RAILWAY COACH FACTORY, KAPURTHALA TECHNICAL TRAINING CENTRE

A PROJECT REPORT ON

WELDING TECHNOLOGY

SUBMITTED BY: JYOTIRAJ THAKURIA B.TECH (2nd YEAR, MECH.) IIT ROPAR

Welding is a fabrication or sculptural process that joins materials, usually metals and thermoplastics, by causing coalescence. This is often done by melting the workpiece and adding a filler material to form a pool of molten material (the weld pool) that cools to become a strong joint, with pressure sometimes used in conjugation with heat or by itself to produce the weld. Until the end of the 19th century, the only welding process was forge welding, which blacksmith has used for centuries to join iron and steel by heating and hammering them. Arc and Oxyfuel welding were among the first processes to develop late in the century, and resistance welding followed soon after. Welding technology advanced quickly during the early 20th century as World War I and World War II drove the demand for reliable and inexpensive joining methods. Following the wars, several modern welding techniques were developed like Shielded Metal Arc Welding (SMAW) as well as semi-automatic and automatic processes such as Gas Metal Arc Welding (MIG or MAG), Tungsten Inert Gas Shielded Arc Welding (TIG), Submerged Arc Welding (SAW), Flux Cored Arc Welding, Electroslag Welding. Development continued with the invention of Laser Beam Welding, Electron Beam Welding, Electromagnetic Pulse Welding and Friction Stir Welding. Today, Robot Welding is commonplace in industrial settings. In most welding procedures metal is melted to bridge the parts to be joined so that on solidification of the weld metal the parts become united. The common processes of this type are grouped as fusion welding. Heat must be supplied to cause the melting of the filler metal

and the way in which this is achieved is the major point of distinction between the different processes. The method of protecting the hot metal from the attack by the atmosphere and the cleaning or fluxing away of contaminating surface films and oxides provide the second important distinguishing feature. For example, welding can be carried out under a shield comprising of a mixture of metal oxides and silicates which produce a glass-like flux, or the whole weld area may be swept clear of air by a stream of gas such as argon, helium or carbon dioxide which is harmless to the hot metals. In the solid phase joining such melting does not occur and hence the method can produce joints of high quality.

Leather Apron It is used to protect the operators clothes from burning due to spatter. It also act as a shield to the harmful UV rays. Leather Hand Glove It is used to protect the operators hand from burning due to spatter and to handle hot job. It also acts as an insulator. It also act as a shield to the harmful UV rays. Arm Sleeve It is used to protect the users clothes and arm from spatter.It also act as a shield to the harmful UV rays. Black Glass It is used mainly in oxyfuel welding. It is a black glass which absorbs the harmful UV rays and protects the users eyes from exposure to those rays and spatter. Fire Arrester It is mainly used in Oxyfuel welding. It only allows outflow of gases and prevents inflow, thus protects from explosion.

 Chipping Goggle (white) It is worn during removal of slag from the job, it protect our eyes from small hot bits of slag during chipping. Welding Goggle (black) It is used during welding or cutting with Oxyfuel welding.

Wire Cutting It is used to cut damaged, bent or accidently ejected wire feeded during MIG welding. Spark Lighter It is used to initiate the combustion of acetylene with oxygen to give the high temperature flame during Oxyfuel welding Cylinder Key It is used to tighten the contact tip holder in Oxyfuel welding. Gas Nozzle A gas nozzle is designed to control the direction and to increase its velocity as it exits. It is used to converge (concentrate) the outflowing gas so that the flame could be sharp enough. Gas Diffuser It is used to control the characteristics of a fluid at the entrance to a thermodynamic open system. It is used to increase the pressure of the gas. Wire Brush It is used to clean the job before welding otherwise there will be more spatter (spatter is caused by dirty oily jobs) and also after removing the slag.

 Hose Clamp It is used to clamp the hose of acetylene and oxygen pipes in Oxyfuel welding. Electrode Holder It is used to hold the electrode during Arc welding. It handle is insulated and protects the user from shocks. Chipping Hammer It is used to remove slag from the job after welding. Tong It is used to handle hot job during chipping, replace hot welded jobs etc. Gas Welding Blow Pipe It is used to blow the gas mixture of acetylene and oxygen and to regulate the gas flow according to requirement of the flame depending on jobs. Contact Tip Holder It is part from where flame comes out in oxyfuel welding. It has 5 to 6 holes from which flames come out. Welding Gauge It is instrument to measure welding characteristics like undercut, excess weld metal, fillet leg length, misalignment, angle of preparation, fillet weld throat. Screw Driver It is used to tighten any nuts and bolts, etc.

The weld joint is where two or more metal parts are joined by welding. The five basic types of weld joints are the butt, corner, tee, lap, and edge, as shown in figure 3-6.

Distortion Porosity & Blow Holes Slag Inclusion Under Cut Incomplete Penetration Excessive Penetration Crater Crack Spatter Lack Of Fusion

Arc strike cracking occurs when the arc is struck but the spot is not welded. This occurs because the spot is heated above the materials upper critical temperature and then essentially quenched. This forms martensite, which is brittle, and micro-cracks. Usually the arc is struck in the weld groove so this type of crack does not occur, but if the arc is struck outside of the weld groove then it must be welded over to prevent the cracking.

Welding methods that involve the melting of metal at the site of the joint necessarily are prone to shrinkage as the heated metal cools. Shrinkage then introduces residual stresses and distortion. Distortion can pose a major problem, since the final product is not the desired shape. To alleviate certain types of distortion the workpieces can be offset so that after welding the product is the correct shape. The following pictures describe various types of welding distortion:

Transverse shrinkage

Angular distortion

Longitudinal Fillet shrinkage distortion

Neutral axis distortion

There are two types of inclusions: linear inclusions and isolated inclusions. Linear inclusions occur when there is slag or flux in the weld. Slag forms from the use of a flux, which is why this type of defect usually occurs in welding processes that use flux, such as shielded metal arc welding, flux-cored arc welding, and submerged arc welding, but it can also occur in gas metal arc welding. This defect usually occurs in welds that require multiple passes and there is poor overlap between the welds. The poor overlap does not allow the slag from the previous weld to melt out and rise to the top of the new weld bead. It can also occur if the previous weld left and undercut or an uneven surface profile. To prevent slag inclusions the slag should be cleaned from the weld bead between passes via grinding, wire brushing, or chipping.

Lack of fusion is the poor adhesion of the weld bead to the base metal; incomplete penetration is a weld bead that does not start at the root of the weld groove. Incomplete penetration forms channels and crevices in the root of the weld which can cause serious issues in pipes because corrosive substances can settle in these areas. These types of defects occur when the welding procedures are not adhered to; possible causes include the current setting, arc length, electrode angle, and electrode manipulation.

Undercutting is when the weld reduces the cross-sectional thickness of the base metal, which reduces the strength of the weld and workpieces. One reason for this type of defect is excessive current, causing the edges of the joint to melt and drain into the weld; this leaves a drain-like impression along the length of the weld. Another reason is if a poor technique is used that does not deposit enough filler metal along the edges of the weld. A third

reason is using an incorrect filler metal, because it will create greater temperature gradients between the center of the weld and the edges. Other causes include too small of an electrode angle, a dampened electrode, excessive arc length, and slow speed.

Porosity is gas pores found in the solidified weld bead. As seen in Figure 10-4, these pores may vary in size and are generally distributed in a random manner. However, it is possible that porosity can only be found at the weld center. Pores can occur either under or on the weld surface. The most common causes of porosity are atmosphere contamination, excessively oxidized work piece surfaces, inadequate deoxidizing alloys in the wire and the presence of foreign matter. Atmospheric contamination can be caused by:

1) Inadequate shielding gas flow. 2) Excessive shielding gas flow. This can cause aspiration of air into the gas stream. 3) Severely clogged gas nozzle or damaged gas supply system (leaking hoses, fittings, etc.) 4) An excessive wind in the welding area. This can blow away the gas shield.

CLASSIFICATION OF WELDING 1. FUSION WELDING i) RADATION ii) THERMOCHEMICAL iii) ELECTRICAL a. ELECTRON BEAM b. RESISTANCE ELECTROSLAG c. ARC GAS SHIELDED NON CONSUMABLE o CARBON ARC o ATOMIC HYDROGEN o TIG o PLASMA ARC COMSUMABLE FLUX SHIELDED MANUAL METAL ARC SUBMERGED ARC CONTINUOUS COVERED ARC

 FLUX CORED ELECTRODE STUD WELDING

2. PRESSURE WELDING i) HOT a. ELECTRICAL RESISTANCE LAP JOINT SPOT SEAM PROJECTION BUTT JOINT UPSET FLASH b. FRICTION WELDING c. GAS PRESSURE WELDING d. ROLL WELDING e. FORGE WELDING f. DIFFUSION WELDING ii) COLD a. INDENTATION b. ROLL BONDING

c. ULTRASONIC d. EXPLOSIVE
GAS WELDING
Gas Welding is one of the most oldest, versatile and popular welding methods used. In the oxyfuel gas welding process , heat is produced by burning a combustible gas, most commonly acetylene, mixed with oxygen to produce a welding flame temperature of about 3100oC. Salient points about oxyacetylene welding: 1. The heat is obtained by combustion of acetylene and oxygen. Here primary combustion occurring in the inner zone gives: C2 H2 + O2 2CO + H2 + Heat And the second reaction in the outer zone gives: 2CO + H2 + 1.5O2 2CO2+ H2O + Heat 2. The maximum temperature at the tip of inner cone reaches up to 3000-3500C. Therefore, most gas welding is performed by keeping this inner zone tip just above the metal to be welded so that maximum temperature is available for welding. Filler materials are used to supply additional material to the weld zone. The flame, since it is less concentrated than an electric arc, causes slower weld cooling, which can lead to greater residual stresses and weld distortion, though it eases the welding of high alloy steels. Gas welding is widely used for welding pipes and in maintenance and repair work because of the ease in transporting oxygen and fuel cylinders. Once you learn the basics of gas welding, you will find the oxyfuel process adaptable to brazing, cutting, and heat treating all types of metals Depending on the ratio of O2 to acetylene, three flame are obtained:

1. A neutral flame is obtained when the ratio of oxygen and acetylene is 1. Most gas welding operations are carried out by this flame. 2. An oxidizing flame is obtained when this ratio is more than 1. This type of flame is not suitable for welding of steels since excess oxygen present reacts with carbon in steel and is generally used for welding of copper and its alloys. 3. When the ratio in mixture is less than 1 a carburizing flame is obtained. In this type of flame acetylene decomposes into carbon and hydrogen and the flame temperature gets reduced. Joining operations such asbrazing and soldering which require lower temperature generally use this flame

Metal is merely melted by the flame of the oxyfuel gas torch and blown away to form a gap or kerf. When ferrous metal is cut, actually burning of oxygen takes place according to one or more of the following reactions. Fe + O Fe +Q 3Fe + 2O2Fe3O4+ Q 4Fe+3 O22Fe2O 3+ Q Because these reactions cannot take place below 815C oxyfuel flame is first used to raise the metal temperature where burning can be initiated. Then a stream of pure oxygen is added to the torch (or the oxygen content of the oxyfuel mixture is increased) to oxidize the iron. The liquid iron and iron oxides are then expelled from the joint by the kinetic energy of the oxygen gas stream.

The process is suitable when edge finish or tolerance is not critical because low rate of heat input, and need of preheating ahead of the cut, oxyfuel produces a relatively large heat affected zone and thus associated distortion zone. Theoretically heat generated due to burning of Fe is sufficient to continue cutting however due to losses additional heat supply is needed. If the work is already hot due from the other processes, supply of oxygen through a small diameter pipe is needed to continue cut. This is called Oxygen Lance Cutting. A workpiece temperature of 1200C is needed to sustain the cutting. Low carbon steel from 5 to 75 mm can be cut.

ARC WELDING
Arc welding is a process that uses an electric arc to join the metals being welded. A distinct advantage of arc welding over gas welding is the concentration of heat. In gas welding the flame spreads over a large area, sometimes causing heat distortion. The concentration of heat, characteristic of arc welding, is an advantage because less heat spread reduces buckling and warping. This heat concentration also increases the depth of penetration and speeds up the welding operation; therefore, you will find that arc welding is often more practical and economical than gas welding. All arc-welding processes have three things in common: ma heat source, filler metal, and shielding. The source of heat in arc welding is produced by the arcing of an electrical current between two contacts.

Shielded metal arc welding (fig. 3-3) is performed by striking an arc between a coated-metal electrode and the base metal. Once the arc has been established, the molten metal from the tip of the electrode flows

together with the molten metal from the edges of the base metal to forma sound joint. This process is known as fusion. The coating from the electrode forms a covering over the m

weld deposit, shielding it from contamination; therefore the process is called shielded metal arc welding. The main advantages of shielded metal arcwelding are that high-quality welds are made rapidly at a lowcost.

The primary difference between shielded metal arc welding and gas shielded arc welding is the type of shielding used. In gas shielded arc welding, both the arcand the molten puddle are covered by a shield of inert gas.

The shield of inert gas prevents atmospheric contamination, thereby producing a better weld. The primary gases used for this process are

helium, argon, or carbon dioxide. In some instances, a mixture of these gases is used. The processes used in gas shielded arc welding are known as gas tungsten arc welding(GTAW) (fig. 3-4) and gas metal arc welding (GMAW). You will also hear these called TIG and MIG. Gas shielded arc welding is extremely useful because it can be used to weld all types of ferrous and nonferrous metals of all thicknesses. Now that we have discussed a few of the welding processes available, which one should you choose? There are no hard-and-fast rules. In general, the controlling factors are the types of metal you are joining, cost involved, nature of the products you are fabricating, and the techniques you use to fabricate them. Because of its flexibility and mobility, gas welding is widely used for maintenance and repair work in the field. On the other hand, you should probably choose gas shielded metal arc welding to repair a critical piece of equipment made from aluminum or stainless steel. No matter what welding process you use, there some basic information you need to know. The remainder of this chapter is devoted to this type of information. Study this information carefully because it allows you to follow welding instructions, read welding symbols, and weld various types of joints using the proper welding techniques.

Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert gas (MIG) welding or metal active gas (MAG) welding, is a semi-automatic or automatic arc welding process in which a continuous and consumable wire electrode and a shielding gas are fed through a welding gun. A constant voltage, direct current power source is most commonly used with GMAW, but constant current systems, as well as alternating current, can be used. There are four primary methods of metal transfer in GMAW, called globular, short-circuiting, spray, and pulsed-spray, each of which has distinct properties and corresponding advantages and limitations. Originally developed for welding aluminum and other non-ferrous materials in the 1940s, GMAW was soon applied to steels because it allowed for lower welding time compared to other welding processes. The cost of inert gas limited its use in steels until several years later, when the use of semi-inert gases such as carbon dioxide became common. Further developments during the 1950s and 1960s gave the process more versatility and as a result, it became a highly used industrial process. Today, GMAW is the most common industrial welding process, preferred for its versatility, speed and the relative ease of adapting the process to robotic automation. The automobile industry

in particular uses GMAW welding almost exclusively. Unlike welding processes that do not employ a shielding gas, such as shielded metal arc welding,

TIG Welding

Gas tungsten arc welding is also known as tungsten inert gas(tig) welding, is an arc welding process that uses a nonconsumable tungsten electrode to produce the weld. The weld area is protected from atmosphere contamination by a shielding gas(usually an inert gas such as argon), and a filler metal is normally used, though some welds known as autogenous welds do not require it. A constant-current welding power supply produces energy which is conducted across the arc through a column of highly ionized gas and metal vapors known as plasma. GTAW is most commonly used to weld thin sections of stainless steel and non-ferrous metals such as aluminum, magnesium, and copper alloys. The process grants the operator control over the weld than competing processes such as SMAW, GMAW, allowing for stronger, high quality welds. However, GTAW is comparatively more complex and difficult to master and it is significantly slower than other welding processes

Resistance Welding involves the generation of heat by passing current through the resistance caused by contact between two or more metal surfaces . Small pools of molten metal are formed at the weld area as high current (1,000A 1,00,000 A) is passed through the metal. In general, resistance welding are efficient and cause little pollution, but their equipment are costly.

Spot Welding is a popular resistance welding used to join overlapping metal sheets. Here, two opposing solid cylindrical electrodes are pressed against the joint and two metallic sheets to be welded. At low pressures, the resistance and heat are high and melted metal tend to squeeze out of the weld. At high pressure, the resistance decreases and heat is less and smaller weld formed provides lower weld strength. Thus, for a given set of conditions, optimum electrode current and electrode pressure are indicated.

The advantage of the method include effective energy use, limited workpiece deformation, high production rate, easy automation and no required filler materials. Weld strength is significantly lower than other welding methods making the process suitable for only certain application. It is extensively used in automobile industry with the help of industrial robots.

Submerged Arc Welding(SAW)

SAW is a common arc welding process. It requires a continuously fed consumable solid or tubular (flux cored) electrode. The molten weld and the arc zone are protected from atmospheric contamination by being submerged under a blanket of granular fusible flux consisting of lime, silica, manganese oxide, calcium fluoride and other compounds. When molten the flux becomes conductive and provides a current path between the electrode and the work. this thick layer of flux completely covers the molten metal thus preventing sparks and spatter as well as suppressing the intense ultraviolet radiation and the fumes are part of the shielded metal arc welding(SMAW) process.

Saw is normally operated in the automotive or mechanized mode, however semi-automatic(handheld) saw guns with pressurized or gravity flux feed delivery are available. The process is normally limited to the flat or horizontal fillet welding position(although horizontal groove position welds have been done with special arrangements to support the flux).deposition rates approaching 100 lb./h(45 kg/hr.) have been reported compared to 10 lb./hr.(5 kg /hr.) for shielded metal arc welding. Although current ranging from 300 to 2000A are commonly utilized. Currents up to 5000A have also been used. Constant voltage welding power supplies are most commonly used, however constant current systems in combination with a voltage sensing wire feeder are available.

LASER BEAM WELDING

Laser Beam Welding is a technique used to join multiple pieces of metal through the use of laser. The beam provides a concentrated heat source, allowing for narrow deep welds and high welding rates. The process is frequently used in high volume application with the help of robots. Laser beam welding has a high power density (of the order of 1 MW/ cm^2).

 MASTER TIG AC/DC-3500W

Make Input Output Frequency

KEMPPI 3ph 50/60 Hz 400V10% TIG DC- 3A/10V-350A/24V TIG AC-10A/20V-350A/24V 60Hz-200Hz

PROMIG-5200 WELDING SET

Make Input Output O.C.V

KEMPPI 3ph-40015% @80% = 520A @100% = 440A 65V

FAST MIG WELDING Set

Model Manufacture Input Load Capacity Wire feed speed Degree protection Feeding Mech.

MSF-57 KEMPPI 440v-AC 440V@100% ED 0-25m/min IP-23 4 roll feed

 SIGMA-500c(Programmable)

Make Input Output Curent range O.C.V

Weight

MIGATRONIC(DENMARK) 3ph15% 500A at 60% 40A-500A 83V 71Kg

Submerged Arc Welding Power Source(DC)

Make Input Output O.V.C O.V.R

ADOR FONTECH LTD. 3ph-415 15% 100A-800A 71V 20-25V

Submerged Arc Welding (Welding Tractor)

Input Welding Wire Wire feed rate Welding speed

110 V DC 2.4mm-4mm 0.5-2.5mm/min 20-72m/min

Plasma Cutting Machine

Machine Input powerOutput power O.V.C Wt. Size Quality cut Air pressure

PLA-cut 50DP 415v, 50Hz-3ph, 10kva 10amp-50amp 250V 23kg 490x270x37(mm) 8mm 3.5-4.0kg

MIG MAG Welding Set

Make Input Output Spot Welding Machine

KEMPPI 380-415V 50-60Hz, 3ph 40amp/12V

Model Input Heating Cooling

BSW-30P 415V,2ph,50Hz AC @5% duty cycle 30kva @100% duty cycle 21kva Transformer: natural Air electrode

WELDING APPROVAL TEST

LOCATION TYPE OF JOINT PROCESS WELDING POSITION WIRE CURRENT VOLTAGE WIRE AMPS. E SPEED mm V. M/Min 1.2 1.2 1.2 100-120 100-110 100-120 15 14 15 3.9 3.0 4.0

A B C

BUTT JOINT FILLET JOINT

CORNER JOINT

MAG MAG MAG

FLAT H&V H & V.D

WELDING APPROVAL TEST FIGURE

S. N LOCATIO N TYPE OF PROCESS RANGE OF APPROVA L SIZE OF WELDING ELECTROD POSITION E WELDING PARAMETERS FOR REFERENCE CURREN T 1. 2. AB A*B* FILLET CORNE R FILLET BUTT FILLET CORNE R MAG MAG 3 TO 16MM -DO1.2MM -DOHORIZONTAL VERTICAL UPWARD DOWNHAND/FL AT OVERHEAD VERTICAL DOWNWARD 220240A 90-100A VOL TAG E 2628 2022 2022 1820 2224 SPEED

480 -DO-

3. 4. 5.

CD EF E*F*

MAG MMA W MAG

-DO2 TO 16MM 3 TO 16MM

-DO3.15MM 1.2MM

-DO80-90A 100120A

-DO350 450

FILLET 6. GH BUTT MAG 2 TO 4 MM 1.0/1.2 MM DOWNHAND/FL AT -DO2224 -DO-

VARIABLE FREQUENCY VARIATION

MATERIAL THICKNESS ELECTRODE DIAMETER IN. 0.035 MM 0.9 0.9 0.9 1.2 1.2 1.2 1.2 1.3 1.3 AVERAGE PEAK BACKGROUND ARC CURRENT CURRENT CURRENT VOLTAGE (ELECTRODE) (A) (A) (A) (POSITIVE) 50 150 20 16 60 160 20 17 70 180 20 18 80 200 25 19 90 250 35 21 120 250 150 22 150 250 200 23 120 275 90 24 200 350 150 26

GA 22 20 18 16 14 11 3/16 1/4 3/8

IN. 0.031 0.037 0.050 0.063 0.078 0.126 0.188 0.250 0.275

MM 0.8 0.9 1.3 1.6 2.0 3.2 4.8 6.4 9.5

MATERIAL THICKNESS

WIRE FEED SPEED

TRAVEL SPEED

SHIELDING GAS

GA. 22 20 18 16 14 11 3/16 3/8

IN 0.031 0.037 0.050 0.063 0.078 0.125 0.188 0.250 0.375

MM 0.8 0.9 1.3 1.6 2.0 3.2 4.8 6.4 9.5

FLOW IN./MIN MM/MIN IN./MIN MM/MIN FT^3/MIN 75 1900 30 760 20 90 2300 30 760 20 115 2900 30 760 20 80 2000 20 500 25 120 3000 20 500 25 200 5000 15 375 25 240 6000 10 250 25 215 5500 9 225 25 300 7500 8 200 25

LITRES/MIN 9 9 9 12 12 12 12 12 12

NOTE: FOR SQUARE GROOVE OR FILLET, USE ROOT OPENING MATERIAL THICKNESS, FILLET EQUAL TO THICKNESS. FOR MILD CARBON AND LOW ALLOY STEELS, SHIELDING GAS 95% + 5% OXYGEN

MIG/MAG WELDING VARIATION

MATERIAL THICKNESS TYPE OF WELD NO. OF PAS S ELECTRODE DIA WELDIN G CURREN T AMPSDC 300 ARC VOLTAG E ELEC. POS 24 WIRE FEED TRAVE L SPEED IPM 35 SHIELDING GAS

IN 1/8

MM 3.2 FILLET OR SQUARE GROOVE FILLET OR SQUARE GROOVE VEE GROOVE VEE GROOVE FILLET 1

IN.

MM

IPM 165

FLOW CHF 40-50

1/16 1.6

3/16

4.8

1/16 1.6

350 325 375 400 450 350

25 24 25 26 29 25

230 210 260 100 120 230

32

40-50

1/4 1/4 1/4

6.4 6.4 6.4

2 2 1

1/16 1.6 3/32 2.4 1/16 1.6

30 35 32

40-50 40-50 40-50

1/4 3/8 3/8 3/8 3/8

6.4 9.5 9.5 9.5 9.5

FILLET VEE GROOVE VEE GROOVE FILLET FILLET

1 2 2 2 1

3/32 2.4 1/16 1.6 3/32 2.4 1/16 1.6 3/32 2.4

400 325 375 400 450 350 425 325 375 375 400 450 425 350 425 325 375 350 400 450 425

26 24 25 26 29 25 27 24 26 26 26 29 27 25 27 24 26 25 26 29 27

100 210 260 100 120 230 110 210 269 250 100 120 110 230 105 110 210 230 100 120 110

32 24 28 20 20

40-50 40-50 40-50 40-50 40-50

1/2

12.7

VEE GROOVE VEE GROOVE FILLET FILLET

1/16 1.6

24

40-50

1/2 1/2 1/2

12.7 12.7 12.7

3 3 3

3/32 2.4 1/16 1.6 3/32 2.4

30 24 26

40-50 40-50 40-50

3/4

19.1

3/4

19.1

3/4 3/4 1 1

19.1 19.1 24.1 24.1

DOUBLE VEE GROOVE DOUBLE VEE GROOVE FILLET FILLET FILLET FILLET

1/16 1.6

24

40-50

3/32 2.4

24

40-50

5 4 7 6

1/16 3/32 1/16 3/32

1.6 2.4 1.6 2.4

350 425 350 425

25 27 25 27

230 110 230 110

24 26 24 26

40-50 40-50 40-50 40-50

NOTE : USE ONLY IN FLAT AND HORIZONTAL FILLET POSITION. 1) FOR FILLET WELDS, MATERIAL THICKNESS INDICATES FILLET WELD SIZE. 2) SHIELDING GAS IS ARGON PLUS 1% TO 5% OXYGEN.

HANDLING STAINLESS STEEL WHILE WELDING

DOS
1. Handle stainless steel with clean gloves to guard against finger marks. 2. Stack stainless steel on wood or non-metallic material. 3. Stack stainless steel and carbon steel separately. 4. Clean before welding to remove the effects of: a. Hydrocarbons: Grease, oil, lubricants. b. Tools: hammers, backing bars c. Shop dust, dirty gloves. 5. Always use the specified electrode & wire dia. for different welding. 6. Clean the sheet before doing any process with clean cloth. 7. Use only stainless steel wire brushes that never have been used on carbon steel. 8. Electrode should be dry when used.

DONTs
1. Avoid walking on stainless steel with dirty shoes or hob nail boots. 2. Avoid stacking of stainless steel with ferrous metal. 3. Avoid stacking of stainless steel with sheets/components directly on floor. 4. Protect the stainless steel from grinding sparks.

9. Slag removal is important.

5. Avoid stainless steels contamination with grinding dust, welding spatter, rust or scale. 6. Avoid putting scratch, dent marks on stainless steel sheet. 7. Avoid use of only compressed air to blow away dirt and welding slag. 8. Avoid removing of the protective poly firm from the stainless steel sheets unnecessarily. 9. Rising temperature under

10. Clean the welding spatter after welding.

11. Use correct parameter for good welding. 12. Lifters that portion should be stainless steel or nylon which touches the SS. 13. Corrosion resistance improves when ground surface becomes smooth. 14. Protect the surface of stainless steel. 15. Clean oxides to avoid further progress of corrosion.

cut, lack of fusion, slag inclusion, and unfinished welding seam increase risk of pit and crevice corrosion. 10. Avoid scratching the electrode on stainless steel surface to start the arc. 11. Avoid number of beads as overheating of stainless steel causes rust. 12. Avoid putting ignition marks Avoid uneven/rough grinding. 13. Avoid using off-cuts of sheets for filling welding gaps. 14. Avoid leaving stainless steel sheets on the floor exposed to traffic. 15. Placing tack welds in an improper sequence can lead to distortion of sheets.

ASM International (2003). Trends in Welding Research. Materials Park, Ohio: ASM International. ISBN 0-87170-780-2. Blunt, Jane; Nigel C. Balchin (2002). Health and Safety in Welding and Allied Processes. Cambridge: Woodhead. ISBN 1-85573-5385. Cary, Howard B; Scott C. Helzer (2005). Modern Welding Technology. Upper Saddle River, New Jersey: Pearson Education. ISBN 0-13-113029-3. Henderson, J.G. (1953). Metallurgical Dictionary. New York, New York: Reinhold Publishing Corporation. Hicks, John (1999). Welded Joint Design. New York: Industrial Press. ISBN 0-8311-3130-6. Kalpakjian, Serope; Steven R. Schmid (2001). Manufacturing Engineering and Technology. Prentice Hall. ISBN 0-201-36131-0. Lincoln Electric (1994). The Procedure Handbook of Arc Welding. Cleveland: Lincoln Electric. ISBN 99949-25-82-2.. Workshop technology &manufacturing process bu S.K Garg. TTC library

Rail Coach Factory, Kapurthala happens to be in the league of the best production premises throughout Asia. It is a place where excellence has not just been pursued but created too. For those engineering students who wish to have good industrial exposure, this is the place to be. Being here for training has been a great experience and I Believe that whatever I got to learn here will surely help me in the future. I wish to thank Mr. R.K Sharma(chief instructor TTC), R.C Nasa (chief instructor of welding dept.) and Mr. Tarlok Singh Bhullar and Act Apprentices for supporting me with their knowledge and expertise and infusing with in attitude of a dedicated professional. I appreciate the planned manner in which TTC is being run. I am also grateful to the various experts who rendered typical and very useful information on the various aspects of coach design & manufacturing, basic manufacturing processes and the management system implied here at RCF.