SYLLABUS OF WELDING TRAINING

DEFINITION OF WELDING
Welding is a process of joining two similar or dissimilar metals where
joining is done by heating to a suitable temperature, with or without the
application of pressure and with or without the use of filler metal. The filler
metal either has a melting point approximately the same as base metal or has
a melting point below that of the base metal but above 800
0
F !"0
0
#$.
%fter welding, the weld metal should have similar physical properties and
chemical composition as that of the base metal.
WELDING PROCESSES
#ommon Types of Welding &rocesses are'
(. )hielded *etal %rc Welding. )*%W$
+. ,as welding or -xy.Fuel Welding. -FW$
". ,as Tungsten %rc Welding. ,T%W$
!. Flux #ored %rc Welding. F#%W$
/. ,as *etal %rc Welding. ,*%W$
0. )ubmerged %rc Welding. )%W$
1. SMAW PROCESS
12F343T3-4 -F %5#
%n arc is created between the covered metal electrode and the wor6
piece due to flow of electricity.
This arc provides the heat or energy to melt the base metal and
electrode coating. 2lectrode is consumed in the arc and provides the
filler metal for the joint.
The process is suitable for the entire range of plate or pipe
thic6nesses, for almost all commercial metals and alloys and for
surfacing and repair wor6.
ARC WELDING POWER SOURCE
7 There are 2 types ! "e#$%&' (a)h%&es.
($ %.#. Welding *achine' 3nput current is %.# and output current i.e.,
current available in the electrode holder$ is %.#.
2xample' Transformer type.
ARC WELDING
POWER
SOURCE
AC
OUT PUT
DC
OUT PUT
TRANSFORMER GENERATOR RECTIFIER
INVERTER
+$ 1.#. Welding *achine' 3nput current is %.# and output current
i.e., current available in the electrode holder$ is 1.#.

2xample'
(. 5ectifier type
+. ,enerator type
". 3nverter type
MAIN FEATURES OF WELDING ARC
(. % welding arc is the passage of electricity across a gap between an
electrode and the parent metal or wor6 piece.
+. 8eat is generated at the surface of the electrode and of the parent
metal.
". 8eating of the electrode end causes melting and this causes transfer of
metal to the weld pool.
!. 8eating at the parent metal produces fusion of the joint faces.
/. 8eat input to the weld is a function of arc voltage, arc current and
travel speed.
0. %rc length is related to arc voltage.
9. The current supplied to an arc is generally %# or 1#.
STRAIG*T POLARITY OR DC ELECTRODE NEGATI+E ,DCEN-
When the electrode holder is connected to the negative pole it is 6nown as
straight polarity. %s the holder is connected to negative pole, it is also 6nown
as 1# 2lectrode 4egative 1#24$.

2xample' %ll 5utile coated electrodes are connected to negative pole
RE+ERSE POLARITY OR DC ELECTRODE POSITI+E ,DCEP-
When the electrode holder is connected to the positive pole it is 6nown as
reverse polarity. %s the holder is connected to positive pole, it is also 6nown
as 1# 2lectrode &ositive 1#2&$.
2xample' 200(0 #ellulosic$ and 290(8 :ow 8ydrogen 3ron &owder$
are connected to positive pole.
WELDING ACCESSORIES
The following items are re;uired for conducting welding'.
7 Welding cables.
7 2lectrode holders.
7 2arthing clamp.
7 #hipping hammer.
7 File < 5ound and Flat.
7 Tris;uare.
7 8ammer.
7 #hiesel.