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WELDING PROCESS
Engineering Collage Tuwa
(ECT)
SUBJECT- UTILAZATION OF ELECTRICAL
ENERGY & TRACTION
UNDER ASSI. PROF.:- SHRI JAVED DHANTIYA
NAME OF STUDENT ENROLLMENT NO.
VASANI MASUM K. 160553109011
ARPIT S. SONI 160553109010
LAKHARIA PREET 160553109005
RATHOD KIRTI V. 150550109007
-Welding is a materials joining process which
produces coalescence of materials by heating
them to suitable temperatures with or without the
application of pressure or by the application of
pressure alone, and with or without the use of filler
material.
– Welding is used for making permanent joints.
– It is used in the manufacture of automobile bodies, aircraft
frames, railway wagons, machine frames, structural works,
tanks, furniture, boilers, general repair work and ship
building.
WELDING
TYPES
• 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
Classification of
welding processes:
(i). Arc welding
• Carbon arc
• Metal arc
• Metal inert gas
• Tungsten inert gas
• Plasma arc
• Submerged arc
• 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
Arc welding
• Equipments:
• A welding generator (D.C.) or Transformer (A.C.)
• Two cables- one for work and one for electrode
• Electrode holder
• Electrode
• Protective shield
• Gloves
• Wire brush
• Chipping hammer
• Goggles
Arc Welding Equipments
Metal arc welding
Arc Welding
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
Carbon Arc Welding
Arc welding
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.
Comparison of A.C. and D.C. arc welding
Alternating Current (from Transformer)
More efficiency
Power consumption less
Cost of equipment is less
Higher voltage – hence not safe
Not suitable for welding non ferrous metals
Not preferred for welding thin sections
Any terminal can be connected to the work or electrode
Comparison of A.C. and D.C. arc welding
Direct Current (from Generator)
Less efficiency
Power consumption more
Cost of equipment is more
Low voltage – safer operation
suitable for both ferrous non ferrous metals
preferred for welding thin sections
Positive terminal connected to the work
Negative terminal connected to the electrode
GAS WELDING
• Sound weld is obtained by selecting proper size of
flame, filler
material and method of moving torch
• The temperature generated during the process is
33000c
• When the metal is fused, oxygen from the
atmosphere and the torch
combines with molten metal and forms oxides, results
defective
weld
• Fluxes are added to the welded metal to remove
oxides
• Common fluxes used are made of sodium,
potassium. Lithium and
borax.
• Flux can be applied as paste, powder,liquid.solid
coating or gas.
Weld joints
Brazing Brazing and Soldering
It is a low temperature joining process. It is performed at
temperatures above 840º F and it generally affords
strengths
comparable to those of the metal which it joins. It is low
temperature in that it is done below the melting point of the
base
metal. It is achieved by diffusion without fusion (melting) of
the base
Brazing can be classified as
Torch brazing
Dip brazing
Furnace brazing
Induction brazing
Brazing
Advantages & Disadvantages
Advantages
• Dissimilar metals which canot be welded can be
joined by brazing
• Very thin metals can be joined
• Metals with different thickness can be joined easily
• In brazing thermal stresses are not produced in the
work piece.
Hence there is no distortion
• Using this process, carbides tips are brazed on the
steel tool
holders
Disadvantages
• Brazed joints have lesser strength compared to
welding
• Joint preparation cost is more
• Can be used for thin sheet metal sections
Soldering
• It is a low temperature joining
process. It is performed at
temperatures below 840ºF for
joining.
• Soldering is used for,
• Sealing, as in automotive
radiators or tin cans
• Electrical Connections
• Joining thermally sensitive
components
• Joining dissimilar metals
TYPES OF WELDING

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TYPES OF WELDING

  • 1. WELDING PROCESS Engineering Collage Tuwa (ECT) SUBJECT- UTILAZATION OF ELECTRICAL ENERGY & TRACTION UNDER ASSI. PROF.:- SHRI JAVED DHANTIYA NAME OF STUDENT ENROLLMENT NO. VASANI MASUM K. 160553109011 ARPIT S. SONI 160553109010 LAKHARIA PREET 160553109005 RATHOD KIRTI V. 150550109007
  • 2. -Welding is a materials joining process which produces coalescence of materials by heating them to suitable temperatures with or without the application of pressure or by the application of pressure alone, and with or without the use of filler material. – Welding is used for making permanent joints. – It is used in the manufacture of automobile bodies, aircraft frames, railway wagons, machine frames, structural works, tanks, furniture, boilers, general repair work and ship building. WELDING
  • 3. TYPES • 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
  • 4. Classification of welding processes: (i). Arc welding • Carbon arc • Metal arc • Metal inert gas • Tungsten inert gas • Plasma arc • Submerged arc • 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
  • 5. Arc welding • Equipments: • A welding generator (D.C.) or Transformer (A.C.) • Two cables- one for work and one for electrode • Electrode holder • Electrode • Protective shield • Gloves • Wire brush • Chipping hammer • Goggles
  • 8. Arc Welding 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
  • 10. Arc welding 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.
  • 11. Comparison of A.C. and D.C. arc welding Alternating Current (from Transformer) More efficiency Power consumption less Cost of equipment is less Higher voltage – hence not safe Not suitable for welding non ferrous metals Not preferred for welding thin sections Any terminal can be connected to the work or electrode
  • 12. Comparison of A.C. and D.C. arc welding Direct Current (from Generator) Less efficiency Power consumption more Cost of equipment is more Low voltage – safer operation suitable for both ferrous non ferrous metals preferred for welding thin sections Positive terminal connected to the work Negative terminal connected to the electrode
  • 13. GAS WELDING • Sound weld is obtained by selecting proper size of flame, filler material and method of moving torch • The temperature generated during the process is 33000c • When the metal is fused, oxygen from the atmosphere and the torch combines with molten metal and forms oxides, results defective weld • Fluxes are added to the welded metal to remove oxides • Common fluxes used are made of sodium, potassium. Lithium and borax. • Flux can be applied as paste, powder,liquid.solid coating or gas.
  • 15. Brazing Brazing and Soldering It is a low temperature joining process. It is performed at temperatures above 840º F and it generally affords strengths comparable to those of the metal which it joins. It is low temperature in that it is done below the melting point of the base metal. It is achieved by diffusion without fusion (melting) of the base Brazing can be classified as Torch brazing Dip brazing Furnace brazing Induction brazing
  • 17. Advantages & Disadvantages Advantages • Dissimilar metals which canot be welded can be joined by brazing • Very thin metals can be joined • Metals with different thickness can be joined easily • In brazing thermal stresses are not produced in the work piece. Hence there is no distortion • Using this process, carbides tips are brazed on the steel tool holders Disadvantages • Brazed joints have lesser strength compared to welding • Joint preparation cost is more • Can be used for thin sheet metal sections
  • 18. Soldering • It is a low temperature joining process. It is performed at temperatures below 840ºF for joining. • Soldering is used for, • Sealing, as in automotive radiators or tin cans • Electrical Connections • Joining thermally sensitive components • Joining dissimilar metals