A PRESENTATION ON

WELDING TECHNOLOGY

WELDING TECHNOLOGY
POWER PLANT A BRIEF OVERVIEW MATERIAL SELECTION METALLURGY A BRIEF INTRODUCTION WELDING IN A POWER PLANT WELDING INTRODUCTION, ITS BACKGROUND MATERIAL INVOLVED IN POWER PLANT FUNDAMENTALS OF WELDING

DEFINITIONS SYMBOLS FOR WELDING TYPE OF JOINTS, WELD WELD JOINT DESIGN WELD POSITIONS WELD QUALITY

WELDING PROCESSES

STEAM POWER PLANTS

WHAT IS SUB CRITICAL? WHAT IS SUPER CRITICAL?

THERMODYNAMIC CONCEPTS (IN BRIEF)

EXISTING SUPERCRITICAL UNITS

DESIGN FEATURES
MATERIAL DEVELOPMENT

STEAM POWER PLANTS

DEFINITION OF CRITICAL CONDITIONS CRITICAL IS A THERMODYNAMIC EXPRESSION DESCRIBING THE STATE OF A SUBSTANCE BEYOND WHICH THERE IS NO CLEAR DISTINCTION BETWEEN THE LIQUID AND GASEOUS PHASE.

THE CRITICAL PRESSURE AND TEMPERATURE FOR WATER ARE PRESSURE = 225.56 Kg / cm2

TEMPERATURE

374.150 C

STEAM POWER PLANTS

p =225.56 Kgf/cm2
LIQUID REGION
CRITICAL POINT

p = 15 Kgf/cm2

VAPOR REGION

p = 1.0332 Kgf/cm2

LIQUID - VAPOR REGION

Saturated vapor line

Saturated liquid line

v Temperature - Specific Volume Diagram for Water

STEAM POWER PLANTS

1 3 4

GEN.
2

BOILER

DEAERATOR
9

CONDENSER

6 8 7

11

10

HPH

BFP

LPH

CEP

SCHEMATIC DIAGRAM OF SUB - CRITICAL STEAM POWER PLANT

STEAM POWER PLANTS

T - s DIAGRAM
HEATING IN REHEATER

TEMPERATURE T

HEATING IN SUPERHEATER

HEATING IN HP HEATERS, ECONOMIZER

11
HEATING IN STEAM GENERATOR STEAM EXPANSION IN I.P. TURBINE, L.P. TURBINE

10
PUMPING BY BFP

9
HEATING IN LP HEATERS

STEAM EXPANSION IN H.P. TURBINE

7
PUMPING BY CEP

5
STEAM CONDENSATION IN CONDENSER

SPECIFIC ENTROPY s

STEAM POWER PLANTS

SUB - CRITICAL STEAM POWER PLANT

th

33 - 36%

TO IMPROVE THERMAL EFFICIENCY INCREASE TEMPERATURE (SUPERHEAT) INCREASE INLET PRESSURE TO HPT (p1) REDUCE CONDENSER PRESSURE

WHY SHOULD AN ENGINEER STUDY MATERIALS ?

EVERY SINGLE THING CONSTRUCTED FROM SOME OTHER MATERIAL OR

TO KNOW THE RANGE OF MATERIALS & PROPERTIES OF MATERIAL

TO KNOW - PROPERTIES ARE DEPENDENT ON STRUCTURE

TO KNOW HOW THE PROPERTIES CAN BE MODIFIED BY VARIETY OF TREATMENT TO KNOW ENVIRONMENTAL & SOCIAL FACTORS ASSOCIATED WITH PRODUCTION & UTILIZATION OFMATERIAL

TO

KNOW

HOW

TO

SELECT

MOST

SUITABLE

MATERIAL

IN

PARTICULAR DESIGN REQUIREMENT

WHY SHOULD AN ENGINEER STUDY MATERIALS ?

THERE IS COMPLEX INTERRELATIONSHIPS BETWEEN MATERIAL, MANUFACTURING PROCESS AND DESIGN

KNOW THE MAJOR CLASSIFICATIONS OF MATERIALS

MAIN CHARACTERISTICS OF EACH CLASS

SOME KNOWLEDGE OF BASIC COSTS OF SOME MATERIALS

HOW THE COST & ENERGY CONTENT ARE AFFECTED BY

PROCESSING

DESIGN, MATERIALS AND MANUFACTURE

MATERIALS

DESIGN

MANUFACTURE

UTILIZE MATERIALS IN MOST EFFECTIVE & EFFICIENT MANNER MATERIAL SHALL BE RECYCLED WHEN PRODUCT HAS REACHED THE END OF ITS LIFE

ENVIRONMENTAL & SOCIOLOGICAL FACTORS

DESIGN, MATERIALSAND MANUFACTURE DESIGN, MATERIALS AND MANUFACTURE

WHAT DESIGNER HAS TO KNOW ABOUT THE MATERIAL ?

DOES THE MATERIAL POSSESS THE NECESSAY PROPERTIES? CAN THE MATERIAL BE FORMED TO THE DESIRED SHAPE? WILL THE PROPERTIES OF THE MATERIAL ALTER WITH TIME DURING SERVICE? WILL THE MATERIAL BE ADVERSELY AFFECTED BY ENVIRONMENTAL CONDITIONS AND RESIST CORROSION AND OTHER FORM OF ATTACK? WILL THE MATERIAL GIVE SUFFICIENT RELIABILITY & QUALITY? CAN THE PRODUCT BE MADE AT AN ACCEPTABLE COST

CLASSIFICATION OF ENGINEERING MATERIALS

ENGINEERING MATERIALS

METALS

POLYMERS

CERAMICS & INORGANIC GLASSES

COMPOSITES

ENGINEERING MATERIAL PROPERTIES & QUALITIES

PHYSICAL PROPERTIES DENSITY MECHANICAL PROPERTIES YIELD STRENGTH CHEMICAL PROPERTIES RESILIENCE TO OXIDATION OTHER NON MECH. PROPERTIES ELECTRICAL ECONOMIC PROPERTIES RAW MATERIAL & PROCESSING COST AVAILABILITY AESTHETIC PROPERTIES APPEARANCE

MELTING POINT
HARDNESS

TENSILE STRENGTH
COMPRESSIVE STRENGTH

CORROSION
SOLVENT & ENVIRONMENTAL FACTORS

MAGNETIC
OPTICAL

TEXTURE
ABILITY TO ACCEPT SPECIAL FINISHES

ELASTIC MODULI DAMPING CAPACITY

TORSIONAL STRENGTH DUCTILITY FATIGUE STRENGTH CREEP STRENGTH FRACTURE TOUGHNESS

THERMAL

A TENNIS RACQUET - MATERIAL SELECTION

REQUIREMENT OF THE MATERIAL MATERIAL AVAILABLE PROGRESSIVE TRENDS

HIGH STRENGTH STIFFNESS LOW COST

LAMINATED WOOD

EARLY 1970 ALL RACQUETS MADE OF LAMINATED WOOD DISADVANTAGE ABSORB MISTURE, WATER LEAD TO VARIATIONS IN PERFORMANCE, WRAPPING OF FRAME

STEEL, ALUMINIUM

LATE 1970 - FRAMES WITH STEEL & ALUMINUM HIGH STRENGTH / WEIGHT RATIO STRONG, RIGID, LIGHT FRAME DISAGVANTAGE - LOW DAMPING COEFFICIENTS LEADS TO AMOUNT OF VIBRATIONS TRANSMITTED TO PLAYERS HAND & ARM INCREASED

FIBRE REINFORCED COMPOSITES

EARY 1980s COMPOSITES

USING CONTINUOUS GLASS OR CARBON FIBRES IN A POLYESTER OR EPOXY LIGHT WT. FRAME HIGH STRENGTH & STIFFNESS HIGHER DAMPING COEFFICIENTS

OVERHEAD ELECTRIC TRANSMISSION LINES - MATERIAL SELECTION

REQUIREMENT OF THE MATERIAL MATERIAL AVAILABLE DESIGN FEASIBILITY

HIGH ELECTRICAL CONDUCTIVITY

FOUR BEST METALS IN SILVER & GOLD TOO COSTLY, DESCENDING ORDER OF RULED OUT
ELECTRICAL CONDUCTIVITY

SILVER COPPER GOLD ALUMINIUM

(SHOULD HAVE HIGH PURITY )

COPPER IS MORE THAN ALUMINIUM

EXPENSIVE

SELECTED MATERIAL ALUMINIUM PROBLEM STRENGTH ? LOW

PURE

TENSILE

SOLUTION OVER HEAD TRANSMISSION CABLES ARE MADE OF ALUMINIUM WIRES BRAIDED AROUND A STEEL WIRE CORE TO GIVE STRENGTH

OVERHEAD POWER WIRES FOR RAILWAYS - MATERIAL SELECTION

REQUIREMENT OF THE MATERIAL

MATERIAL AVAILABLE

DESIGN FEASIBILITY

HIGH ELECTRICAL FOUR BEST METALS IN CONDUCTIVITY DESCENDING ORDER OF ELECTRICAL CONDUCTIVITY SILVER MATERIAL SHOULD COPPER BE HARD TO RESIST GOLD ABRASIVE EFFECT OF ALUMINIUM PANTOGRAPH ARM OF THE VEHCILE.
(SHOULD HAVE HIGH PURITY )

SOLUTION WIRES MADE OF COPPER ALLOY CONTAINING 1 % CADMIUM CADMIUM GREATLY INCREASE THE HARDNESS LITTLE ADVERSE EFFECT ON ELECTRICAL CONDUCTIVITY

DEFINITIONS
METALLURGY

METALLURGY IS THE DOMAIN OF MATERIAL SCIENCE AND MATERIAL ENGINEERING THAT STUDIES THE PHYSICAL AND CHEMICAL BEHAVIOUR OF METALLIC ELEMENTS AND THEIR MIXTURES, WHICH ARE CALLED ALLOYS.

DEFINITIONS
EXTRACTION METALLURGY

EXTRACTION

METALLURGY

IS

THE

PRACTICE

OF

SEPARATING METALS FROM THEIR ORE, AND REFINING THEM INTO A PURE METAL. IN ORDER TO CONVERT A METAL OXIDE OR SULPHIDE TO A METAL, THE METAL OXIDE MUST BE REDUCED EITHER

CHEMICALLY OR ELECTROLYTICALLY.

DEFINITIONS
METALLURGY IN PRODUCTION ENGINEERING
IN PRODUCTION ENGINEERING, METALLURGY IS CONCERNED WITH THE PRODUCTION OF METALLIC COMPONENTS FOR USE IN CONSUMER OR ENGINEERING PRODUCTS.

THIS INVOLVES

PRODUCTION OF ALLOYS, SHAPING, HEAT TREATMENT AND SURFACE TREATMENT OF THE PRODUCT

DEFINITIONS
TASK OF METALLURGIST

THE TASK OF THE METALLURGIST IS TO ACHIEVE DESIGN CRITERIA SPECIFIED BY THE MECHANICAL

ENGINEER,

SUCH

AS

COST,

WEIGHT,

STRENGTH,

TOUGHNESS, HARDNESS, CORROSION RESISTANCE AND PERFORMANCE IN EXTREMES OF TEMPERATURE.

DEFINITIONS
EXTENSIVE USE OF METALLURGY IN

STEEL MAKING & PROCESSING

HEAT-TREATMENT FORGING FOUNDRY WELDING

DEFINITIONS
ELEMENTS
A CHEMICAL ELEMENT, OFTEN CALLED SIMPLY ELEMENT, IS A SUBSTANCE THAT CANNOT BE DIVIDED OR CHANGED INTO DIFFERENT METHODS. SUBSTANCES BY ORDINARY CHEMICAL

THE SMALLEST PARTICLE OF SUCH AN ELEMENT IS AN

ATOM, WHICH CONSISTS OF ELECTRONS CENTERED ON A NUCLEUS OF PROTONS AND NEUTRONS. AS ON TODAY 116 KNOWN ELEMENTS 90 OCCUR NATURALLY 26 DERIVED ARTIFICIALLY

DEFINITIONS
METALS
IN CHEMISTRY, A METAL (GREEK: METALLON) IS AN

ELEMENT THAT READILY FORMS IONS (CATIONS) AND HAS

METALLIC BONDS, AND METALS ARE SOMETIMES DESCRIBED AS A LATTICE OF POSITIVE IONS (CATIONS) IN A CLOUD OF ELECTRONS.

METALS ARE PROPERTIES

DISTIGUISHED

BYIONIZATION

&

BONDING

DEFINITIONS
METALS, NON METALS AND METALLOIDS
ON THE PERIODIC TABLE, A DIAGONAL LINE DRAWN FROM

BORON (B) TO POLONIUM (Po) SEPARATES THE METALS

FROM THE NON-METALS.

ELEMENTS ON THIS LINE ARE

METALLOIDS, (SEMIMETALS)
METALS

ELEMENTS TO THE LOWER LEFT OF THE LINE ELEMENTS TO THE UPPER RIGHT OF THE LINE

NON - METALS

STANDARD PERIODIC TABLE

Group 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Period

1 H
3 Li 11 Na 19 K 37 Rb 55 Cs 4 Be 12 Mg 20 Ca 38 Sr 56 Ba 21 Sc 39 Y * 22 Ti 40 Zr 72 Hf 23 V 41 Nb 73 Ta 24 Cr 42 Mo 74 W 25 Mn 43 Tc 75 Re 26 Fe 44 Ru 76 Os 27 Co 45 Rh 77 Ir 28 Ni 46 Pd 78 Pt 29 Cu 47 Ag 79 Au 30 Zn 48 Cd 80 Hg 5 B 13 Al 31 Ga 49 In 81 Tl 6 C 14 Si 32 Ge 50 Sn 82 Pb 7 N 15 P 33 As 51 Sb 83 Bi 8 O 16 S 34 Se 52 Te 84 Po 9 F 17 Cl 35 Br 53 I 85 At

2 He
10 Ne 18 Ar 36 Kr 54 Xe 86 Rn

87 Fr

88 Ra

**

104 Rf
57 La 89 Ac

105 Db
58 Ce 90 Th

106 Sg
59 Pr 91 Pa

107 Bh
60 Nd 92 U

108 Hs
61 Pm 93 Np

109 Mt
62 Sm 94 Pu

110 Ds
63 Eu 95 Am

111 Rg
64 Gd 96 Cm

112 Uub
65 Tb 97 Bk

113 Uut
66 Dy 98 Cf 99 Es

114 Uuq
67 Ho 100 Fm

115 Uup
68 Er

116 Uuh
69 Tm 101 Md

117 Uus
70 Yb 102 No

118 Uuo
71 Lu 103 Lr

LANTHANIDES
ACTINIDES

CRYSTALLINE STRUCTURE
B.C.C.
CHROMIUM TUNGSTEN VANADIUM MOLYBDENUM IRON (EXCEPT IN TEMP. RANGE 910-1400 OC)

F.C.C.
ALUMINIUM COPPER LEAD NICKEL SILVER

C.P.H.
TITANIUM ZINC ZIRCONIUM MAGNESIUM COBALT

IRON (EXCEPT IN TEMP. RANGE 910-1400 OC)

CRYSTALLINE STRUCTURE

BODY CENTERED CUBIC (B.C.C.)

FACE CENTERED CUBIC (F.C.C.)

SOME COMMON UNIT CELLS

CRYSTALLINE STRUCTURE

CLOSED PACKED HEXAGONAL (CPH)

SOME COMMON UNIT CELLS

SOLIDIFICATION PROCESS OF METALS

METAL IN LIQUID STATE NO DISTINCT STRUCTURE ATOMS MOVE FREELY AMONG THEMSELVES AS MOLTEN METAL COOLS HEAT ENERGY DECREASES LESS MOBILITY OF ATOMS NEAR TO SOLIDIFICATION ATOMS ATTRACTED TOGETHER IN A DEFINITE PATTERNS THREE DIMENSIONAL LATTICE

ALSO CALLED SPACE LATTICES

CRYSTAL

CRYSTALLINE STRUCTURE

GRAINS

GRAIN BOUNDARY

ATOMS IN A CRYSTAL

POLYCRYSTALLINE SOLID

CRYSTAL IMPERFECTIONS
POINT DEFECTS

VACANCY

INTERSTITIAL IMPURITY

SUBSTITUTIONAL IMPURITY

CRYSTAL IMPERFECTIONS
LINE DEFECTS

EDGE DISLOCATION

SCREW DISLOCATION

SURFACE DEFECTS

PROPERTIES DEPENDENT ON CRYSTAL STRUCTURE AND DEFECT

PROPERTIES DEPENDENT ON
BASIC CRYSTAL STRUCTURE
DENSITY SPECIFIC HEAT COEFFICIENT OF THERMAL EXPANSION

CRYSTAL IMPERFECTION
ELECTRICAL CONDUCTIVITY YIELD STRESS CREEP

MELTING POINT
ELEASTIC CONSTANTS HARDNESS DUCTILITY

FRACTURE STRENGTH
SEMICONDUCTIVITY WORK HARDENING FATIGUE STRENGTH

DEFINITIONS
ALLOY
AN ALLOY IS A COMBINATION, EITHER IN SOLUTION OR COMPOUND, OF TWO OR MORE ELEMENTS, AT LEAST ONE OF WHICH IS A METAL, AND WHERE THE RESULTANT MATERIAL HAS METALLIC PROPERTIES.

BINARY ALLOY TERNARY ALLOY QUATERNARY ALLOY

TWO COMPONENTS THREE COMPONENTS FOUR COMPONENTS

THE RESULT IS A METALLIC SUBSTANCE WITH PROPERTIES DIFFERENT FROM THOSE OF ITS COMPONENTS.

DEFINITIONS
ALLOY
PROPERTIES OF ALLOY IS BETTER THAN ITS COMPONENTS. STEEL IS STRONGER THAN IRON BRASS IS MORE DURABLE THAN COPPER

ALLOYS DO NOT HAVE A SINGLE MELTING POINT ALLOYS HAVE MELTING RANGE IN WHICH MATERIAL IS MIXTURE OF LIQUID AND SOLID PHASES. TEMPERATURE AT WHICH MELTING BEGINS TEMPERATURE AT WHICH MELTING COMPLETE SOLIDUS LIQUIDUS

DEFINITIONS
ALLOYS
MOST METALS IN COMMON USE ARE IN THE FORM OF ALLOY SUBSTITUTIONAL SOLID SOLUTION INTERSTITIAL SOLID SOLUTION INTER-METALLIC COMPOUND

PHASE

EACH GROUPING WITH ITS OWN CRYSTALLINE STRUCTURE

MICROSTRUCTURE

OVERALL ARRANGEMENT OF GRAINS, GRAIN BOUNDARIES & PHASES PRESENT IN ALLOY

SOLID SOLUTIONS

INTERSTITIAL SOLID SOLUTION

SUBSTITUTIONAL SOLID SOLUTION

EQUILIBRIUM PHASE DIAGRAM OF Cu Ni ALLOY

1500
MELTING TEMPERATURE OF Ni = 1452O C MELTING TEMPERATURE OF Cu = 1083O C

B 1452O C

1400

LIQUID
P LIQUID + SOLID

TEMPERATURE C

1300

1200

Z Q

SOLID

1100 1083 1000 A

Ni %

25

50

75

100

Cu %

100

75

50

25

COOLING CURVE OF A PUR IRON

1537 1500

LIQUID

IRON (B.C.C.)
1400

TEMPERATURE

1200

IRON (F.C.C.)

910 900

IRON (B .C.C.)

TIME

PERCENTAGE OF CARBON
ALLOY
WROUGHT IRON

% OF CARBON
No Carbon ( < 0.08%)

LOW CARBON STEELS

MILD STEEL

0.15 % Carbon (Max) 0.25 - 1.5 % Manganese

0.15 - 0.29 % Carbon

MEDIUM CARBON STEEL

HIGH CARBON STEELS LOW ALLOY STEELS CAST IRON

0.25 - 0.50 % Carbon 0.60 - 1.65 % Manganese

0.50 - 1.03 % Carbon 0.30 - 1.00% Manganese 0.29 % Carbon (Max.) Total Metal Alloys <= 2.0 % 2.1 % Carbon

IRON CARBON EQUILIBRIUM DIAGRAM

1537 1492 1400

+L L (LIQUID)

+ +L

TEMPERATURE OC

(AUSTENITE)
1125

L + Fe3C

+
910 E 723 C
PEARLITE (EUTECTOID) CEMENTITE + PEARLITE

EUTECTIC

+ Fe3C

CEMENTITE

(FERRITE)
FERRITE + PEARLITE

+ Fe3C

C%

0.83
STEEL

2.00
CAST IRON

4.3

6.67

MICROSTRUCTURE OF PHASES OF CARBON STEEL

MICROSTRUCTURE
MICROSTRUCTURE REFERS OF THE MICROSCOPIC DESCRIPTION OF THE INDIVIDUAL CONSTITUENTS OF A MATERIAL. THE LENGTH SCALE IS 100-1 MICROMETER, WELL ABOVE THE ATOMIC LEVELS. IN METALS OR OTHER HOMOGENOUS MATERIALS, THIS IMPLIES A

UNIFORM MICROSTRUCTURE,
IN ALLOYS, SEDIMENTARY ROCKS AND BIOLOGICAL MATTER THE MICROSTRUCTURE CONTAINS ALL THE INFORMATION REGARDING THE DISTRIBUTION OF THE INDIVIDUAL CONSTITUENTS WITHIN THE MATERIAL.

MICROSTRUCTURE
FERRITE

STATE

OCCURENCE
WITH CEMENTITE IN LOW CARBON STEEL & IN WROUGHT IRON

REMARKS
IT IS ALMOST PURE IRON

- IRON

VERY SMALL AMOUNT OF DISSOLVED CARBON

SOFT, DUCTILE & WEAK

MICROSTRUCTURE
AUSTENITE

STATE

OCCURENCE

REMARKS

- IRON WITH (UP IN CARBON STEEL, IT IS IT EXISTS AT 723O C TO 1400O C

PRESENT AT TO 2%) CARBON IN NOT ROOM TEMPERATURE SOLID SOLUTION VERY SOFT & DUCTILE FOR HEAT TREATMENT, STEELS BROUGHT IN THIS STATE. ROLLING & FORGING ARE DONE IN THIS STATE.

MICROSTRUCTURE
CEMENTITE

STATE

OCCURENCE

REMARKS

Fe3C

ALONG WITH FERRITE IN HARD & BRITTLE STEELS. IMPORTANT CONSTITUENTS IT PRESENCE IN STEELS OF WHITE CAST IRON & ALONG WITH FERRITE MAKES TOOL STEEL THEM TOUGH, HARD & STRONG

MICROSTRUCTURE
PEARLITE

STATE

OCCURENCE

REMARKS

ALTERNATIVE CHIEF CONSTITUENTS OF SOFTER & MORE DUCTILE LAYERS OF ANNEALED, NORMALIZED & THAN CEMENTITE FERRITE & EUTECTOID STEEL CEMENTITE HARDER & STRONGER THAN FERRITE

MICROSTRUCTURE
MARTENSITE

STATE

OCCURENCE

REMARKS
HARD & BRITTLE. VERY LITTLE DUCTILITY

FORCED SOLUTION IN HARDENED STEEL OF CARBON IN IRON

BRINELL HARDNESS NUMBER

120 160 200 240 280 320 360

ELONGATION, PERCENTAGE

20

25

30

15

10

0.0 0.1

PIPE FORGINGS
STRUCTURAL STEEL, COLD ROLL STEEL

BOILER PLATES, SHEET STEEL, RIVETS, BOLTS,

VERY MILD & MILD STEEL

0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

ELONGATION

HYPOEUTECTOID STEEL

MACHINE PARTS, AXLES, SHAFTS , STEEL CASTINGS

LOW & MEDIUM CARBON STEEL

TENSILE STRENGTH

WOOD WORKING TOOLS, BAND SAW

EEFECT OF CARBON CONTENT ON ELONGATION, HARDNESS AND TENSILE STRENGTH OF STEEL

PERCENTAGE, CARBON
SPRINGS, METAL WORKING TOOLS, WIRES & CABLES
1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7

EUTECTOID STEEL DIES, LATHE TOOLS, ROCK DRILL

HYPEREUTECTOID STEEL

HIGH CARBON STEEL

KNIVES, SAW, FILES, RAZORS, DIES, BALL BEARING, WIRE DRAWING DIES

HARDNESS

120

15

TENSILE STRENGTH Kg / mm2

30

45

60

75

90

A SCHEMATIC VIEW OF A POWER PLANT

QUANTUM OF WELDING IN A POWER PLANT (2* 500 MW)

AREA OF WELDING
STRUCTURAL WELDING (SG, TG, CHP, ETC)

QUANTUM OF WELDING (NO. OF JOINTS)

> 10,000 Nos
PLATE MATERIAL MILD STEEL (IS 2062) PLATE THICKNESS (t)

60 mm t 6 mm

PIPE WELDING

> 10,000 Nos

PIPE MATERIAL
CARBON STEEL ALLOY STEEL STAINLESS STEEL

PIPE THK (t) mm

100 t 6 100 t 6 20 t 6

PIPE OD mm
25 d 400 25 d 400 25 d 200

INTRODUCTION TO WELDING
WELDING INVOLVES MORE SCIENCES & VARIABLES THAN ANY OTHER INDUSTRIAL PROCESS

IT IS A COMPLEX PROCESS
NUMEROUS EXAMPLES OF STRUCTURES / EQUIPMENT WHERE WELDING IS INVOLVED WORLD TALLEST BUILDING MOON ROCKET ENGINE NUCLEAR REACTORS POWER PLANTS AUTOMOBILE ETC.

INTRODUCTION TO WELDING
WELDING IS THE MOST EOCONOMIC & EFFICIENT WAY TO MAKE PERMANENT JOINT IN METALS
EXCESS METAL TO MAKE RIVETTED JOINT

WELDED JOINT

EOCONOMICAL MORE STRENGTH

INTRODUCTION TO WELDING
WELDING IS THE MOST EOCONOMIC & EFFICIENT WAY TO MAKE PERMANENT JOINT IN METALS
ECONOMICAL WELDED JOINT

EXCESS METAL TO MAKE SLEEVE JOINT IN PIPE LINE

INTRODUCTION TO WELDING
WELDING IS THE BEST WAY TO PROTECT AND CONSERVE
MATERIALS BY PROTECTING THEIR SURFACE WITH SPECIAL METAL OVERLAYS

OVERLAID PART IN CINDER CRUSHER ROLL

SPECIAL

ALLOYS

DEPOSITED

ON

BASE

METAL

TO

PROVIDE

CORROSION - RESISTANT SURFACES HARD SURFACING OVERLAYS TO MAKE WEAR RESISTANT SURFACES

INTRODUCTION TO WELDING
THERE ARE MANY WAYS TO MAKE A WELD ARC WELDING MOST POPULAR IDENTIFIED WITH SPARK DO NOT CAUSE SPARK

SOME WELDING PROCESSES IN SOME CASES

NO ELECTRICITY

WELDING HAS BECOME COMPLEX & TECHNICAL

IT REQUIRES CONSIDERABLE KNOWLEDGE TO SELECT THE PROPER WELDING PROCESS

INTRODUCTION TO WELDING ADVANTAGES OF WELDING

LOWEST COST JOINING METHOD AFFORD LIGHTER WEIGHT THROUGH BETTER UTILIZATION OF MATERIALS JOIN ALL COMMERCIAL METALS CAN BE USED ANYWHERE PROVIDE DESIGN FLEXIBILITY

LIMITATIONS
SOME WELDING DEPENDS ON HUMAN FACTOR IT OFTEN REQUIRES INTERNAL INSPECTION

INTRODUCTION TO WELDING
ALL METALS COMMERCIALLY USED FOR STRUCTURAL OR STRENGTH PARTS ARE WELDABLE. SOME METALS SOME METALS EASY TO WELD. DIFFICULT TO WELD. REQUIRES SPECIAL PROCEDURES & TECHNIQUES.

WELDABILITY
THE CAPACITY OF MATERIALS TO BE WELDED UNDER THE IMPOSED FABRICATION CONDITIONS INTO A SPECIFIC SUITABLY DESIGNED STRUCTURE AND TO PERFORM SATISFACTORILY IN THE INTENDED SERVICE.

WELDING HISTORICAL DEVELOPMENT EARLIEST EXAMPLES OF WELDING

BRONZE AGE
SMALL GOLD CIRCULAR BOXES MADE BY PRESSURE WELDING LAP JOINT
ESTIMATED 2000 YRS. AGO PRESENTLY ON EXHIBIT AT NATIONAL MUSEUM IN DUBLIN, IRELAND

IRON AGE

EGYPTIANS LEARNED TO WELD PIECES OF IRON TOGETHER TOOLS FOUND - 1000 B.C. EXHIBIT IN BRITISH MUSEUM IN LONDON

WELDING HISTORICAL DEVELOPMENT

MIDDLE AGE
BLACKSMITHING WAS DEVELOPED. IRON WELDED BY HAMMERING. IRON PILLAR OF DELHI - 310 A.D. MADE OF IRON BILLETS WELDED TOGETHER IT IS 7.6 m TALL, TOP DIA 300 mm BOTTOM DIA 400 mm TOTAL WT. = 5.4 MT SOME EXAMPLES IN EUROPE WELDING WHAT WE KNOW TODAY INVENTED DISCOVERY OF ACETYLENE EDMUND DAVY OF ENGLAND

19th CENTURY 1836

MID 19th CENTURY

ELECTRIC GENERATOR INVENTED

WELDING HISTORICAL DEVELOPMENT

LATE 19TH CENTURY GAS WELDING & CUTTING DEVELOPED RESISTANCE WELDING BECAME PRACTICAL JOINING PROCESS 1890 1900 1920 1930 ARC WELDING USING METAL ELECTRODE COATED ELECTRODE INTRODUCED AUTOMATIC WELDING INTRODUCED CONCEPT OF GTAW REFINED STUD WELDING

1948
1957 1958

GAS SHIELDED METAL ARC WELDING

PLASMA ARC WELDING,ELECTRON BEAM ELECTROSLAG WELDING

LATEST

LASER BEAM WELDING

DEFINITIONS WELDING PROCESSES & GROUPING

PROCESS

A DISTINCTIVE PROGRESSIVE ACTION OR SERIES OF ACTION

INVOLVED IN THE COURSE OF PRODUCING A BASIC TYPE OF RESULT

AWS HAS GROUPED THE PROCESSES TOGETHER ACCORDING TO MODE OF HEAT TRANSFER AS PRIMARY CONSIDERATION.

SECONDARY FACTOR IS INFLUENCE OF CAPILLARY ATTRACTION

IT DISTINGUISHES BRAZING, SOLDERING FROM ARC WELDING, GAS WELDING OR RESISTANCE WELDING

AWS MASTER CHART OF WELDING & ALLIED PROCESSES

ARC WELDING (AW) BRAZING (B)

SOLID STATE WELDING (SSW)

SOLDERING (S)

WELDING PROCESSES

OTHER WELDING

RESISTANCE WELDING (RW)

OXYFUEL GAS WELDING (OFW)

AWS MASTER CHART OF WELDING & ALLIED PROCESSES

THERMAL SPRAYING (THSP)

ALLIED PROCESSES

ADHESIVE BONDING (ABD)

OXYGEN CUTTING (OC)

THERMAL CUTTING (TC)

ARC CUTTING (AC)

OTHER CUTTING

POPULAR WELDING PROCESSES & LETTER DESIGNATIONS

GROUP
ARC WELDING

WELDING PROCESS
CARBON ARC ELECTRO GAS FLUX - CORED ARC GAS METAL ARC PLASMA ARC SHIELDED METAL ARC STUD ARC SUBMERGED ARC OXYACETYLENE WELDING OXYHYDROGEN WELDING

DESIGN.
CAW EGW FCAW GMAW PAW SMAW SW SAW OAW OHW

OXYFUEL GAS WELDING

RESISTANCE FLASH WELDING WELDING PROJECTION WELDING SEAM WELDING SPOT WELDING UPSET WELDING

FW RPW RSEW RSW UW

POPULAR WELDING PROCESSES & LETTER DESIGNATIONS

GROUP

WELDING PROCESS

DESIGN.
CW DFW EXW FOW FRW HPW ROW UW EBW ESW FLOW IW LBW PEW TW

SOLID STATE COLD WELDING WELDING DIFFUSION WELDING EXPLOSION WELDING FORGE WELDING FRICTION WELDING HOT PRESSURE WELDING ROLL WELDING ULTRASONIC WELDING OTHER ELECTRON BEAM WELDING ELECTROSLAG PROCESSES FLOW INDUCTION LASER BEAM PERCUSSION THERMIT

METHODS OF APPLYING WELDING

MANUAL
WELDING WITH TORCH, GUN OR ELECTRODE HOLDER HELD AND MANIPULATED BY HAND.

SEMI AUTOMATIC
MANUAL WELDING WITH EQUIPMENT THAT AUTOMATICALLY CONTROLS ONE OR MORE OF WELDING CONDITIONS.

METHODS OF APPLYING WELDING

MECHANISED
WELDING WITH EQUIPMENT THAT REQUIRES MANUAL ADJUSTMENT OF THE EQUIPMENT CONTROLS IN RESPONSE TO VISUAL OPERATION OF THE WELDING WITH THE TORCH MOUNTED GUN OR ELECTRODE HOLDER HELD BY A MECHANICAL DEVICE.

AUTOMATIC
NO MANUAL ADJUSTMENT OF THE EQUIPMENT CONTROLS

METHODS OF APPLYING WELDING

ARC WELDING ELEMENTS/FUNCTION MANUAL SEMI MECHANIZED AUTOMATIC AUTOMATIC

Start & maintain the arc Feeds the Electrode into the arc Control the heat for proper penetration Moves the arc along the joint (travels) Guide the arc along the joint

Person Person Person Person Person

Machine Machine Person Person Person

Machine Machine Machine Machine Person

Machine Machine Machine Machine Machine prearrange d path Machine Does not correct

Manipulates the torch Person to direct the arc Corrects the arc to overcome deviations Person

Person Person

Person Person

METHODS OF APPLYING WELDING

WELDING OR CUTTING PROCESS MANUAL SEMI MECHANIZED AUTOMATIC AUTOMATIC

GAS METAL ARC FLUX CORED ARC GAS TUNGUSTEN ARC PLASMA ARC SUBMERGED ARC SHIELDED METAL ARC OXYFUEL GAS

Not possible Not possible Most Popular Popular Not possible Most Popular Most Popular

Most Popular Most Popular Possible rare Not Used Little Used Not Used Not Used

Used Used Used Used Most Popular Not Used Little Used

Popular Popular Used Used Popular Not Used Little Used

FUNDAMENTALS OF WELDING
DEFINITIONS
To understand welding, it is necessary To be familiar with the basic terms used by the industry.

WELDING
A joining process that produces coalescence of materials by heating them to the welding temperature, with or without the application of pressure or by the application of pressure alone, and with or without the use of filler metal
It is used to make welds.

FUNDAMENTALS OF WELDING WELD

A localized coalescence of metals or non-metals produced either by heating materials to the welding temperature, with or without application of pressure, or by the application of pressure alone and with or without the use of filler metal.

COALESCENCE
Coalescence means the growing together or growth into one body of materials being welded.

FUNDAMENTALS OF WELDING
WELDMENT
An assembly, whose component parts are joined by welding. Can be made of May contain many or few metal parts metals of different Compositions,

Pieces may be
Example -

in the form of sheet, plate, pipe etc.

All welded ship, A skyscraper, Bicycle frame, etc.

FUNDAMENTALS OF WELDING JOINT

Junction of members or the edges of members

that are to be joined or have been joined

FIVE BASIC TYPES OF THE JOINT BUTT JOINT Two parts in approximately the same plane

FUNDAMENTALS OF WELDING
CORNER JOINT Two parts located approx. at right angle to each other

T - JOINT Parts approximately at right angles in the form of T

FUNDAMENTALS OF WELDING
LAP JOINT Between overlapping parts in parallel plane

EDGE JOINT Between the edge of two or more parallel parts.

FUNDAMENTALS OF WELDING
DIFFERENT TYPES OF WELDS
They are best described by their shapes

FILLET WELD A weld of approximately triangular cross - section joining two surfaces approximately at right angle to each other.

FUNDAMENTALS OF WELDING
GROOVE WELD A weld made in the groove between two members joined.

FLANGE WELD

Primarily used for light gauge or sheet metal joint

DIFFERENT TYPES OF WELDS

TYPE OF WELD
FILLET WELD POPULAR MOST

SYMBOL

FIGURE

CAN BE SINGLE /DOUBLE

PLUG OR SLOT WELD

USED WITH PREPARED HOLE PLUG WELD ROUND HOLE SLOT WELD ELONGATED HOLE

SPOT OR PROJECTION WELD

USED WITH OUT PREPARED HOLE USE ARC OR RESISTANCE

DIFFERENT TYPES OF WELDS

TYPE OF WELD
SEAM WELD
CONTINUOUS, RESISTANCE USE ARC OR

SYMBOL

FIGURE

GROOVE WELD MOST POPULAR

CAN BE SINGLE OR DOUBLE HAVE MANY VARIATIONS

BACK OR BACKING WELD

BEAD TYPE BACK OR BACKING WELD OF SINGLE GROOVE WELD

DIFFERENT TYPES OF WELDS

TYPE OF WELD
SURFACE WELD
SURFACE BUILD UP BY WELDING

SYMBOL

FIGURE

FLANGE WELD
USED FOR LIGHT GAGE METAL JOINTS

STUD WELD
SPECIAL APPLICATION WELDING PROCESS

JOINT EDGE PREPARATION

Why is edge preparation done?

TO PROVIDE ACCESS TO JOINT INTERIOR HELP IN PROPER FUSION

How the edge preparation done ?

BY FLAME CUTTING PLASMA ARC CUTTING GRINDING

EDGE SHAPES
Square Edge Shape

Single - Bevel Edge Shape

Double - Bevel Edge Shape Single - J Groove Edge Shape

Double - J Groove Edge Shape

EDGE PREPARATION TERMINOLOGY

BEVEL DEPTH GROOVE ANGLE

BEVEL ANGLE

ROOT FACE SIZE

ROOT OPENING

V - GROOVE JOINT

SELECTION OF JOINT PREPARATION

What determines which joint preparation geometry to use?

Kind of joint loads (Tension, Compression, etc) Level of Joint Loading Static or Dynamic loading Thickness & Type of Metal Joined Welding Position One side/ both sides access to the weld Skills of the welders

PARTS OF THE GROOVE WELD

TERMS USED TO DESCRIBE THE PARTS OF A GROOVE WELD

LEG OR SIZE OF THE WELD

FACE TOE REINFORCEMENT ROOT PENETRATION

GROOVE WELD

FACE

REINFORCEMENT

TOE

TOE

DEPTH OF FUSION WELD SIZE (leg)

FUSION FACE
FUSION ZONE

WELD INTERFACE ROOT

ROOT REINFORCEMENT

PARTS OF THE FILLET WELD

TERMS USED TO DESCRIBE THE PARTS OF A FILLET WELD

LEG OR SIZE OF THE WELD

FACE TOE REINFORCEMENT ROOT PENETRATION ACTUAL THROAT & THEORETICAL THROAT

FILLET WELD
TOE WELD INTERFACE ACTUAL THROAT

WELD SIZE (Leg) TOE

THEORETICAL THROAT

ROOT

WELD FUSION FACE DEPTH OF FUSION

FUSION ZONE

WELDING TERMINOLOGY
AXIS OF THE WELD
AN IMAGINARY LINE DRAWN PARALLEL TO THE WELD BEAD THROUGH THE CENTER OF THE WELD.

TRAVEL ANGLE
SMALLEST ANGLE FORMED BETWEEN THE

ELECTRODE AND THE AXIS OF THE WELD

WORK ANGLE
THE SMALLEST ANGLE FORMED BY A PLANE, DEFINED BY THE ELECTRODE AND THE AXIS OF THE WELD, AND THE WORK PIECE.

WELDING TERMINOLOGY
PUSH ANGLE DURING FOREHAND WELDING
TRAVEL ANGLE, WHEN THE ELECTRODE IS POINTING TOWARDS THE DIRECTION OF WELD PROGRESSION

DRAG ANGLE DURING BACKHAND WELDING

TRAVEL ANGLE, WHEN THE ELECTRODE IS POINTING AWAY FROM THE DIRECTION OF WELD PROGRESSION

WELDING TERMINOLOGY

WELDING POSITIONS
FLAT POSITION 1G HORIZONTAL POSITION 2G

PLATE - VERTICAL AXIS OF WELD - HORIZONTAL

PLATE & AXIS OF WELD - HORIZONTAL

FLAT POSITION 3G

OVERHEAD POSITION 4G

PLATE - VERTICAL AXIS OF WELD - VERTICAL

PLATE & AXIS OF WELD - HORIZONTAL

WELDING POSITIONS FOR GROOVE WELD :- PLATE

WELDING POSITIONS
FLAT POSITION 1F HORIZONTAL POSITION 2F

AXIS OF WELD HORIZONTAL AXIS OF WELD HORIZONTAL

VERTICAL POSITION 3F

OVERHEAD POSITION 4F

AXIS OF WELD VERTICAL

AXIS OF WELD HORIZONTAL

WELDING POSITIONS FOR FILLET WELD :- PLATE

WELDING POSITIONS
PIPE POSITION FLAT 1G PIPE POSITION HORIZONTAL 2G

AXIS OF CYLINDER VERTICAL AXIS OF CYLINDER HORIZONTAL PIPE SHALL BE TURNED WHILE WELDING

PIPE POSITION HORIZONTAL FIXED 5G V

PIPE POSITION 6G

450 50

AXIS OF PIPE AT 450 AXIS OF CYLINDER HORIZONTAL PIPE SHALL NOT BE TURNED OR ROLLED WHILE WELDING

WELDING POSITIONS FOR GROOVE WELD :- PIPE

WELD SYMBOLS
GROOVE WELD
FILLET SCARF V BEVEL U

FLARE V

FLARE BEVEL

WELD SYMBOLS

FILLET

PLUG OR SLOT

STUD

SPOT OR
PROJECTION

SEAM

BACK OR BACKING

SURFACING

EDGE

WELDING SYMBOL
FINISH SYMBOL GROOVE WELD SIZE CONTOUR SYMBOL DEPTH OF BEVEL; SIZE OR SRENGTH OF CERTAIN WELDS SPECIFICATION; PROCESS OR OTHER REFERENCE GROOVE ANGLE; INCLUDED COUNTERSUNK IN PLUG WELD ROOT OPENING; DEPTH OF FILLING IN PLUG WELD LENGTH WELD PITCH WELD FIELD SYMBOL OF

OF

THE

F A R

OF

THE

WELD

S (E)
T
TAIL (MAY BE OMMITTED WHEN REFERENCE IS NOT USED.) WELD SYMBOLS

L-P

WELD ALL AROUND SYMBOL

(N)

REFERENCE LINE
ARROW CONNECTING REFERENCE LINE TO ARROW SIDE OF THE MEMBER OR ARROW SIDE OF THE JOINT

NO. OF SPOT, SEAM, STUD, PLUG,SLOT OR PROJECTION WELD ELEMENTS IN THIS AREA REMAIN AS SHOWN WHEN TAIL AND ARROW ARE REVERESED WELD SYMBOLS SHALL BE CONTAINED WITH IN LENGTH OF REFERENCE LINE

WELDING SYMBOL - EXAMPLES

DESIRED WELD

LEFT SIDE VIEW

FRONT VIEW

ARROW SIDE V - GROOVE WELD SYMBOL

DESIRED WELD

LEFT SIDE VIEW

FRONT VIEW

OTHER SIDE V - GROOVE WELD SYMBOL

DESIRED WELD

LEFT SIDE VIEW

FRONT VIEW

BOTH SIDE V - GROOVE WELD SYMBOL

WELDING SYMBOL - EXAMPLES

OTHER SIDE ARROW SIDE ARROW SIDE ARROW SIDE OTHER SIDE OTHER SIDE ARROW SIDE

OTHER SIDE

OTHER SIDE ARROW SIDE

OTHER SIDE

WELDING SYMBOL - EXAMPLES

ARROW SIDE

OTHER SIDE

WELD CROSS SECTION

SYMBOL

ARROW SIDE

WELD CROSS SECTION

OTHER SIDE

SYMBOL

OTHER SIDE

ARROW SIDE

WELD CROSS SECTION

SYMBOL

ARROW SIDE

OTHER SIDE

WELD CROSS SECTION

SYMBOL

WELDING SYMBOL - EXAMPLES

ARROW SIDE

OTHER SIDE

WELD CROSS SECTION

SYMBOL

ARROW SIDE

WELD CROSS SECTION

OTHER SIDE

SYMBOL

OTHER SIDE

ARROW SIDE

WELD CROSS SECTION

SYMBOL

ARROW SIDE

OTHER SIDE

WELD CROSS SECTION

SYMBOL

WELDING SYMBOL - EXAMPLES

4 4 2-4

4 2-4

LENGTH AND PITCH OF CHAIN INTERMITTENT WELD

WELDING SYMBOL - EXAMPLES

DESIRED WELD

SYMBOL

ENTIRE SURFACE BUILD UP BY WELDING

SHIELDED METAL ARC WELDING

AWS DESIGNATION
COMMON NAMES

SMAW
ARC WELDING, STICK WELDING, STICK ELECTRODE WELDING

DEFINITION
AN ARC WELDING PROCESS WITH AN ARC BETWEEN A COVERED ELECTRODE AND THE WELD POOL. SHIELDING IS DONE FROM THE DECOMPOSITION OF THE ELECTRODE COVRERING, WITHOUT THE APPLICATION OF PRESSURE AND WITH FILLER METAL FROM ELECTRODE.

SHIELDED METAL ARC WELDING

EQUIPMENT SET-UP

WELDING POWER SUPPLY UNIT ELECTRODE HOLDER, LEAD & ITS TERMINAL GROUND CLAMP, LEAD & ITS TERMINALS WELDING ELECTRODES

SHIELDED METAL ARC WELDING

HOW DOES THE SMAW PROCESS WORK ?

SMAW is a manual process.

ELECTRIC CIRCUIT is established between the Welding Power Supply, Electrode, Arc, Work Electrons flowing through the gap between electrode and the work - produces an ARC

Arc furnishes HEAT to melt both electrode & base metal

TEMPERATURE within arc > 3300o C Tiny Globules of metal forms at the tip of electrode

SHIELDED METAL ARC WELDING

METAL TRANSFER IN SMAW

BY GRAVITY BY GAS EXPANSION

BY ELECTROMAGNETIC FORCES
BY SURFACE TENSION

SHIELDED METAL ARC WELDING

ELECTRODE IS COATED WITH FLUX HEAT CAUSES FLUX COMBUSTION & DECOMPOSITION GASEOUS SHIELD TO PROTECT TIP, WORK & MOLTEN POOL

SHIELDED METAL ARC WELDING

FLUX CONTAIN METAL POWDER TO

PROVIDE ADDITIONAL HEAT INCREASE DEPOSITION RATE ENHANCE WELD PROPERTIES

METALS WELDABLE BY SMAW

BASE METAL
ALUMINIUM BRONZE COPPER COPPER NICKEL CAST & MALLEABLE IRON WROUGHT IRON INCONEL NICKEL MONEL LOW CARBON STEEL LOW ALLOY STEEL HIGH & MEDIUM CARBON STEEL ALLOY STEEL STAINLESS STEEL

WELDABLE BY SMAW
POSSIBLE BUT NOT POPULAR WELDABLE POSSIBLE BUT NOT POPULAR WELDABLE WELDABLE WELDABLE WELDABLE WELDABLE WELDABLE WELDABLE WELDABLE WELDABLE WELDABLE WELDABLE

SHIELDED METAL ARC WELDING

Range of Thickness Range of Current Open Circuit Voltage Voltage Across Arc 3.2 mm to 200 mm 25 - 600 Amp 50 - 100 Volts 17 - 40 Volts

SHIELDED METAL ARC WELDING

POLARITY
STRAIGHT POLARITY

CONNECTION OF ELECTRODE WORK PIECE

NEGATIVE POSITIVE

CHARACTERISTICS
MORE HEAT LIBERATED IN NEGATIVE POLE ELECTRODE MELTS OFF FASTER

ALSO CALLED ELECTRODE NEGATIVE (DCEN)

SHIELDED METAL ARC WELDING

POLARITY
REVERSE POLARITY

CONNECTION OF
ELECTRODE POSITIVE WORK PIECE NEGATIVE

CHARACTERISTICS
RESULTS IN DEEPER PENETRATION ALSO CALLED ELECTRODE POSITIVE (DCEP)

SHIELDED METAL ARC WELDING

Type of Currents AC DCEN or DCSP DCEP or DCRP

DCEN

AC

DCEP

EFFECT OF WELD BEAD PENETRATION AT SAME WELDING CURRENT

SHIELDED METAL ARC WELDING

ADVANTAGES

LOW COST EQUIPMENT CAN WELD MANY DIFFERENT METAL RELATIVELY PORTABLE & USEFUL IN CONFINED SPACE

WELD CAN BE PERFORMED IN ANY POSITION

SAME EQUIPMENT WELD VARIOUS THICKNESS

SHIELDED METAL ARC WELDING

DISADVANTAGES

NOT SUITABLE FOR THK < 2 MM LOW OPERATOR DUTY CYCLE & OVERALL DEPOSITION RATE NOT ALL ELECTRODE CAN BE USED MORE CHANCES OF DEFECT BECAUSE OF FREQUENT START STOP

GAS METAL ARC WELDING

AWS DESIGNATION COMMON NAMES GMAW MIG WIRE FEED WELDING

DEFINITION
AN ARC WELDING PROCESS THAT USES AN ARC BETWEEN
CONTINUOUS FILLER METAL ELECTRODE AND THE WELD POOL. SHIELDING IS DONE FROM AN EXTERNALLY

SUPPLIED

GAS

AND

WITHOUT

THE

APPLICATION

OF

PRESSURE.

GAS METAL ARC WELDING

EQUIPMENT SET-UP

WELDING POWER SUPPLY UNIT PRESSURE REGULATOR (FOR SHIELDING GASES) COMPRESSED GAS CYLINDERS

WIRE FEEDER WELDING GUN

GAS METAL ARC WELDING

HOW DOES THE GMAW PROCESS WORK ?

TRIGGER TURNS ON WELDING POWER SUPPLY.

ARC BETWEEN ELECTRODE WIRE & WORK

ARC FURNISHES HEAT TO MELT BOTH THE ELECTRODE WIRE TIP & BASE METAL
WIRE FEEDING MECHANISM ELECTRONICALLY OPERATED VALVE, REGULATOR, OPENS & FEEDS SHIELDING GAS WELDER CAN MANIPULATE THE GUN & LAY DOWN THE WELD IN DESIRED PATTERN

GAS METAL ARC WELDING

Applications What metals can GMAW weld ?

Aluminum

Carbon Steel Copper Low Alloy Steels Magnesium Nickel Stainless Steels Titanium

Thickness Range

0.13 mm & above

GAS METAL ARC WELDING

Joint Design GMAW & SMAW

Same Joint Design

For Maximum Economy & Efficiency, Groove Weld should be modified.

600 450

SMAW

GMAW

GAS METAL ARC WELDING

Shielding Gas
What gases are commonly used for GMAW shielding ?

Ar + CO2 Ar Ar + He Ar + O2 CO2 He He + Ar + CO2 CO2 is commonly used on Mild Steel for Min. Cost 75% CO2 + 25% Ar used for general Welding of CS & Low AS

GAS METAL ARC WELDING

Welding Variables
Major Welding Variables affecting penetration, bead shape & Weld Quality

Always DCRP polarity

Arc Voltage Electrode Diameter Electrode Extension Electrode Orientation Shielding Gas Travel Speed Welding Current Wire Feed Rate

GAS TUNGSTEN ARC WELDING

AWS DESIGNATION
COMMON NAMES

GTAW
TIG WELDING HELIARC (DURING DEVELOPMENT) WIG (WOLFRAM INERT GAS) ( IN EUROPE)
WOLFRAM GERMAN NAME OF TUNGSTEN

DEFINITION
AN ARC WELDING PROCESS THAT USES AN ARC BETWEEN A TUNGSTEN ELECTRODE (NON-CONSUMABLE) AND THE WELD POOL. SHIELDING IS DONE FROM AN EXTERNALLY

SUPPLIED

GAS

AND

WITHOUT

THE

APPLICATION

OF

PRESSURE. FILLER METAL MAY OR MAY NOT USED.

GAS TUNGSTEN ARC WELDING

EQUIPMENT SET-UP

WELDING POWER SUPPLY UNIT TUNGSTEN ELECTRODE GTAW TORCH & ASSOCIATED CABLES

PRESSURE REGULATOR FOR SHIELDING GAS COMPRESSED AIR CYLINDERS

GAS TUNGSTEN ARC WELDING

How does the GTAW process work ?

CONTINUOUS ARC BETWEEN ELECTRODE WIRE & WORK INTENSE HEAT OF THE ARC APPROX. 5500O C IT MELTS BOTH THE FILLER WIRE TIP & BASE METAL

INERT GAS IS SUPPLIED THROUGH THE TORCH

ON THINNER METALS, EDGE JOINT & FLANGE JOINT - NO FILLER IS ADDED LESS SPATTER, LITTLE OR NO SMOKE

METALS WELDABLE BY GTAW

BASE METAL
ALUMINIUM BRONZE COPPER COPPER NICKEL CAST & MALLEABLE IRON WROUGHT IRON INCONEL NICKEL MONEL LOW CARBON STEEL LOW ALLOY STEEL HIGH & MEDIUM CARBON STEEL ALLOY STEEL STAINLESS STEEL

WELDABLE BY GTAW
WELDABLE WELDABLE WELDABLE WELDABLE POSSIBLE, BUT NOT POPULAR POSSIBLE, BUT NOT POPULAR WELDABLE WELDABLE WELDABLE WELDABLE WELDABLE WELDABLE WELDABLE WELDABLE

GAS TUNGSTEN ARC WELDING

Range of Thickness 0.13 mm to 51 mm

Range of Current
Range of Voltage

1 - 1000 Amp
10 - 40 Volts

Shape of the Arc

Polarity Used

Inverted Funnel
DCEN DCEP AC

GAS TUNGSTEN ARC WELDING

Since the arc temperature is well above the melting point of the tungsten GTAW Electrode, Why doesnt the electrode melt ? Very Small amount of electrode does melt & ends up in the weld.
The electrode resists melting because

Tungsten is having Highest Melting Point of all metals - 3420 o C Tungsten has High Thermal Conductivity Torch Collets are designed to remove heat from the electrodes

GAS TUNGSTEN ARC WELDING

ELECTRODE
+ + + + + + + + + -

WORK PIECE

DCEN
HEAT BALANCE PENETRATION 70% AT WORK END 30% AT ELECTRODE DEEP, NARROW

DCEP
30% AT WORK END 70% AT ELECTRODE SHALLOW, WIDE

AC
50% AT WORK END 50% AT ELECTRODE MEDIUM

GAS TUNGSTEN ARC WELDING

Shielding Gas
What gases are commonly used for GTAW shielding ?

Helium - 99.99 % purity (minimum) Argon - 99.95 % purity (minimum)

Joint Design
More or less same as SMAW

GAS TUNGSTEN ARC WELDING

Welding Variables
Major Welding Variables affecting penetration, bead shape & Weld Quality

Arc polarity

Arc Current Size of part to be welded Thermal Conductivity of the part Shielding Gas Travel Speed

GAS TUNGSTEN ARC WELDING

ADVANTAGES

HIGH QUALITY WELD IN ALMOST ALL METALS & ALLOYS.

VERY LITTLE, IF ANY, POST WELD CLEANING IS REQUIRED. VERY LITTLE OR NO SPATTER

WELDING CAN BE PERFORMED IN ALL POSITIONS

REDUCTION OF SMOKE & FUEL NO SLAG PRODUCED JOINS DISSIMILAR METALS

GAS TUNGSTEN ARC WELDING

DISADVANTAGES

REQUIREMENT OF HIGHER SKILL

LOWER DEPOSITION RATE

EQUIPMENT MORE COMPLEX & EXPENSIVE

GAS TUNGSTEN ARC WELDING

INDUSTRIAL USE AND TYPICAL APPLICATIONS
AIRCRAFT INDUSTRY
SPACE VEHICLE SHELL WELDING STRUCTURE WELDING WELDING INVOLVED IN VARIOUS TANKS THOUSANDS OF METER OF TUBING INVOLVED IN ROCKET ENGINE.

SMALL DIAMETER THIN WALL TUBING

ROOT PASS WELDING IN PIPING

WELDING OF THIN MATERIAL - VIRTUALLY EVERY INDUSTRY REPAIR OF TOOLS & DIES REPAIR ALUMINUM & MAGNESIUM PARTS

REPAIR OF HIGHLY CRITICAL ITEM.