Gas and Arc Welding

Gas and Arc
Welding
Welding and Types of Welding
Session 1
Outline
Why is Welding?
What is Welding?
Types of Welding Processes
Welding Applications and Selection of Welding Process
Summary
References
Preview of next lecture
Welding and Types of Welding 2
Why is Welding?
Welding joints are strong
Welding joints are permanent
Welding is free from corrosion
Welding is efficient and economical method
Welding is only method that can be used in air,
water and space application
Source: www.bobhaa.com

What is Welding?
Welding is a process of joining two similar
or dissimilar metal by using heat that melting metal
is united by hammering or pressing at perfect
temperature and pressure.
Source: www.clipart.com

Types of Welding
There are main six types of Welding
1. Gas Welding
2. Arc Welding
3. Resistant Welding
4. Solid State Welding
5. Thermo Chemical Welding
6. Under Water Welding
Gas Welding
Oxy acetylene Welding
Oxy Hydrogen Welding

Arc Welding
Carbon Arc Welding
Metal Arc Welding
Submerged Arc Welding
Inert Gas Arc Welding
TIG Welding
MIG Welding
Plasma Arc Welding
Electro slag Welding
Resistant Welding
Spot Welding
Seam Welding
Projection Welding
Butt Welding
Induction Welding

Solid State Welding
Friction Welding
Ultrasonic Welding
Explosive Welding
Forge and Diffusion Welding

Thermo Chemical Welding
Termite Welding
Atomic H2 Welding

Under Water Welding
Electron Beam Welding
Laser Beam Welding

Application
Automobile, Construction of Building, Bridge, Ship and
Submarines, Gas and Water Pipe lines, Water Turbines
etc.
For reducing noise in construction of Hospital building
Fabrication of fission chamber of nuclear power plant
Households appliances like refrigerator, air conditioners

Selection Criteria for Welding
Processes
Types of metal and its metallurgical properties
Types of joint, its location and welding position
Cost of production
Joint design
Accuracy required

Activity
Think/Pair/Share
Make a group of 4 students
You all have 3 minutes to think about answer of the
question
Group will discuss about question in group for 2 minutes
Group will choose a leader for giving answer

Activity Question
What is welding and why it is

required? Cannot we use any
other method than welding?

Summary
So far we have discussed about Welding. Welding is a
joining process and why this process is required. We have
also discuss different types of welding processes and its
application. There is a last and important aspect of
welding is its selection process based on its applications.

References
Welding Technology by Ed. Ibrahim khan, New Age
Publication, pp. 1-5
A Textbook of Production Technology by P C Sharma, S
Chand Publications.
www.wikipedia.com/welding
https://www.youtube.com/watch?v=lzTj9FRyUM0
www.bobhaa.com
www.clipart.com
Preview of next Lecture
In the next lecture, we will learn about Basics of Gas
welding.
We will learn about application of gas welding and oxy
acetylene type of gas welding where oxygen and acetylene
gas used for welding purpose.
Basic of Gas Welding 18

Gas and Arc
Welding
Basics of Gas Welding
Session 2
Summary of last lecture
So far we have discussed about Welding in last lecture.
Now we know Welding is a joining process and why this
process is required. We have also discuss different types
of welding processes and its application. There is a last
and important aspect of welding is its selection process
based on its applications.
Basics of Gas Welding 20

Outline
What is Gas Welding?
Application of Gas Welding
Types of Gas Welding
Oxy acetylene Gas Welding
Types of Flames
Summary
References
Gas Welding
It is a Metal joining process in which the ends of
pieces to be joined are heated at their interface
by producing coalescence with one or more gas
flames (such as oxygen and acetylene),
with or without the use of a filler metal.
Source:
www.weldingtypes.net
Application of Gas Welding
Sheet metal, Tubing, Car bodies
Carbide Tipping, Band saws, Tubular chassis, Frames
Stainless Steel Furnace Components, High Temperature
Processing Equipment, Heat Exchangers
Furnace Parts, Heat Treated Equipment, Heating
Elements, High Temperature Processing Equipment,
Sheeting Headers

Oxy acetylene Gas Welding
The oxyacetylene welding process uses a combination of
oxygen and acetylene gas to provide a high temperature
flame.
Oxygen is commercially made by liquefying air and
separating Oxygen from Nitrogen and stored in the
cylinders.
Calcium Carbide + Water = Lime + Acetylene gas

Source:
www.roymech.co.uk

Source:
www.victortechnologies.co
m
Procedure of Operating
1. Attaching pressure-reducing regulators
2. Connecting gas supplies to the torch
3. Adjusting operating pressures
4. Lighting and adjusting the flame
5. Shutting down the oxy fuel gas welder

Types of Flames
There are three main types of gas flames
1. Neutral Flames
2. Carburizing Flames
3. Oxidizing Flames

Neutral Flames
A neutral flame is obtained when equal amount of O2 and
C2H2 are mixed and burnt at the outlet of welding torch.
The flame consists of two sharply defined zones inner
white flame cone outer envelope of blue color.

Carburizing Flames
This flame is obtained when excess of acetylene is
supplied than which is theoretically required.
This flame is identified by three zones the inner cone
which is not sharply defined, an outer envelope as same in
case of neutral flamed and middle zone surrounds inner
one extended to outer envelope.
It is white in color due to excess acetylene.

Oxidizing Flames
This flame as an excess of oxygen over that required for a
neutral flame. To have this flame set carburizing flame
first convert it to neutral flame and then reduce the supply
of acetylene to get oxidizing flame.
Its inner cone is relatively shorter and excess oxygen
turns the flame to light blue color.

Oxy hydrogen Gas Welding
Oxy hydrogen is a mixture of hydrogen (H2) and oxygen
(O2) gases.
A ratio of 2:1 hydrogen : oxygen is enough to achieve
maximum efficiency; in practice a ratio 4:1 or 5:1 is
needed to avoid an oxidizing flame.
This mixture may also be referred to as knallgas.

Oxy hydrogen will combust when brought to its auto
ignition temperature.
For the stoichiometric mixture, 2:1 hydrogen : oxygen, at
normal atmospheric pressure,
Auto ignition occurs at about 570 C (1065 F).

The minimum energy required to ignite such a mixture
with a spark is about 20 micro joules.
At standard temperature and pressure, oxy hydrogen can
burn when it is between about 4% and 95% hydrogen by
volume.

When ignited, the gas mixture converts to water vapor
and releases energy, which sustains the reaction: 241.8 kJ
of energy (LHV) for every mole of H2 burned.

A pure stoichiometric mixture may be obtained by water
electrolysis, which uses an electric current to dissociate
the water molecules:
electrolysis: 2 H2O 2 H2 + O2
combustion: 2 H2 + O2 2 H2O

Summary
In this lecture we have learned the basics of gas welding
and its most useful type oxy acetylene gas welding
process. At last we learned types of flames.

References
Welding Technology by Ibrahim Khan, New Age International Publication, New Delhi, pp. 8-11
www.wikipedia.org/oxyhydrogene welding
http://www.businessdictionary.com/definition/gas-welding.html
http://strataalloys.com.au/products/13-products/2-gas-welding/19-gas-welding-application
www.aws.org/educators/Library
www.ignou.ac.in/upload/Unit-5.pdf
http://www.alce.vt.edu/teacher-resources/lab-safety-resources/oxyfuel.pdf
www.roymech.co.uk
www.weldingtypes.net
www.victortechnologies.com
www.nptel.iitm.ac.in- Manufacturing Process 1- lecture - mod03lec02

In the next lecture we will discuss about other type of the
gas welding which is oxy hydrogen gas welding where
hydrogen is used in place of acetylene gas.

Gas and Arc
Welding
Basics of Gas Welding
Session 3
Outline
Summary of Last Lecture
Basic Arc Welding
Carbon Arc Welding
Shielded Metal Arc Welding
Activity
References
Basics of Arc Welding 44

In last lecture, we have learned the basics of the gas
welding and its applications. We have also discussed the
oxy acetylene and oxy hydrogen type of the gas welding
which requires oxygen and acetylene for the gas
formation and also learn types of flames.

Electrical Arc Welding
Electric arc welding is one of the fusion welding processes
in which coalescence of the metal is achieved by the heat
from an electric arc between an electrode and work piece.
Electric arc is generated when electrode is brought into
contact with the work and is then quickly separated by a
short distance approximately 2 mm.

The circuit operates at low voltage and high current so arc
is established in the gap due to thermionic emission from
electrode (Cathode) to work piece (Anode). The arc is
sustained due to continuous presence of a thermally
ionized column of gas.
This arc produces at temperature of the order of 5500oC
or higher. In this way a pool of molten metal consisting of
work piece metal and filler metal is formed in the welding
zone.
The electrode is moved along the joint with perpendicular
zigzag motion. The solidified molten weld pool makes the
strong welded joint.
Movement of the electrode relative to work piece is
accomplished by either manually or by mechanical means
in case of automatic welding machines.

Applications
It is widely used in steel fabrication, structural shapes,
longitudinal and circumferential seams of large diameter
pipes, welding pressure vessels, welding of heavy
machinery

Carbon Arc Welding
Carbon arc welding (CAW) is a process which produces
coalescence of metals by heating them with an arc between a
non consumable carbon (graphite) electrode and the work-
piece
In carbon-arc welding a carbon electrode is used to produce
an electric arc between the electrode and the materials being
bonded. This arc produces extreme temperatures in excess of
3,000C. At this temperature the separate metals form a bond
and become welded together
Flux Cored Arc Welding
FCAW wire is actually a fine metal tube filled with
powdered flux materials. An externally supplied shielding
gas is sometimes used, but often the flux itself is relied
upon to generate the necessary protection from the
atmosphere.
The process is widely used in construction because of its
high welding speed and portability.

Shielded metal arc welding (SMAW), also known as manual
metal arc welding (MMA or MMAW), flux shielded arc
welding or informally as stick welding, is a manual arc
welding process that uses a consumable electrode coated in
flux to lay the weld.
An electric current, in the form of either alternating current
or direct current from a welding power supply, is used to
form an electric arc between the electrode and the metals to
be joined.
Because of the versatility of the process and the simplicity
of its equipment and operation, shielded metal arc
welding is one of the world's most popular welding
processes.
It dominates other welding processes in the maintenance
and repair industry.
SMAW continues to be used extensively in the
construction of steel structures and in industrial
fabrication.
Activity
Write difference between all three

processes

References
www.ignou.ac.in/upload
www.michigan.gov/documents/cis_wsh_osc6042_137274_7.doc
A Text book on Production Technology by P C Sharma, S Chand
publication, pp. 347-360
www.Wikipedia.org/arc welding
www.Wikipedia.org/carbon arc welding
www.Wikipedia.org/flux cored arc welding
www.Wikipedia.org/shielded arc welding
Gas and Arc
Welding
Basic of Arc Welding
Session 4
Outline
Tungsten Inert Gas Welding
Metal Inert Gas Welding
Activity
References
Preview of next session
Basic Arc Welding 60

Gas tungsten arc welding (GTAW), also known as
tungsten inert gas (TIG) welding, is an arc welding
process that uses a non-consumable tungsten electrode to
produce the weld.
The weld area is protected from atmospheric
contamination by an inert shielding gas (argon or helium),
and a filler metal is normally used. Autogenous welds do
not require it.

GTAW is most commonly used to weld thin sections of
stainless steel and non-ferrous metals such as aluminum,
magnesium, and copper alloys.
shielded metal arc welding and gas metal arc welding,
allowing for stronger, higher quality welds.
GTAW is comparatively more complex and difficult to
master, and furthermore, it is significantly slower than
most other welding techniques.
Applications
The aerospace industry is one of the primary users of gas
tungsten arc welding
It is used extensively in the manufacture of space vehicles,
and is also frequently employed to weld small-diameter,
thin-wall tubing such as those used in the bicycle industry
GTAW is the welding procedure of choice for critical
welding operations like sealing spent nuclear fuel
canisters before burial
Applications
In fillet weld

Gas metal arc welding (GMAW), sometimes referred to by
its subtypes metal inert gas (MIG) welding or metal active
gas (MAG) welding, is a welding process in which an
electric arc forms between a consumable wire electrode
and the work piece metal(s), which heats the work piece
metal(s), causing them to melt, and join.

A shielding gas feeds through the welding gun, which
shields the process from contaminants in the air. The
process can be semi-automatic or automatic.
A constant voltage, direct current power source is most
commonly used with GMAW, but constant current systems,
as well as alternating current, can be used.

GMAW torch nozzle cutaway image. (1) Torc
handle, (2) Molded phenolic dielectric (show
white) and threaded metal nut insert (yellow
Shielding gas diffuser, (4) Contact tip, (5) N
output face

GMAW on stainless steel

(1)Direction of travel, (2) Contact tube,
(3) Electrode, (4) Shielding gas,
(5)Molten weld metal, (6) Solidified weld m
(7)Work piece.

The basic technique for GMAW is quite simple, since the
electrode is fed automatically through the torch (head of
tip).
GMAW requires only that the operator guide the welding
gun with proper position and orientation along the area
being welded.

Shielding Gas
Shielding gases are necessary for gas metal arc welding to
protect the welding area from atmospheric gases such as
nitrogen and oxygen, which can cause fusion defects,
porosity, and weld metal embrittlement if they come in
contact with the electrode, the arc, or the welding metal.
In GMAW, the electrode wire does not have a flux coating,
and a separate shielding gas is employed to protect the
weld, this eliminates slag.
Activity
Write the difference between TIG and

MIG Processes

References
www.nptel.iitm.ac.in- Manufacturing Process 1- lecture -
mod03lec02
www.wikipedia.org/TIG Welding
www.wikipedia.org/MIG Welding
A Text book on Production Technology by P C Sharma, S
Chand publication, pp. 347-360
Gas and Arc
Welding
Basic of Arc Welding
Session 5
Outline
Plasma Arc Welding
Electro Slag Welding
Activity
References
Preview of Next Lecture
Summary of Last Lecture
In last session we have discussed about Tungsten Inert
Gas welding and Metal Inert Gas welding process. TIG
process uses Non consumable electrode while MIG uses
Consumable electrode. Efficiency of MIG process is higher
in comparison.

Continuous consumable electrode in the form of bare wire
Arc is covered by granular flux
The electrode wire is fed continuously and automatically
from a roll into the welding zone
The flux is introduced in to the joint slightly ahead of the
weld arch by gravity from a hopper

The portion of the flux near to the arc is melted, forming
slag, after mixing with molten metal. Slag can be removed
from the element.
Cover of granular flux not only provides protection from
the environment but also provides good thermal insulation
- slow cooling imparting toughness and ductility to the
joint.

Advantages
High deposition rates
Deep weld penetration
High speed welding of thin sheet steels up to 5 m/min
Low distortion
Welds produced are sound, uniform, ductile, corrosion
resistant and have good impact value
50% to 90% of the flux is recoverable, recycled and reused
Disadvantages
Limited to ferrous (steel or stainless steels) and some
nickel-based alloys
Normally limited to long straight seams or rotated pipes
or vessels.
Requires relatively troublesome flux handling systems.
Flux and slag residue can present a health and safety
concern.
Requires inter-pass and post weld slag removal
Applications
Carbon steels (structural and vessel construction)
Low alloy steels
Stainless steels
Nickel-based alloys
Surfacing applications (wear-facing, build-up, and
corrosion resistant overlay of steels)

Plasma Arc Welding
Plasma arc cutting (PAC) is a common AC process. At high
currents of 600 to 1000 A
PAC is used to cut very thick plate steel in excess of 2 cm
in thickness
The high-velocity jet forces molten metal through the kerf.
Water injection is used to cool the work piece.

Plasma Arc Welding
The PAC power supply can be quite expensive due to the
high open-circuit voltages required to maintain a high arc
voltage. Gas mixtures for PAC make use of argon with
hydrogen or hydrogen with nitrogen

Electro Slag Welding
Electro slag welding (ESW) is a highly productive,
single pass welding process for thick (greater than 25mm
up to about 300mm) materials in a vertical or close to
vertical position.
An electric arc is initially struck by wire that is fed into
the desired weld location and then flux is added.

Activity
Write difference between these three

processes

References
A Text book on Production Technology by P C Sharma, S Chand
publication, pp. 347-360
www.Wikipedia.org/Plasma arc welding
www.Wikipedia.org/electroslag welding
www.Wikipedia.org/submerged arc welding

Preview of next Session
In next lecture we will learn about soldering and brazing
processes.

Gas and Arc
Welding
Soldering and Brazing
Session 6
Outline
Soldering
Applications
Brazing
Applications
References
Soldering and Brazing 98

Soldering
Soldering is a process in which two or more metal items
are joined together by melting and flowing a filler metal
(solder) into the joint, the filler metal having a lower
melting point than the adjoining metal.
Soldering differs from welding in that soldering does not
involve melting the work pieces.

Applications
Soldering is used in plumbing, electronics, and metalwork
from flashing to jewelry
Soldering provides reasonably permanent but reversible
connections between copper pipes in plumbing systems as
well as joints in sheet metal objects such as food cans,
roof flashing, rain gutters and automobile radiators.

Applications
Jewelry components, machine tools and some
refrigeration and plumbing components are often
assembled and repaired by the higher temperature silver
soldering process. Small mechanical parts are often
soldered or brazed as well. Soldering is also used to join
lead came and copper foil in stained glass work. It can
also be used as a semi-permanent patch for a leak in a
container or cooking vessel.
Electronic soldering connects electrical wiring and
electronic components to printed circuit boards (PCBs). 102
Soldering and Brazing
Processes
There are three forms of soldering, each requiring
progressively higher temperatures and producing an
increasingly stronger joint strength
1. Soft soldering, which originally used a tin-lead alloy as
the filler metal,
2. Silver soldering, which uses an alloy containing silver,
3. Brazing which uses a brass alloy for the filler.

Silver Soldering
"Hard soldering" or "silver soldering" is used to join precious
and semi-precious metals such as gold, silver, brass, and
copper.
The solder is usually referred to as easy, medium, or hard. This
refers to its melting temperature, not the strength of the joint.
Extra-easy solder contains 56% silver and has a melting point
of 1,145 F (618 C). Extra-hard solder has 80% silver and
melts at 1,370 F (740 C).

Induction Soldering
Induction soldering uses induction heating by high-
frequency AC current in a surrounding copper coil.
This induces currents in the part being soldered, which
generates heat because of the higher resistance of a joint
versus its surrounding metal (resistive heating).

Fluxes for Soldering
Fluxes for soft solder are currently available in three basic
formulations:
1. Water-soluble fluxes - higher activity fluxes designed to
be removed with water after soldering (no VOCs required
for removal).

2. No-clean fluxes - mild enough to not "require" removal due
to their non-conductive and non-corrosive residue. These fluxes
are called "no-clean" because the residue left after the solder
operation is non-conductive and won't cause electrical shorts.
No-clean flux residue is acceptable on all 3 classes of PCBs as
defined by IPC-610 provided it does not inhibit visual
inspection, access to test points, or have a wet, tacky or
excessive residue that may spread onto other areas.

3. Traditional rosin fluxes - available in non-activated (R),
mildly activated (RMA) and activated (RA) formulations.
RA and RMA fluxes contain rosin combined with an
activating agent, typically an acid, which increases the
wettability of metals to which it is applied by removing
existing oxides.

Brazing
Brazing is a metal-joining process whereby a filler metal
is heated above melting point and distributed between two
or more close-fitting parts by capillary action.
The filler metal is brought slightly above its melting
(liquids) temperature while protected by a suitable
atmosphere, usually a flux. It then flows over the base
metal (known as wetting) and is then cooled to join the
work pieces together.
Brazing
In order to obtain high-quality brazed joints, parts must be
closely fitted, and the base metals must be exceptionally
clean and free of oxides. In most cases, joint clearances of
0.03 to 0.08 mm (0.0012 to 0.0031 in) are recommended
for the best capillary action and joint strength.
The two main methods for cleaning parts, prior to brazing,
are chemical cleaning and abrasive or mechanical
cleaning. In the case of mechanical cleaning.
Flux
Fluxes are generally selected based on their performance
on particular base metals. To be effective, the flux must be
chemically compatible with both the base metal and the
filler metal being used.
Self-fluxing phosphorus filler alloys produce brittle
phosphides if used on iron or nickel. As a general rule,
longer brazing cycles should use less active fluxes than
short brazing operations.
Filler Materials
Aluminum-silicon
Copper
Copper-silver
Copper-zinc (brass)
Gold-silver
Nickel alloy
Silver
Amorphous brazing foil using nickel, iron, copper, silicon, boron,
phosphorus
Atmosphere
As brazing work requires high temperatures, oxidation of the metal
surface occurs in an oxygen-containing atmosphere. This may
necessitate the use of an atmospheric environment other than air.
1. Air
2. Combusted Fuel Gas
3. Ammonia
4. Nitrogen
5. Hydrogen

Atmosphere
6. Inorganic Vapor
7. Noble Gas
8. Vacuum

Common Techniques
1. Torch brazing
2. Furnace brazing
3. Silver brazing
4. Braze welding
5. Cast iron "welding"
6. Vacuum brazing
7. Dip brazing
References
www.wikipedia.org/soldering
www.wikipedia.org/brazing
Production Technology by P C Sharma, S Chand
Publication, pp. 377-380
http://www.lucasmilhaupt.com/en-US/brazingapplications/
http://ewi.org/technologies/soldering-and-brazing-main/
www.ignou.ac.in/upload/Unit-6.pdf
Thank You
120

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Gas and Arc

Welding and Types of Welding 3

Welding and Types of Welding 4

Welding and Types of Welding 6

Welding and Types of Welding 8

Welding and Types of Welding 9

Welding and Types of Welding 10

Welding and Types of Welding 11

Welding and Types of Welding 12

Welding and Types of Welding 13

Welding and Types of Welding 14

What is welding and why it is

Welding and Types of Welding 15

Welding and Types of Welding 16

Basic of Gas Welding 18

Basics of Gas Welding 20

Basics of Gas Welding 23

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Basics of Gas Welding 27

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Basics of Gas Welding 40

Basics of Gas Welding 41

Basics of Gas Welding 42

Basics of Arc Welding 44

Basics of Arc Welding 45

Basics of Arc Welding 46

Basics of Arc Welding 49

Basics of Arc Welding 50

Basics of Arc Welding 52

Write difference between all three

Basics of Arc Welding 57

Basic Arc Welding 60

Basic Arc Welding 61

Basic Arc Welding 67

Basic Arc Welding 68

Basic Arc Welding 69

Basic Arc Welding 70

Basic Arc Welding 71

Basic Arc Welding 72

Basic Arc Welding 73

Write the difference between TIG and

Basic Arc Welding 75

Basic Arc Welding 79

Basic Arc Welding 80

Basic Arc Welding 83

Basic Arc Welding 86

Basic Arc Welding 87

Basic Arc Welding 91

Basic Arc Welding 92

Write difference between these three

Basic Arc Welding 94

Basic Arc Welding 95

Basic Arc Welding 96

Soldering and Brazing 98

Soldering and Brazing 99