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WELDING AND ITS EQUIPMENTS

WELDING:
Welding is a materials joining process which produces coalescence of materials by heating them to suitable temperatures with or without the application of pressure or by the application of pressure alone, and with or without the use of filler material.

BATCH 7

TYPES OF WELDING:
Plastic Welding or Pressure Welding The piece of metal to be joined are heated to a plastic state and forced together by external pressure (Ex) Resistance welding Fusion Welding or Non-Pressure Welding
The material at the joint is heated to a molten state and allowed to solidify (Ex) Gas welding, Arc welding

CLASSIFICATION OF WELDING:
i). Arc welding Carbon arc Metal arc Metal inert gas Tungsten inert gas Plasma arc Submerged arc (ii). Gas Welding
Oxy-acetylene Air-acetylene Oxy-hydrogen

(iii). Resistance Welding Spot Seam Projection

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EQUIPMENTS USED IN WELDING:

ARC WELDING:
A welding generator (D.C.) or Transformer (A.C.) Two cables- one for work and one for electrode Electrode holder Electrode Protective shield Gloves Wire brush Chipping hammer Goggles

Arc Welding Equipments

ARC WELDING:
Uses an electric arc to coalesce metals Arc welding is the most common method of welding metals Electricity travels from electrode to base metal to ground

ARC WELDING:
Advantages Most efficient way to join metals Lowest-cost joining method Affords lighter weight through better utilization of materials Joins all commercial metals Provides design flexibility

Limitations Manually applied, therefore high labor cost. Need high energy causing danger Not convenient for disassembly. Defects are hard to detect at joints.

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RESISTANCE WELDING:
A group of fusion welding processes that use a combination of heat and pressure to accomplish coalescence Heat generated by electrical resistance to current flow at junction to be welded Principal RW process is resistance spot welding (RSW) TYPES: SPOT WELDING SEAM WELDING PROJECTION WELDING.

SPOT WELDING:
(a) Spot welding cycle (b) Plot of force and current Cycle: (1) parts inserted between electrodes, (2) electrodes close, (3) current on, (4) current off, (5) electrodes opened

ADVANTAGES:
No edge preparation is needed. Low cost. High speed of welding.

Resistance Seam Welding (RSEW):

Uses rotating wheel electrodes to produce a series of overlapping spot welds along lap joint Can produce air-tight joints Applications:
Gasoline tanks Automobile mufflers Various sheet metal containers

DISADVANTAGES:
Only point welding is possible.

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Seam welding:

Projection welding:
In this process one of the work piece being joined is dimpled at the points to be welded. That is a small projectioner are made on one of the sheets hence the name of projection welding. This type of welding is widely attaching small components and fasteners to structural members.

Resistance Projection Welding:

(1) Start of operation, contact between parts is at projections; (2) when current is applied, similar to spot welding are formed at the projections

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ADVANTAGES:
This methods of welding gives longer electrode life. The electrodes also serve as a part of an assembly fixture. The current per weld is slightly less than for spot welding.

DISADVANTAGES:
All projections should be seated in one blow. Most job require special electrodes.

APPLICATIONS:
A common use of projection welding is attaching small fasteners, nuts, special bolts, stud, and similar parts to large components.

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