This document discusses various welding processes, including arc welding. It describes arc welding as the most common metal joining method that uses an electric arc between an electrode and base metal to generate heat and join metals. The document categorizes common welding processes and provides examples, such as gas metal arc welding, tungsten inert gas welding, submerged arc welding, electro-slag welding, and atomic hydrogen welding. It provides brief descriptions and applications for some of these processes.

1. Dr. Shailesh Kumar Dewangan
Assistant Professor
Department of Production Engineering,
BIT Mesra Ranchi
Welding Process
Arc Welding

2. Welding
• Welding is a process of joining with similar or
dissimilar metal with the application of heat
and with and without application of pressure.
• Filler rod may or may not be used.

3. • Plastic Welding or Pressure Welding
The piece of metal to be joined are heated to a
plastic state and forced together by external
pressure
(Ex) Resistance welding
• Fusion Welding or Non-Pressure Welding
The material at the joint is heated to a molten state and allowed
to solidify
(Ex) Gas welding, Arc welding
TYPES

4. Classification of welding processes:
(i). Arc welding
• Shielded Metal arc
• Metal inert gas
• Tungsten inert gas
• Plasma arc
• Submerged arc
• Atomic Hydrogen
• Electro-slag
(ii). Gas Welding
• Oxy-acetylene
• Air-acetylene
• Oxy-hydrogen
(iii). Resistance Welding
• Butt
• Spot
• Seam
• Projection
• Percussion
(iv)Thermit Welding
(v)Solid State Welding
Friction
Ultrasonic
Diffusion
Explosive
(vi)Newer Welding
Electron-beam
Laser
(vii)Related Process
Oxy-acetylene cutting
Arc cutting
Hard facing
Brazing
Soldering

6. Arc Welding Equipment's

8. Uses an electric arc to coalesce
metals
Arc welding is the most common
method of welding metals
Electricity travels from electrode
to base metal to ground
Arc Welding

9. Advantages
– Most efficient way to join
metals
– Lowest-cost joining method
– 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.

10. MIG
MIG is similar to MMA in that heat for welding is produced by
forming an arc between a metal electrode and the workpiece.
But we use very long electrode wire rolled on pulley.
Applications
Welding Sheets and Heavy plates, production
welding by robots on cars

11. • Tungsten electrode acts as a cathode
• A plasma is produced between the tungsten cathode and the
base metal which heats the base metal to its melting point
• Filler metal can be added to the weld pool
BASE METAL PUDDLE
POWER
SOURCE
ARC COLUMN
SHIELDING GAS
TUNGSTEN
ELECTRODE
Tungsten Inert Gas (TIG)

12. SAW – Submerged Arc Welding
• 300 – 2000 amps (440 V)
• Consumable wire electrode
Gas Metal Arc Welding (GMAW) Torch
• Shielding provided by flux granules
• Automated process (limited to flats)
• Low UV radiation & fumes
• Flux acts as thermal insulator
• High speed & quality (4 – 10x SMAW)
• Suitable for thick plates http://www.twi.co.uk

13. ESW- Electro Slag Welding

14. Atomic hydrogen Welding