Welding Processes

Ship Structures

A Brief History of Welding

Late 19th Century
Scientists/engineers apply advances in electricity to heat
and/or join metals (Le Chatelier, Joule, etc.)
Early 20th Century
Prior to WWI welding was not trusted as a method to join two
metals due to crack issues
1930s and 40s
Industrial welding gains acceptance and is used extensively
in the war effort to build tanks, aircraft, ships, etc.
Modern Welding
the nuclear/space age helps bring welding from an art to a
science

Types of Welding
Fusion Welding
Homogeneous
Gas Welding
Electroslag
High Energy Beam
Electric Arc

Pressure Welding

Heterogeneous
Brazing

Friction Welding

Soldering
MIG
TIG
Shielded Metal Arc Stick

Weldability of a Metal
Metallurgical Capacity
Parent metal will join with the weld metal without
formation of deleterious constituents or alloys

Mechanical Soundness
Joint will be free from discontinuities, gas porosity,
shrinkage, slag, or cracks

Serviceability
Weld is able to perform under varying conditions
or service (e.g., extreme temperatures, corrosive
environments, fatigue, high pressures, etc.)

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

SMAW Shielded Metal Arc Welding

Welding Processes

Consumable electrode
Flux coated rod
Flux produces protective gas around weld pool
Slag keeps oxygen off weld bead during cooling

General purpose weldingwidely used

Thicknesses 1/8 3/4
Portable

Power... Current I (50 - 300 amps)

Voltage V (15 - 45 volts)
Power = VI 10 kW

Electric Arc Welding -- Polarity

Welding Processes

SMAW - DC Polarity
Straight Polarity

Reverse Polarity

()
(+)
Shallow penetration
(thin metal)

AC - Gives pulsing arc

- used for welding thick sections

(+)
()
Deeper weld penetration

GMAW Gas Metal Arc Welding (MIG)

Welding Processes

DC reverse polarity - hottest arc

AC - unstable arc

Gas Metal Arc Welding (GMAW) Torch

MIG - Metal Inert Gas

Consumable wire electrode
Shielding provided by gas
Double productivity of SMAW
Easily automated

Groover, M., Fundamentals of Modern Manufacturing,, p. 734, 1996

SAW Submerged Arc Welding

Welding Processes

300 2000 amps (440 V)

Consumable wire electrode

Gas Metal Arc Welding (GMAW) Torch

Shielding provided by flux granules

Low UV radiation & fumes
Flux acts as thermal insulator
Automated process (limited to flats)
High speed & quality (4 10x SMAW)
Suitable for thick plates

http://www.twi.co.uk

GTAW Gas Tungsten Arc Welding (TIG)

Welding Processes

Current I (200 A DC)

(500 A AC)
Power 8-20 kW

a.k.a. TIG - Tungsten Inert Gas

Non-consumable electrode
With or without filler metal
Shield gas usually argon
Used for thin sections of Al, Mg, Ti.
Most expensive, highest quality

Weld Metal Protection

During fusion welding, the molten metal in the
weld puddle is susceptible to oxidation
Must protect weld puddle (arc pool) from the
atmosphere
Methods
Weld Fluxes
Inert Gases
Vacuum

Weld Fluxes
Typical fluxes
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

Inert Gases
Argon, helium, nitrogen, and carbon
dioxide
Form a protective envelope around the
weld area
Used in
MIG
TIG
Shield Metal Arc

Vacuum
Produce high-quality welds
Used in electron beam welding
Nuclear/special metal applications
Zr, Hf, Ti

Reduces impurities by a factor of 20

versus other methods
Expensive and time-consuming

Types of Fusion Welding

Oxyacetylene Cutting/Welding
Shielded Metal Arc (Stick)
Metal Inert Gas (MIG)
Tungsten Inert Gas (TIG)

Oxyacetylene Welding
Flame formed by burning a mix of acetylene
(C2H2) and oxygen
TORCH TIP

Inner Cone: 5000-6300 deg F

2300 deg F

Combustion Envelope 3800 deg F

Fusion of metal is achieved by passing the

inner cone of the flame over the metal
Oxyacetylene can also be used for cutting
metals

Shielded Metal Arc (Stick)

An electric arc is generated between a coated
electrode and the parent metal
The coated electrode carries the electric
current to form the arc, produces a gas to
control the atmosphere and provides filler
metal for the weld bead
Electric current may be AC or DC. If the
current is DC, the polarity will affect the weld
size and application

Shielded Metal Arc (cont)

Process:
Intense heat at the arc melts the tip of the
electrode
Tiny drops of metal enter the arc stream and are
deposited on the parent metal
As molten metal is deposited, a slag forms over
the bead which serves as an insulation against air
contaminants during cooling
After a weld pass is allowed the cool, the oxide
layer is removed by a chipping hammer and then
cleaned with a wirebrush before the next pass.

Inert Gas Welding

For materials such as Al or Ti which
quickly form oxide layers, a method to
place an inert atmosphere around the
weld puddle had to be developed

Metal Inert Gas (MIG)

Uses a consumable electrode (filler wire made of the
base metal)
Inert gas is typically Argon
CONSUMABLE
ELECTRODE

DRIVE WHEELS

POWER
SOURCE

SHIELDING GAS

BASE METAL

ARC COLUMN

PUDDLE

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
TUNGSTEN
ELECTRODE
POWER
SOURCE

TUNGSTEN
ELECTRODE

(CATHODE)

++
SHIELDING GAS

BASE METAL

ARC COLUMN

PUDDLE

++

--BASE METAL (ANODE)

Welding Positions
INCREASING DIFFICULTY

FLAT
HORIZONTAL

VERTICAL

OVERHEAD

Weld Defects
Undercuts/Overlaps

Grain Growth
A wide T will exist between base metal and HAZ.
Preheating and cooling methods will affect the brittleness of
the metal in this region

Blowholes
Are cavities caused by gas entrapment during the
solidification of the weld puddle. Prevented by proper weld
technique (even temperature and speed)

Weld Defects
Inclusions
Impurities or foreign substances which are forced into the weld
puddle during the welding process. Has the same effect as a
crack. Prevented by proper technique/cleanliness.

Segregation
Condition where some regions of the metal are enriched with an
alloy ingredient and others arent. Can be prevented by proper
heat treatment and cooling.

Porosity
The formation of tiny pinholes generated by atmospheric
contamination. Prevented by keeping a protective shield over the
molten weld puddle.

Residual Stresses
Rapid heating and cooling results in thermal stresses
detrimental to joint strength.
Prevention
Edge Preparation/Alignment beveled edges and space
between components to allow movement
Control of heat input skip or intermittent weld technique
Preheating reduces expansion/contraction forces (alloys)
and removes moisture from the surface
Peening help metal stretch as it cools by hitting with a
hammer. Use with care since it may work harden the metal
Heat Treatment soak the metal at a high temperature to
relieve stresses
Jigs and Fixtures prevent distortion by holding metal fixed
Number of Passes the fewer the better.

Joint Design

BUTT JOINT
FILLET JOINT
STRAP JOINT

LAP JOINT

CORNER JOINT

Generalized Welding Symbol

FAR SIDE DETAILS

Field weld symbol

Weld Geometry

Electrode
Material

L1-L2

L1-L2

ARROW SIDE DETAILS

Weld all-around for

pipes, etc.

D = Weld Depth (usually equal to plate thickness)

L1 = Weld Length
L2 = Distance between centers for stitched welds

The Field Weld Symbol is a guide for installation. Shipyards

normally do not use it, except in modular construction.

Example Welding Symbol

Geometry symbol for V-groove
One-sided welds are max 80% efficient
Two sided are 100% efficient
1/2

1/2

1/2

1/2

Weld Symbols (Butt Joints)

Backing

Weld Symbol (Fillet Joints)

Weld Symbol (Corner Joints)

Solid-State Welding Processes

Cold Welding
Pressure is applied to the
workpieces through dies or
rolls
Preferably both work pieces
should be ductile
The work pieces should
cleaned thoroughly
Fig: The roll bonding or cladding process

Can not join dissimilar

metals

Ultrasonic Welding
Surfaces of the two
components are
subjected to a static
forces and oscillating
shearing force
Produces a strong,
solid-state bond
Versatile and reliable
for joining metals

Fig: a) Components of an ultrasonic welding machine for

lap welds.The lateral vibration of the tool tip cause
plastic deformation and bonding at the interface of
the work piece b)Ultrasonic some welding using a
roller c)An ultrasonically welded part

Friction Welding
Developed in the 1940s
Parts are circular in shape
Can be used to join a wide variety of materials

Fig: Sequence of operation in the friction welding process 1)Left-hand component is rotated at high speed. 2)
Right-hand component is brought into contact under an axial force 3)Axial force is increased;the flash begins to
form 4) Left-hand component stops rotating;weld is completed.The flash can subsequently be removed by
machining or grinding

Friction Welding
Process can be fully automated
Can weld solid steel bars up to 250mm in outside diameter

Fig:Shape of friction zone in friction welding,as a function of the force applied and the rotational speed

Inertia Friction Welding

Modification of Friction Welding
Energy is supplied by a fly wheel
The parts are pressed together by a normal force
As friction at the interface increases, the fly wheel slows down
The weld is completed when the flywheel stops

Fig : The principle of the friction stir welding

process. Aluminum-alloy plates up to 75mm
(3in) thick have been welded by this process

Linear Friction Welding

Parts are joined by a linear reciprocating motion
Parts do not have to be circular or tubular
In this application, one part is moved across the face
of the other part using a balanced reciprocating
mechanism

Friction Stir Welding (FSW)

New Process for welding aerospace metals
Research is being directed towards using this
process for polymers
FSW uses a 3rd nonconsumable tool inserted
between the two bodies to heat the material to
be joined

Resistance Welding
Developed in the early 1900s
A process in which the heat required for welding is
produced by means of electrical resistance across the
two components
RW does not requiring the following:
Consumable electrodes
Shield gases
Flux

Resistance Spot Welding

RSW uses the tips of two opposing solid cylindrical electrodes
Pressure is applied to the lap joint until the current is turned
off in order to obtain a strong weld

Fig: (a) Sequence in the resistance spot welding

Resistance Spot Welding

Surfaces should be clean
Accurate control of and timing of electric current and of pressure
are essential in resistance welding

Fig: b)Cross-section of a spot weld,showing the

weld nugget and the indentation of the
electrode on the sheet surfaces.This is one
of the most commonly used process in
sheet-metal fabrication and in automotivebody assembly

Resistance Seam Welding

RSEM is modification of spot welding wherein the electrodes are
replaced by rotating wheels or rollers
The electrically conducting rollers produce a spot weld
RSEM can produce a continuous seam & joint that is liquid and gas
tight

Fig : (a) Seam-Welding Process in which rotating rolls act as electrode (b)
Overlapping spots in a seam weld. (c) Roll spot weld (d) Resistance-welded gasoline tank

Resistance Projection Welding

RPW is developed
by introducing high
electrical resistance
at a joint by
embossing one or
more projections on
the surface to be
welded
Weld nuggets are
similar to spot
welding
Fig: a) Resistance projection Welding b)A welded bracket c) &
d) Projection welding of nuts r threaded hosses and stack

Resistance Projection Welding

The electrodes exert pressure to compress
the projections
Nuts and bolts can be welded to sheet and
plate by this process
Metal baskets, oven grills, and shopping
carts can be made by RPW

Flash Welding
Heat is generated from the arc as the ends as the two members
contacts
An axial force is applied at a controlled rate
Weld is formed in plastic deformation

Fig : (a)Flash-welding process for end-to end welding of solid rods or tubular parts
(b) & (c) Typical parts made by flash welding (d)Design Guidelines for flash welding

Stud Welding

Small part or a threaded rod or hanger serves as a electrode

Also called as Stud arc welding
Prevent oxidation to concentrate the heat generation
Portable stud-welding is also available

Fig:The sequence of operation in stud welding,which is used for welding bars threaded rods and
various fasteners onto metal plates

TERIMAKASIH
Semoga bermanfaat & dimanfaatkan