University of Bahrain

Course: Manufacturing Processes I (MENG 210)

Outline:
• Consumable electrode processes- Fusion welding
• Non-consumable electrode processes- Fusion welding
• Resistance welding- Fusion welding
• Sold state welding
• Welding defects

Welding Processes

Instructor: Prof. Dr. G. Hussain

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Department of Mechanical Engineering
 Fusion Welding

Consumable Electrode AW Processes

 Shielded Metal Arc Welding
 Gas Metal Arc Welding
 Flux-Cored Arc Welding
 Submerged Arc Welding

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CE Welding Processes Fusion Welding

1. Shielded Metal Arc Welding (SMAW)

Uses a consumable electrode consisting of a filler metal rod
coated with chemicals that provide flux and shielding
 Sometimes called "stick welding"
 Power supply, connecting cables, and electrode holder
available for a few thousand dollars

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CE Welding Processes Fusion Welding

1. Shielded Metal Arc Welding (SMAW)

Spattering

Shielded metal arc welding (SMAW).

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CE Welding Processes Fusion Welding

1. Shielded Metal Arc Welding (SMAW)

 Composition of filler metal usually close to base metal
 Coating:
- powdered cellulose (wood/cotton powder) mixed with
oxides, carbonates, and other ingredients, held together
by a silicate binder
- Gases on melting of coating protects/stablizes the arc
and slag covers the molten pool to prevent its oxidation
- Metal powders sometime is also included to increase
deposition rate
 Welding stick is clamped in electrode holder connected
to power source
 Current depends on the metal thickness, metal type and
5 electrode diameter
 CE Welding Processes Fusion Welding

1. Shielded Metal Arc Welding (SMAW)

- Used to weld mainly ferrous metals. Not used for Al
- Electrode needs to be changed periodically, reducing productivity
- Variation in electrode length/diameter affects the resistance and
hence heating
- This is relatively cheaper welding
process

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CE Welding Processes Fusion Welding
2. Gas Metal Arc Welding (GMAW)

Heavy spattering

Gas metal arc welding (GMAW).

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CE Welding Processes Fusion Welding

2. Gas Metal Arc Welding (GMAW)

Uses a consumable bare metal wire as electrode and shielding
is accomplished by flooding arc with a gas
 Wire is fed continuously and automatically from a spool
through the welding gun
 Shielding gases include inert gases such as argon and helium
& CO2 OR Mixtures of gases
 Inert gas is used for non ferrous alloys & SS; CO2 is used for
steels
 Bare electrode wire plus shielding gases eliminate slag on
weld bead - no need for manual grinding and cleaning of
slag
 High production rates as compared to SMAW
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CE Welding Processes Fusion Welding

3. Flux Cored Arc Welding (FCAW)

Flux-cored arc welding. Presence or absence of externally supplied shielding gas

distinguishes the two types: (1) self-shielded, in which core provides ingredients
for shielding, and (2) gas-shielded, which uses external shielding gases.
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CE Welding Processes Fusion Welding

3. Flux Cored Arc Welding (FCAW)

Adaptation of shielded metal arc welding, to overcome

limitations of stick electrodes
 Electrode is a continuous consumable tubing (in coils)
containing flux and other ingredients (e.g., alloying
elements) in its core
 It is noted for its high quality welds and also can provide
high production , may be higher than GMAW
 Spatter forms

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CE Welding Processes Fusion Welding

4. Submerged Arc Welding (SAW)

Submerged arc welding.

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CE Welding Processes Fusion Welding

4. Submerged Arc Welding (SAW)

Uses a continuous, consumable bare wire electrode, with

arc shielding provided by a cover of granular flux
 Electrode wire is fed automatically from a coil
 Completely submerges operation, preventing sparks,
spatter, and radiation
- The flux falls under gravity, therefore parts are always held
horizontally
- Needs a backing plate beneath the joint, used as a heat sink
- Higher production rate, even higher than FCAW, GMAW
- Used for low C, alloys steels. Not used for Die steel, non
ferrous metal
- Highest heat transfer factor from arc into base metal
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 Fusion Welding

Nonconsumable Electrode Processes

 Gas Tungsten Arc Welding
 Plasma Arc Welding
 Stud Welding
 Resistance Welding

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 NCE Welding Processes Fusion Welding

1. Gas Tungsten Arc Welding (GTAW)

- High quality welds
- Useful for thin sheets
- Low production rates
- Expensive process
- Suitable for autogenous welding

1. Why Tungsten is used as

electrode?
2. Can we weld Al & SS
with other processes?

Gas tungsten arc welding.

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 NCE Welding Processes Fusion Welding

1. Gas Tungsten Arc Welding (GTAW)

Uses a non-consumable tungsten electrode and an inert gas
for arc shielding
 Melting point of tungsten = 3410C
 Used with or without a filler metal
 When filler metal used, it is added to weld pool from
separate rod or wire
 Applications:
- Can be used for all metals, but most common for AL & SS
- Can be used for dissimilar metal welding
- Cast iron, W, lead difficult to weld with this method

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 NCE Welding Processes Fusion Welding

2. Plasma Arc Welding (PAW)

- Good arc stability
- High Temp (28000C)
- Better penetration control
- High travel speeds
- Any metal can be welded including tungsten, Cast iron, Pb, Mg

- High equipment cost

- Need larger torch size than other AW
processes, which tends to restrict access in Plasma arc welding (PAW).
narrow joint configuration
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NCE Welding Processes Fusion Welding

2. Plasma Arc Welding (PAW)

Special form of GTAW in which a constricted plasma arc is
directed at weld area
 Tungsten electrode is contained in a nozzle that focuses a
high velocity stream of inert gas (argon) into arc region to
form a high velocity, intensely hot plasma arc stream
 Temperatures in PAW reach 28,000C (50,000F), due to
constriction of arc, producing a plasma jet of small
diameter and very high energy density

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NCE Welding Processes Fusion Welding

3. Carbon Arc Welding (CAW)

- NC Carbon electrode is used for generating arc
- Useful for repairing broken castings
- Also used in Brazing

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 Fusion Welding

5. Resistance Welding (RW)

A group of fusion welding processes that use a combination
of heat and pressure to accomplish coalescence
 Heat generated by electrical resistance to current flow at
junction to be welded
 Principal RW process is resistance spot welding (RSW)

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 Fusion Welding
Resistance Welding

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 Fusion Welding

a. Resistance Spot Welding (RSW)

Resistance welding process in which fusion of
faying surfaces of a lap joint is achieved at one
location by opposing electrodes
 Used to join sheet metal parts using a series of
spot welds
 Widely used in mass production of automobiles,
appliances, metal furniture, and other products
made of sheet metal
 Typical car body has ~ 10,000 spot welds
 Annual production of automobiles in the world is
measured in tens of millions of units

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 Fusion Welding

b. Resistance Seam Welding (RSEW)

Stick electrodes are replaced by
roller electrodes

- Used for fabricating thin gasoline tanks &

automobile muffler
- Distortion of parts is a matter of concern

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 Fusion Welding

b. Resistance Welding: Example

H= I^2Rt

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 Fusion Welding

c. High Frequency Resistance welding

High frequency AC is used - Used for fabricating long pipes
Frequency: (500KHz)

No Sparking
Sparking
Coil does not make physical contact with pipe.
Heating is done due to induction process

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 Fusion Welding

Electron Beam Welding (EBW)

-

[Link]

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 Fusion Welding

Electron Beam Welding (EBW)

Fusion welding process in which heat for welding is provided by a
highly-focused, high-intensity stream of electrons striking work
surface
 Electron beam gun operates at:
 High voltage (e.g., 10 to 150 kV typical) to accelerate electrons
 Beam currents are low (measured in milliamps)
 But Power Density is High: f = Heat Transfer factor
 Two Types:Vacuum & Non-Vacuum
 Vacuum welding gives high penetration and weld quality
 Almost all metals including refractory & dissimilar metals can be
welded
 Narrow HAZ
Disads: Generates x-rays, tight fit up requirement, costly equipment
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 Fusion Welding

Laser Beam Welding (LBW)

[Link]

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 Fusion Welding

Laser Beam Welding (LBW)

Fusion welding process in which coalescence is achieved by
energy of a highly concentrated, coherent light beam
focused on joint
 Laser = "light amplification by stimulated emission of
radiation"
 LBW normally performed with shielding gases to prevent
oxidation
 Filler metal not usually added
 High power density in small area, so LBW often used for
small parts

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 Fusion Welding

Comparison: LBW vs. EBW

 No vacuum chamber required for LBW
 No x-rays emitted in LBW
 Laser beams can be focused and directed by optical
lenses and mirrors
 LBW not capable of the deep welds and high
depth-to-width ratios of EBW
 Maximum LBW depth = ~ 19 mm (3/4 in), whereas EBW
depths = 50 mm (2 in)

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Solid State Welding: Solid Sate Welding

1. Forge Welding
 Components to be joined are heated to hot working
temperatures and then forged together by hammer or
other means.
 It is oldest welding method, loosing use in industry

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Solid State Welding: Solid Sate Welding

2. Cold Welding
 Surfaces are coalesced by applying high pressure b/w 02
clean surfaces at room temp
 At least one of the welded metals must be very ductile
 Soft metals such as Al, Cu can be readily welded
 The applied compressive forces reduce thickness by 50%
due to plastic deformation
 Heavy presses are used for large parts
Applications:
Making of electrical connections

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Solid State Welding: Solid Sate Welding

3. Roll Welding
 Coalescence b/w the sheets is obtained by applying
pressure b/w the 02 sheets using rollers.
 It can be done with/without application of heat
Application:
Cladding SS onto carbon steels to prevent corrosion

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Solid State Welding: Solid Sate Welding

4. Diffusion Welding
 Coalescence b/w the parts is obtained by diffusion of
atoms
 Diffusion is achieved by heating (0.5Tm) and application
of pressure with minimal plastic deformation of faying
edges.
- Sufficient time (could be 1hr) is given for diffusion
under pressure and Temp
Application:
- In aerospace/ nuclear industry for High strength &
refractory metals.
- Dissimilar metals: a filler layer of a different metal is
sandwiched b/w 02 different base metals to promote
diffusion
[Link]
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Solid State Welding: Solid Sate Welding

5. Explosive Welding
 Necessary heat and pressure is provided by explosion of a
detonated explosive
 No filler is used
 Progressive welding at 8500m/sec
 Metallurgical bonding takes place, as thin layer of metal at the
interface of faying surfaces undergoes melting
Application: [Link]
- For cladding sheets

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 Solid State Welding: Solid Sate Welding

6. Friction Welding
-

Rotation stopped
when temp reaches
hot working range [Link]

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Solid State Welding: Solid Sate Welding

6. Friction Welding
 Coalescence is achieved by friction heating combined with
pressure
 Friction is induced by mechanical rubbing b/w the 02 surfaces
 Then the parts are driven towards each other with sufficient
force to form a metallurgical bond
 No shielding gas required
 Low HAZ

Application:
- Welding of shafts & tubular parts in Automobile, Aircraft,
and Petroleum industry

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Homework

Solve 31.3, 31.4, 31.6, 31.9, 31.11, 31.20, 31.21

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Welding Defects
 Cracks
 Cavities
 Solid inclusions
 Imperfect shape or unacceptable contour
 Incomplete fusion

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Welding Cracks
Fracture-type interruptions either in weld or in base metal
adjacent to weld
 Serious defect because it is a discontinuity in the metal
that significantly reduces strength
 Caused by
 embrittlement
 low ductility of weld and/or base metal
 high restraint during contraction
 high thermal stresses

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 Welding Cracks

Various forms of welding cracks.

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Cavities
Two cavity types, similar to defects found in castings:
1. Porosity - small voids in weld metal formed by gases
entrapped during solidification
Caused by
 inclusion of atmospheric gases
 sulfur in weld metal
 surface contaminants
2. Shrinkage voids - cavities formed by shrinkage during
solidification

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Solid Inclusions
 Solid inclusions - solid material entrapped in weld metal
 Most common form is slag inclusions generated during
AW processes that use flux
 Instead of floating to top of weld pool, globules of slag
become encased during solidification
 Metallic oxides that form during welding of certain metals
such Al2O3
 Tungsten due to overheating melts down and becomes
the part of weldment

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 Incomplete Fusion

Also known as lack of fusion, it is simply a weld

bead in which fusion has not occurred
throughout entire cross section of joint

Lack of penetration means

that fusion has not
penetrated deep enough into
the root of joint
Several forms of incomplete fusion.
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 Imperfect Weld Shape

Same joint but with several weld defects: (b) undercut, in which a portion of
the base metal part is melted away; (c) underfill, a depression in the weld
below the level of the adjacent base metal surface; and (d) overlap, in
which the weld metal spills beyond the joint onto the surface of the base
part but no fusion occurs.

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