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Subject:Manufacturing Processes
Topic:Arc Welding
Arc Welding
• Arc welding is a group of welding processes
wherein coalescence is produced by heating with
an electrical arc.
• The fusing of two or more pieces of metal
together by using the heat produced from an
electric arc welding machine.
• It is used without the application of pressure and
with or without the use of filler metal depending
upon the base plate thickness.
How an arc is formed?
• The arc is like a flame of
intense heat that is
generated as the electrical
current passes through a
highly resistant air gap.
Arc Welding Processes
• Various Arc Welding Processes:
1.Carbon Arc Welding
2.Shilded Metal Arc Welding
3.Submerged Arc welding
4.TIG Welding
5.MIG Welding
6.Electroslag Welding
7.Electrogas Welding
8.Plasma Arc Welding
9.Arc Spot Welding
10.Stud Arc Welding
1.Carbon Arc Welding
• This welding is produced by
heating the workpiece with an
electric arc struck between a
carbon electrode and the
workpiece.
• Various joints which can be
carbon arc welded are
lap,butt,flange,corner and
bevel.
• It can be used for welding
steel,aluminium,nickel, copper,
etc.
2.Shilded Metal Arc Welding
• This welding is produced by heating
the workpiece with an electric arc set
up between a flux coated electrode and
the workpiece.
• The flux coating melts from the
electrode, produces a gaseous shield
slag to prevent atmospheric
contamination of the molten weld
metal.
• It is simple,easy and cost is fairly low.
• It is used in tan,boiler,ship
building,pipe joining,building
constructions, etc.
3.Submerged Arc welding
• This welding is produced by heating
electric arc setup between a bare metal
electrode and the job.
• In this welding granular or copper
coated electrode is used.
• This welding is carried out without
sparks,smoke,flash or spatter.
• It is used in fabrication of
pipes,shructural shapes, rail
road,cranes,automotive,nuclear power
welding etc.
• It can weld metals like mild steel,alloy
steels.
4.TIG Welding(Tungsten Inert Gas)
• This welding is produced by heating the job with
an electric arc struck between the tungsten
electrode and the job.
• A shielding gas is used to avoid atmospheric
contamination of the molten weld pool.
• In this method mainly two rods are used: filler rod
and tungsten electrode.
• The welding torch and the filler metal are
generally kept inclined at angle of 70-80 degree.
4.TIG Welding(Tungsten Inert Gas)
• It is suitable for high quality
welding of thin materials.
• It is used for weld
aluminium,magnesium, copper
nickel,carbon,stainless
steel,titanium,etc.
• Used for precision welding in
atomic energy, aircrft, chemical
and instrument industry.
5.MIG Welding(Metal Inert Gas)
• This welding is produced by heating the job with
an electric arc between a continuously fed metal
electrode and the job.
• The arc and the molten metal are shielded by an
inert gas like, argon,helium,carbon dioxide.
• Torch is moved along the joint in a steady manner
and torch angle is about 70 degree.
• Thick and thin both types of workpieces can be
welded effectively.
5.MIG Welding(Metal Inert Gas)
• It can weld
carbon,aluminium,magnesiu
m,nickel, and their
alloys,titanium etc.
• Used for manufacture of
refrigerator parts.
• MIG is mainly used in
industries like,
aircraft,automobile,pressure
vessel and ship building.
6.Electroslag Welding
• This welding is produced by molten
slag which melts the filler metal and
the surface of the work to be
welded.
• The temperature of molten slag is
16500 C.
• Heavy plates,forging and castings
can be butt welded
• It can also weld low-mudium carbon
steel,high strength structural steel,
etc.
7.Electrogas Welding
• Heat required for welding is obtained
by maintaining continuous electric arc
between the electrode and the molten
weld pool during welding.
• An inert gas shields the molten weld
pool from oxidation.
• Used for joining thick plates in vertical
position.
• Used for ships,bridges,offshore drilling
rigs,etc.
8.Plasma Arc Welding
• Plasma arc welding (PAW) is an arc welding process
similar to gas tungsten arc welding (GTAW). The electric
arc is formed between an electrode and the workpiece.
The key difference from GTAW is that in PAW, by
positioning the electrode within the body of the torch, the
plasma arc can be separated from the shielding gas
envelope.
• The plasma is then forced through a fine-bore copper
nozzle which constricts the arc and the plasma exits
the orifice at high velocities (approaching the speed of
sound) and a temperature approaching 28,000 °C
(50,000 °F) or higher.
• Arc plasma is the temporary state of a gas.
8.Plasma Arc Welding
• It is either transferred arc or
non transferred arc typed. It is
hand operated or mechanized.
At present, almost all
applications require
automated system. The torch
is water cooled to increase the
life of the nozzle and the
electrode.
9.Arc Spot Welding
• This welding is produced
between two surfaces is obtained
with the help of a spot formed
by heating with an electric arc
setup between a tungsten
electrode and one of the two
costly fit surfaces.
• Used in automobile industries,
fabrication of sheet
metal,fabrication of pulleys.
10.Stud Arc Welding
• This welding is produced by
heating with an electric arc drawn
between a metal stud,bolt,rivet or
a similar part and the base metal.
• It is simple,efficient,economical
and very fast method.
• It is used to weld ferrous and non-
ferrous metals.
• Used for fabrication industry,rail
road,farm and military
equipments.
Manufacturing Processes (Arc Welding)

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Manufacturing Processes (Arc Welding)

  • 2. Arc Welding • Arc welding is a group of welding processes wherein coalescence is produced by heating with an electrical arc. • The fusing of two or more pieces of metal together by using the heat produced from an electric arc welding machine. • It is used without the application of pressure and with or without the use of filler metal depending upon the base plate thickness.
  • 3. How an arc is formed? • The arc is like a flame of intense heat that is generated as the electrical current passes through a highly resistant air gap.
  • 4. Arc Welding Processes • Various Arc Welding Processes: 1.Carbon Arc Welding 2.Shilded Metal Arc Welding 3.Submerged Arc welding 4.TIG Welding 5.MIG Welding 6.Electroslag Welding 7.Electrogas Welding 8.Plasma Arc Welding 9.Arc Spot Welding 10.Stud Arc Welding
  • 5. 1.Carbon Arc Welding • This welding is produced by heating the workpiece with an electric arc struck between a carbon electrode and the workpiece. • Various joints which can be carbon arc welded are lap,butt,flange,corner and bevel. • It can be used for welding steel,aluminium,nickel, copper, etc.
  • 6. 2.Shilded Metal Arc Welding • This welding is produced by heating the workpiece with an electric arc set up between a flux coated electrode and the workpiece. • The flux coating melts from the electrode, produces a gaseous shield slag to prevent atmospheric contamination of the molten weld metal. • It is simple,easy and cost is fairly low. • It is used in tan,boiler,ship building,pipe joining,building constructions, etc.
  • 7. 3.Submerged Arc welding • This welding is produced by heating electric arc setup between a bare metal electrode and the job. • In this welding granular or copper coated electrode is used. • This welding is carried out without sparks,smoke,flash or spatter. • It is used in fabrication of pipes,shructural shapes, rail road,cranes,automotive,nuclear power welding etc. • It can weld metals like mild steel,alloy steels.
  • 8. 4.TIG Welding(Tungsten Inert Gas) • This welding is produced by heating the job with an electric arc struck between the tungsten electrode and the job. • A shielding gas is used to avoid atmospheric contamination of the molten weld pool. • In this method mainly two rods are used: filler rod and tungsten electrode. • The welding torch and the filler metal are generally kept inclined at angle of 70-80 degree.
  • 9. 4.TIG Welding(Tungsten Inert Gas) • It is suitable for high quality welding of thin materials. • It is used for weld aluminium,magnesium, copper nickel,carbon,stainless steel,titanium,etc. • Used for precision welding in atomic energy, aircrft, chemical and instrument industry.
  • 10. 5.MIG Welding(Metal Inert Gas) • This welding is produced by heating the job with an electric arc between a continuously fed metal electrode and the job. • The arc and the molten metal are shielded by an inert gas like, argon,helium,carbon dioxide. • Torch is moved along the joint in a steady manner and torch angle is about 70 degree. • Thick and thin both types of workpieces can be welded effectively.
  • 11. 5.MIG Welding(Metal Inert Gas) • It can weld carbon,aluminium,magnesiu m,nickel, and their alloys,titanium etc. • Used for manufacture of refrigerator parts. • MIG is mainly used in industries like, aircraft,automobile,pressure vessel and ship building.
  • 12. 6.Electroslag Welding • This welding is produced by molten slag which melts the filler metal and the surface of the work to be welded. • The temperature of molten slag is 16500 C. • Heavy plates,forging and castings can be butt welded • It can also weld low-mudium carbon steel,high strength structural steel, etc.
  • 13. 7.Electrogas Welding • Heat required for welding is obtained by maintaining continuous electric arc between the electrode and the molten weld pool during welding. • An inert gas shields the molten weld pool from oxidation. • Used for joining thick plates in vertical position. • Used for ships,bridges,offshore drilling rigs,etc.
  • 14. 8.Plasma Arc Welding • Plasma arc welding (PAW) is an arc welding process similar to gas tungsten arc welding (GTAW). The electric arc is formed between an electrode and the workpiece. The key difference from GTAW is that in PAW, by positioning the electrode within the body of the torch, the plasma arc can be separated from the shielding gas envelope. • The plasma is then forced through a fine-bore copper nozzle which constricts the arc and the plasma exits the orifice at high velocities (approaching the speed of sound) and a temperature approaching 28,000 °C (50,000 °F) or higher. • Arc plasma is the temporary state of a gas.
  • 15. 8.Plasma Arc Welding • It is either transferred arc or non transferred arc typed. It is hand operated or mechanized. At present, almost all applications require automated system. The torch is water cooled to increase the life of the nozzle and the electrode.
  • 16. 9.Arc Spot Welding • This welding is produced between two surfaces is obtained with the help of a spot formed by heating with an electric arc setup between a tungsten electrode and one of the two costly fit surfaces. • Used in automobile industries, fabrication of sheet metal,fabrication of pulleys.
  • 17. 10.Stud Arc Welding • This welding is produced by heating with an electric arc drawn between a metal stud,bolt,rivet or a similar part and the base metal. • It is simple,efficient,economical and very fast method. • It is used to weld ferrous and non- ferrous metals. • Used for fabrication industry,rail road,farm and military equipments.