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Welding Processes education power point ppt
- 1. Welding Processes Gautam singh(M.E 4th yr) 10030104014
- 2. WELDING – Welding isa 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.
- 3. Types of Welding FusionWelding Pressure Welding Homogeneous Heterogeneous Brazing Soldering Gas Welding Electroslag High Energy Beam Electric Arc MIG TIG Shielded Metal Arc – “Stick” Friction Welding
- 4. Fusion Welding Principles •Base metal is melted • Filler metal may be added • Heat is supplied by various means – Oxyacetylene gas – Electric Arc – Plasma Arc – Laser
- 5. Fusion Welding BASE METAL WELD SOLIDIFIEDSLAG ARC POOL WELDING ATMOSPHERE CORE WIRE ELECTRODE COATING ARC STREAM PENETRATION DEPTH
- 6. Weld Fluxes • Typicalfluxes – SiO2, TiO2, FeO, MgO, Al2O3 – Produces a gaseous shield to prevent contamination – Act as scavengers to reduce oxides – Add alloying elements to the weld – Influence shape of weld bead during solidification
- 7. Inert Gases • Argon,helium, nitrogen, and carbon dioxide • Form a protective envelope around the weld area • Used in – MIG – TIG – Shield Metal Arc
- 8. Types of FusionWelding • Oxyacetylene Cutting/Welding • Shielded Metal Arc (“Stick”) • Metal Inert Gas (MIG) • Tungsten Inert Gas (TIG)
- 9. Oxyacetylene Welding • Flameformed by burning a mix of acetylene (C2H2) and oxygen • Fusion of metal is achieved by passing the inner cone of the flame over the metal • Oxyacetylene can also be used for cutting metals Inner Cone: 5000-6300 deg F Combustion Envelope 3800 deg F 2300 deg F TORCH TIP
- 10. Gas Welding (Oxy-acetylene) Anumber of welding processes use a flame produced by burning a mixture of fuel gas and oxygen. The gas usually used is Acetylene but other gases are also used. Separate cylinders and a hose pipe from each cylinder transports the gases to a torch. Gas and fuel mix in the torch burns @ 3100°C.
- 11. Metal Inert Gas(MIG) • Uses a consumable electrode (filler wire made of the base metal) • Inert gas is typically Argon BASE METAL PUDDLE POWER SOURCE DRIVE WHEELS CONSUMABLE ELECTRODE ARC COLUMN SHIELDING GAS
- 12. Tungsten Inert Gas(MIG) • 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 + + BASE METAL (ANODE) TUNGSTEN ELECTRODE (CATHODE) - - - + +
- 13. Submerged Arc Welding(SAW) Similar to MIG welding, SAW involves formation of an arc between a continuously-fed bare wire electrode and the workpiece Applications SAW welding taking place in the flat position. Ideal for heavy workpieces Carbon-manganese steels,low alloy steels and stainless steels
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- 15. Weld Symbols (ButtJoints) Backing
- 16. Weld Symbol (FilletJoints)
- 17. Weld Symbol (CornerJoints)