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WELDING
\ Man 1facturing process is the production of workpieces having defined geometric shapes
welding c )mes under the process of joining.
Joining

Temporary Permanent

~ Jt bolt Screw Welding Soldering Brazing

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SOLDEl{ING :- The joining of two metal pieces by means of heat & filler metal is known as
solderin l

Wt en the melting point of filler metal is below 400.0c then· the process is called soft
solderirg . And the filler metal used is known as "Solder';. It is an alloy of lead and tin .
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W11en the melting point of filler metalis·above 400°c the process is called hard solder-
ing and the solder is mixtb(:- Of silver alloy and tin . -

Soldering

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Soft Soldering Hard Soldering
-- Temperature - below 400°c Temperature - above 400°c
Solder (Lead + Tin) Solder (Silver alloy + Ti n)
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BRAZING :- The joining of two metal pieces by means of heat and special type of filler
metal ,s known as "spelter" having the melting point temperature above 400°c but th'e lower
than ~1 e melting point tem~erature of parts to be joined .

The copper base silver alloys are commonly used as filler metal for Brazing .

Brazing ·
/ remperature -above 400°c and below the melting poiht tempeture of the part to be joined
[ Spelter -·(Copper base silver alloys)

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~elding :-
, Velding is a process of joining two similar or dissimilar metals by fusion , with or with out
.se of filler metal (Electrodes) and with or without application of pressure.
1
~rypes of fusion welding
Autogenous Welding :- The process of joining similar metals without the add ition
of filler metal is called Autogenous welding .
Homogenous Welding :- The process of joining similar metals with the help of filler
~ - metal of the same metal is called ho·mog~nous welding .
'). Hetrogenous Welding :- Th·e process of joining dissimilar metals using filler metal
· is called hetrogenous welding .

Weldability :-
Neldability is defined as the capacity of being welded easily.
Welding depends upon the following factor -
1. Melting point temperature of parts to be joined.

2. Thermal conduc~vity.

3. Thermal expansion.

4. Surface condition.

J. Change in micro structure .

General classification of welding

3enerally there two types of welding :-

1. · Forge I pressure I plastic

2. Fusion/ non-pressure/ non plastic -

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/ Press.ure
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Forge : Heat ~ Fusion

Filler Metal/
• j

-
 ------
Straight Polari\y .. When the work i . . .. "'"·
arid electrode to the negative then ·t _P etce_,shconne~ted to pos,t,ve terminal of heat Supply ~
I IS S ra1g t polarity. )l
l
(-)
.__t--- - --+-_J
(+) - - - 0.C. Supply '
Electrode _ _ __ _ __j

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I" : /:.-//(?'J«:1
/½l
------__J
~ workpiece
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l.
Reversed Polarity. :- When the work piece is connected to the negative terminal of heat 1'
s Jpply and electrode to the positive then it is reversed polarity. ·

Electrode --t (+) (-) p.C. Supply

I ~ -------'
~work· piece

Arc blow :- It is defined as the deflection of arc from its intented path due to the creation of
new electromagnetic field, which having direction perpendicular to the direction of electric
current.

_ _ _ O.C. Supply
(+) (-)
Electrode

~orkpiece
~ f2rge Welding :- In forge welding the work piece is heated to plastic state and than
joir ed together by applying pressure on them .

Forge Welding
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Heat source
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I I Friction
Black smith fire Electric current
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Resistance welding Friction welding
Forge welding

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Seam Projection upset butt Percussion
Spot
welding welding welding wel~ing welding

Fusion Welding :- In fusi_on welding the edge of workpiece to be joined and the ti.lier
mE tal are heated to a temperature above the melting point of the metal and allowed to
so-,dify.

Fusion Welding
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Heat Sowce

Gas Electric Current 1

Chemical reaction
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oxy acetylene
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I I 'Thermit welding
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Metal arc Carbon arc Inert Gas Submerged - Stud arc
welding welding weld/ng arc welding - welding

TIG MIG
(Tungsten Inert Gas Welding) (Metal Inert Gas Welding)

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Terms accounts in welding :-
Polarity:- The polarity occurs only in D.C. weldin . There is .
anj reversed polarity. The things which is connect~d to th . tw~.type of polarity straight
mt"lt 50% more then that of another one. e positions of D.C. source will
 Ammeter
Electrode Holder

Source of
efectrtc Insulated
Vottmeter
current cables
20 to 40 Arc
A.C. or O.C.

Metal table

Set Up of Metal Arc Welding

I Sketch Arc We.lding

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Tungsten Inert gas (TIG) welding : -

In tungsten inert gas welding the heat is produced from an ar5t, between non consumable
tungsten electrode and work piece . The whole weldfn g zone is sh ielded by an
atmosphere of inert gas (helium or ~rgan) supplied from a source and the nozzl~ of the
gas surrounds the tungsten electrode , when the gas leaves the nozzl~ it completely
surrounds the tip of electrode and work piece under it through this process the work
piece is melted and the joining process takes place. In this process AC or DC supply
may be use.1TIG is used for copper alloy, stain steel alloy, cast iron , aluminum etc.

Ml~tal inert gas welding (MIG) :-

In metal gas inert welding·is similar to tungsten inert gas welding except that the electrode
is consumable instead of nonconsumable. In this process filler metal wire of desired
composition is automatically and continuously fed from a reel of wire. The filler metal is
deposited by the arc which is completely surrounded by an inert gas by virtue of this
joining process takes place.

Draw TIG and MIG Welding

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