CHAPTER 1

INTRODUCTION

1.1 Definition of welding

Welding is a process of joining similar or dissimilar materials. Welding is carried out by the use of
heat or pressure or both and with or without added metal.
Welding is to provide a means to join pieces by raising their temperature to the fusion point
so that they form a sort of pool of molten metal at the ends to be joined, and if needed, supplement
this pool with filler metal (wire or rod) which normally has nearly the same composition as that of
the parent pieces and then allow the said pool to form a homogeneous mixture and solidify at the
ends to form a weld.
1.2 Importance of Welding
Welding provides a permanent joint. The Welded parts become a single entity. In all
fabrication companies Welding is very essential. Since Welding has been used in steel fabrication
its uses has expanded in other industrial sectors like construction, mechanical and car
manufacturing etc. In industry like aerospace, oil and construction application of large and heavy
equipment in their procedure and processes is a very common thing.

1.3 The History of Welding

There are a lot of ways to join two materials together. Adhesives like glues or cements and
fasteners like staples or rivets or screws or nails will create a pretty strong bond. However, when you
are trying to join metal parts together, none of the above is likely to work. For a more permanent
bond, welding is the answer.
The welding process involves pumping gas into the welding torch or gun by an electric power
source to create a high heat flame. The flame is applied directly to the base metal pieces to melt
them at the edges while a filler wire is fed into the joint or seam to fuse the pieces together. The

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welder the torch or gun moves down the joint to create a seam
1.4 Types of welding
Based on the heat source used welding processes can be categorized as follows:
1. Solid state welding
2. Fusion welding or Liquid state welding
 Arc welding
 Gas welding
 Resistance welding
 High energy beam welding etc.

1. Solid state welding

Solid-state welding processes do not involve melting of the work piece materials to be
joined. Common types of solid-state welding are ultrasonic welding, explosion welding,
electromagnetic pulse welding, friction welding, friction-stir-welding etc.

2. Fusion welding or Liquid state welding

Fusion welding is a generic term for welding process that rely on melting to join materials of
similar compositions and melting points. Due to the high-temperature phase transitions
inherent to this process, a heat-affected zone is created in the material.

 Arc Welding
In arc welding process an electric power supply is used to produce an arc between
electrode and the work-piece material to joint, so that work-piece metals melt at the interface
and welding could be done. Power supply for arc welding process could be AC or DC type.
The electrode used for arc welding could be consumable or non-consumable. For non-
consumable electrode an external filler material could be used. Among all these types of
welding processes arc welding is widely used for different types of materials

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  Gas Welding
In gas welding process a focused high temperature flame produced by combustion of gas
or gas mixture is used to melt the work pieces to be joined. An external filler material is used
for proper welding. Most common type gas welding process is Oxy-acetylene gas welding
where acetylene and oxygen react and producing some heat.

 Resistance Welding
In resistance welding heat is generated due to passing of high amount current (1000–
100,000 A) through the resistance caused by the contact between two metal surfaces. Most
common types
Resistance welding is Spot-welding, where a pointed electrode is used. Continuous type spot
resistance welding can be used for seam-welding where a wheel-shaped electrode is used.

 High Energy Beam Welding

In this type of welding a focused energy beam with high intensity such as Laser beam or
electron beam is used to melt the work pieces and join them together. These types of welding
mainly used for precision welding or welding of advanced material or sometimes welding of
dissimilar materials, which is not possible by conventional welding process.

1.5 . Arc welding

Arc welding is used to join metal to metal by using electricity to create enough heat to melt
metal, and the melted metals when cool result in a binding of the metals. It is a type of
welding that uses a welding power supply to create an electric arc between an electrode and
the base material to melt the metals at the welding point. They can use either direct (DC) or
alternating (AC) current, and consumable or non-consumable electrodes. The welding region
is usually protected by some type of shielding gas, vapour, or slag. Arc welding processes
may be manual, semi-automatic, or fully automated. First developed in the late part of the
19th century,

arc welding became commercially important in shipbuilding during the Second World War.

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 Today it remains an important process for the fabrication of steel structures and vehicles.

1.6. Arc welding types

Different types of arc welding are given below:-

a) Shielded Metal Arc Welding (SMAW) or Manual Metal Arc Welding:

This is most common type arc welding process, where a flux coated consumable
electrode is used. As the electrode melts, the flux disintegrates and produces shielding gas
that protect the weld area from atmospheric oxygen and other gases and produces slag which
covers the molten filler metal as it transfer from the electrode to the weld pool. The slag
floats to the surface of weld pool and protects the weld from atmosphere as it
solidifies.

Fig 1.6 Shielded metal arc welding

(b) Gas Metal Arc Welding (GMAW) or Metal inert or active gas welding
(MIG/MAG): In this type of welding process a continuous and consumable wire electrode is
used.
A shielding gas generally argon or sometimes mixture of argon and carbon dioxide are blown
through a welding gun to the weld zone.

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.

Fig: Gas Metal Arc Welding

c) Gas Tungsten Arc Welding (GTAW) or Tungsten Inert Gas (TIG):

GTAW or TIG welding process is an arc welding process uses a non-consumable tungsten electrode
to produce the weld. The weld area is protected from atmosphere with a shielding gas generally
Argon or Helium or sometimes mixture of Argon and Helium. A filler metal may also feed manually
for proper welding. GTAW most commonly called TIG welding process was developed during
Second World War. With the development of TIG welding process, welding of difficult to weld
materials e.g. Aluminum and Magnesium become possible. The use of TIG today has spread to a
variety of metals like stainless steel, mild steel and high tensile steels, Al alloy, Titanium alloy. Like
other welding system, TIG welding power sources have also improved from basic transformer types
to the highly electronic controlled power source today.

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FIg:1.6 Tungsten inert gas welding

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 CHAPTER 2
LITERATURE REVIEW

[1] M. P. Groover stated that in arc welding (AW), selecting appropriate values for process variables is
essential in order to control heat-affected zone (HAZ) dimensions and get the required bead, which is
critical for obtaining high quality. In this investigation, mathematical model were developed to study the
effects of process variable and heat input on various metallurgical aspect, the namely, the widths of the
HAZ, weld interface, and grain growth and grain refinement regions of the HAZ. The colour
metallography technique and response surface methodology were also used. Direct and interaction effects
of the process variables and heat input on the characteristics of the HAZ were presented in graphical
forms. The study of heat input and wire feed rate have a positive effect, but welding speed has a negative
effect on all HAZ characteristics; 2) width of grain growth and grain refinement zones increased and weld
interface decreased with an increase in arc voltage; and 3) width of HAZ is maximum (about 2.2mm)
when wire-feed rate and welding speed are at their minimum limits.

[2] C. Thaulow, A. J. Paaw, K. Guttormsen have done Investigation on effect of welding current
on welding speed and hard ness of HAZ and weld metal of mild steel conclude that withincrease in
welding ampere Heat generation wa increased so melting of electrode becomesfaster hence welding time
decreased and welding speed was increased, and with increased, andHAZ were decreased with increase in
welding ampere which shows hardness of HAZ washigher than both the weld metal zone and base metal
zone.

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 CHAPTER 3
EQUIPMENT AND PARAMETERS

3.1 EQUIPMENTS
Different types of Equipment used in arc welding are:-

 Arc welding power source

Both direct current (DC) and alternating current (AC) are used for electric arc welding
process, each having its particular applications. DC welding supply is usually obtained from
generators driven by electric motor or if no electricity is available by internal combustion engines.
For AC welding supply, transformers are predominantly used for almost all arc welding where
mains electricity supply is available. They have to step down the usual supply voltage (200-400
volts) to the normally open circuit welding voltage (50-90 volts).

 Welding cables
Welding cables are required for conduction of current from the power source through the electrode
holder, the arc, the work-piece and back to the welding power source. These are insulated copper or
Aluminium cables.

 Electrode Holder
Electrode holder is used for holding the electrode manually and conducting current to it. These are
usually matched to the size of the lead, which in turn matched to the amperage output of the arc welder.
Electrode holders are available in sizes that range from 150 to 500 Amps.
 Electrode
An electrode is a piece of wire or a rod of a metal or alloy, with or without coatings. An
arc is set up between electrode and work-piece. Welding electrodes are classified into the following
types
1. Consumable Electrodes
i. Bare Electrodes
ii. Coated Electrode
2. Non-consumable Electrodes

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 i. Carbon or Graphite Electrodes
ii. Tungsten Electrodes

Consumable electrodes are made up of different metals and their alloys. The end of this electrode
starts melting when the arc is struck between the electrode and workpiece. Thus consumable
electrode itself acts as a filler metal. Bare electrodes consist of a metal or alloy wire without any
flux coating on them. Coated electrodes have flux coating which starts melting as soon as an
electric arc is struck. This coating on melting performs many functions like prevention of joint from
atmospheric contamination, arc stabilizers etc.
Non-consumable electrodes are made up of high melting point materials like carbon, pure tungsten
or alloy tungsten etc. These electrodes do not melt away during welding. But practically, the
electrode length goes on decreasing with the passage of time, because of oxidation and vaporization
of the electrode material during welding. The materials of non-consumable electrodes are usually
copper coated carbon or graphite, pure tungsten, thoriated or zirconiated tungsten.

 Hand Screen
Hand screen is used for protection of eyes and supervision of weld bead.
 Gloves
Gloves are used for protect our hand from current or work-piece.
 Wire brush
Wire brush is used to clean the surface to be weld.
 Chipping hammer
Chipping Hammer is used to remove the slag by striking.

3.2 PARAMETERS

 Welding Current:

Welding current is the most influential variable in arc welding process which controls the electrode
burn off rate, the depth of fusion and geometry of the weld elements. Welding current is most
important variable affecting melting rate, the deposition rate, depth of penetration and the amount

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of base metal melted. Current are taken as a constant value of 200 A over whole process. Current
could be DC or AC.

DC provides steady arc and smooth metal transfer, good wetting action, uniform weld bead
size, especially suited to thin section welding, give better quality weld in vertical and
overhead welding position. So I choose DC Power supply for both electric arc welding.

 Welding Voltage:

This is the electrical potential difference between the tip of the welding wire and the
surface of the molten weld pool. It determines the shape of the fusion zone and weld
reinforcement. High welding voltage produces wider, flatter and less deeply penetrating
welds than low welding voltages.
Heat input rate or arc energy = V×I×60/v joules per mm
Where, V is arc voltage in volts,
I is welding current in ampere, v is 1speed of welding in mm/min.

Welding Speed
Electrode along the seam or the rate of the travel of the work under the electrode along the seam.
Some general statements can be made regarding speed of travel

Speed of welding = Travel of electrode/ arc time mm/min. Variation of welding

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 CHAPTER 4
EXPERIMENTAL SETUP

4.1 Parameters with ranges

Parameter Range

Welding current (100-140) A

Voltage 50 V

Speed (3.5-4) mm/s

Distance of tip from weld Centre 3 mm

Current type DC

Dimension 150×150×8 mm

TABLE 1: Experimental planning preparation

4.2 Procedure
Step 1
We have taken two pairs of mild steel plates on which welding have been done using mild steel
rutile coated E6013 electrode for each pair of plate.

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 Fig: V Groove MS plate

Step 2

After grinding the plates, the plates are to be joined by the process of shielded metal arc welding.
Then the welding is performed on the plates by filling the filler metal in the V groove by the help of
current (i.e. the voltage is kept 100-120v). The filler metal is nothing but the electrode.

Note: To achieve a satisfactory weld, the plates are literally supported with an external material so
while welding the base plates the plates do not bend and change their shape.
Step 3

At this stage, the plates are to be cooled at the room temperature and the support is removed and the
waste metal is grinded after welding.

Step 4
Welding portion is completed; finally we obtain proper butt joint.

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 CHAPTER 5
APPLICATIONS

Although most of the welding processes at the time of their developments could not get their
place in the production except for repair welding, however, at the later stage these found proper
place in manufacturing/production. Presently welding is widely being used in fabrication of
pressure vessels, bridges, building structures, aircraft and space crafts, railway coaches and general
applications. It is also being used in shipbuilding, automobile, electrical, electronic and defense
industries, laying of pipe lines and railway tracks and nuclear installations etc.

General Applications:
Welding is vastly being used for construction of transport tankers for transporting oil, water,
milk and fabrication of welded tubes and pipes, chains, LPG cylinders and other items. Steel
furniture, gates, doors and door frames, body and other parts of white goods items such as
refrigerators, washing machines, microwave ovens and many other items of general applications
are fabricated by welding.
Pressure Vessels:
One of the first major use of welding was in the fabrication of pressure vessels. Welding made
considerable increases in the operating temperatures and pressures possible as compared to riveted
pressure vessels.
Bridges
Early use of welding in bridge construction took place in Australia. This was due to problems in
transporting complete riveted spans or heavy riveting machines necessary for fabrication on site to
remote areas. The first all welded bridge was erected in UK in 1934. Since then all welded bridges
are erected very commonly and successfully.

Ship Building
Ships were produced earlier by riveting. Over ten million rivets were used in „Queen Mary' ship
which required skills and massive organization for riveting but welding would have allowed the
semiskilled/ unskilled labor and the principle of prefabrication. Welding found its place in ship

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building around 1920 and presently all welded ships are widely used. Similarly submarines are also
produced by welding.

Building Structures
Arc welding is used for construction of steel building leading to considerable savings in steel and
money. In addition to building, huge structures such as steel towers etc also require welding for
fabrication.
Aircraft and Spacecraft
Similar to ships, aircrafts were produced by riveting in early days but with the introduction of jet
engines welding is widely used for aircraft structure and for joining of skin sheet to body. Space
vehicles which have to encounter frictional heat as well as low temperatures require outer skin and
other parts of special materials. These materials are welded with full success achieving safety and
reliability.
Railways
Railways use welding extensively for fabrication of coaches and wagons, wheel tyres laying of
new railway tracks by mobile flash butt welding machines and repair of cracked/damaged tracks by
thermite welding.

Automobiles
Production of automobile components like chassis, body and its structure, fuel tanks and
joining of door hinges require welding.

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 CHAPTER 6
RESULT AND CONCLUSION

RESULTS:

 Arc welding is used to join metal to metal by using electricity.

 Arc welding is used for joining of hard metal like Aluminum stainless steel.
 Its is also used for transporter tankers for transporting oil, water, milk and fabrication of welded
tubes and pipes.
 Welding has been used in steel fabrication its uses has expanded in other industrial sector like
construction mechanical and car manufacturing.

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CONCLUSION:

 In conclusion, we can conclude that there are some problems that happened in
arc welding process.
 The first problem that happened in arc welding process is the thicknesses of arc line on
metal plate. We can overcome it such as we can improve our skill with we can reduce
the movement of speed when doing arc welding.
 The second problem is combination of the metal plate is not strong. It may cause the
work be crack or don‟t have enough quality. To overcome this problem is we need to add
more electrodes at the work.
 After we make some work of welding, we can know the main factor why the work in our
welding is not too good. The main factor is lack of skill from us. So that we need to improve
ourselves by do the weld properly and use the right method in welding.

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2008. Retrieved 9 October2014.
 ^ "Beginnings of submerged arc welding" (PDF). Archived from the original (PDF) on 2016-03-
04.
 ^ Houldcroft, P. T. (1973) [1967]. "Chapter 3: Flux-Shielded Arc Welding". Welding Processes.
Cambridge University Press. p. 23. ISBN 978-0-521-05341-9.
 Marco, David; Eisinger, George; Hayes, David L. (1992). "Testing of work environments
for electromagnetic interference". Pacing Clin Electrophysiol. 15 (11 Pt 2): 2016–
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 Hertha Ayrton. The Electric Arc, pp. 20 and 94. D. Van Nostrand Co., New York, 1902.
 Jump up to: a Anders, A. (2003). "Tracking down the origin of arc plasma science-II. early
continuous discharges". IEEE Transactions on Plasma Science.
 www.weldingschool.com
 www.aws.org
 www.linde.gas.com
 www.arcwelding.com
 www.nptl.ac.in
 Gas tungsten arc welding
 Weight of weld metal table

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