ME-101

Workshop Technology

Welding

1
 Course Outline for Welding

 Brief details of Welding

• Gas Welding
• Electric Arc Welding
Introduction to
• Soldering
• Brazing

Welding is a materials joining process by heating them to suitable temperatures

with or without the application of pressure or by the application of pressure
alone, and with or without the use of filler material.

2
 Welding
• Welding is used for making permanent joints.
• Applications:
It is used in manufacturing of

Automobile Bodies Structural Works Boilers

Aircraft Frames Tanks, Machine Frames General Repair Works
Railway Furniture Ship Building

3
Welding Applications

4
 Types of Welding

 Plastic Welding or Pressure Welding

o The piece of metal to be joined are heated to a plastic state and forced together
by external pressure e.g. Resistance welding

 Fusion Welding or Non-Pressure Welding

o The material at the joint is heated to a molten state and allowed to solidify e.g.
Gas welding, Arc welding

5
 Classifications of Welding Processes
1) Arc welding 4) Thermit Welding
• Carbon arc
• Metal arc 5) Solid State Welding
• Metal inert gas • Friction
• Tungsten inert gas • Ultrasonic
• Plasma arc • Diffusion
• Submerged arc • Explosive
• Electro-slag
2) Gas Welding 6) Newer Welding
• Oxy-acetylene • Electron-beam
• Air-acetylene • Laser
• Oxy-hydrogen
3) Resistance Welding 7) Related Process
• Spot • Oxy-acetylene cutting
• Seam • Arc cutting
• Projection • Hard facing
• Percussion • Brazing
• Soldering
6
 Arc Welding Equipments
• A welding generator (D.C.) or Transformer (A.C.)
• Two cables- one for work and one for electrode
• Electrode holder
• Electrode
• Protective shield
• Gloves
• Wire brush
• Chipping hammer
• Goggles

7
 Arc Welding Equipments
• Uses an electric arc to coalesce (bringing them together) metals

• Arc welding is the most common method of welding metals

• Electricity travels from electrode to base metal to ground

8
 Arc Welding Advantages & Limitations
Advantages
• Most efficient way to join metals
• Affords lighter weight through better
utilization of materials
• Joins all commercial metals
• Provides design flexibility
Limitations
• Manually applied, therefore high
labor cost
• Need high energy causing danger
• Not convenient for disassembly
• Defects are hard to detect at joints

9
Comparison of A.C and D.C Arc Welding
Alternating Current (from Transformer)

• More efficiency
• Power consumption is less
• Cost of equipment is less
• Higher voltage – hence not safe
• Not preferred for welding thin sections
• Any terminal can be connected to the work or electrode

10
Comparison of A.C and D.C Arc Welding
Direct Current (from Generator)

• Less efficiency
• Power consumption is more
• Cost of equipment is more
• Low voltage – safer operation
• Preferred for welding thin sections
• Positive terminal connected to the work
• Negative terminal connected to the electrode

11
 Gas Welding
The workpiece are heated on the joining surfaces with hot gas, a filler
is generally used.

• Perfect weld is obtained by selecting proper size of flame, filler material and
method of moving torch.

• The temperature generated during the process is 33000C.

• When the metal is fused, oxygen from the atmosphere and the torch combines
with molten metal and forms oxides, results defective weld.

• Fluxes are added to the welded metal to remove oxides. (Lower Melting Point)

• Common fluxes used are made of sodium, potassium, Lithium and borax.

• Flux can be applied as paste, powder, liquid, solid coating or gas.

12
 Gas Welding Equipment
1. Gas Cylinders
Pressure
• Oxygen – 125 kgf/cm2
• Acetylene – 16 kgf/cm2
2. Regulators
• Working pressure of oxygen 1 kgf/cm2
• Working pressure of acetylene 0.15 kgf/cm2
• Working pressure varies depends upon the thickness of the
work pieces welded.
3. Pressure Gauges
4. Hoses (a flexible tube)
5. Welding torch
6. Check valve
7. Non return valve

13
Oxyacetylene Welding

14
 Oxyacetylene Welding
• This is the oldest of all welding processes.
An oxyacetylene weld is produced by
heating with a flame obtained from the
combustion of oxygen and acetylene.
• Three types of flames can be obtained:
reducing, neutral and oxidizing flames.
• The neutral one (equal proportions of
oxygen and acetylene) is the most widely
used.
• The reducing flame has excess acetylene
and is used in welding nickel, certain alloy
steels and non-ferrous metals.
• An oxidizing flame (with excess oxygen) Typical uses
is used for welding brass and bronze. Widely used for fabrication and
• Oxyacetylene welding has been replaced repair of metals.
in many applications by arc welding
15
 Three Types of Flames
Neutral Flame

• 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).

16
 Three Types of Flames
Oxidizing Flame

• 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.

• An oxidizing flame (with excess oxygen)

is used for welding brass and bronze.

• Used for welding brass and brazing

operation

17
 Three Types of Flames
Carburizing Flame

• 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).

• The reducing flame has excess acetylene

and is used in welding nickel, certain alloy
steels and non-ferrous metals.

18
 Weld Joints
There are Five basic types of Joints

19
 Brazing & Soldering
Soldering (Soft Solders)
Soldering is a thermal process, by which material joints are produced in
metallic materials with the help of another liquefied metal (solder), whose
melting point is lower than that of materials being joined. The solder wets the
base material without melting it.
•It is a low temperature joining process.
• It is performed at temperatures below 840ºF for joining.
• Soldering is used for,

o Sealing, as in automotive radiators or tin cans

o Electrical Connections
o Joining thermally sensitive components
o Joining dissimilar metals

20
 Brazing & Soldering
Soldering (Soft Solders)
• In SOLDERING, a lower melting point
alloy is introduced into a controlled gap
between the metal surfaces to be joined.
• There is little difference in principle
between soldering and brazing, except
that if the alloy used has a melting
point lower than 450ºC (840ºF) the
technique is
known as soldering.
• The joint strength is not as high as for a
brazed joint.
Typical uses
• The surfaces must be cleaned or
Widely used in the electrical and
otherwise prepared before the solder is
electronic industries and for radiators,
applied.
domestic pipe joints and fittings of all
• A flux protects the clean surfaces and
sorts
assists the flow of the liquid alloy.

21
 Brazing & Soldering
Brazing (Hard Solders)

• It is performed at temperatures above 840ºF and it generally affords strengths

comparable to those of the metal which it joins.
• It is low temperature in that it is done below the melting point of the base metal
• It is achieved by diffusion without fusion (melting) of the base

Filler metal: brass or solder

Filler metal: brass
or solder
Base metal
Base metal

Characteristics of a brazed or soldered joint

Characteristics of a brazed or
soldered joint

22
 Brazing & Soldering
Advantages & Disadvantage
 Advantages

• Dissimilar metals which cannot be welded can be joined by brazing

• Very thin metals can be joined
• Metals with different thickness can be joined easily
• In brazing thermal stresses are not produced in the work piece. Hence there is no
distortion
• Using this process, carbides tips are brazed on the steel tool holders

 Disadvantages

• Brazed joints have lesser strength compared to welding

• Joint preparation cost is more
• Can be used for thin sheet metal sections
23
 Brazing & Soldering
Process of Soldering
The soldering process takes place in 3 stages

1. Wetting: Once material has been heated to working temperature, the molten
solder begins to wet the surface of the workspace. The molten solder and the
solid base material come into close contact and form a layer of alloy.

2. Flowing: Heat is liberated in alloying, which provides energy for the solder to
spread and penetrate the soldering gap.

3. Bonding: The flowing solder permeates the base material along the grain
boundaries, in which process both materials diffuse into each other. The sort of
alloy formation, in which one of the components remains solid, is known as
diffusion. It involves migration of individual atoms in mixed phases.
• The strength of the diffused layer is greater than that of the solder itself. Thus
seems, in which the thickness of the solder is less, are stronger.

24