Welding is the process that is joining two metals or materials by raising the joining area's temperature to the softening or melting point, and with or without applying the pressure of the joining area.

1. WJO 695 Welding and Joining
Final Presentation Submitted to The Academic Department
Of the School of Science and Engineering
In Partial Fulfillment of the Requirements
For the Doctorial Degree in Mechanical Engineering
ATLANTIC INTERNATIONAL UNIVERSITY
Yasir Dhaif Mahdi Alnaseri
ID# UD67080SME76152
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2. Welding & Joining
Welding is the process that is joining two metals or materials by raising the
joining area's temperature to the softening or melting point, and with or without
applying the pressure of the joining area.
When two metals, specifically metallic materials, are joined by fusion
produced by applying a different heat source type.
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3. Welding & Joining
In the joining process, two components are joined together without using a
heat source to produce fusion for the joining process, such as utilizing riveting to
joint two plates.
Generally, welding represents one of the joining process types.
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4. Types of Joining Process
 Welding
 Riveting
 Soldering
 Brazing
 Coupling
 Fastening
 Press Fit
 Others 4

5. Welding Joining Process
Fig. (1) Arc Welding Process
Murua, Maialen & Suarez, Alfredo & Galar, Diego & Santana, Roberto. (2020). Tool-Path Problem in Direct Energy Deposition Metal-Additive
Manufacturing: Sequence Strategy Generation. IEEE Access. PP. 1-1. 10.1109/ACCESS.2020.2994748. 5

6. Riveting Joining Process
Fig. (2) Riveting Joining Process
Gao, Dalong & Ersoy, Ugur & Stevenson, Robin & Wang, Pei-Chung. (2009). A New One-Sided Joining Process for Aluminum Alloys: Friction
Stir Blind Riveting. Journal of Manufacturing Science and Engineering-transactions of The Asme 6

7. Soldering Joining Process
Fig. (3) Soldering Joining Process
Zaimi, N & Mohd Salleh, Mohd Arif Anuar & Abdullah, Mohd Mustafa Al Bakri & Mostapha, Marliza & Madalina Simona, Baltatu & Ahmad,
R. (2020). Void Distributions in Sn-3.0Ag-0.5Cu (SAC305) Composite Lead Free Solder Subjected to Thermal Ageing Using Acoustic Micro
Imaging Technique. IOP Conference Series: Materials Science and Engineering.
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8. Brazing Joining Process
Fig. (4) Brazing Joining Process
This photo adapted from https://www.goudsmit.co.uk/brazing-assembly-technique-goudsmit-uk/
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9. Coupling Joining Process
Fig. (5) Coupling Joining Process
This photo adapted from https://couplingcorp.com/products/rigid-coupling/
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10. Fastening Joining Process
Fig. (5) Fastening Joining Process
This photo adapted from http://www.railroadfasteners.com/elastic-rail-fastening-system.html
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11. Press-fit Joining Process
Fig. (6) Press-fit Joining Process
This photo adapted from https://www.assemblymag.com/articles/91576-increasing-strength-and-reliability-of-interference-fits
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12. History of Welding
 Pure copper represents the first metal utilized in metal-working due to its
availability (soft and ductile (easily hammered, bent, or draw into a new form)).
 As early as 4000 B.C., uses of pure copper were reported in Sinai (Egypt) and the
island of Cyprus.
 The welding process started 3000 years ago when the forged weld was utilized to
form metals, bronze, and iron.
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13. History of Welding
 The tremendous ancient civilizations were indicated using metal-works because it
is easy to use and handle.
 Roman, Chinese, and Egyptians have developed their civilizations by using the
metal-works in their daily lives, such as forged welding in weapon industry.
 Between (1000 to 1200)A.D., the blast furnace was found to melt the iron in
Catalonia's Province in Spain.
 The first cast iron product was produced in the early 1600s. 13

14. History of Welding
 In the nearly 1800s, the Japanese manufactured and produced steel by repeated
welding and forging (they utilized fluxes to control the carbon amounts in steel).
 The Industrial Revolution (IR) introduced modern techniques that enhanced
molding, welding, forming, and joining technologies.
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15. Early Development in Welding
 By 1800, acetylene had been utilized in oxyacetylene welding, cutting, and
heating.
 By 1801, when Sir Humphry Davy was conducting electricity experiments, he
discovered the electric arc, which becomes the most crucial factor in welding
process development.
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16. Early Development in Welding
 By 1888, Bare metal electrode welding was founded in Russia.
 By 1892, the first patent for spot welding equipment was recorded to C.L. Coffin
in the United States of America.
 Until about 1920, the Bare electrode method represented the most commonly
used method in the United States.
 Welding technology and other industrial application were introduced rather
slowly until WW1. 16

17. Development of Modern Welding
 In 1936, one of the first high frequency and stabilized a.c. industrial welding
machines were manufactured by Miller Electric Manufacturer Company.
 Because of the high rate of metal deposition and the absence of arc blow, the a.c,
welding equipment has become the most popular tool.
 At WW2, the inert gas welding technology innovated and became handy to
produce high purity and critical application welding.
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18. Development of Modern Welding
 By 1930, the patent of utilizing the arc welding within an inert gas was
recorded to Hobart and Devers.
 The arc welding within an inert gas was not well received by industry due
to the high-cost argon and helium and a lack of suitable torch tool.
 Later in 1942, the Linde Company obtained a license to develop the gas
tungsten arc welding (GTAW) or tungsten inert gas (TIG).
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19. Development of Modern Welding
 In 1948, the first patent for gas metal arc welding (GMAW) was issued in
the United States.
 Late in 1950, the self-shielded flux-cored wires were introduced.
 In early 1970, all positions of flux-cored wires became available.
 During 1980 and continuing today, the welding industry develops
dramatically.
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20. Development of Modern Welding
 Rapid changes are evolving in the welding industry as engineers
devise more advanced filler metal formulas to improve arc
performance and weld quality on even the most exotic of materials.
 Some welding processes were developed for limited applications and
are used to fill a particular need.
 Other methods are evolving that may significantly change the way
welds will be made in the future.
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21. Development of Modern Welding
 Nowadays, there are over 90 welding processes in use.
 The demands of the industry in the future will force new and improved
developments in machines, gases, torches, electrodes, procedures and
technology.
 As the industry expands and improves its technology, new welding processes
will become an indispensable part of progress.
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22. Development of Modern Welding
 As the industry expands, enhances and improves its technology, new welding
processes will become an indispensable part of progress.
 Nowadays, five welding organizations provide guidance and standards related to
the welding industry:
* American Petroleum Institute (API)
* American Society of Mechanical Engineers (ASME)
* American Welding Society (AWS)
* American National Standards Institute (ANSI)
* American Bureau of Shipping (ABS)
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23. Types of Welding
 Arc Welding
 Oxy-fuel Welding
 Resistance Welding
 Solid-state Welding
 Electron Beam Welding
 Electro-slag Welding
 Flow Welding (Formally Cast Welding)
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24. Types of Welding
 Percussion Welding
 Laser Beam Welding
 Induction Welding
 Thermite Welding
 Electro-gas Welding
 Stud Arc Welding
 Laser Hybrid Welding
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25. Types of The Electric Arc Welding
 Arc spot welding
 Atomic-hydrogen welding
 Electro-gas welding
 Plasma arc welding
 Stud welding
 Submerged welding
 Underwater welding 25

26. Types of The Electric Arc Welding
 Magnetically impelled arc butt welding
 Carbon arc welding
 Gas tungsten arc welding
 Flux cored arc welding
 Gas metal arc welding
 Shielded metal arc welding
 Bare metal arc welding 26

27. Types of The Oxy-fuel Welding
 Air acetylene welding
 Oxy-acetylene welding
 Oxygen / Propane welding
 Oxy-hydrogen welding
 Pressure gas welding
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28. Types of The Resistance Welding
 Upset welding
 Resistance seam welding
 Resistance spot welding
 Projection welding
 Flash welding
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29. Types of The Solid-state Welding
 Co-extrusion welding
 Cold pressure welding
 Diffusion welding
 Explosion welding
 Electro-magnetic pulse welding
 Forge welding
 Friction welding 29

30. Types of The Solid-state Welding
 Friction stir welding
 Friction stir spot welding
 Hot pressure welding
 Hot iso-static welding
 Roll welding
 Ultrasonic welding
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31. Types of The Welding Joints
There are five basic types of the welding joints:
1. The butt joint
2. The edge joint
3. The corner joint
4. The lap joint
5. The T-joint
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32. Types of The Welding Joints
Fig. (7) The Welding Joints
This photo adapted from https://www.educationdiscussion.com/types-welded-joints/
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33. Weld Types
There are four basic weld types:
1. The plug (slot) weld
2. The groove weld
3. The fillet weld
4. The bead (surface) weld
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34. Bead Welds
 Single-pass deposit of weld metal.
 Utilizes to build a pad of metal.
 Utilizes to replace metal on worn.
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35. Groove Welds
 Consist of one or more beads deposited in a groove.
 Utilizes for butt joints.
 It may take V or U shape based on how these grooves are referred to
on a butt joint such as V-groove and U-groove butt joint.
 This weld is applicable on both plate and pipe.
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36. Fillet Welds
 consist of one or more beads deposited in a right angle formed by
two plates.
 Utilizes for lap joints and T-joints.
 Fillet welds take a triangular cross section due to the location they
are placed in the weld joint.
 The face of the weld can be convex, concave, or flat. 36

37. Plug Welds
 Similar to slot welds.
 Utilizes for filling slotted or circular holes in lap joints.
 A fillet weld may be made around the faying surface of the joint.
 The plug weld may or may not completely fill the joint as shown.
 The hole or slot may be open at one end.
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38. Welding Positions
There are six basic positions for welding:
 Flat,
 Horizontal,
 Vertical,
 Overhead,
 Rotated Pipe,
 and Inclined Pipe
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39. Welding Positions
Fig. (8) The Welding Positions
This photo adapted from https://weldguru.com/welding-positions/ 39

40. Welding Positions
Flat Position:
The flat position (number 1) (1 refers to a flat position – either 1F or
1G) is the welding position utilized to weld from the upper side of the
joint at a point where the weld axis is:
 a horizontal
 and the weld face locates in the approximately horizontal
plane.
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41. Welding PositionsHorizontal Position:
The horizontal position (number 2) (2 refers to a horizontal
position – either 2F or 2G) is the fillet welding position that the weld is
located on the upper side of the horizontal surface and against the
vertical surface. For groove welds, it is the position that the weld face
lies in the vertical plane, and the weld plane at the point of welding is
the horizontal, while the plate remains in the vertical orientation.
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42. Welding PositionsVertical Position:
The vertical position (number 3)(3 is the vertical position – either
3F or 3G) is the welding position that the weld direction at the point of
welding is:
 the vertical and the weld face lies in the vertical plane.
 Welding travel direction may be up or down.
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43. Welding PositionsOverhead Position:
The overhead position (number4) (4 is the overhead position –
either 4F or 4G) is the welding position that welding is performed from
the underside of the joint. The overhead position is the reverse of the flat
position.
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44. Welding PositionsRotated Pipe Position:
The horizontal fixed position (rotated pipe position 5G) is the
welding position that welding will be in the horizontal position. The
pipe always remains fixed, unlike the flat welding position (1G). To
perform this position of welding, the welder should move around the
pipe's outer surface in the vertical direction.
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45. Welding PositionsInclined Pipe Position:
The inclined (slop) welding position (it is called 6G) is the
welding position that the pipe is at slop (approximately 45 degrees from
the X or Y axes.
To perform this position of welding:
 The welder should move around the pipe's outer surface.
 The unique experienced welder is required with expert consultation.
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46. Welding Defects
 Lack of metal penetration.
 Excessive welding penetration.
 Lack of fusion.
 Lack of side-wall fusion.
 Lack of root fusion.
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47. Welding Defects
 Gas cavities.
 Cracks.
 Solid inclusions.
 Under-cut.
 Root concavity (Suck back).
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48. Welding Defects
 Bad stop-start.
 Spatter.
 Burn through.
 Misalignment.
 Poor toe blend.
 Arc strike.
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