TRAINING PROGRAM
A PRACTICAL APPROACH TO
WELDING ENGINEERING
WELDING PROCESS CHART
1) FUSION WELDING
A) ARC WELDING
SMAW
TIG
MIG,MAG,FCAW
SAW
B) OXY FUEL WELDING
C) ELECTROSLAG WELDING
D) THERMIT WELDING
E) POWER BEAM WELDING
2) PRESSURE WELDING
A)RESISTANCE WELDING
B) SOLID STATE WELDING
INTRODUCTION
Definition : Fusion Welding is defined as
melting together and coalescing
materials by means of heat
Energy is supplied by thermal or
electrical means
Fusion welds made without filler metals
are known as autogenous welds
Welding Processes
A concentrated heat source melts the material in the weld
area; the molten area then solidifies to join the pieces
together
Sometimes a filler material is added to the molten pool to
strengthen the weld
TYPE OF ARC WELDING
PROCESS
SMAW (Shielded Metal Arc
Welding)
GMAW (Gas Metal Arc Welding)
GTAW (Gas Tungsten Arc Welding)
Oxygen/ Fuel Welding
WELDING PPE
SMAW
Also referred to as “Stick Welding”
Used for everything from pipeline
welding, farm repair and complex
fabrication.
Uses a “stick” shaped electrode.
Can weld: steel, cast iron, stainless
steel, etc.
Can also hardface with correct
electrode.
TYPE OF FLUX COVERING
THE THREE MAIN ELECTRODE COVERING TYPE USED IN
MAAWELDING
1) RUTILE – GENERAL PURPOSE – (AWS E6013)
2) BASIC – LOW HYDROGE (E7018)
3) CELLULOSE – DEEP PENETRATION/FUSION
SMAW WELDING BASIC
EQUIPMENT
Examples of SMAW
Welds
ADVANTAGES &
DISADVANTAGES OF
SMAW
ADVANTAGE
FIELD OR SHOP USE
RANGE OF CONSUMABLES
ALL POSITIONS
PORTABLE
SIMPLE EQUIPMENT
SUITABLE FOR RESTRICTED ACCESS
DISADVANTAGES
HIGH WELDER SKILL REQUIRED
SLAG INCLUDION
LOW DEPOSITION RATE AND OPERATING FACTOR
HIGH LEVEL OF FUMES
Joints, Welds &
Positions
Electric arc welding uses five (5)
types of joints, five (5) types of welds
and five (5) positions. Corner
Five (5) joints:
Butt Lap
Edge T
Five types of
welds
1. Surface
2. Groove
3. Fillet
4. Plug
5. Slot
1. Surface
Welds
• Surface welds are welds were a material has been applied to the surface
of another material.
May or may not be blended with the work piece.
• Two common applications are for hard
surfacing and padding.
2. Groove
Welds
Groove welds are
used to fuse the
sides or ends of two
pieces of metal.
The primary use of groove welds is to complete butt joints.
3. Fillet Welds
Fillet welds have a triangular cross section and are used to
fuse two faces of metal that are at a 90 degree angle to each
other.
Lap Joint Outside Corner T Joint
4. Plug Welds
Plug welds are used to
attach two surfaces
together when a complete
joint is not required and
the design does not allow
for any weld bead outside
the dimensions of the
metal.
The weld is completed by establishing the arc on the bottom plate and
then continuing to weld until the hole is full.
The holes can be made with a drill bit or punch.
5. Slot Welds
Slot welds are identical to plug welds except for the
shape of the holes. For slot welds, slots are machined
or stamped in the upper plate.
They are complete the same as plug welds.
Joints, Welds & Positions
Arc Welding Positions
Flat Horizontal
Vertical Up
Vertical Down
Overhead
Weld Nomenclature
Bead
Penetration
Base metal
Joint Angle Reinforcement
Bead
Root Face
Excessive
Penetration
Root Opening
Weld Nomenclature-cont.
Reinforcement
Toe
Face
Throat
Leg
Toe
Root Leg
Weld Nomenclature-cont.
A tack weld is used to hold
Cover Pass the joint at the desired
Filler Pass gap.
Root Pass
If it is not used, the
heat of the weld will
Tack Weld cause the joint to
close.
The root pass is used to fuse the root of the weld.
If the root pass does not have adequate penetration, it
must be cut or gouged out before the weld is completed.
The filler pass is used to fill in the joint.
A pattern bead or multiple stringer beads will be used.
The cover pass doesn’t add very much strength to the weld. It
is used for appearance and to fill in surface voids.
Bead Patterns
Pattern beads are used
whenever a wider bead
is needed.
Hardsurfacing
Filler pass
Cover pass
Reduce penetration
Common patterns:
Circle
Crescent
Figure 8
WELDING INSPECTION
1) NON DESTRUCTIVE TESTING
MAGNETIC PARTICLE INSPECTION (MT)
DYE PENETRANT INSPECTION (PT)
RADIOGRAPHIC INSPECTION (RT)
ULTRASONIC INSPECTION (UT)
2) DESTRUCTIVE TESTING
TENSILE TEST
TOUGHNESS TESTING
HARDNESS TEST
METALLOGRAPHIC EXAMINATION (MACRO/MICRO)
DYE PENETRANT
INSPECTION
STEP 1. PRE-CLEANING
CLEANING PREPARATION IS VERY IMPORTANT ON THIS
METHOD. USUALLY SOLVENT REMOVAL IS BEEN USED.
STEP 2. APPLY PENETRANT
AFTER THE APPLICATIONO F THE PENETRANT THE PENETRANT
IS NORMALLY LEFT ON THE COMPONENTS SURFACE FOR
APPROXIMATELY 15 MINUTES.
STEP 3. APPLY DEVELOPER
AFTER THE EXCESS PENETRANT IS BEEN REMOVED, A THIN
LAYER OF DEVELOPER IS APPLIED.
ADVANTAGES & DISADVANTAGES OF
DYE PENETRANT
ADVANTAGE
SIMPLE TO USE
INEXPENSIVE
QUICK RESULTS
MORE SENSITIVE THAN VISUAL INSPECTION
LOW OPERATOR SKILL REQUIRED
DISADVANTAGES
SURFACE BREAKING DEFECT ONLY
LITTLE INDICATION OF DEPTHS
POST CLEANING REQUIRED
QUESTIONS?
THANK YOU