Chapter-6 Welding

Introduction
Welding is a process for joining two similar or dissimilar metals by fusion. It joins
different metals/alloys, with or without the application of pressure and with or without the
use of filler metal. The fusion of metal takes place by means of heat. The heat may be
generated either from combustion of gases, electric arc, electric resistance or by chemical
reaction. During some type of welding processes, pressure may also be employed, but this is
not an essential requirement for all welding processes. Welding provides a permanent joint
but it normally affects the metallurgy of the components. It is therefore usually accompanied
by post weld heat treatment for most of the critical components. The welding is widely used
as a fabrication and repairing process in industries. Some of the typical applications of
welding include the fabrication of ships, pressure vessels, automobile bodies, off-shore
platform, bridges, welded pipes, sealing of nuclear fuel and explosives, etc.

6.1 Terminological Elements of Welding Process

The terminological elements of welding process used with common welding joints
such as base metal, fusion zone, weld face, root face, root opening toe and root are depicted
in Fig. 6.1

Fig. 6.1 Terminological Elements of Welding Process

6.1.1 Edge preparations for welding the edges of joining surfaces of metals are
prepared first. Different edge preparations may be used for welding butt joints, which are
given in Fig 6.2.
 Fig 6.2 Butt Welding Joint edge preparation
6.1.2 Welding joints Some common welding joints are shown in Fig. 6.3. Welding
joints are of generally of two major kinds namely lap joint and butt joint. The main types are
described as under.
[Link] Lap weld joint
Single-Lap Joint This joint, made by overlapping the edges of the plate, is not
recommended for most work. The single lap has very little resistance to bending. It can be
used satisfactorily for joining two cylinders that fit inside one another.
Double-Lap Joint This is stronger than the single-lap joint but has the disadvantage
that it requires twice as much welding.
Tee Fillet Weld This type of joint, although widely used, should not be employed if
an alternative design is possible.

Fig. 6.3. Types of welding joints

 Single-Vee Butt Weld It is used for plates up to 15.8 mm thick. The angle of the vee
depends upon the technique being used, the plates being spaced approximately 3.2 mm.
Double-Vee Butt Weld It is used for plates over 13 mm thick when the welding can be
performed on both sides of the plate. The top vee angle is either 60° or 80°, while the bottom
angle is 80°, depending on the technique being used.
6.1.3 Welding Positions - As shown in Fig. 6.4, there are four types of welding
positions, which are given as:
1. Flat or down hand position
2. Horizontal position
3. Vertical position
4. Overhead position
[Link] Flat or Downhand Welding Position- The flat position or down hand
position is one in which the welding is performed from the upper side of the joint and the
face of the weld is approximately horizontal. This is the simplest and the most convenient
position for welding. Using this technique, excellent welded joints at a fast speed with
minimum risk of fatigue to the welders can be obtained.
[Link] Horizontal Welding Position- In horizontal position, the plane of the
workpiece is vertical and the deposited weld head is horizontal. The metal deposition rate in
horizontal welding is next to that achieved in flat or downhand welding position. This
position of welding is most commonly used in welding vessels and reservoirs.
[Link] Vertical Welding Position - In vertical position, the plane of the work piece
is vertical and the weld is deposited upon a vertical surface. It is difficult to produce
satisfactory welds in this position due to the effect of the force of gravity on the molten metal.
The welder must constantly control the metal so that it does not run or drop from the weld.
Vertical welding may be of two types viz., vertical-up and vertical-down. Vertical-up welding
is preferred when strength is the major consideration. The vertical-down welding is used for
a sealing operation and for welding sheet metal.
[Link] Overhead Welding Position- The overhead position is probably even more
difficult to weld than the vertical position. Here the pull of gravity against the molten metal
is much greater. The force of the flame against the weld serves to counteract the pull of
gravity. In overhead position, the plane of the work piece is horizontal. But the welding is
carried out from the underside. The electrode is held with its welding end upward.

Fig. 6.4. Different types of welding positions

6.2 Advantages and Disadvantages of Welding
Advantages

1. Welding is more economical and is much faster process as compared to other

processes (riveting, bolting, casting etc.)
2. Welding, if properly controlled results permanent joints having strength equal or
sometimes more than base metal.
3. Large number of metals and alloys both similar and dissimilar can be joined by
welding. 4. General welding equipment is not very costly.
4. Portable welding equipment can be easily made available.
5. Welding permits considerable freedom in design.
6. Welding can join welding jobs through spots, as continuous pressure tight seams,
end-to-end and in a number of other configurations.
7. Welding can also be mechanized.
Disadvantages

1. It results in residual stresses and distortion of the workpiece.

2. Welded joint needs stress relieving and heat treatment.
3. Welding gives out harmful radiations (light), fumes and spatter.
4. Jigs, and fixtures may also be needed to hold and position the parts to be welded
5. Edges preparation of the welding jobs are required before welding
6. Skilled welder is required for production of good welding
7. Heat during welding produces metallurgical changes as the structure of the welded
joint is not same as that of the parent metal.
6.3 Classification of welding processes
There are various ways of classifying the welding and allied processes. For example, they
may be classified on the basis of source of heat, i.e., blacksmith fire, flame, arc, etc. and the
type of interaction i.e., liquid / liquid (fusion welding) or solid/solid (solid state welding).
Welding processes may also be classified in two categories namely plastic (forge) and fusion.
However, the general classification of welding and allied processes is given as under

1. Gas welding
a) Oxy-acetylene
b) Air-acetylene
c) Oxy-hydrogen
2. Arc welding
a) Carbon arc welding d. Metal arc g. Gas-metal arc(MIG)
b) Plasma arc welding e. Electro-slag h. Gas-tungsten arc (TIG)
c) Submerged arc welding f. Flux-cored i. Atomic-hydrogen arc
 3. Resistance welding
a) Butt c. Spot e. Seam
b) Projection d. Percussion
4. Thermit welding
5. Solid state welding
a) Friction c. Ultrasonic
b) Explosive d. Diffusion
6. Newer welding (Radiant Energy welding)
a) Electro-beam
b) Laser
6.4 Arc Welding Processes
The process, in which an electric arc between an electrode and a workpiece or between
two electrodes is utilized to weld base metals, is called an arc welding process. The basic arc
welding circuit is shown in Fig 6.5. However the basic elements involved in arc welding
process are shown in Fig.6.6. Most of these processes use some shielding gas while others
employ coatings or fluxes to prevent the weld pool from the surrounding atmosphere. The
various arc welding processes are: Carbon Arc Welding, Shielded Metal Arc Welding, Gas
Tungsten Arc Welding, Gas Metal Arc Welding, Plasma Arc Welding, Stud Arc Welding,
Electro gas Welding.

Fig 6.5. The basic arc welding circuit

 Fig 6.6. Arc welding process setup

6.4.1 Mechanism of arc welding

Arc welding uses an electric phenomenon called arc discharge. An arc discharge is
an electric discharge phenomenon of a gas and refers to current released in air. When the
voltage applied to two spatially separated electrodes is gradually increased, the air
insulation finally breaks and current flows between the electrodes, emitting bright light and
high heat at the same time. The generated arc-shaped light is called an electric arc or arc as
shown in the fig 6.7. Arc welding is welding using the heat of an arc as a heat source.
In arc welding, positive voltage is applied to the electrode (welding rod/wire) and negative
voltage is applied to the base material. This makes an arc occur from the base material to the
electrode.
The output current of the arc is about 5 to 1,000 A and the output voltage is about 8 to 40 V.
The temperature of the arc is about 5,000°C to 20,000°C. The melting temperature of iron is
about 1,500°C. Consequently, the base material and electrode are heated to a high
temperature and fuse together.

Fig 6.7. Arc formation between workpiece and electrode

6.4.2 Polarity in Arc Welding – Straight, Reverse & Alternating Polarity

Arc welding is one type of fusion welding process where base metals are fused by applying
heat in order to form coalescence. Required heat is supplied by an electric arc constituted
between positive and negative terminals of an electric circuit inbuilt with a power source.
For welding purpose work metal is made one terminal and the electrode is made another,
and thus arc constitutes in between them in the external circuit. Since electrons always flow
from negative terminal to positive terminal of any external circuit, so based on the
connection made, two cases are possible:

1. Electrode is connected with negative terminal of the power source; whereas, base
metals are connected with positive terminal.
2. Base metals are connected with the negative terminal of the power source; whereas,
electrode is connected with positive terminal.
However, if the power source provides alternating current (AC) then both conditions occur
one after another in every cycle. Basically arc welding power sources can provide either DC
or AC type current. Some modern power sources also contain facility to convert one from
another (integrated with AC-DC converter), so these sources can supply both AC and DC
power. Therefore, arc welding can be carried out in any of the following three polarities;
however, each has certain advantages over others as elaborated in the successive sections.

Three different polarities used in arc welding

 Direct Current Straight Polarity—occurs when electrode is made negative and base
plates are made positive. Thus electrons flow from electrode tip to base plates.
 Direct Current Reverse Polarity—occurs when electrode is made positive and base
plates are made negative. Thus electrons flow from base plates to electrode.
 Alternating Current Polarity—if power source provides AC current then above two
cases will occur one after another in every cycle. In one half of the cycle, electrode will
be negative (so base plates will be positive) and in the next half, electrode will be
positive (so base plate will be negative). Number of cycles per second depends on
frequency of supply. For example, with a 60Hz supply, 60 cycles occur in every
second.

[Link] Direct Current Electrode Positive (DCEP) polarity in arc welding

With direct current (DC) power supply, when electrode is connected with positive terminal
and base plates with the negative terminal, then it is termed as Direct Current Electrode
Positive (DCEP) or Direct Current Reverse Polarity (DCRP). So electrons liberate from base
plate and flow towards electrode via the outer circuit. Continuous flow of avalanche of
electrons in a small passage produces the arc (source of heat).
Electrons, emitting from the base plates (negative polarity), are accelerated due to presence
of potential difference and are allowed to strike the electrode (positive polarity) at a very
high velocity. Upon striking, kinetic energy of electrons is converted to thermal energy,
which ultimately results in high heat generation at the vicinity of electrode tip. As a thumb
rule, it is considered that two-third (66%) of the entire arc heat is generated at electrode;
whereas, only one-third (33%) heat is generated at base plate. As a result, electrode melts
down quickly and metal deposition rate increases (for consumable electrodes only). On the
other hand, base plates do not fuse properly due to lack of sufficient heat and thus various
defects arise, such as insufficient fusion, lack of penetration, high reinforcement, etc.
However, stream of electron flow from base plate remove oil, coating, oxide layer or dust
particles present on the base plate surface (termed as oxide cleaning action).

Advantages of DCEP polarity in arc welding

 Better arc cleaning action so less chance of inclusion defects.

 High volume deposition rate for consumable electrode, so faster welding.
 Better performance for welding thin plates. It reduces distortion level, residual stress,
complete cutting, etc.
 Suitable for joining metals with low melting points, such as copper and aluminum.

Disadvantages of DCEP polarity in arc welding

 Shorter electrode life for non-consumable electrodes.
 Higher level of reinforcement if speed is not adjusted properly.
 Insufficient melting and incomplete penetration.
 Cannot fuse properly thick plates or metals having high melting point.

[Link] Direct Current Electrode Negative (DCEN) polarity in arc welding

Opposite to DCEP, when the electrode is connected with negative terminal and base plates
with the positive terminal, then it is termed as Direct Current Electrode Negative (DCEN) or
Direct Current Straight Polarity (DCSP). So electrons flow from electrode to base plates.
Consequently, more heat generates at the base plate as compared to electrode, so metal
deposition rate reduces. Also various defects caused by insufficient fusion of base metal
eliminate. But DCEN lacks cleaning action, so inclusion defects may arise if base plates are
not cleaned properly prior to welding. Pros and cons of DCEN polarity are discussed below.

Advantages of DCEN polarity in arc welding

 Sufficient fusion of base metals and thus proper penetration can be achieved.
 Less chance of tungsten inclusion (with TIG welding) and also low reinforcement.
 Better choice for welding metals with high melting point, such as titanium, stainless
steel, etc.
 Thick plates can also be joined properly.

Disadvantages of DCEN polarity in arc welding

 No arc cleaning action so chances of inclusion defects.
 High distortion level.
 High residual stress generation at welded components.
 Broader heat affected zone (HAZ).
 Lower productivity due to lower deposition rate.
  Not suitable for welding thin plates.

[Link]. Alternating Current (AC) polarity in arc welding

AC polarity offers advantages of both DCEN and DCEP; however, to some extent only. With
AC power source, in half of the cycle electrode becomes negative and in next half of the cycle,
electrode becomes positive. This cycle repeats 50 or 60 times in a second depending on
frequency of supply (50Hz or 60Hz). Some power sources also provide provisions to alter
this frequency.

Advantages of AC polarity in arc welding

 Moderate arc cleaning action.
 Compatible with most of the electrode types (but not all).
 Better fusion and weld metal penetration.
 Suitable for a wide range of plate thickness.

Fig. 6.8 Polarity in Arc Welding – Straight, Reverse & Alternating Polarity

[Link] How polarity affects arc welding performance

Polarity is one of the crucial factors that influences quality of welded joints. Prior to welding,
the welder must select appropriate polarity depending on requirement, type of filler,
electrode type, and base material. The following list shows the parameters that are
commonly affected by weld polarity.
 Filler deposition—With consumable electrode, DCEP polarity increases metal
deposition rate. Read:
 Weld penetration—DCEN polarity increases weld penetration
 Base plate cleaning—DCEP helps in cleaning base plates during welding, thus
reduces chance of inclusion defects.
  Reinforcement—DCEP causes globular mode of metal transfer, so increases weld
bead width.
 HAZ—DCEN polarity heats up the base plates quickly and if speed is not adjusted then
HAZ becomes broader.
 Weld bead appearance—AC, highly depends on many other factors.

6.5 Arc Welding Equipment

Arc welding equipment, setup and related tools and accessories are shown in figure
6.9. Few of the important components of arc welding setup are described as under.

6.5.1 Arc welding power source Both direct current (DC) and alternating current (AC) are
used for electric arc welding, each having its particular applications. DC welding supply is
usually obtained from generators driven by electric motor or if no electricity is available by
internal combustion engines. For AC welding supply, transformers are predominantly used
for almost all arc welding where mains electricity supply is available. They have to step down
the usual supply voltage (200- 400 volts) to the normal open circuit welding voltage (50-90
volts).

6.5.2 Welding cables

Welding cables are required for conduction of current from the power source through the
electrode holder, the arc, the workpiece and back to the welding power source. These are
insulated copper or aluminum cables.

6.5.3 Electrode holder Electrode holder is used for holding the electrode manually and
conducting current to it. These are usually matched to the size of the lead, which in turn
matched to the amperage output of the arc welder. Electrode holders are available in sizes
that range from 150 to 500 Amps.

6.5.4. Hand Screen used for protection of eyes and supervision of weld bead.

6.5.5 Chipping hammer is used to remove the slag by striking.

6.5.6 Wire brush is used to clean the surface to be weld.

6.5.7 Protective clothing Operator wears the protective clothing such as apron to keep
away the exposure of direct
heat to the body.
 Fig. 6.9. Arc Welding Equipment

6.5.8 Electrodes for arc welding

An electrode is a piece of wire or a rod of a metal or alloy, with or without coatings. An arc is
set up between electrode and workpiece. Welding electrodes are classified into following
types:

1. Consumable Electrodes- a) Bare Electrodes b) Coated Electrodes

2. Non-consumable Electrodes – a) Carbon or Graphite Electrodes b)
Tungsten Electrodes

Consumable electrode is made of different metals and their alloys. The end of this
electrode starts melting when arc is struck between the electrode and workpiece. Thus
consumable electrode itself acts as a filler metal. Bare electrodes consist of a metal or
alloy wire without any flux coating on them.
Coated electrodes have flux coating which starts melting as soon as an electric arc is
struck as shown in the figure 6.10. This coating on melting performs many functions like
prevention of joint from atmospheric contamination, arc stabilizers etc.

Fig. 6.10. Coated electrodes with AWS nomenclature

Functions of Electrode Coating Ingredients

The covering coating on the core wire consists of many materials which perform a
number of functions as listed below:

 Slag forming ingredients, like silicates of magnesium, aluminium, sodium, potassium,

iron oxide, china clay, mica etc., produce a slag which because of its light weight forms
a layer on the molten metal and protects the same from atmospheric contamination.
 Arc stabilizing constituents like calcium carbonate, potassium silicate, titanates,
magnesium silicates, etc.; add to arc stability and ease of striking the same.
 Gas shielding ingredients, like cellulose, wood, wood flour, starch, calcium carbonate
etc. form a protective gas shield around the electrode end, arc and weld pool
 Deoxidizing elements like ferro-manganese, and ferro-silicon, refine the molten
metal.
 It limits spatter, produces a quiet arc and easily removable slag.
 Alloying elements like ferrous alloys of manganese, molybdenum etc., may be added
to impart suitable properties and strength to the weld metal and to make good the
loss of some of the elements, which vaporize while welding.
 Iron powder in the coating improves arc behavior, bead appearance helps increase
metal deposition rate and arc travel speed.
 The covering improves penetration and surface finish.
 Core wire melts faster than the covering, thus forming a sleeve of the coating which
constricts and produces an arc with high concentrated heat.
 Coating saves the welder from the radiations otherwise emitted from a bare electrode
while the current flows through it during welding.
  Proper coating ingredients produce weld metals resistant to hot and cold cracking.
Suitable coating will improve metal deposition rates.
Non-consumable electrodes are made up of high melting point materials like carbon,
pure tungsten or alloy tungsten etc. These electrodes do not melt away during welding.
But practically, the electrode length goes on decreasing with the passage of time, because
of oxidation and vaporization of the electrode material during welding. The materials of
non-consumable electrodes are usually copper coated carbon or graphite, pure tungsten.

6.6 Welding Defects

Defects are common in any type of manufacturing, welding including. In the process,
there can be deviations in the shape and size of the metal structure.

6.6.1 Weld Crack - The most serious type of welding defect is a weld crack and it’s
not accepted almost by all standards in the industry. It can appear on the surface, in the weld
metal or the area affected by the intense heat. There are different types of cracks, depending
on the temperature at which they occur:

1. Hot cracks. These can occur during the welding process or during the
crystallization process of the weld joint. The temperature at this point can rise
over 10,000C.
2. Cold cracks. These cracks appear after the weld has been completed and the
temperature of the metal has gone down. They can form hours or even days
after welding. It mostly happens when welding steel. The cause of this defect
is usually deformities in the structure of steel.
3. Crater cracks. These occur at the end of the welding process before the
operator finishes a pass on the weld joint. They usually form near the end of
the weld. When the weld pool cools and solidifies, it needs to have enough
volume to overcome shrinkage of the weld metal. Otherwise, it will form a
crater crack.
Causes of cracks:

 Use of hydrogen when welding ferrous metals.

 Residual stress caused by the solidification shrinkage.
 Base metal contamination.
 High welding speed but low current.
 No preheat before starting welding.
 Poor joint design.
 A high content of sulfur and carbon in the metal.
Remedies:

 Preheat the metal as required.

 Provide proper cooling of the weld area.
  Use proper joint design.
 Remove impurities.
 Use appropriate metal.
 Make sure to weld a sufficient sectional area.
 Use proper welding speed and amperage current.
 To prevent crater cracks, make sure that the crater is properly filled.
 Porosity

6.6.2 Porosity occurs as a result of weld metal contamination. The trapped gases
create a bubble-filled weld that becomes weak and can with time collapse.

Causes of porosity:

 Inadequate electrode deoxidant.

 Using a longer arc.
 The presence of moisture.
 Improper gas shield.
 Incorrect surface treatment.
 Use of too high gas flow.
 Contaminated surface.
 Presence of rust, paint, grease or oil.
Remedies:

 Clean the materials before you begin welding.

 Use dry electrodes and materials.
 Use correct arc distance.
 Check the gas flow meter and make sure that it’s optimized as required with
proper with pressure and flow settings.
 Reduce arc travel speed, which will allow the gases to escape.
 Use the right electrodes.
 Use a proper weld technique.
6.6.3. Undercut- This welding imperfection is the groove formation at the weld toe,
reducing the cross-sectional thickness of the base metal. The result is the weakened weld
and workpiece.
 Causes:

 Too high weld current.

 Too fast weld speed.
 The use of an incorrect angle, which will direct more heat to free edges.
 The electrode is too large.
 Incorrect usage of gas shielding.
 Incorrect filler metal.
 Poor weld technique.
Remedies:

 Use proper electrode angle.

 Reduce the arc length.
 Reduce the electrode’s travel speed, but it also shouldn’t be too slow.
 Choose shielding gas with the correct composition for the material type you’ll
be welding.
 Use of proper electrode angle, with more heat directed towards thicker
components.
 Use of proper current, reducing it when approaching thinner areas and free
edges.
 Choose a correct welding technique that doesn’t involve excessive weaving.
 Use the multi pass technique

6.6.4. Incomplete Fusion This type of welding defect occurs when there’s a lack of
proper fusion between the base metal and the weld metal. It can also appear between
adjoining weld beads. This creates a gap in the joint that is not filled with molten metal.

Causes:

 Low heat input.

 Surface contamination.
 Electrode angle is incorrect.
 The electrode diameter is incorrect for the material thickness you’re welding.
 Travel speed is too fast.
 The weld pool is too large and it runs ahead of the arc.
 Remedies:

 Use a sufficiently high welding current with the appropriate arc voltage.
 Before you begin welding, clean the metal.
 Avoid molten pool from flooding the arc.
 Use correct electrode diameter and angle.
 Reduce deposition rate.
6.6.5. Incomplete Penetration occurs when the groove of the metal is not filled
completely, meaning the weld metal doesn’t fully extend through the joint thickness.

Causes:

 incomplete penetration There was too much space between the metal you’re
welding together.
 moving the bead too quickly, which doesn’t allow enough metal to be
deposited in the joint.
 using a too low amperage setting, which results in the current not being strong
enough to properly melt the metal.
 Large electrode diameter.
 Misalignment.
 Improper joint.
Remedies:

 Use proper joint geometry.

 Use a properly sized electrode.
 Reduce arc travel speed.
 Choose proper welding current.
 Check for proper alignment.

6.6.6. Slag Inclusion is one of the welding defects that are usually easily visible in the
weld. Slag is a vitreous material that occurs as a byproduct of stick welding, flux-cored arc
welding and submerged arc welding. Is can occur when the flux, which is the solid shielding
material used when welding, melts in the weld or on the surface of the weld zone.
 Causes:

 Improper cleaning.
 The weld speed is too fast.
 Not cleaning the weld pass before
starting a new one.
 Incorrect welding angle.
 The weld pool cools down too fast.
 Welding current is too low.
Remedies:

 Increase current density.

 Reduce rapid cooling.
 Adjust the electrode angle.
 Remove any slag from the previous bead.
 Adjust the welding speed.
6.6.7 Spatter occurs when small particles from the weld attach themselves to the
surrounding surface. It’s an especially common occurrence in gas metal arc welding. No
matter how hard you try, it can’t be completely eliminated. However, there are a few ways
you can keep it to a minimum.

Causes:

 The running amperage is too high.

 Voltage setting is too low.
 The work angle of the electrode is too steep.
 The surface is contaminated.
 The arc is too long.
 Incorrect polarity.
 Erratic wire feeding.
Remedies:

 Clean surfaces prior to welding. Reduce the arc length.

 Adjust the weld current.
 Increase the electrode angle.
 Use proper polarity.
 Make sure you don’t have any feeding issues.
6.7 Brazing and Soldering
Brazing is a metal joining process whereby a filler metal is heated above melting point
and distributed between two or more close fitting parts by capillary action. In brazing,
metallic parts are joined by a non-ferrous filler metal or alloy. Brazing involves the
melting of comparatively low melting point filler material against the base metal pieces
to be joined while they are clean and free from oxides, oil grease, etc. The molten filler
material Wets the base metal surfaces Spreads along the joint by capillary action Adheres
and solidifies to from the brazed joint. Brazing gives much stronger joint compare to
soldering. Filler material used in this processes are generally two types Copper based
alloy and Silver based alloy. The parts to be joined by brazing are carefully cleaned, the
flux applied and the parts clamped in position for joining. Borax is generally used as flux.

Soldering is a method of joining two or more pieces of metal by means of a fusible alloy
or metal, called solder, applied in molten state.

Solders are essentially alloys of lead and tin. To improve the mechanical properties
and temperature resistance, solders are added to other alloying elements such as zinc,
cadmium and silver in various proportions. To improve the mechanical properties and
temperature resistance, solders are added to other alloying elements such as zinc,
cadmium and silver in various proportions. Solvent cleaning, acid pickling and even
mechanical cleaning are applied before soldering.
 V- Butt Joint
Experiment No. Date-

Aim - preparation of butt joint as shown in figure using Manual metal arc welding
process.

Raw material – 2 MS flat pieces of size (…. ×….×….).

Tools required:

1. welding transformer,
2. connecting cables,
3. electrode holder,
4. ground clamp,
5. electrodes,
6. hipping hammer,
7. Welding shield etc.
Procedure:

1. The given metallic pieces filled to the desired size.

2. On both pieces beveled in order to have V groove.
3. The metallic pieces are thoroughly cleaned from rust grease, oil, etc.
4. The metallic pieces are connected to terminals of Trans former.
5. Select electrode diameter based on thickness of work piece and hold it on the
electrode holder.
6. Select suitable range of current for selected dia.
7. Switch on the power supply and initiates the arc by either striking arc method
or touch and drag method.
8. Take welding to be done before full welding.
9. In full welding process after completion one part before going to second part.
Slag is removed from the weld bed. With the metal wire brush or chipping
hammer.
 10. Then the above process will be repeated until to fill the groove with weld bed
or weld metal.
Precautions:

1. Use goggles, gloves in order to protect the human body.

2. Maintain the constant arc length.
Result:

Conclusion: