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2 Welding Technology and Design

welding, plasma welding are also dealt with. Pressure welding and some special
welding techniques like electro-slag welding etc. are also discussed in detail. Figure
1.1 shows the broad classification of the welding processes.
Though the different processes have their own advantages and limitations and
are required for special and specific applications, manual metal arc welding
continues to enjoy the dominant position in terms of total weld metal deposited.
The TIG process produces the finest quality weld on all weldable metals and alloys.
The arc temperature may be upto 20,000 K. Although TIG welding produces the
highest quality welds, it is a slow and expensive process. Metal inert gas welding
process (MIG) is economical with consumable electrode fed at a predetermined
rate.
Plasma arc welding (PAW) has made substantial progress in utilising the high
heat energy of an ionised gas stream. The jet temperature can be as high as 50,000
K. Foils down to a thickness of 0.01 mm can also be welded in this process and
hence this process is more useful in electronic and instrumentation applications.
All the processes like TIG, MIG and PAW can be successfully used for either
semi-automatic or automatic applications. But they are all open arc processes where
radiation and comparatively poor metal recovery put a limit on using high currents.
High productivity and good quality welds can be achieved by submerged arc
welding process with weld flux and wire continuously fed. The slag provides the
shielding of the weld pool with provision for addition of alloying elements whenever
necessary.
Electron beam welding and laser welding are classified under high energy density
processes. Figure 1.2 shows the heat intensity (w/sq.cm) and heat consumption
(wh/cm) for different welding processes discussed above.
For efficient welding the power source should provide controlled arc
characteristic necessary for a particular job. In one case a forceful deeply penetrating
arc may be required, while in another case, a soft less panetrating arc may be
necessary to avoid ``burn through''. The welding process will also require a
particular type of power source. Table 1.1 gives the power source required for
widely used welding process. The process details are discussed in the following:
Table 1.1 Power source for arc welding process

Process Output Current Polarity


Characteristics

Shield metal variable AC or DC DCSP


arc, TIG, voltage DCRP
Submerged arc* AC
Flux cored constant DC DCSP
voltage DCRP
Gas Metal arc constant DC DCRP
voltage

*In some applications, the SAW process can use constant voltage DC also.

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