METAL CASTING AND WELDING 15ME35A

MODULE4

WELDING PROCESSES

Welding definition

Welding is process of joining two materials (similar or dissimilar) by the application

of heat with or without the application of pressure and addition of filler mate ial. All metals
and alloys can be welded. The materials to be joined are held in contact together and the
required energy is applied mainly in the form of heat. This heat fuses the mate ial and on
cooling the joint solidifies. The joint formed is called welded joint. He t is the main source of
energy, which can be obtained by electricity, gas or chemic l re ction or friction. Welding is a
fabrication process.

Advantages:
 
Any metal/alloy can be welded
 
Any shape of component can be generated
 
Strength of the joint will be the same as that of the base metal.
Disadvantages / Limitations:

Harmful radiation and fumes may be generated during the process

Residual stresses may be setup in the welded joint
Skilled operator may be required
Structure of the weld portion will differ from parent metal.

Application:

Fabrication of aircraft and automobile components, bridges, building structures,

ships, pressure vessel, pipes, etc.

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 METAL CASTING AND WELDING

Classification of welding

Welding Classification

Fusion welding Pressu e welding

Gas Arc Thermit * Forge welding

Welding welding welding * G s p essu e welding

* Resistance welding

Manual Gas Automat c

Arc welding shielded flux Spot Seam Butt

welding Shield weld ng welding welding

Welding

The detailed classification of welding processes are:

Gas welding

* Air acetylene welding * Oxy hydrogen welding

* Oxy acetylene welding * Pressure gas welding

Arc Welding

* Carbon arc welding * Shielded metal arc welding

* Flux cored arc welding * Submerged arc welding

* Tungsten inert gas welding * Metal inert gas welding

* Plasma arc welding * Electro slag welding

* Stud arc welding

Resistance Welding
* Spot welding * Projection welding

* Flash welding * High frequency resistance welding

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 METAL CASTING AND WELDING
* Resistance butt welding

Solid State welding

* Cold welding * Explosive welding

* Friction welding * Roll welding

* Diffusion welding * Forge welding

* Hot pressure welding * Ultrasonic welding

Thermo chemical welding

* Thermit welding * Atomic welding

Radiant Energy welding

* Electronic beam welding * Laser beam welding

Using consumables electrodes

* Metal arc welding * Gas sh elded metal arc welding

* Submerged arc welding * Plasma welding

Commonly welded metals

Metals that are welded on a regular basis are classified under two categories:

Ferrous Metals Non Ferrous Metals

Ex. Wrought iron Ex. Aluminium alloys

Carbon steel Copper alloys

Cast steel

Stainless steel

ARC WELDING

It is a fusion welding process. Here an electric arc is used as the heat source. An
electric arc is a continuous stream of electron flowing between two electrodes into a
medium. This gives rise to intense heat generation. This is used to melt the surface and
deposit the metal from the electrode resulting in a joint on cooling.

Principle:

The source of heat for arc welding process is an ‘electric arc’ generated between two

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 METAL CASTING AND WELDING

electrically conducting materials. One of the workpiece material called electrode is

connected to one pole of the electric circuit, while the other workpiece which forms the
second conducting material is connected to the other pole of the circuit.

When an arc is struck between a metal electrode and the work, the arc heats the metal
and forms a pool of liquid. The electrode material can be either non-consumable or
consumable. The non-consumable electrode made of tungsten, graphite, etc., serve only
strike the arc, whereas, the consumable electrode which is made of the same material as that
of workpiece strike the arc and gets consumed. The electrode gets consumed as and when
the metal is deposited. The liquid pool of metal mix the work and becomes a pa t of it. On
cooling, solid metal of homogeneous bond results. A joint is formed. The distance between
the tip of the electrode and the work through which arc is formed is te med s ‘a c length’.

Metal Arc Welding (MAW)

 
It is also referred as consumable electrode arc welding.

Arc is struck between the work and electrode which melts and furnishes the

required feed metal.
 
Both the rod and the work melt.
 
Both AC and DC supply can be used.
 
Arc supplies the required heat.

The temperature and the heat nput can be ncreased or decreased by increasing or

decreasing the arc current.
 
High arc current and low arc length produces high intense heat.
 
The metallic rod is normally coated with a flux.
 
The flux coating melts and produces slag which covers the molten metal at the joint.
 
The slag formed will also give the arc stability.
 
An arc length of 0.6 to 0.8 times the electrode diameter yields high quality weld.
Flux Shielded Metal Arc Welding (FSMAW)

he welding is carried out manually, and then it is referred to as Manual Metal Arc
Welding (MMAW).
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 METAL CASTING AND WELDING

The surface of the work is cleaned to remove dirt to obtain a sound weld.
The work pieces are held in position.
Welding leads are connected to the power source and the work piece.
Power is switched on and a suitable current is allowed to pass.
Electrode is gripped by means of a holder and strikes the arc, by moving the electrode
near to the workpiece.
The arc length is adjusted, such that continues stable arc and supply of molten metal.
During welding, slag is used as a protection to the molten metal.
Flux acts as a shield to the weld portion.
This is referred to as Flux Shielded Metal Arc Welding (FSMAW).

Tungsten inert gas welding (TIG)

An arc is struck between the non-consumable tungsten elect ode nd the workpiece in
the presence of an inert gas such as helium or a gon, which is p ssed ne r the arc thereby
creates a shield. This is referred to as Tungsten Ine t Gas Welding (TIG). A filler rod is used
to supply molten metal to the joint. Fig. 4.3 shows the TIG welding. Pressure of the gas
varies between 0.1 to 0.15 N/mm2. Mainly DC supply is used.

Fig. 4.3 Tungsten inert gas welding (TIG)

Advantages:

Suitable for thin metals

Clear visibility of the arc provides the operator to have greater control over the weld.
Strong and high quality of joints are obtained.
No flux is used, no slag formation, results in clean weld joint.

Disadvantages:
 
TIG is most difficult process compared to all the other welding process.
 
Skilled operator is required.
 
Process is slower.
 
Not suitable for thick metals.
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 METAL CASTING AND WELDING

Application:

TIG welding is most commonly used to weld stainless steel and non-ferrous materials
such as aluminium and magnesium. Aerospace industry is one of the primary user,
refrigerators, air conditioners and chemical plants are other users.

Metal Inert Gas Welding (MIG)

Metal inert gas welding, in which the workpiece is joined by the heat obtained from an
electric arc struck between a metal consumable electrode (uncoated) and the wo kpiece in
the presence of an inert gas, which is a mixture of argon & carbon dioxide. The consumable
metal electrode itself will supply the required metal. No filler is equi ed. Fig. 4.4 shows the
MIG welding.

Fig. 4.4. Metal Inert Gas Welding (MIG)

Advantages:
 
MIG welding is fast and economical.
 
Weld deposition rate is high due to continuous wire feed.
 
No flux is used, no slag formation, clean weld is obtained.
 
Process can be automated.
Disadvantages:

Equipment is costlier.
Dross & porosity are the most prevalent quality problem.

Application:

It is used extensively in sheet metal & automobile industry.

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 METAL CASTING AND WELDING

Submerge Arc Welding (SAW)

An arc is struck between a consumable electrode and the parent metal, buried under a
granular flux such as TiO2, SiO2. Granular flux is allowed to drop through the hopper near
the arc. Flux melts and forms a liquid. The rod supplies the molten metal for welding.
Liquid flux covers the molten metal with an impermeable slag and protects the weld until it
cools. Fig. 4.5 shows the SAW.

Fig. 4.5 Su merge Arc Welding (SAW)

Advantages:
 
Weld deposition rate is high due to cont nuous wire feed.
 
High productivity process due to h gh heat generation.
 
Deep weld penetration.
 
Can be automated.
 
Less smoke, as the flux hides the arc.
Disadvantages:
Use of powdered flux restricts the process to be carried only on a flat position.
Need for extensive flux handling.
Slow cooling rate may lead to hot cracking defects.
Applications:
Used especially for large products in the fabrication of pressure vessels, penstocks, boilers,
etc.

Atomic Hydrogen Welding (AHW)

It is a welding process wherein fusion is produced by heating the job with an electric
arc maintained between two tungsten electrodes in an atmosphere of hydrogen, which also
acts as a shielding gas. Filler rod and pressure may or may not be applied depending upon the
condition.
Principle:
It possesses the features of both arc and flame welding processes.
The job does not form a part of the electric circuit.
Combined energy of the arc and a chemical reaction is utilized for welding.
Electric arc is struck between two tungsten electrodes.
This arc supplies energy for a chemical reaction.

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 METAL CASTING AND WELDING

Chemical reaction:

The molecular hydrogen passes through the electric arc and it dissolves into
atomic hydrogen by absorbing the energy supplied by the electric arc.

H2 H +H – 100700 cal

The atomic hydrogen thus formed is unstable and has a tendency to revert back to
molecular state. This recombination takes place as the atomic hydrogen touches a relatively
cold work piece to be welded. The recombination is an exothermic eaction which liberates
o
large amount of heat (app., 3730 C). This heat combined with that of the a c is utilized for
welding process. Because of very high heat conductivity of hyd ogen at elevated
temperatures, the heat is delivered to work piece at very f st r tes.

Equipment

1. Welding torch with tungsten electrodes and cable.

2. Hydrogen gas supply.
3. AC power source (a transformer with an open ci cuit voltage of about 300 volts).
Fig. 4.6 shows the detail.

Operation:
 
Hydrogen gas supply is made and current is switched on.

he arc is struck by bringing the two tungsten electrodes in touch with each other

momentarily and then separating them by a pre-determined distance (say 1.5 mm).
 
Depending upon the thickness of the job to be welded a current value can be set.
 
The atomic hydrogen welding arc is held over the job till a molten pool forms.

The welding torch is carried along the surface to be welded with the arc edge touching

the surface.
 
Hydrogen creates a reducing atmosphere and avoids weld metal contamination.
 
Depending upon job thickness filler metal may or may not be added.

For welding a mild steel plate of 10mm thickness, about 60 amps of arc current is

required.



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 METAL CASTING AND WELDING

Advantages:

No flux or separate shielding gas is used; hydrogen itself acts a shielding gas and avoids
metal oxidation.

The job does not form a part of the electrical circuit.

The arc remains between two tungsten electrodes and can be moved to other places
easily without getting extinguished.

Welding of thin materials is also possible which otherwise may not be successfully
carried out by metallic arc welding.

Due to high concentration of heat, welding can be carried out at fast ates and with less
distortion of work piece.

Disadvantages:

The process cannot be used for depositing la ge qu ntities of met ls.

Welding speed is less as compared to that of metallic a c or MIG welding.

The process becomes uneconomical for certain applications because of higher operating
cost as compared to that of other welding processes.

Application:

The process can be used for the weld ng of most of the metals and alloys like plain carbon
steel, alloy steel, stainless steel, aluminium, copper, nickel and their alloys.

SPECIAL TYPE OF WE DING

RESISTANCE WELDING

Whenever a heavy electric current is passed through a material, the material will offer
resistance to the flow of current. This results in local heating of the material. This principle
is used to generate the required heat at the joint for welding. The quantity of heat generated
in the material due to the current flow is given by Joules law :
2
Q= 0.24 x I R t
Where,

Q α I2 R t

Q= Heat generated in calories

0.24= Constant of proportionally
2
I = Current in the Circuit in amperes
R= Resistance in the circuit in Ohms
t= Time of flow of current in seconds


Heat generated is very rapid as very high currents of 300-105 amps with a voltage upto

25 volts is used.
 
A transformer is used for the purpose.
 
AC source is used.
 
The parts to be joined are heated to plastic state and high pressure is applied.
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 METAL CASTING AND WELDING
 
This results in joint, after cooling.
 
Current consumed depends on the area of contact and time.
 
Pressure applied is approximately around 25-55 N/mm2.
 
No filler metal is required for the purpose.
 
Copper electrode is used to carry the current to the joint.

Resistance welding can be used for all metals except tin, lead & zinc, as they

pose several problems.
Advantages of Resistance Welding
 
No filler rod required
 
Fast rate of welding is possible
 
Semi skilled workers can be employed
 
Both similar and dissimilar metals can be welded
 
Very high reliability and reproducibility obtained in the welds
 
Semi automatic equipments can be used

Disadvantages of resistance welding
 
Initial cost of equipments is high
 
Needs good control and maintenance of equ pments

 Higher thickness of metal cannot e welded
 
Process is simple and the operat on s very rapid. Used for mass production.

Application of resistance welding
 
Used for joining sheets, bars, rods and tubes.
 
Used for welding aircraft automobile parts.
 
Used for general engineering fabrication purposes like grills, containers, tanks, etc.,
Types of Resistance Welding

1. Butt welding
2. Spot welding
3. Seam welding
4. Projection welding

1. BUTT WELDING

Two metal pieces of the same cross section are held together by clamps and pressed.
A current is now applied through the secondary coil of the transformer.
Heat is generated at the contact surface and a joint result.
The weld joint will be bulging and round.
It has to be machined.
Fig 4.7 shows resistance butt welding.
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 METAL CASTING AND WELDING

Fig. 4.7 Resistance Butt Welding

Advantages

Joint obtained is clean, as filler metal is not used in this p ocess.

Produces defect free joint.
Oxides, scales and other impurities are thrown out of the weld joint due to high
pressure applied at elevated temperatures.

Disadvantages

The process is suitable for parts w th s m lar cross-sectional area.

Joint preparation is a must for proper heating of workpiece.

Applications

Used for producing joints in long tubes and pipes.

2. SPOT WELDING
It is the simplest form of resistance welding.
sed for welding sheet metal, both ferrous and non-ferrous metals of 8 mm thick and
less.
Consists of two electrodes (water cooled), one is fixed and other is movable.
he sheets are cleaned first and are placed between the electrodes.
Bottom electrode is fixed and the top electrode is movable.
By operating a foot lever the movable electrode is brought in contact with the sheet
2
and a pressure of 22-25 N/mm is applied.
A low voltage of 30-40V and high current of 120-300 amps is passed between
the electrodes.
This results in intense heat and the sheet gets welded within 10-15 sec.
Soon after the current is switched off with pressure on.
After the weld cools, pressure is released.
Materials having higher thermal conductivity can be easily welded.
Fig. 4.8 shows the details.

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 METAL CASTING AND WELDING

Fig. 4.8 Spot Welding

Spot welding cycle

During one welding cycle there w ll be 4 d fferent timings involved.
Squeeze time: It is the time (0-1) between the nitial application of pressure on the work
through the electrode and the initial appl cat on of current for making the weld. Full electrode
pressure is obtained during the period. Upper electrode comes in contact with it and full
pressure is realized. Slowly the pressure is increased and maintained as welding current is
applied.

Weld time: Period 1 - 2, weld current is applied through the electrodes for a known time.

Hold time: The pressure is maintained after welding at full pressure for some time
then cooled at point 3.

Off time: It is the time interval from the end of the hold time to the starting of squeeze
time for the next cycle.

3. SEAM WELDING
Here two copper wheels act as electrode through which current is passed and pressure
is applied.


Work pieces are kept between the electrodes and current is passed through

the electrodes and pressure is applied.

A weld is formed. Continuous weld is formed as the work is moved between the

electrodes.
 
Heat is generated due to the flow of current and the work offers resistance to this.
 
Either current or pressure can be varied to control the heat generated.
 
This changes the contact resistance.

A series of overlapping welds are formed and the spacing can be controlled by
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 METAL CASTING AND WELDING

controlling the movement of the work.

Used for making continuous welds between two overlapping sheets of metal for

producing water tight joint.
 
Fig. 4.9 shows the details.

Fig. 4.9 Seam Welding

PROJECTION WELDING

It is similar to Spot Welding.

Copper platens are held in the arms.
The work pieces are held in pos t on n the arms.
One piece has projections and the other s flat.
Current is passed and pressure s appl ed.
The projections flatten and the two pieces get welded.
Large number of welds can be done at various points by having projections.
Any metal or alloy can be welded.
Fig 4.10 shows the details.

FRICTION WELDING

Heat produced due to friction is utilized and by applying pressure a joint is formed.
The heat is enough to fuse the work pieces.
One of the work pieces is held stationary and the other work piece is pressed against it
and kept rotating at high speed, a very high pressure is applied and the rotation is
stopped.

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 METAL CASTING AND WELDING

Perfect joint results.

 No preparation of the surface required. The surfaces to be welded must be flat. Process is
well suited to non ferrous alloys.
 Pipes, tubes, bars of carbon steel, stainless steel. Al, Ti alloy, steels can be welded with
ease.
 Dissimilar metal can be joined.
 Initial pressure, heating time and final upsetting pressure can be varied to suit the
requirement.
Fig. 4.11 shows the details of friction welding.

EXPLOSIVE WELDING

 Explosive forces generated by the ignition of explosive materials will travel at very high
velocities.

 These forces are used to cause ripples in the base metal and lock them together.  he base

metal parts are placed at an angle to each other.

 he parts are covered with flexible rubber and it explosive material is covered.  he whole

arrangement is kept in a special chamber.

 A detonator is used to detonate the explosive material.
 The force of detonation
 results in ripples in the parts and the shock waves will lock the
parts together.

 Like and unlike metals can be joined.

 Normally big items are welded.

 Fig. 4.12 shows the details.


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 METAL CASTING AND WELDING

THERMIT WELDING

Thermit welding is primarily a fusion welding p ocess in which the weld if effected by
pouring superheated liquid thermit steel around the parts to e welded.

The high temperature obta ned from the reaction of finely divided metallic oxide
(usually iron oxide) and alumin um s employed to rise the temperature of the parts to be
welded to above their fusion point. The l qu d metal acts as filler.

Thermit welding is based on casting & foundry practice.

It essentially consists of providing, by means of a chemical (thermit) reaction a volume
of molten metal which is poured into the joint to be welded. Certain metals are
preferentially welded by this method.

Chemical Reaction
1. 3 Fe3 O4 + 8 Al 9 Fe + 4 Al2O3 + 7193 Kcal of heat

2. 3 CuO + 2 Al 3 Cu + Al2O3 + 275.3 Kcal of heat

he chemical affinity of aluminium for oxygen is the basic for the thermit process.
hermit reaction is an exothermic one.
Thermitical temperature from reaction (1) is 3088oC, but due to radiant heat losses
o
and losses to reaction vessel, this temperature is reduced to 2538 C.
The thermit mixture is ignited with the help of a special ignition powder
consisting largely of barium peroxide.
This in turn is ignited by a burning magnesium ribbon or by a spark.
Fig. 4.13 shows, Thermit welding process.

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 METAL CASTING AND WELDING

Application of thermit welding:

 
Joining of heavy sections.
 
Welding of pipe joints.
 
Repair field as repair of shafts, machinery frames, etc.
 
Welding of railway rails.
Advantages:

The heat necessary for welding s obta ned from a chemical reaction and thus no costly

power supply is required.
 
Hence broken parts (rail etc) can be welded on the site itself.
Disadvantages:

Thermit welding is applicable only to ferrous metal parts of heavy reaction i.e., mill

housings and railway reactions.
 
The process is uneconomical if used to weld cheap metals or light parts.
LASER WELDING (Laser Beam Welding)

Lasers are devices which are capable of generating a very intense beam of optical
radiation. The word laser is an acronym of Light Amplification by the Stimulated Emission
of Radiation.
Laser welding is a process wherein a coalescence beam is produced by the heat
obtained from the application of a concentrated light beam impinging upon the surface to be
joined.

Principle & Theory of Operation :


Ruby is Aluminium Oxide (Al2O3) with Chromium dispersed throughout, constituting

about 1/2000 of the crystal.
 
The ends of crystal are silvered to form mirrors internally.
 
Around the outside of the crystal are placed flash tubes containing xenon.
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 METAL CASTING AND WELDING
 
This flash tube converts electrical energy into light.
 
Capacitor bank stores electrical energy.
 
It energizes the flash tube by an appropriate triggering system.

When subjected to electrical discharge, xenon transforms electrical energy into white

light.

As the ruby is exposed to the intense light flashes, the chromium atoms are exited

and pumped to a high energy level.

The atoms drop immediately to an intermediate energy level with the evolution of heat

and eventually back to their original states with the evolution of ed fluo escent light.

As the red light emitted by one excited atom hits another excited atom, the second

atom gives off red light which is in phase with the colliding red light wave.

This becomes a chain reaction and finally a narrow l ser be m comes out of the ruby

crystal.
 This beam is focused by an optical focusing lens to p oduce sm ll intense spot of laser

on the job, thereby heating up and melting it to facilitate the welding operation.
Fig. 4,14 shows the details.

Advantages :

Welds can be made inside transparent glass or plastic housings.

A wide variety of materials can be welded.

It permits welding of small, closely spaced components with welds as small as a few
microns in diameter.

Laser beam being highly concentrated produces narrow size of HAZ.

Heat-treated alloy can be welded without affecting their heat treated condition.

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 METAL CASTING AND WELDING

As no electrode is used, electrode contamination is eliminated.

Since it is light, it can be focused to microscopic dimensions and directed with great
accuracy.

The laser beam concentrated energy can be precisely controlled.

Areas not readily accessible can be welded.

No protection is needed against atom contamination.

Disadvantages :

The major drawback is the slow welding speeds (25 to 250 mm/min) esulting f om the
pulse rate and puddle sizes at the fusion point.

It is limited to depths of approximately 1.5 mm and ddition l energy only tends to

create gas voids and undercuts in the weld.
Materials such as Mg tend to vaporize and p oduce seve e su f ce voids.

Applications :

o Laser is a high energy light beam that can oth welded and cut the metals.
o For connecting leads on small electron c components and in integrated circuitry in the
electronic industry.
o To weld lead wires having polyurethane nsulation without removing the insulation.
o To join hard high melting polyurethane metal alloys.
o In space and aircraft industry for welding light gauge materials.
o It can join dissimilar metals and other difficult metals to weld such as Cu, Ni, Al, Ti,
stainless steel, zirconium, tantalum, etc.
o Laser can weld wire - to - wire, sheet-to-sheet, wire-to-sheet, tube-to-sheet and
small diameter stud welds.
o Laser beam is used for micro welding purposes.
o It’s particularly suitable for the welding of miniature and micro-miniature size
components.

( he operation is similar to that, when the sun rays are made to concentrate on a single spot on a
paper, which is placed below a magnifying lens, the paper burns. The laser energy source is a
refinement of this process)

ELECTRON BEAM WELDING (EBM)

Principle & Theory of Operation :

Heat is generated by focusing a stream of highly accelerated electrons on the

work piece.
 The temperature realized is sufficient to melt.
 Welding can be easily carried out. Electron beam welding is a fusion welding process.
 High velocity electrons are made to strike the metal.

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 METAL CASTING AND WELDING

 The kinetic energy of the electrons gives almost completely into

heat. This heat melts and fuses the metal.
 An electromagnet is used to focus the beam of electron accurately.
 A heated filament is used as a source of electrons which are made to flow through a
circular ring shaped anode.
An electromagnetic coil is used to focus the electron beam and is made to fall on
the workpiece to be welded.
The workpiece itself is placed in a vacuum chamber. Provision is made to move
the workpiece.
A tungsten filament which serves as a cathode emits a mass of elect on that a e
accelerated and focused to a 0.25 to 1 mm diameter beam of high ene gy density upto
2
0.5 to 10kW/mm .
o
The heat generated is about 2500 C.
This is sufficient to melt and vaporize the wo kpiece m te i l nd thus fills a narrow
weld gap even without a filler rod.

Construction:

Electron Beam Welding set up cons sts of electron emitting and accelerating unit beam

focusing unit, a vacuum chamber to hold the workpiece.
 
A vacuum of 10-4 to 10-2 mm of Hg s used.

The penetrating power of electron beam depends on the speed of electron which in turn

is controlled by the accelerating unit (15-30 KV DC).
 
Electron beam welds are very narrow and the energy density is nearly 5x108 W/mm2.
 
Fig. 4.15 shows the details of Electron Beam Welding

Working:

 Joint preparation of workpiece is very important to get a sound weld.

 The edges are to be cleaned thoroughly, free of oxide, dust, grease,
etc.

ARUN.R, Assistant Professor, Dept., of Mech Engg., SVIT, Bengaluru-64. Page 19

 METAL CASTING AND WELDING

 The work pieces are demagnetized before welding.

 They should be free from residual magnetism or else the electron beam gets deflected.
 The residual magnetism can be removed by placing the work piece in an
inductive field of 50 cycles frequency.

Merits :
 
Heavy sections upto 100 mm thick stainless steel can be welded easily.
 
Very thin sections of 0.025 mm can be welded.
 
Control of welding is easy.
 
Narrow welding can be done.
 
Neat welding can be done.

Demerits :

Size of workpiece is limited. Initial cost of equipment is high.

Skilled operators are required.

The workpiece should be electrically conductive in nature.

Application :

Used for welding super alloys, refractory metals, reactive metals and stainless steels.
Titanium, beryllium, molybdenum and zirconium components are welded.
Used in aircraft, automobile industry, farm equipments, electronics, missile industry.
Used for welding gears, cams, etc.

EDGE PREPARATION
Before starting the welding process, the edges of the two workpieces to be welded should be
prepared well to obtain a sound weld. This process is called edge preparation and involves two
operations:
(a) Preparation of joint and
(b) Cleaning of joint.

(a) Joint preparation

Joint preparation involves cutting or beveling the edges of the two workpieces to suitable
shapes so that heat would be able to penetrate to the entire depth of the workpiece. Figure 4.1
shows the different shapes that can be prepared based on the application.

ARUN.R, Assistant Professor, Dept., of Mech Engg., SVIT, Bengaluru-64. Page 20

 METAL CASTING AND WELDING

Figure 4.1(a) shows a square or straight joint suitable for workpieces with thickness less than 5
mm. Some workpieces are beveled only on one side, as in single-V or single-U joints, but for
very thick plates, beveling is required on both sides as shown in figu e 4.1 (d) nd (e).

(b) Cleaning of joint

Workpiece surfaces are often chemically contaminated y dirt, grease, oxides etc. Most metals
are very reactive, and in air, they become coated with an oxide layer or with adsorbed gas. This
layer prevents intimate contact from be ng made etween the two metal surfaces. Hence, the
edges of the workpieces and the area adjo n ng them should be cleaned thoroughly to remove
the contaminants.
Cleaning is done either chemically by using acetone or carbon tetrachloride solution or
mechanically by using wire brush, hand files or grinding process.

ARUN.R, Assistant Professor, Dept., of Mech Engg., SVIT, Bengaluru-64. Page 21