The document outlines various welding processes including fusion welding, gas welding, arc welding, and specialized techniques like plasma and electron beam welding. It covers the principles, equipment, and characteristics of different welding methods, as well as brazing and soldering processes. Additionally, the document discusses filler materials, fluxes, and adhesive bonding types utilized in these processes.

1. JOINING PROCESSES
Fusion welding processes – Types of Gas welding – Equipments used –
Flame characteristics – Filler and Flux materials - Arc welding equipments -
Electrodes – Coating and specifications – Principles of Resistance welding –
Spot/butt, seam welding – Percusion welding - Gas metal arc welding – Flux
cored – Submerged arc welding – Electro slag welding – TIG welding –
Principle and application of special welding processes - Plasma arc welding
– Thermit welding – Electron beam welding – Friction welding – Diffusion
welding – Weld defects – Brazing and soldering process – Methods and
process capabilities – Filler materials and fluxes – Types of Adhesive
bonding.

2. Fusion welding
The metal at the joint is heated to a molten state and then it is
allowed to solidify. E.g. – gas welding , Arc welding, Thermit
welding
The metal at the joint is heated to a plastic state and are pressed
together to make the joint. E.g. – Electric resistance welding,
Forge welding
Plastic welding

3. Types of gas welding
2. Air – Acetylene welding
Air taken from the atmosphere and compressed , mixed the acetylene to
the required proportion. Temperature is lower than oxy-acetylene
welding.
3. Oxy – Hydrogen welding
Oxygen and hydrogen gases are mixed with the required proportion. It
is used for low temperature welding metals like aluminium, lead.
1. Oxy – Acetylene welding
 Hottest region - 3200°C
 Acetylene pressure not more than 1.5 atm
 Oxygen pressure – HP -0.1 to 3.5 bar, LP – 0.5
to 3.5bar,Torch pressure upto 0.06bar.
 CaC2+2H2O Ca(OH)2+C2H2+127.3 Kj/mol.

4. Gas Welding Equipments

5. Flame Characteristics
1. Neutral Flame
 Equal quantity of oxygen and acetylene.
 Inner cone develops heat to melt the metal.
 Outer cone are
2. Carburising Flame  More acetylene than oxygen.
 Sharp Inner cone
 White intermediate cone called feather cone
 Bluish Outer cone

6. Flame Characteristics
3. Oxidising Flame
 More oxygen than acetylene.
 Smaller Inner cone
 Outer cone

7. Gas Welding Technique
1. Leftward or Forward Welding
2. Rightward or Backward Welding

8. Arc Welding Equipment
Heat is developed by an electric arc

9. Filler rod – Gas Welding Equipment
To supply additional metal to make the joint. Metal rod as a parent metal.
D=t/2 + 1
Electrode – Arc Welding Equipment
1. Consumable electrodes
It used to produce arc between work and electrode but also provides
filler material during welding
2. Non- Consumable electrodes
Made of carbon, graphite which do not consume during welding
Arc length remains constant and stable.

10. Specification and choice of Electrodes

11. RESISTANCE WELDING

12. 1.0 SPOT WELDING
RESISTANCE WELDING

13. 2.0 BUTT WELDING
1. Upset butt welding 2. Flash butt welding
RESISTANCE WELDING

14. 3.0 SEAM WELDING
RESISTANCE WELDING

15. 4.0 PERCUSSION WELDING
RESISTANCE WELDING

16. 5.0 GAS METAL ARC WELDING (MIG WELDING)
MIG – METAL INERT GAS WELDING

17. FLUX CORE
When the flux is required continuously or where large quantity of flux has to be
supplied, on that time the flux is used in the form of wire wound on a rotating drum or
reel called as flux core.
1. Submerged Arc welding (SAW)

18. 2. Electro Slag welding (ESW)
FLUX CORE

19. 3. Tungsten Insert Gas Welding(TIG)
FLUX CORE

20. SPECIAL WELDING
1. Plasma Arc welding (PAW)
a) Transferred type

21. SPECIAL WELDING
2. Thermit welding

22. SPECIAL WELDING
3. Electron Beam welding

23. SPECIAL WELDING
4. Friction welding

24. BRAZING
Joining of two metal pieces by using a filler metal and the
liquid temperature is above 450 deg C.
Joining of two metal pieces by using a filler metal and the
liquid temperature is below 430 deg C.
SOLDERING

25. METHODS AND PROCESS CAPABILITES - BRAZING
 Torch brazing
Acetylene, natural gas and butane are combined with air or oxygen.
 Furnace brazing
The heat is supplied by gas or electric heating coils.
 Induction brazing
Heated by placing within the field of high frequency induction coil.
 Dip Brazing
Chemical dip - Filler metal placed in molten bath or flux.
Molten metal bath – The assembled parts are first prefluxed and then
immersed into molten bath.
 Resistance brazing
Rapid heating minimizes oxidation and the heat affected zone is small
 Laser brazing and electron beam brazing
Laser beam and electron beam are used to join the metal.

26. METHODS AND PROCESS CAPABILITES - SOLDERING
 Hard Soldering
The filler metal is silver. Also called as Siler soldering.
 Soft Soldering
Soldering iron is copper rod.
 Dip Soldering
A large amount of solder is melted in a closed tank and parts to
be soldered are cleaned and properly dipped in a flux bath.
 Wave soldering
Parts is not dipped into the solder tank but wave is generated in
the tank.

27. FILLER MATERIALS
FLUX MATERIALS
1. Chlorides 2. Borax and boric acid,
3. Borates, 4. Fluorides.

28. TYPES OF ADHESIVE BONDING