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1
HEAVY ENGINEERING INDUSTRY
IN TODAY’S
ADVANCES IN
WELDING TECHNIQUES
4
Welding is an operation for
• joining two or more materials.
• with or without,
– application of heat or pressure or both.
– addition of filler.
5
TYPES OF WELDING
• FUSION WELDING
• ELECTRIC RESISTANCE WELDING
• SOLID-STATE WELDING ………...
6
FUSION WELDING
• Melting of base material and/or filler.
• Heat source
– Flame
– Electric arc
– High energy beam
– Electric resistance, high frequency current
– Friction
– Chemical energy
8
FUSION WELDING PROCESSES
• Shielded Metal Arc Welding SMAW
• Gas Tungsten Arc Welding GTAW
• Gas Metal Arc Welding GMAW
• Flux Cored Arc Welding FCAW
• Submerged Arc Welding SAW
• Electro-Slag Strip Cladding ESSC
• Plasma Arc Welding PAW
• Electron Beam Welding EBW
• Laser Beam Welding LBW
36
SOME APPLICATIONS IN HED
Thick Walled High Pressure Reactors
Dished End
Shell Courses
Skirt
Support Ring
37
SOME APPLICATIONS IN HED
Thick Walled High Pressure Reactors
Nozzle
Long seam/circ. Seam
Support Ring
Overlay on Shell & Dished End
Dished End Petal Seams
44
FABRICATION CRITICALITIES
• High deposition rates required for increased Productivity
Requires mechanization & automation
• Problems due to,
- heavy thickness
- weldability
Requires Preheating and Postheating during welding
Stress Relieving after welding
46
Mechanization
• Welding on profile (nozzle welding)
• Step overlay technique
• Use of seam tracker
• Flexible automation
53
PID
CONTROLLER
INFRA-RED
SENSOR
PROCESSOR
TEMP.
RECORDER
GAS
HEADERS
INFRA-RED SENSOR
GAS
HEADERS-
ON /OFF
Auto Pre-heat/Post-heat Control
54
Pre-heating/Post-heating
Low flame
High flame
Infra-red Sensor-Circseam
0°C
600°C Actual Temperature Plot
55
STRESS RELIEVING / POST WELD HEAT TREATMENT
Bogie-Hearth Furnace
14 x 9 x 9 m
Quenching Facility
56
02 Sept. 2000
THANK YOU

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Welding_Proceses.ppt