
6. Welding Nozzles
7. Spark Lighter
8. Filler Rod
9. Flux (if required)
10. Welding Goggles
11. Leather Gloves
12. Apron
13. Safety Shoes

4.5 Types of Gas Flames

Oxygen–
Approximate
Type of Flame Acetylene Characteristics Typical Applications
Temperature
Ratio
Sharp inner cone, no Mild steel, stainless
Neutral Flame 1:1 3200–3250°C excess oxygen or steel, cast iron,
acetylene aluminium, copper
High-carbon steel,
Carburizing Less than 1 Three distinct zones with
aluminium, nickel
(Reducing) (Excess 3000–3150°C a visible acetylene
alloys, hard-facing,
Flame acetylene) feather
brazing
Greater than 1
Oxidizing Short, pointed inner cone Brass, bronze, copper
(Excess 3400–3500°C
Flame with a hissing sound alloys, gas cutting
oxygen)

4.6 Welding Parameters

Parameter Typical Range
Flame Temperature 3100–3200°C
Oxygen Pressure 1–2 bar
Acetylene Pressure 0.1–0.5 bar
Torch Angle 40–50°
Filler Rod Diameter 2–4 mm

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4.7 Welding Procedure
1. Clean the workpieces thoroughly.
2. Prepare the joint if necessary.
3. Connect cylinders and check for gas leakage.
4. Ignite acetylene and adjust oxygen to obtain a neutral flame.
5. Heat the joint uniformly.
6. Add filler rod while maintaining the molten pool.
7. Move the torch steadily along the joint.
8. Allow the weld to cool naturally.
9. Clean the welded joint.
10. Inspect the weld visually.

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5. METAL INERT GAS WELDING (MIG WELDING / GAS METAL ARC WELDING)

5.1 Introduction
Metal Inert Gas (MIG) Welding, also known as Gas Metal Arc Welding (GMAW), is a modern
fusion welding process widely used in manufacturing, automobile, aerospace, shipbuilding, and
fabrication industries. In this process, an electric arc is established between a continuously fed
consumable wire electrode and the workpiece. The heat generated by the arc melts both the base
metal and the electrode wire, producing a strong and continuous weld. A shielding gas surrounds
the molten weld pool to protect it from atmospheric contamination.
MIG welding is known for its high welding speed, excellent weld quality, ease of automation, and
minimal post-weld cleaning. It is suitable for welding mild steel, stainless steel, aluminium,
copper, magnesium, and their alloys. Due to its continuous wire feed, MIG welding offers high
productivity and is widely employed in both manual and robotic welding applications.

5.2 Principle of MIG Welding

MIG welding operates on the principle of creating an electric arc between a continuously fed
consumable wire electrode and the workpiece. The arc produces intense heat (approximately 6000–
6500°C) that melts the electrode wire and the base metal, forming a molten weld pool. A shielding
gas, such as argon, carbon dioxide, or a mixture of both, protects the molten metal from oxidation
and contamination. As the welding torch moves along the joint, the molten metal solidifies to
form a strong welded joint. A basic setup for MIG welding is shown in Figure 4.

Figure 4: Layout of MIG Welding Setup

5.3 Working Principle

The working of MIG welding involves the following steps:
1. Connect the welding machine, work clamp, shielding gas cylinder, and wire feed unit.
2. Install the required wire electrode and adjust the wire feed speed.
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 3. Set the appropriate welding current, voltage, and gas flow rate.
4. Hold the welding torch at an angle of approximately 10–20° in the direction of welding.
5. Strike the arc by pressing the torch trigger.
6. The wire electrode continuously feeds into the weld pool while the shielding gas protects
the molten metal.
7. Move the torch steadily along the joint while maintaining a constant arc length.
8. Release the torch trigger at the end of the weld and allow the joint to cool naturally.

5.4 Equipment Used in MIG Welding

The basic equipment required includes:
1. MIG Welding Power Source
2. Wire Feed Unit
3. Welding Torch (MIG Gun)
4. Consumable Wire Electrode
5. Shielding Gas Cylinder (Argon, CO₂, or Argon–CO₂ mixture)
6. Gas Pressure Regulator and Flow Meter
7. Gas Hose
8. Work Clamp (Earth Clamp)
9. Contact Tip
10. Nozzle
11. Welding Helmet with Auto-Darkening Filter
12. Leather Gloves
13. Welding Apron
14. Safety Shoes

5.5 Types of Shielding Gases

Shielding Gas Composition Characteristics Typical Applications

Carbon Deep penetration, economical, Mild steel fabrication and
100% CO₂
Dioxide (CO₂) more spatter structural work
Aluminium, magnesium,
Stable arc, smooth weld bead,
Argon (Ar) 100% Argon copper and non-ferrous
low spatter
metals
Argon–CO₂ 75–95% Argon + Good arc stability, moderate Mild steel, stainless steel,
Mixture 5–25% CO₂ penetration, reduced spatter automotive applications

5.6 Welding Parameters

Parameter Typical Range
Arc Temperature 6000–6500°C
Welding Current 50–350 A
Arc Voltage 18–35 V

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 Parameter Typical Range
Wire Feed Speed 2–15 m/min
Shielding Gas Flow Rate 10–20 L/min
Electrode Wire Diameter 0.8–1.6 mm
Torch Angle 10–20°

5.7 Welding Procedure

1. Clean the workpieces thoroughly to remove rust, oil, grease, and dirt.
2. Prepare the joint according to the required joint design.
3. Connect the welding machine, work clamp, shielding gas cylinder, and wire feed unit.
4. Select the appropriate electrode wire and shielding gas.
5. Set the required welding current, voltage, wire feed speed, and gas flow rate.
6. Position the welding torch at an angle of 10–20°.
7. Press the torch trigger to strike the arc and begin welding.
8. Move the torch steadily while maintaining a uniform arc length and travel speed.
9. Release the trigger at the end of the weld and allow the welded joint to cool naturally.
10. Inspect the weld visually and remove any spatter, if necessary.

6. Students Remarks:
 How did this module help you understand the basic principles of welding and the

importance of proper welding techniques?

 How did this experiment improve your understanding of different welding processes, such
as Arc Welding and MIG/Gas Welding, and their industrial applications?
 What practical skills and safety precautions did you learn during the welding sessions?
 Which welding operation or activity did you enjoy the most and why?
 Did you face any difficulties while striking the arc, maintaining the weld pool, controlling
the torch/electrode, or producing a sound weld bead?
 Has this module improved your confidence in performing basic welding operations and
handling welding equipment safely?

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