An Introduction to

Welding

Compiled & Presented

by
Shashank P Joshi
Why is a joint necessary? When?
 Whenever a shape & size of the
product or its part cannot be
produced as a whole (integral
unit) with structural continuity, a
joint is necessary.
Why is a joint necessary? When?
 When the product configuration is complex and
casting process results with inadequate
properties and/or is uneconomical, the desired
shape & size can be achieved by breaking the
product into parts and building the product by
joining.

 Or when the application demands dismantling for

the purpose of maintenance or replacement.
 Broad Division
of
Joining Processes

Temporary Permanent
Joining Processes Joining processes

Use of Fasteners Welding

Use of flanges Brazing

Press Fits - use

Soldering
of interface friction

Riveting
What is a ‘weld’?
 A weld is a localized coalescence of metals
or nonmetals.
 The localized coalescence is created by
bringing the surfaces to be joined together
at welding temperature, by application of
either heat alone or both heat & pressure
or application of the pressure alone ;
with or without addition of filler material.
What is a ‘weld’? A Braze? Asolder?
 In welding, brazing and soldering,
the objective is to form a continuous
metallic bridge between the two
surfaces, such that the bonding is of
the same character as that which
maintains the integrity of the metal
itself.
 But there is metallurgical difference
in metallic bridge of a weld, a braze,
and a solder.
A Welding Process
 A joining process that produces localized
coalescence of materials by either heating
the joining surfaces to welding
temperature with or without application of
pressure or pressure alone, and with or
without the use of filler material.
 Are brazing and soldering processes
create a coalescence?
A Joint
 A joint is an arrangement of components
which are to be joined or has been joined.
 A Weldment – May contain one or more
than weld joints.
 Weld Joint is a conjunction of two terms –
a ‘weld’ and a ‘joint’; describes type of
weld and type of joint.
Five Types of Joints
Corner
Butt

Lap

Edge

Tee
Five types of welds
(Refers to shape of weld)

Groove weld

Spot and Seam welds

Fillet weld

Other type of weld

Flange and Surface weld Plug and slot welds
 Surface Welds
Surface welds are material that has been
applied too and blended with the surface of
the work piece.
Two common applications are for hard
surfacing and padding
Crat er
Joint penet rat ion Weld bead

Base met al
Direct ion of t ravel
 Groove Welds
Weld
Weld reinf orcement Widt h Weld t oe

Root face
Ro ot reinforcement
Ro ot op ening

The primary use of groove welds is to complete butt joints.

Groove welds are used to fuse the sides or ends of
two pieces of metal.
Fillet Welds
Fillet welds have a
triangular cross
section and are used Act ual t hroat

to fuse two faces of Eff ect ive t hroat Weld t o e

metal that are at a Weld Face

Weld t oe

90 degree angle to
each other.
Weld root
Joint root Weld leg

Lap Corner

Tee
Plug Welds
 Plug welds are used to attach two
surfaces together when a complete joint
is not required and the design does not
allow for any weld bead outside the
dimensions of the metal.

The holes can be made with a drill

bit.
The weld is completed by establishing
the arc on the bottom plate and then
continuing to weld until the hole is full.
Slot Welds
Slot welds are identical to plug welds
except for the shape of the holes.
For slot welds, slots are machined or
stamped in the upper plate.

They are completely the same as

plug welds.
 Five Welding Positions

Flat Horizontal

Vertical down
Vertical up

Overhead
Basic Requirements of Welding to be fulfilled by
every welding process
I. A supply of energy to create union by
heat or pressure or heat & pressure
both.
II. A mechanism for removing superficial
contamination from the joint faces.
III. Avoidance of atmospheric
contaminations or its effects.
IV. Control of weld metallurgy.
Basic Mechanisms of Formation of a
Weld
 The simplest welding process would be
one in which the two parts to be joined
have their surfaces prepared to contours
matching with atomic precision. Such
surfaces brought together in vacuum, so
as to enable electrons to be shared
between atoms across the interface could
result in an ideal weld.
 Not feasible at present.
 The objective is to achieve atomic contact
between the parts to be joined, or in other
words a coalescence must be created.
Union by Flow
 Pressure is applied so
that abutting
surfaces are F F
plastically deformed
(sheared) giving the
required intimacy of
F F
contact at least at
the asperities.
Plastic deformation of
 Heating may be done faying surfaces
in order to facilitate
plastic deformation.
Union by Molten Metal Bridging
 Heat energy is
supplied to form a
molten pool – a Q
bridge of liquid
metal
 The required
adjustments in
contour and
structure are then
effected as molten
metal solidifies.
Heat Flow in Fusion Welding
3 Dimensional Heat Flow
2 Dimensional Heat Flow
Schematic Representation of an
Instantaneous Heat Source
SPECTRUM OF PRACTICAL HEAT
INTENSITIES USED FOR FUSION
WELDING

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Classification of Welding Processes
 According to Mechanism of formation of
weld:
Fusion welding, Pressure welding
 According to Metallurgical aspects:
Autogeneous, Homogeneous,
Heterogeneous
 Mode of Operation:
Manual, Semi-automatic, Automatic,
Automated, Mechanized, Synergic.
Classification of Welding Processes
 According to type of Energy Source:
Arc Welding – SMAW, SAW, TIG or GTAW,
GMAW; Resistance Welding – Resistance
Spot, Resistance Butt; Gas Welding –
OFW: Ultrasonic welding, Laser Beam
welding, Electron beam welding, Friction
welding, Thermit welding, Plasma arc
welding, Explosive welding,
 According to type of Joint:
Stud welding, Pipe welding, Spot welding,
Projection welding, Butt welding,
References
1. Welding Process Technology by P.T.
Houldcroft
2. Modern Welding Technology by Howard
B. Cary
3. Welding Processes and Technology
by Dr. R. S. parmar
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