CHAPTER WELDING LIGHTLY COATED ELECTRODE – A filler metal

electrode consisting of a metal wire with light coating

ARC – A sustained electric discharge, where current
applied subsequent to the drawing operation, primarily
flows through the gap between two electrodes.
for stabilizing the arc.
ARC CUTTING – Process which melts the metals to cut
MACHINE OXYGEN CUTTING – Cutting with an
with the heat of an arc between an electrode and the base
equipment that performs the operation under the constant
metal.
observation and control of an oxygen cutting operator.
ARC EYE – A burn on the exterior surface of the
MACHINE WELDING – Welding with an equipment
operators eye, due to its exposure to an open arc. Also
which performs the operation under the constant
called FLASH EYE.
observation and control of a welding operator.
ARC GAP – Distance between the tips of two electrodes,
MANUAL WELDING – Welding performed and
normally between an electrode and the workpiece. Also
controlled completely by hand.
known as ARC LENGTH.
MELTING POINT – The temperature at which a metal
ARC PLASMA – A gas that has been heated to an at
melts.
least partially ionized condition, enabling it to conduct an
MELTING RANGE – Temperature range between
electric current.
solidus and liquidus.
ARC SPOT WELD – Spot welding made by an arc
MELTING RATE – The weight or length of electrode
welding process.
melted in unit time.
ARC WELDING – A group of welding processes which
METAL ARC CUTTING – Processes that sever metals
produces coalescence of metals by heating them with an
by melting them with the heat of an arc between a metal
arc, with or without the application
electrode and the base metal.
of pressure, and with or without the use of filler metal.
METAL BATH BRAZING – is a dip process wherein
ATOMIC HYDROGEN WELDING – An arc welding
the filler metal is obtained from the molten metal bath.
process which produces coalescence of metals by heating
This is confined to joining comparatively small work
them with an electric arc maintained between electrodes
such as joints in wire.
in an atmosphere of hydrogen.
METAL CORED ELECTRODE – A composite filler
Shielding is provided by hydrogen.
metal electrode consisting of a metal tube or other
AUTOGENOUS WELD – A fusion weld made without
hollow configuration containing alloying ingredients.
the addition of filler metal.
METAL ELECTRODE – A filler or non-filler metal
AUTOMATIC OXYGEN CUTTING – Cutting with an
wire or rod, either bare or covered, used in an arc
equipment without constant observation and adjustment
welding or cutting.
of the controls by an operator.
METAL POWDER CUTTING – An oxygen cutting
AUTOMATIC WELDING – Welding which permits
process that severs metals through the use of powder
the operation without adjustment of controls by an
such as iron, to facilitate cutting.
operator. 130 Handbook of Mechanical Engineering Terms
NEUTRAL FLAME – An oxyfuel gas flame in which
BACKHAND WELDING – A welding technique in
the proportion used is neither oxidizing nor reducing.
which the welding torch or gun is directed opposite to the
NON-DESTRUCTIVE TESTING – Testing of welds
progress of welding.
or metal without causing any damage to the item being
BACK WELD – A weld deposited at the back of a single
tested.
groove weld.
OVER WELDING – Depositing more filler metal than
BARE ELECTRODE – A filler metal electrode of a
required.
single metal or alloy, produced into a wire, strip or bar
OXYACETYLENE CUTTING – Process that severs
form and without any coating or covering on it.
metals by the chemical reaction of oxygen with the base
BARE METAL ARC WELDING – Process which
metal at elevated temperatures caused by combustion of
produces coalescence of metals by heating them with an
acetylene with oxygen.
electric arc between a bare or lightly coated metal
OXYACETYLENE WELDING – Process that
electrode and the work piece.
produces coalescence of metals by heating them with the
BASE METAL – The metal to be welded, brazed,
flame obtained by combustion of acetylene with oxygen.
soldered or cut.
OXY FUEL CUTTING – A group of cutting processes
BLIND JOINT – A joint, no portion of which is visible.
used to sever metals by means of the chemical reaction
BORAX – is the old standard flux for brazing, exists in
of oxygen with the base metal at
two forms—ordinary borax and amorphous or fused
elevated temperatures produced by flames obtained from
borax.
combustion of fuel gas and oxygen e.g., oxy hydrogen
cutting, oxy natural gas cutting, oxy propane cutting.
BRAZING – A group of welding processes that produces
coalescence of materials by heating them to the brazing
temperature, using a filler metal having a liquidus above
450°C and below the solidus of the base
metal.
BUTT JOINT – A joint between two members aligned
approximately in the same plane.
CARBON ARC CUTTING – Cutting of base metals by
melting them with the
heat of an arc produced between a carbon electrode and
the base metal.
CARBON ELECTRODE – A non-filler metal electrode
used in arc welding or cutting, consisting of a carbon or
graphite rod, which may be coated with copper or other
coatings.
CARBON ARC WELDING – A brazing process that
produces coalescence of metals by heating them with an
electric arc produced between two carbon electrodes. The
filler material is distributed in the joint by
capillary action.
COLD WELDING – A solid state welding process in
which pressure is applied at room temperature to produce
coalescence of metals with substantial deformation at the
weld.
COMPOSITE ELECTRODE – Multicomponent filler
metal electrodes in various physical forms such as
standard wires, tubes and covered wire. Welding 131
CONTINUOUS WELD – A weld that extends
continuously from one end of a joint to the other.
COVERED ELECTRODE – An electrode consisting of
a core of a bare electrode or metal cored electrode to
which a covering, sufficient to provide a slag layer on the
weld metal, has been applied.
COVER PLATE (eye protection) – A removable pane
of colourless glass, plastic coated glass or plastic that
covers the filter plate and protects it
from weld spatter, pitting or scratching when used in a
helmet, hood or goggles.
CRATER – A depression at the termination of a weld
bead.
DECARBURIZING FLAME – A flame which removes
carbon from the molten metal.
DEPOSITION EFFICIENCY (arc welding) – Ratio of
the weight of deposited metal to the net weight of the
filler metal consumed, exclusive of stubs i.e., left out
electrode bits.
DEPTH OF FUSION – Distance that fusion extends into
the base metal or previous pass from the surface melted
during welding.
DIFFUSION WELDING – A solid state welding
process that produces coalescence of the faying surfaces
by the application of pressure at elevated temperature.
EDGE JOINT – A joint between the edges of two or
more parallel or nearly parallel members.
OXY FUEL GAS WELDING – A group of welding
processes that produces coalescence by heating materials
with an oxyfuel gas flame or flames with or without the
application of pressure and with or without the use of
filler metal e.g., oxy hydrogen welding.
OXYGEN LANCE CUTTING – An oxygen cutting
process used to sever metals with oxygen supplied
through a consumable lance. The preheat to start cutting
is obtained by other means.
PLASMA ARC CUTTING – Process that severs metal
by melting a localized area with a constricted arc and
removing the molten material with high velocity jet of
hot, ionized gas issuing from the constricted orifice.
PLASMA ARC WELDING – Process that produces
coalescence of metals by heating them with a constricted
arc between an electrode and the
workpiece (transferred arc) or the electrode and the
constricting nozzle (non-transferred arc). Shielding is
obtained from the hot ionized gas issuing from the
orifice which may be supplemented by an auxiliary
source of shielding gas.
PLUG WELD – A weld made in a circular hole or one
member of a joint, fusing that member to another
member.
POROSITY – Cavity type discontinuities formed by
gas entrapment during solidification.
POST HEATING – Application of heat to an assembly
after a welding, brazing, soldering, thermal spraying or
thermal cutting.
PRE HEATING – Application of heat to the base metal
immediately before welding, brazing, soldering, thermal
spraying and cutting.
PRESSURE GAS WELDING – An oxyfuel gas
welding which produces coalescence simultaneously
over the entire area of faying surfaces by heating them
with gas flames obtained from combustion of a fuel gas
with oxygen and by the application of pressure, without
the use of filler metal.
PROJECTION WELDING – is a modification of spot
welding in which the current and pressure are localized
at the weld section by the use of embossed, machined, or
coined projections on one or both pieces of
the work.
PROTECTIVE ATMOSPHERE – Gas or vacuum
envelope surrounding the workpieces used to prevent or
facilitate removal of oxides and detriment surface
substances.
RANDOM INTERMITTENT WELDS – Intermittent
welds on one or both sides of a joint in which the weld
increments are made without regard to spacing.
ELECTROGAS WELDING – Arc welding in which
coalescence is effected by heating the metals with an arc
produced between a continuous filler metal electrode and
the work. Shielding is by inert gas.
ELECTRO SLAG WELDING – A welding process
producing coalescence of metals with molten slag that
melts the filler metal and the surfaces of the workpieces.
The weld pool is shielded by slag.
EMISSIVE ELECTRODE – A filler metal electrode
consisting of a core of a bare electrode or a composite
electrode to which a very light coating
has been applied to produce a stable arc.
EXPLOSION WELDING – A solid state welding
process in which coalescence is effected by high velocity
movement of the workpieces, produced by a controlled
detonation.
132 Handbook of Mechanical Engineering Terms
FACE SHIELD (eye protection) – Device positioned in
front of the eyes and over all or a portion of the face to
protect the eyes and face.
FILLET WELD – A weld of approximately triangular
cross-section joining two surfaces approximately at right-
angles to each other in a lap joint,
T joint or corner joint.
FILLER METAL – Metal to be added in making a
welded, brazed or soldered joint.
FIRE CRACKER WELDING – Shielded metal arc
welding process in which a length of covered electrode is
placed along the joint in contact with
the workpieces. During welding, a stationary electrode is
consumed as the arc travels the length of the electrode.
FISH EYE – A discontinuity found on the fracture
surface of a weld in steel. It consists of a small pore or
inclusion surrounded by an approximately round bright
area.
FLOW WELDING – Process which produces
coalescence of metals by heating them with molten filler
metal poured over the surfaces to be
welded until the welding temperature is attained and until
sufficient filler metal has been added.
FLUX – Material used in welding to prevent, dissolve or
facilitate removal of oxides and other undesirable surface
substances.
FLUX CORED ARC WELDING – Process in which
coalescence of metals is effected by heating them with an
arc between a continuous filler metal (consumable)
electrode and the work. Shielding is by the flux contained
within the tubular electrode.
FLUX CORED ELECTRODE – A composite hollow
filler metal electrode containing within it ingredients to
provide such functions as shielding atmosphere,
deoxidation, arc stabilization and slag formation.
FOREHAND WELDING – A welding technique in
which the welding torch or gun is directed toward the
progress of welding.
PULSED POWER WELDING – An arc welding
process variation in which the power is cyclically
programmed to pulse so that effective but short
duration values of a parameter can be utilized. Also
called PULSED VOLTAGE or PULSED CURRENT
WELDING e.g., gas metal arc welding (pulsed arc), gas
tungsten arc welding (pulsed arc).
REDUCING ATMOSPHERE – A chemically active
protective atmosphere which at elevated temperature
will reduce metal oxides to their metallic state.
REDUCING FLAME – A gas flame having a reducing
effect owing to excess fuel gas.
RESIDUAL STRESS – Stress present in a member that
is free to external forces or thermal gradients.
RESISTANCE BRAZING – is an electric brazing
process wherein the heat is obtained by passing an
electric current through the parts being brazed.
RESISTANCE WELDING – In this, the metal parts to
be joined are heated by their resistance to the flow of an
electric current e.g., spot welding, seam welding.
ROLL WELDING – A solid state welding process that
produces coalescence of metals by heating and by
applying pressure with rolls sufficient to cause
deformation at the faying surfaces.
SEAL WELD – Any weld designed primarily to
provide a specific degree of tightness against leakage.
SEAM WELD – A continuous weld between or upon
overlapping members, in which coalescence may start
and occur on the faying surfaces, or may have proceeded
from the outer surface of one member.
SEMI AUTOMATIC ARC WELDING – Arc welding
with equipment that controls only the filler metal feed.
The advance of the welding is manually controlled.
SEMI BLIND JOINT – A joint in which one extremity
of the joint is not visible.
SERIES SUBMERGED ARC WELDING – A
submerged arc welding process variation in which
electric current is established between two consumable
electrodes which meet just above the surface of the
workpieces which are not part of the electric circuit.
SHIELDED CARBON ARC WELDING – A carbon
arc welding process in which shielding is effected by the
combustion of a solid material fed into the arc or from a
blanket of flux on the workpieces or both.
SHIELDED METAL ARC CUTTING/WELDING –
Cutting or welding effected by heating the workpieces
with an arc between a covered metal electrode and the
workpiece. Shielding is obtained from decomposition
of the electrode covering,
SHIELDING GAS – Protective gas used to prevent
atmospheric contamination.
SHORT CIRCUITING TRANSFER ARC
WELDING – Metal transfer
in which molten metal from a consumable electrode is
deposited during repeated short circuits.
FORGE WELDING – Process that produces
coalescence of metals by heating them in air in a forge
and by applying pressure or blows sufficient to
cause permanent deformation at the surface.
FUSION – Melting together of filler metal and base
metal (substrate) or of base metal only which results in
coalescence.
FUSION WELDING – Arc welding process that uses
fusion of the base metal to make the weld.
FUSION ZONE – Area of base metal melted as
determined on the crosssection of a weld.
GAS METAL ARC CUTTING – Process in which
metals are severed by melting them with the heat of an arc
produced between a continuous filler metal electrode and
the workpiece. Shielding is obtained entirely from an
externally supplied gas.
GAS CARBON ARC WELDING – Process which
produces coalescence of metals by heating them with an
electric arc between a carbon electrode and the
workpiece. Shielding is effected by a gas or gas mixture.
GAS METAL ARC WELDING – Process that produces
coalescence of metals by heating them with an arc
between a continuous filler metal
electrode and the workpiece. Shielding is obtained by
external gas supply.
GAS REGULATOR – A device for controlling the
delivery of gas at some substantially constant pressure.
GAS TUNGSTEN ARC CUTTING – Process in which
materials are severed by melting them with an arc
produced by a tungsten electrode and the workpiece.
Shielding is effected by a gas.
GAS TUNGSTEN ARC WELDING – Process that
produces coalescence of metals by heating them with an
arc produced between a tungsten (non-consumable)
electrode and the workpiece. Shielding is obtained from a
gas.
GAS WELDING – Process in which heat is furnished by
a flame resulting from the combustion of a fuel gas, such
as acetylene or hydrogen with oxygen; oxyacetylene
being capable of producing the highest temperature flame
is the most used.
GLOBULAR TRANSFER – Transfer of molten metal in
large drops from a consumable electrode across the arc in
arc welding.
GOUGING – The forming of a bevel or groove by
material removal.
HAND SHIELD – A protective device, used in arc
welding, for shielding the eyes, face and neck. A hand
shield is equipped with a suitable filter plate and is
designed to be held by hand.
HEAT AFFECTED ZONE – The portion of the base
metal that has not been melted, but whose mechanical
properties or microstructure have been altered by the heat
of welding, brazing, soldering or cutting.
SHRINKAGE VOID – A cavity type discontinuity
normally formed by shrinkage during solidification.
SILVER BRAZING – Brazing process that employs
silver alloys. Also called hard soldering or silver
soldering.
SLAG INCLUSION – Non-metallic material entrapped
in weld metal or between weld metal and base metal.
SLOT WELD – A weld made in an elongated hole in
one member of a joint fusing that member to another
member. The hole may be open at one end.
SOLDER – A filler metal used in soldering which has a
liquidus not exceeding 450°C.
SOLDERING – A group of welding processes that
produces coalescence of materials by heating them to a
suitable temperature and by using a filler metal having a
liquidus not exceeding 450°C and below the solidus
of the base metals.
SOLID STATE WELDING – A group of welding
processes that produces coalescence at temperatures
essentially below the melting point of the
base metal being joined, without the addition of a
brazing filler metal. Pressure mayor may not be used.
SPATTER – The metal particles expelled during fusion
welding, that do not form a part of the weld.
SPELTER – is common brass, the first material used to
make a brazed joint in ferrous material.
SPOT WELD – Weld made between or upon
overlapping members in which
coalescence may start and occur on the faying surfaces
or may proceed from the surface of one member. The
weld cross section (plan) is approximately circular.
SPRAY TRANSFER ARC WELDING – Metal
transfer in which molten metal from a consumable
electrode is propelled axially across the arc in small
droplets.
STACK CUTTING – Thermal cutting of stacked metal
plates arranged so that all the plates are severed by a
single cut.
STAGGERED INTERMITTENT WELD – An
intermittent weld on both sides of a joint in which the
weld increments on one side are alternated
with respect to those on the other side.
STRINGER BEAD – A type of weld bead made
without appreciable weaving motion.
STUD WELDING – A general form for the joining of a
metal stud or similar part to a workpiece. Welding may
be effected by arc, resistance, friction or other suitable
process, with or without external gas shielding.
SUBMERGED ARC WELDING – An arc welding
process in which the arc and molten metal are shielded
by a blanket of granular, fusible material on the workpie
SURFACING – Application by welding, brazing or
thermal spraying of a layer(s) of material to a surface to
obtain desired properties or dimensions as opposed to
making a joint.
HELMET (eye protection) – Device designed to be
worn on the head to protect eyes, face and neck from arc
radiation, radiated heat, spatter, or other harmful matter
expelled during arc welding.
HOT PRESSURE WELDING – Process that produces
coalescence of metals with heat and application of
pressure sufficient to produce macrodeformation
of the base metal. Vacuum or other shielding media is
used.
HOTWIRE WELDING – Arc welding process in which
a filler metal wire is resistance heated by current flowing
through the wire as it is fed into the weld pool.
INERT GAS – A gas which does not normally combine
chemically with the base metal or filler metal.
INTERMITTENT WELD – A weld in which the
continuity is broken by recurring unwelded spaces.
JOINT – Junction of members or the edges of members
which are to be joined or have been joined.
JOINT EFFICIENCY – The ratio of the strength of a
joint to the strength of the base metal expressed in per
cent.
KERF – Width of the cut produced during a cutting
process.
LAP JOINT – A joint formed between two overlapping
members in parallel planes.
LASER BEAM CUTTING – Process that severs
materials by melting or vaporizing them with the heat
obtained from a laser beam, with or without the
application of gas jets to augment the removal of material.
LASER BEAM WELDING – Process that produces
coalescence of materials with the heat obtained from the
application of a concentrated coherent light beam
impinging upon the joint.
TACK WELD – A weld made to hold parts of a
weldment in proper alignment until final welds are
made.
THERMIT MIXTURE – A mixture of metal oxide and
finely divided aluminium with the addition of alloying
metals as required.
THERMIT WELDING – Welding process that
produces coalescence of metals by heating them with
superheated liquid metal from a chemical
140 Handbook of Mechanical Engineering Terms
reaction between a metal oxide and aluminium, with or
without the application of pressure.
T-JOINT – A joint between two members located
approximately at rightangles to each other in the form of
a T.
TORCH BRAZING – A brazing process in which the
heat required is furnished by a fuel gas flame.
TWIN CARBON ARC WELDING – Process that
produces coalescence of metals by heating them with an
electric arc between two carbon electrodes. No shielding
is used.
UNDER WELDING – Depositing less filler material
than required.
WEAVE BEAD – A type of weld bead made with
transverse oscillation.
WELD – A localized coalescence of metals or non-
metals produced either by heating the materials to the
welding temperature, with or without the application of
pressure or by the application of pressure alone and with
or without the use of filler material.
WELDING ELECTRODE – A component of the
welding circuit through
which current is conducted and which terminates at the
arc, molten