Classification of Welding

Processes
22MEE27 - WELDING TECHNOLOGY
 Prerequisites

MANUFACTURING ENGINEERING MATERIALS

TECHNOLOGY, AND METALLURGY
 Unit - I Welding Principles, Gas and
Arc Welding Processes
Classifications of Welding Processes – Power
Sources – Arc Characteristics – V-I Characteristics –
Metal Transfer Modes – Electrodes and Fluxes –
Types of Weld Joints – Weld Position – Gas Welding:
Oxy-Acetylene Welding – Oxy-Hydrogen Welding –
Arc Welding: Shielded Metal Arc Welding –
Submerged Arc Welding – Gas Tungsten Arc
Welding – Gas Metal Arc Welding – Plasma Arc
Welding – Electro Slag Welding – Electro-Gas
Welding Process – Advantages – Limitations and
their Applications.
 Welding
• Welding is a permanent
joining process that
involves the coalescence
of materials, usually
metals or thermoplastics,
by applying heat,
pressure, or both, with or
without the use of filler
material, to form a strong
metallurgical bond at the
joint.
 • Fusion Welding

Broad
Classification • Pressure Welding
of Welding

• Fusion + Pressure
Welding
 • No pressure used

• Only heat melts the base metal

• Examples:
Fusion
Welding - Arc Welding (SMAW, MIG, TIG)

- Gas Welding

- Thermit, Laser, and EBW

 • No melting

• Pressure joins the materials

• Examples:
Pressure - Forge Welding
Welding
- Friction Welding

- Ultrasonic Welding

- Explosion Welding
 • Both heat and pressure used

• Examples:
Fusion +
Pressure - Resistance Spot Welding
Welding
- Percussion Welding

- Flash Welding
 • Electrical Energy: Arc,
Resistance, EBW
• Chemical Energy: Gas,
Classification Thermite
by Energy
Source • Mechanical Energy:
Friction, Ultrasonic
• Radiant Energy: Laser,
Electron Beam
 • With Filler: Arc,
Gas, TIG, MIG
Classification
by Filler
Material
• Without Filler:
Resistance, Friction,
Laser (optional)
Classification by Automation Level

• Manual: • Semi-
SMAW, Gas Automatic:
Welding MIG Welding

• Automatic:
Robotic TIG,
Laser Systems
Welding Process Overview

Gas Welding: Chemical

SMAW: Electric arc,
flame, Filler: Yes,
Filler: Yes, Pressure: No
Pressure: No

Resistance Spot:
Friction: Mechanical,
Electric resist, No filler,
No filler, Pressure: Yes
Pressure: Yes

Laser Beam: Laser,

Optional filler, No
pressure
 • Arc Welding: Bridges, pipelines

• Gas Welding: Pipes, sheet metal

Applications
• Resistance: Car manufacturing
of Processes

• Friction: Engine parts

• Laser: Electronics, aerospace

 Advantages &
Disadvantages
• **Fusion Welding:** + Strong joints, - HAZ
• **Pressure Welding:** + No filler, - Limited use
• **Fusion + Pressure:** + Efficient, - Costly
 •Welding Helmet 🧯
•Protects eyes and face from sparks, UV
radiation, and flying debris.
•Safety Goggles 🧯
•Shield eyes from dust, grinding particles,
Safety in Welding
and bright light.
•Gloves 🧯
•Heat-resistant leather gloves to protect
hands from burns and electric shock.
•Protective Clothing 🧯
•Flame-resistant jackets or aprons to guard
against sparks and spatter.
•Safety Boots 👢
•Steel-toe and heat-resistant footwear to
prevent injuries from falling objects and hot
metal.
•Respirator or Welding Fume Mask 😷
•Protects from inhaling toxic fumes or metal
particles.
 Assessment Questions
• 1. Difference between fusion and pressure
welding?
• 2. Classify based on energy source
• 3. Examples with/without filler
• 4. Applications of resistance welding
Fundamentals of an Electric Arc Welding
 • An ionized gas consists of free electrons
Fundamentals of that flow in one direction and positive
ions that flow in the other direction.
an Electric Arc • Collisions with mostly neutral atoms
produce a tremendous resistive heating
of the gas, so, in a sense, the arc is a
large resistor. The extreme heat also
maintains the ionization process.
• Electromagnetic radiation is given off
due to the high temperatures resulting
in the characteristic glow of the arc. In
addition to the observable visible
wavelengths, large amounts of invisible
infrared and ultraviolet wavelengths are
emitted.
• The ionized glowing gas that makes up
the arc is often referred to as plasma.
In order for the arc to be maintained,
the power supply must be able to
supply the high current and low voltage
demanded by the arc.
 Welding Position

• A significant factor in arc welding is the position of

welding. Welding position refers to the manner in
which the weld joint is oriented in space relative to the
welder.
• A flat position is the most common position in which
the weld joint lays flat (such as on a table) and the
molten weld pool is held in the joint by gravity.
• The most extreme is an overhead position that is
directly opposite to a flat position.
• In this case, the molten metal is held solely by its
surface tension. Overhead position welding is very
difficult and requires significant welder skill.
 Filler Metals
• Filler metals are materials added to the weld
pool to help fuse the base metals. They can
come in various forms depending on the
welding process:
• Wires (used in MIG/GMAW and TIG/GTAW)
• Rods (used in TIG welding)
• Flux-cored wires (used in FCAW)
 Why Filler Material Is Important in Arc
Welding
• Joins the Base Metals It melts and fuses with the base metals to form
a solid, continuous weld.
• Compensates for Gaps In many weld joints (like butt or groove joints),
there's a physical gap that needs to be filled to ensure structural
integrity.
• Enhances Strength The right filler metal can match or even exceed
the strength of the base metal, improving the durability of the weld.
• Improves Metallurgical Properties Filler materials can be alloyed to
enhance corrosion resistance, toughness, or ductility of the weld
zone.
• Supports Different Welding Positions Some filler materials are
formulated to perform better in vertical or overhead positions,
helping welders maintain control.
• Enables Dissimilar Metal Welding Specialized filler metals allow
welding between different types of metals (e.g., stainless steel to
carbon steel).
 Electrodes
Electrodes conduct the electric current that creates
the arc. They can be:
• Consumable: These melt and become part of the
weld (e.g., SMAW, GMAW).
 Made of similar material to the base metal.
 Often coated with flux
• Non-consumable: These do not melt; a separate
filler rod is used (e.g., GTAW/TIG).
 Tungsten (pure or alloyed with thorium,
lanthanum, or cerium).
 Requires separate filler rod.
 Shielding

• When metals are heated to high

temperatures approaching or
exceeding their melting point,
reactions with the surrounding
atmosphere are accelerated and the
metals become very susceptible to
contamination. Elements that can be
most damaging are oxygen,
nitrogen, and hydrogen.
Contamination from these elements
can result in the formation of
embrittling
Gas Shielding
• In the case of GTAW and PAW, inert gasses are used with
argon being the most common.
• Helium and blends of helium and argon can also be used.
Helium is more expensive than argon, but it transfers more
heat from the plasma column to the part due to the higher
thermal conductivity of its ionized gas.
• In some cases, small amounts of hydrogen are added to
argon to improve heating by transferring energies of
molecular dissociation of the hydrogen in the plasma column
to the work.
Flux Shielding

• The processes of SMAW, SAW, and FCAW use flux for shielding.
• A welding flux is a material used to prevent or minimize the
molten and heated solid metal from forming potentially
detrimental constituents such as oxides and nitrides, and to
facilitate the removal of such substances if they form or are
present prior to welding.
 Fluxes are used in arc welding processes in three different ways.
They are:
(1) applied in a granular form to the surface ahead of the
weld (SAW),
(2) bound with a binding agent to bare electrode wire (SMAW),
(3) contained in
the core of a tubular wire (FCAW).
Weld Joints
 Primary Operating Variables in Arc
Welding
• Voltage – Arc Voltages with the GTAW process
tend to be lower (10–20 V), whereas consumable
electrode arcs are more in the 20–40 V range.
• Current - General current range for most arc
welding processes is between 50 and 500 A, but
applications of Plasma and GTAW to very small
parts can involve current levels in single digits or
lower. At the other extreme, SAW currents can
approach 2000 A.
Electrode Feed Rate/Wire Feed Speed
• If the welder is not feeding the electrode fast
enough relative to the current determined
melt‐off rate, then the arc length will
lengthen.
• The welder increases the feed rate to shorten
the arc and vice versa if the electrode is being
fed too fast.
• Typical wire feed speeds range between 100
and 500 inches/min.
 Welding Travel Speed
• Welding travel speed refers to how fast the
welding arc is moved relative to the work piece.
• The heat input equation clearly shows that travel
speed, like current, plays a direct role in the
amount of heat into the part per unit length of
weld.
• Faster speeds produce less heat into the work
piece per unit length and reduced weld size.
• Typical travel speeds range between 3 and 100
inches/min.
Metal Transfer Mode
• The type of metal transfer mode
affects a number of things, including
weld shape, heat input and depth of
fusion, spatter, and the ability to weld
in different positions.
• The transfer modes are a function of
wire diameter, current, and shielding
• gas, and where applicable, special
capabilities of the arc welding power
supply.
• Transfer modes are designated as
spray, globular, short circuit, and
pulsed spray.
I-VCharacteristic of Arc Welding Power
Supplies
• The I-V characteristic shows how the power
supply output voltage varies with output
current, and indicates whether the power
supply is considered a constant voltage (CV) or
a constant current (CC) type.
As can be seen, constant current
power supplies allow only small
changes in current when the arc
length and arc voltage changes.
Constant current machines are
generally required for the manual
welding processes of SMAW and
GTAW
• Constant voltage machines work well for the
semiautomatic processes where the electrode is
fed automatically at a steady speed, referred to
as the wire feed speed.
• A rather subtle process of self‐regulation of the
arc length takes place continuously to produce a
stable arc.
• The CV power supply with a constant wire feed
system is used almost exclusively for GMAW,
FCAW, and SAW
Oxyacetylene Welding (OAW)
 1. Introduction to OAW
• Definition: Gas welding using acetylene and
oxygen flame
• Used for mild steel, non-ferrous, and sheet
metals
• Manual, portable, and versatile process
 2. Basic Equipment
• Oxygen Cylinder: Black, ~2000 psi
• Acetylene Cylinder: Maroon, ~250 psi
• Pressure Regulators: Reduce pressure
• Hoses: Red (acetylene), Blue (oxygen)
• Welding Torch: Mixes gases and controls flame
• Nozzles/Tips: Controls flame size
• Protective Gear: Goggles, gloves, apron
 3. Working Principle
• O₂ and C₂H₂ mixed in torch
• Ignition produces flame up to 3200°C
• Melts base metal; filler rod added if needed
• Cooling forms weld joint
 4. Types of Flames
• Neutral Flame: Equal O₂ & C₂H₂, general use
• Carburizing Flame: Excess C₂H₂, for high
carbon steel, lead
• Oxidizing Flame: Excess O₂, for brass, bronze,
cast iron
 5. Welding Techniques
• Leftward Welding: For thin sheets (<5 mm)
• Rightward Welding: For thicker plates
• Filler Rod: Manually added for gap filling
 6. Advantages
• Low equipment cost
• Portable and simple
• Suitable for cutting, brazing, heating
 7. Limitations
• Not for large-scale/heavy welding
• Slower process
• Larger heat affected zone
• Lower flame temperature than arc welding
 8. Safety Precautions
• No oil/grease on oxygen fittings
• Use check valves to prevent backfire
• Do not exceed pressure limits
• Store cylinders upright, away from heat
• Ensure proper ventilation
 9. Applications
• Automotive bodywork
• Sheet metal fabrication
• Pipeline repairs
• Art and sculpture welding
• Maintenance and repair tasks
Oxy-Hydrogen Welding (OHW)
 1. Introduction
• Definition: Gas welding using hydrogen and
oxygen flame
• Used for precision welding and thin materials
• Flame Temperature: ~2800°C
 2. Principle of Operation
• O₂ and H₂ are mixed in the torch and ignited
• Produces a clean, high-temperature flame
• Melts base metal, filler rod optional
• Joint forms upon solidification
 3. Basic Equipment
• Oxygen Cylinder: Black, high-pressure
• Hydrogen Cylinder: Red/Green, pressure-
regulated
• Regulators, Hoses (Green = O₂, Red = H₂)
• Torch and Nozzles: Control gas mix and flame
• Protective Gear: Goggles, gloves, apron
 4. Flame Characteristics
• Neutral Flame: Equal O₂ & H₂, ~2800°C,
general use
• Oxidizing Flame: Excess oxygen, rarely used
• Reducing Flame: Excess hydrogen, protects
metal from oxidation
 5. Welding Technique
• Manual welding with slow, steady torch
movement
• Can be used with or without filler rod
• Best suited for thin, delicate materials
 6. Materials Welded
• Aluminum, Copper, Platinum, Gold
• Glass and quartz (special cases)
• Thin sheets and micro-joints
 7. Advantages
• Clean flame, no carbon/sulfur contamination
• Ideal for reactive or high-purity materials
• Portable and safe
• Precise flame control
 8. Disadvantages
• Lower temperature than oxyacetylene
• Not suitable for heavy welding
• Hydrogen requires careful handling
• Limited industrial use
 9. Safety Precautions
• Ensure leak-free connections
• Use flame arrestors and check valves
• Proper ventilation (hydrogen is flammable)
• Do not expose hydrogen cylinders to heat
• Wear proper PPE: goggles, gloves, apron
 10. Applications
• Jewelry and medical instrument welding
• Scientific glassware fabrication
• Electronics assembly
• Light metal sheets
• Aerospace and lab equipment
 11. Conclusion
• Clean, precise welding process for special
applications
• Not suitable for general or heavy welding
• Valuable for high-purity and delicate material
joining
Gas Metal Arc Welding (GMAW /
MIG)
 Introduction
• • Gas Metal Arc Welding (GMAW), commonly
known as Metal Inert Gas (MIG) welding.
• • Uses a consumable wire electrode and a
shielding gas.
• • Arc is formed between the wire electrode
and the workpiece.
• • Suitable for both thin and thick materials.
 Working Principle
• • A continuous solid wire electrode is fed
through the welding gun.
• • An arc is created between the wire and the
workpiece, melting both.
• • Shielding gas (argon, CO₂, or a mix) protects
the weld from contamination.
• • As the wire melts, it fills the joint, creating
the weld.
 Equipment Used in GMAW
• • Power source (usually DC)
• • Wire feed unit
• • Welding torch/gun
• • Shielding gas supply (argon, CO₂, or mixture)
• • Ground clamp and control system
 Process Parameters
• • Welding current and voltage
• • Wire feed speed
• • Electrode diameter and material
• • Shielding gas composition and flow rate
• • Travel speed
• • Contact tip to work distance (CTWD)
 Advantages of GMAW
• • High deposition rate
• • Easy to learn and operate
• • Suitable for automation
• • No need to remove slag
• • Can weld a wide range of materials
 Limitations of GMAW
• • Requires clean surface for quality welds
• • Sensitive to wind (shielding gas dispersion)
• • Limited to indoor use unless properly
shielded
• • Equipment is more complex than SMAW
• • May require post-weld cleaning
 Applications of GMAW
• • Automotive industry
• • Construction and fabrication
• • Shipbuilding
• • Railway and transportation
• • Repair and maintenance work
S. NO PARAMETER TIG WELDING (GTAW) MIG WELDING (GMAW)
1 Full Form Gas Tungsten Arc Welding Gas Metal Arc Welding

Non-consumable tungsten Consumable metal wire

2 Electrode Type
electrode electrode

Filler wire fed automatically

3 Filler Material Optional, added manually
through the torch

Pure inert gases (Argon or Inert or active gases (Argon,

4 Shielding Gas
Helium) CO₂, or mixtures)

5 Welding Speed Slower Faster

High (requires precision Low to moderate (easier for

6 Skill Requirement
and control) beginners)

Clean but may require post-

7 Weld Appearance Very clean and aesthetic
weld cleaning
S. NO PARAMETER TIG WELDING (GTAW) MIG WELDING (GMAW)

Suitable for both thin and thick

8 Material Thickness Best for thin materials
materials

Aerospace, nuclear, Automotive, construction,

9 Applications
precision tools general fabrication

Automation Easily automated for high-

10 Difficult to automate
Compatibility volume production

11 Slag Formation No slag No slag

Higher (equipment and Lower (cheaper equipment

12 Cost
argon cost) and faster process)

13 Arc Stability Very stable, fine control Stable but less precise than TIG

More portable, suitable for

14 Portability Less portable
fieldwork
Gas Tungsten Arc Welding (GTAW
/ TIG)
 Introduction
• • Gas Tungsten Arc Welding (GTAW), also
known as Tungsten Inert Gas (TIG) welding.
• • Non-consumable tungsten electrode is used
to produce the weld.
• • Shielding gas (argon or helium) protects the
weld area from atmospheric contamination.
• • Can be used with or without filler metal.
 Working Principle
• • An arc is established between a non-
consumable tungsten electrode and the
workpiece.
• • The heat generated by the arc melts the
base metal and filler metal (if used).
• • Inert gas (argon/helium) flows around the
weld zone to prevent oxidation.
• • Weld quality is maintained by stable arc and
precise control.
• The tungsten electrode does not melt during
the process. A filler rod may be added
manually if required, depending on the joint
type and material thickness. The process is
usually done using DCEN (Direct Current
Electrode Negative) for most metals, while AC
is used for aluminum and magnesium.
 Equipment Used in GTAW
• • Power source (usually DC or AC)
• • Tungsten electrode
• • Welding torch with gas nozzle
• • Shielding gas supply (argon or helium)
• • Filler rod (optional)
 Process Parameters
• • Welding current (DCEN, DCEP or AC)
• • Arc voltage
• • Electrode type and diameter
• • Shielding gas flow rate
• • Travel speed
• • Filler material type
 Advantages of GTAW
• • High-quality and precise welds
• • Suitable for thin materials
• • No slag formation
• • Can weld a wide range of metals
• • Minimal spatter and clean weld area
 Limitations of GTAW
• • Slow welding speed
• • Requires skilled operator
• • Higher initial equipment cost
• • Not suitable for thicker materials without
preheating
• • Argon gas cost is relatively high
 Applications of GTAW
• • Aerospace and aviation industry
• • Food and beverage processing equipment
• • Nuclear and chemical industries
• • Bicycle and automotive parts
• • Pressure vessels and pipe welding
Shielded Metal Arc Welding
(SMAW)
Lecture Content
 1. Introduction
• SMAW: Manual arc welding process using a
consumable electrode.
• Also known as 'stick welding'.
• Electric arc forms between electrode and
metal to produce weld.
 2. Principle of Operation
• Electric arc generates intense heat (~6000°C).
• Electrode melts and deposits filler metal into
joint.
• Flux coating produces shielding gas and slag to
protect weld.
 3. Equipment Used
• Welding Power Source (AC/DC)
• Electrode Holder and Cable
• Ground Clamp
• Consumable Electrodes (flux-coated)
• Protective Equipment: Helmet, gloves, apron
 4. Electrode Composition
• Core Wire: Filler metal for joint
• Flux Coating: Forms gas shield, slag, stabilizes
arc
• Electrode Types: E6010, E6013, E7018 etc.
• Classification: E (Electrode), 60 (Tensile
Strength in ksi), 1 (position), 0/3/8 (coating)
 5. Welding Procedure
• Prepare base metal (cleaning, beveling if
needed)
• Select electrode and set current
• Strike arc using touch or scratch method
• Maintain arc length (~3 mm)
• Move steadily, allow slag to form and cool
 6. Advantages
• Simple and low-cost equipment
• Portable and versatile
• Effective for outdoor welding
• Good for thick sections and structural work
 7. Limitations
• Slag must be removed after welding
• Lower efficiency due to electrode change
• Requires skilled welder
• Not ideal for thin sheets
 8. Safety Precautions
• Wear proper PPE: helmet, gloves, apron
• Ensure proper grounding
• Avoid moisture in electrodes (can cause
porosity)
• Ventilate work area (fumes can be harmful)
 Construction and structural
steelwork

Shipbuilding and pipelines

9.
Applications
Repair and maintenance

Industrial fabrication
Submerged Arc Welding (SAW)
 Introduction
• • Submerged Arc Welding (SAW) is a common
arc welding process.
• • Involves formation of an arc between a
continuously fed electrode and the workpiece.
• • The arc is submerged under a blanket of
powdered flux.
• • Provides high quality and deep weld
penetration.
• • Mostly used for welding thick materials.
 Working Principle
• • Arc is generated between a bare
consumable electrode and the workpiece.
• • The arc and molten metal are protected
from atmospheric contamination by a blanket
of granular flux.
• • Flux melts and forms slag, which floats on
the weld pool.
• • Weld is formed as the electrode melts and
fuses with the base metal.
 Equipment Used in SAW
• • Power source (AC or DC)
• • Wire feed unit
• • Flux hopper and recovery system
• • Travel carriage
• • Electrode and granular flux
 Process Parameters
• • Welding Current
• • Arc Voltage
• • Travel Speed
• • Electrode Diameter
• • Electrode Stick-out
• • Flux Composition and Thickness
 Advantages of SAW
• • High deposition rate
• • Deep weld penetration
• • Minimal welding fume and arc radiation
• • Excellent weld quality
• • High productivity and automation capability
 Limitations of SAW
• • Limited to flat and horizontal positions
• • Not suitable for thin materials
• • Requires handling and recycling of flux
• • Equipment cost is high
• • Only suitable for ferrous materials
 • Pressure vessel fabrication

• Shipbuilding industry

Applications • Structural steel fabrication

of SAW
• Pipeline welding

• Heavy machinery and automotive

parts
Plasma Arc Welding (PAW)
Introduction to Plasma Arc Welding
• • Advanced version of Gas Tungsten Arc
Welding (GTAW / TIG)
• • Invented in 1953 by Robert M. Gage
• • Constricted arc for high energy density
• • Ideal for precision welding
 Working Principle
• • Electric arc between tungsten electrode and
workpiece
• • Arc constricted by copper nozzle – increases
energy density
• • Plasma gas ionized – temperature up to
28,000°C
• • Melts base metal to form weld pool
 Components of PAW Setup
• • Power Supply
• • Plasma Torch
• • Tungsten Electrode
• • Plasma Gas (Argon, Hydrogen, etc.)
• • Shielding Gas (Helium or Argon)
• • Control Panel
• Plasma Arc Welding works by using a constricted arc
formed between a non-consumable tungsten
electrode and the workpiece (or a nozzle in the non-
transferred arc mode).
• This arc ionizes a high-velocity gas (usually argon,
sometimes mixed with hydrogen) to create plasma
— a highly energized state of matter that conducts
electricity.
• This plasma jet reaches temperatures up to
25,000°C, which is significantly hotter and more
concentrated than traditional arc welding.
• The intense heat melts the base metal, and if
necessary, a filler metal can be added to complete
the weld.
• Electric arc is generated between the
tungsten electrode and nozzle or workpiece.
• Plasma gas is passed through the arc,
becoming ionized into high-energy plasma.
• Plasma exits through a small copper nozzle,
creating a focused jet.
• This jet melts the metal, and shielding gas
protects the weld pool from contamination.
 Process Parameters
• Current: 0.1–300 Amps
• Voltage: 20–40 V
• Plasma Gas Flow Rate: 0.2–5 L/min
• Shielding Gas Flow Rate: 10–20 L/min
• Travel Speed: 50–200 mm/min
• Torch Standoff Distance: 2–5 mm
 Modes of Plasma Arc Welding
• Micro Plasma Welding: 0.1–15 Amps
• Medium Current Welding: 15–100 Amps
• Keyhole Plasma Welding: >100 Amps – deep
penetration
 Advantages of PAW
• High energy density – deep penetration
• Stable arc and precise control
• Minimal distortion
• Suitable for automation
• Welds thick and thin materials
 Limitations of PAW
• High initial cost
• Requires skilled operators
• Complex equipment
• Not suitable for all metals
• Limited accessibility in tight spaces
 Applications of PAW
• Aerospace industry (turbine blades, nozzles)
• Nuclear reactor components
• Medical instruments
• Precision welding in electronics
• Automotive industry
Electro-Gas Welding (EGW)
 Introduction to Electro-Gas Welding
• • EGW is a vertical position welding process
• • Developed from Electro Slag Welding (ESW)
• • Uses a continuous arc and shielding gas
• • Suitable for welding thick plates in one pass
 Working Principle
• • Continuous arc maintained between a
consumable electrode and workpiece
• • Shielding gas (e.g., CO₂ or Argon mix)
protects molten weld pool
• • Water-cooled copper shoes retain the weld
pool
• • Filler metal melts and solidifies to form the
weld from bottom up
• Electrogas Welding is a vertical, continuous
welding process for thick plates.
• An arc is struck between a consumable electrode
and the workpiece.
• Unlike ESW, the arc remains active throughout the
welding process.
• Shielding gas is used to protect the weld pool from
atmospheric contamination.
• The heat from the arc melts the electrode and
base metal edges.
• Molten metal fills the joint and solidifies
progressively upward.
• Water-cooled copper shoes confine the molten
pool during the weld.
 Components of EGW Setup
• • Constant Voltage Power Source
• • Wire Feeder with Consumable Electrode
• • Welding Gun and Nozzle
• • Shielding Gas Supply
• • Copper Backing Shoes (Water-Cooled)
• • Wire Guide Mechanism
 Process Parameters
• • Current: 100–800 Amps
• • Voltage: 30–45 V
• • Electrode Diameter: 1.6–6.4 mm
• • Travel Speed: 10–50 mm/min
• • Shielding Gas Flow Rate: 20–50 L/min
 Advantages of EGW
• • High deposition rates
• • One-pass welding for thick plates
• • Lower heat input than ESW – finer grain
structure
• • Good mechanical properties
• • Suitable for automation
 Limitations of EGW
• • Limited to vertical welding only
• • Requires accurate setup and alignment
• • Equipment is bulky
• • Not suitable for thin materials
• • May require preheat and post-weld heat
treatment
 Applications of EGW
• • Shipbuilding and tank fabrication
• • Bridge and building construction
• • Large storage tanks
• • Pressure vessels
• • Structural components in heavy industries
S. Electrogas Welding Electro Slag Welding
No. Parameter (EGW) (ESW)
Arc remains throughout the Arc is extinguished after initial slag
1 Arc Presence
process formation

Heat Heat from resistance of molten

2 Heat from continuous arc
Generation slag

Requires shielding gas (like CO₂ Uses molten slag as shielding

3 Shielding
or Argon) medium

Starts with and maintains the Starts with arc, then transitions to
4 Weld Start
arc slag conduction

Medium to thick plates (~12–80 Very thick plates (typically >25

5 Application
mm) mm, up to 300 mm)

Slightly lower penetration; Deep penetration; preferred for

6 Weld Quality
suitable for structural work heavy-duty applications

Process More complex and requires precise

7 Less complex than ESW
Complexity control
Electro Slag Welding (ESW)
 Introduction to Electro Slag Welding
• ESW is a single-pass welding process for thick
materials (≥25 mm)
• Developed in the 1950s for vertical position
welding
• Uses molten slag to melt the filler and base
metal
 Working Principle
• An arc is initially struck between electrode and
base metal
• Flux melts to form conductive slag pool
• Arc extinguishes, and heat from slag melts
electrode and workpiece
• Weld metal solidifies progressively from
bottom to top
• Electro Slag Welding is a vertical welding process for
thick materials.
• The process starts with an arc between a
consumable electrode and base metal.
• Flux is added, which melts and forms a conductive
molten slag.
• The arc is extinguished as the slag takes over in
conducting the current.
• Heat is generated by the electrical resistance of the
molten slag.
• This heat melts the filler wire and edges of the base
metal.
• The weld progresses upward, solidifying behind
water-cooled copper shoes.
 Components of ESW Setup
• Power Source
• Wire Electrode (consumable)
• Copper Cooling Shoes (retain molten metal)
• Slag Pool (molten flux)
• Flux Hopper
• Water-cooled backing shoes
 Process Parameters
• Current: 600–2000 Amps
• Voltage: 30–50 V
• Electrode Feed Rate: Varies with current
• Slag Depth: Typically 25–50 mm
• Travel Speed: 10–30 mm/min
 Advantages of ESW
• High deposition rates – suitable for thick
sections
• Single-pass welding up to 300 mm
• Minimal arc radiation and spatter
• Uniform heat input – low distortion
• High-quality, strong welds
 Limitations of ESW
• Limited to vertical position welding
• High heat input – possible coarse grain
structure
• Not suitable for thin sections
• Requires flat, vertical surfaces
• Specialized setup and high initial cost
 Applications of ESW
• Shipbuilding and marine structures
• Pressure vessels
• Bridges and heavy structural components
• Hydraulic turbine components
• Steel mill and foundry equipment