A PRESENTATION

ON

WELDING TECHNOLOGY
 WELDING TECHNOLOGY
POWER PLANT A BRIEF OVERVIEW
MATERIAL SELECTION
METALLURGY A BRIEF INTRODUCTION
WELDING IN A POWER PLANT
WELDING INTRODUCTION, ITS BACKGROUND
MATERIAL INVOLVED IN POWER PLANT
FUNDAMENTALS OF WELDING
DEFINITIONS
SYMBOLS FOR WELDING
TYPE OF JOINTS, WELD
WELD JOINT DESIGN
WELD POSITIONS
WELD QUALITY
WELDING PROCESSES
 STEAM POWER PLANTS

WHAT IS SUB CRITICAL?

WHAT IS SUPER CRITICAL?

THERMODYNAMIC CONCEPTS (IN BRIEF)

EXISTING SUPERCRITICAL UNITS

DESIGN FEATURES

MATERIAL DEVELOPMENT
 STEAM POWER PLANTS
DEFINITION OF CRITICAL CONDITIONS

CRITICAL IS A THERMODYNAMIC
EXPRESSION DESCRIBING THE STATE OF A
SUBSTANCE BEYOND WHICH THERE IS NO
CLEAR DISTINCTION BETWEEN THE LIQUID
AND GASEOUS PHASE.

THE CRITICAL PRESSURE AND TEMPERATURE

FOR WATER ARE

- PRESSURE = 225.56 Kg / cm2

- TEMPERATURE = 374.150 C
 STEAM POWER PLANTS
p =225.56 Kgf/cm2
LIQUID
REGION
CRITICAL POINT

VAPOR
REGION
T p = 15 Kgf/cm2

p = 1.0332 Kgf/cm2
Saturated
LIQUID - VAPOR REGION vapor line
Saturated liquid line

v
Temperature - Specific Volume Diagram for Water
 STEAM POWER PLANTS
1
4
3

GEN.
2

BOILER CONDENSER
DEAERATOR

9 6
10 8
11 7

HPH BFP LPH CEP

SCHEMATIC DIAGRAM OF SUB - CRITICAL STEAM POWER PLANT

 STEAM POWER PLANTS
T - s DIAGRAM

HEATING IN
REHEATER

HEATING IN 1
SUPERHEATER
3
TEMPERATURE T

HEATING IN 11
HP HEATERS,
HEATING IN STEAM
ECONOMIZER STEAM EXPANSION IN
GENERATOR
I.P. TURBINE, L.P. TURBINE
10
STEAM EXPANSION
2
PUMPING BY IN H.P. TURBINE
BFP
9
HEATING IN
7 LP HEATERS
PUMPING
BY CEP 5
6 STEAM CONDENSATION IN CONDENSER

SPECIFIC ENTROPY s
 STEAM POWER PLANTS
SUB - CRITICAL STEAM POWER PLANT

th = 33 - 36%

TO IMPROVE THERMAL EFFICIENCY

INCREASE TEMPERATURE (SUPERHEAT)

INCREASE INLET PRESSURE TO HPT (p1)

REDUCE CONDENSER PRESSURE

WHY SHOULD AN ENGINEER STUDY MATERIALS ?

EVERY SINGLE THING CONSTRUCTED FROM SOME MATERIAL OR

OTHER

TO KNOW THE RANGE OF MATERIALS & PROPERTIES OF MATERIAL

TO KNOW - PROPERTIES ARE DEPENDENT ON STRUCTURE

TO KNOW HOW THE PROPERTIES CAN BE MODIFIED BY VARIETY

OF TREATMENT

TO KNOW ENVIRONMENTAL & SOCIAL FACTORS ASSOCIATED WITH

PRODUCTION & UTILIZATION OFMATERIAL

TO KNOW HOW TO SELECT MOST SUITABLE MATERIAL IN A

PARTICULAR DESIGN REQUIREMENT
 WHY SHOULD AN ENGINEER STUDY MATERIALS ?

THERE IS COMPLEX INTERRELATIONSHIPS BETWEEN MATERIAL,

MANUFACTURING PROCESS AND DESIGN

KNOW THE MAJOR CLASSIFICATIONS OF MATERIALS

MAIN CHARACTERISTICS OF EACH CLASS

SOME KNOWLEDGE OF BASIC COSTS OF SOME MATERIALS

HOW THE COST & ENERGY CONTENT ARE AFFECTED BY

PROCESSING
 DESIGN, MATERIALS AND MANUFACTURE

MATERIALS

DESIGN MANUFACTURE

UTILIZE MATERIALS IN MOST EFFECTIVE & EFFICIENT

MANNER

MATERIAL SHALL BE RECYCLED WHEN PRODUCT HAS

REACHED THE END OF ITS LIFE

ENVIRONMENTAL & SOCIOLOGICAL FACTORS

 DESIGN,
DESIGN,MATERIALS ANDMANUFACTURE
MATERIALS AND MANUFACTURE

WHAT DESIGNER HAS TO KNOW ABOUT THE MATERIAL ?

DOES THE MATERIAL POSSESS THE NECESSAY PROPERTIES?

CAN THE MATERIAL BE FORMED TO THE DESIRED SHAPE?

WILL THE PROPERTIES OF THE MATERIAL ALTER WITH TIME

DURING SERVICE?

WILL THE MATERIAL BE ADVERSELY AFFECTED BY

ENVIRONMENTAL CONDITIONS AND RESIST CORROSION AND
OTHER FORM OF ATTACK?

WILL THE MATERIAL GIVE SUFFICIENT RELIABILITY & QUALITY?

CAN THE PRODUCT BE MADE AT AN ACCEPTABLE COST
CLASSIFICATION OF ENGINEERING MATERIALS

ENGINEERING MATERIALS

CERAMICS
METALS POLYMERS & COMPOSITES
INORGANIC GLASSES
 ENGINEERING MATERIAL PROPERTIES & QUALITIES
PHYSICAL MECHANICAL CHEMICAL OTHER ECONOMIC AESTHETIC
PROPERTIES PROPERTIES PROPERTIES NON MECH. PROPERTIES PROPERTIES
PROPERTIES
DENSITY YIELD RESILIENCE TO ELECTRICAL RAW APPEARANCE
STRENGTH OXIDATION MATERIAL &
PROCESSING
MELTING TENSILE CORROSION MAGNETIC TEXTURE
COST
POINT STRENGTH

HARDNESS COMPRESSIVE SOLVENT & OPTICAL AVAILABILITY ABILITY TO

STRENGTH ENVIRONMENTAL ACCEPT
FACTORS SPECIAL
FINISHES
ELASTIC TORSIONAL THERMAL
MODULI STRENGTH

DAMPING DUCTILITY
CAPACITY
FATIGUE
STRENGTH

CREEP
STRENGTH

FRACTURE
TOUGHNESS
 A TENNIS RACQUET - MATERIAL SELECTION

REQUIREMENT MATERIAL PROGRESSIVE TRENDS

OF THE AVAILABLE
MATERIAL

HIGH LAMINATED EARLY 1970

STRENGTH WOOD ALL RACQUETS MADE OF LAMINATED WOOD

STIFFNESS DISADVANTAGE ABSORB MISTURE, WATER LEAD TO

VARIATIONS IN PERFORMANCE, WRAPPING OF FRAME
LOW COST
STEEL, LATE 1970 - FRAMES WITH STEEL & ALUMINUM
ALUMINIUM HIGH STRENGTH / WEIGHT RATIO
STRONG, RIGID, LIGHT FRAME
DISAGVANTAGE - LOW DAMPING COEFFICIENTS LEADS
TO AMOUNT OF VIBRATIONS TRANSMITTED TO PLAYERS
HAND & ARM INCREASED
FIBRE EARY 1980s COMPOSITES
REINFORCED
COMPOSITES USING CONTINUOUS GLASS OR CARBON FIBRES IN A
POLYESTER OR EPOXY
LIGHT WT. FRAME HIGH STRENGTH & STIFFNESS
HIGHER DAMPING COEFFICIENTS
OVERHEAD ELECTRIC TRANSMISSION LINES - MATERIAL SELECTION

REQUIREMENT MATERIAL AVAILABLE DESIGN FEASIBILITY

OF THE
MATERIAL
HIGH FOUR BEST METALS IN SILVER & GOLD TOO COSTLY,
ELECTRICAL DESCENDING ORDER OF RULED OUT
CONDUCTIVITY ELECTRICAL CONDUCTIVITY
SILVER COPPER IS MORE EXPENSIVE
COPPER THAN ALUMINIUM
GOLD
ALUMINIUM SELECTED MATERIAL PURE
ALUMINIUM
(SHOULD HAVE HIGH PURITY )
PROBLEM LOW TENSILE
STRENGTH ?

SOLUTION
OVER HEAD TRANSMISSION
CABLES ARE MADE OF
ALUMINIUM WIRES BRAIDED
AROUND A STEEL WIRE CORE TO
GIVE STRENGTH
OVERHEAD POWER WIRES FOR RAILWAYS - MATERIAL SELECTION

REQUIREMENT OF MATERIAL AVAILABLE DESIGN FEASIBILITY

THE MATERIAL

HIGH ELECTRICAL FOUR BEST METALS IN SOLUTION

CONDUCTIVITY DESCENDING ORDER OF WIRES MADE OF COPPER
ELECTRICAL CONDUCTIVITY ALLOY CONTAINING 1 %
SILVER CADMIUM
MATERIAL SHOULD COPPER
BE HARD TO RESIST GOLD CADMIUM GREATLY
ABRASIVE EFFECT OF ALUMINIUM INCREASE THE HARDNESS
PANTOGRAPH ARM
OF THE VEHCILE. LITTLE ADVERSE EFFECT
(SHOULD HAVE HIGH PURITY )
ON ELECTRICAL
CONDUCTIVITY
 DEFINITIONS

METALLURGY

METALLURGY IS THE DOMAIN OF MATERIAL SCIENCE AND

MATERIAL ENGINEERING THAT STUDIES THE PHYSICAL AND
CHEMICAL BEHAVIOUR OF METALLIC ELEMENTS AND THEIR
MIXTURES, WHICH ARE CALLED ALLOYS.
 DEFINITIONS

EXTRACTION METALLURGY

EXTRACTION METALLURGY IS THE PRACTICE OF

SEPARATING METALS FROM THEIR ORE, AND REFINING THEM
INTO A PURE METAL.

IN ORDER TO CONVERT A METAL OXIDE OR SULPHIDE TO A

METAL, THE METAL OXIDE MUST BE REDUCED EITHER
CHEMICALLY OR ELECTROLYTICALLY.
 DEFINITIONS
METALLURGY IN PRODUCTION ENGINEERING

IN PRODUCTION ENGINEERING, METALLURGY IS

CONCERNED WITH THE PRODUCTION OF METALLIC
COMPONENTS FOR USE IN CONSUMER OR
ENGINEERING PRODUCTS.

THIS INVOLVES

PRODUCTION OF ALLOYS,
SHAPING,
HEAT TREATMENT AND
SURFACE TREATMENT OF THE PRODUCT
 DEFINITIONS
TASK OF METALLURGIST

THE TASK OF THE METALLURGIST IS TO ACHIEVE

DESIGN CRITERIA SPECIFIED BY THE MECHANICAL
ENGINEER, SUCH AS COST, WEIGHT, STRENGTH,
TOUGHNESS, HARDNESS, CORROSION RESISTANCE
AND PERFORMANCE IN EXTREMES OF TEMPERATURE.
 DEFINITIONS
EXTENSIVE USE OF METALLURGY IN

STEEL MAKING & PROCESSING

HEAT-TREATMENT
FORGING
FOUNDRY
WELDING
 DEFINITIONS
ELEMENTS
A CHEMICAL ELEMENT, OFTEN CALLED SIMPLY ELEMENT, IS
A SUBSTANCE THAT CANNOT BE DIVIDED OR CHANGED INTO
DIFFERENT SUBSTANCES BY ORDINARY CHEMICAL
METHODS.

THE SMALLEST PARTICLE OF SUCH AN ELEMENT IS AN

ATOM, WHICH CONSISTS OF ELECTRONS CENTERED ON A
NUCLEUS OF PROTONS AND NEUTRONS.

AS ON TODAY 116 KNOWN ELEMENTS

90 OCCUR NATURALLY
26 DERIVED ARTIFICIALLY
 DEFINITIONS
METALS

IN CHEMISTRY, A METAL (GREEK: METALLON) IS AN

ELEMENT THAT READILY FORMS IONS (CATIONS) AND HAS
METALLIC BONDS, AND METALS ARE SOMETIMES
DESCRIBED AS A LATTICE OF POSITIVE IONS (CATIONS) IN
A CLOUD OF ELECTRONS.

METALS ARE DISTIGUISHED BYIONIZATION & BONDING

PROPERTIES
 DEFINITIONS
METALS, NON METALS AND METALLOIDS

ON THE PERIODIC TABLE, A DIAGONAL LINE DRAWN FROM

BORON (B) TO POLONIUM (Po) SEPARATES THE METALS
FROM THE NON-METALS.

ELEMENTS ON THIS LINE ARE METALLOIDS,

(SEMIMETALS)

ELEMENTS TO THE METALS

LOWER LEFT OF THE LINE

ELEMENTS TO THE NON - METALS

UPPER RIGHT OF THE LINE
 STANDARD PERIODIC TABLE

Group 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Period

1 2
1
H He

3 4 5 6 7 8 9 10
2
Li Be B C N O F Ne

11 12 13 14 15 16 17 18
3
Na Mg Al Si P S Cl Ar

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
4
K Ca Sc Ti V Cr Mn Fe Co Ni Cu Zn Ga Ge As Se Br Kr

37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
5
Rb Sr Y Zr Nb Mo Tc Ru Rh Pd Ag Cd In Sn Sb Te I Xe

*
55 56 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86
6
Cs Ba Hf Ta W Re Os Ir Pt Au Hg Tl Pb Bi Po At Rn

**
87 88 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118
7
Fr Ra Rf Db Sg Bh Hs Mt Ds Rg Uub Uut Uuq Uup Uuh Uus Uuo

57 58 59 60 61 62 63 64 65 66 67 68 69 70 71
LANTHANIDES La Ce Pr Nd Pm Sm Eu Gd Tb Dy Ho Er Tm Yb Lu

ACTINIDES 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103

Ac Th Pa U Np Pu Am Cm Bk Cf Es Fm Md No Lr
 CRYSTALLINE STRUCTURE

B.C.C. F.C.C. C.P.H.

CHROMIUM ALUMINIUM TITANIUM
TUNGSTEN COPPER ZINC

VANADIUM LEAD ZIRCONIUM

MOLYBDENUM NICKEL MAGNESIUM

IRON SILVER COBALT

(EXCEPT IN TEMP.
RANGE 910-1400 OC)
IRON
(EXCEPT IN TEMP.
RANGE 910-1400 OC)
 CRYSTALLINE STRUCTURE

BODY CENTERED CUBIC FACE CENTERED CUBIC

(B.C.C.) (F.C.C.)

SOME COMMON UNIT CELLS

CRYSTALLINE STRUCTURE

CLOSED PACKED HEXAGONAL

(CPH)

SOME COMMON UNIT CELLS

 SOLIDIFICATION PROCESS OF METALS

METAL IN LIQUID STATE NO DISTINCT STRUCTURE

ATOMS MOVE FREELY AMONG

THEMSELVES

AS MOLTEN METAL COOLS HEAT ENERGY DECREASES

LESS MOBILITY OF ATOMS

NEAR TO SOLIDIFICATION ATOMS ATTRACTED TOGETHER

IN A DEFINITE PATTERNS
THREE DIMENSIONAL LATTICE

ALSO CALLED SPACE LATTICES

CRYSTAL
 CRYSTALLINE STRUCTURE

GRAINS

GRAIN BOUNDARY

ATOMS IN A CRYSTAL POLYCRYSTALLINE SOLID

 CRYSTAL IMPERFECTIONS
POINT DEFECTS

VACANCY INTERSTITIAL SUBSTITUTIONAL

IMPURITY IMPURITY
 CRYSTAL IMPERFECTIONS
LINE DEFECTS

EDGE DISLOCATION SCREW DISLOCATION

SURFACE DEFECTS
 PROPERTIES DEPENDENT ON
CRYSTAL STRUCTURE AND DEFECT
PROPERTIES DEPENDENT ON

BASIC CRYSTAL STRUCTURE CRYSTAL IMPERFECTION

DENSITY ELECTRICAL CONDUCTIVITY
SPECIFIC HEAT YIELD STRESS

COEFFICIENT OF THERMAL CREEP

EXPANSION
MELTING POINT FRACTURE STRENGTH

ELEASTIC CONSTANTS SEMICONDUCTIVITY

HARDNESS WORK HARDENING

DUCTILITY FATIGUE STRENGTH

 DEFINITIONS
ALLOY
AN ALLOY IS A COMBINATION, EITHER IN SOLUTION OR
COMPOUND, OF TWO OR MORE ELEMENTS, AT LEAST ONE
OF WHICH IS A METAL, AND WHERE THE RESULTANT
MATERIAL HAS METALLIC PROPERTIES.

BINARY ALLOY TWO COMPONENTS

TERNARY ALLOY THREE COMPONENTS
QUATERNARY ALLOY FOUR COMPONENTS

THE RESULT IS A METALLIC SUBSTANCE WITH

PROPERTIES DIFFERENT FROM THOSE OF ITS
COMPONENTS.
 DEFINITIONS
ALLOY
PROPERTIES OF ALLOY IS BETTER THAN ITS COMPONENTS.

STEEL IS STRONGER THAN IRON

BRASS IS MORE DURABLE THAN COPPER

ALLOYS DO NOT HAVE A SINGLE MELTING POINT

ALLOYS HAVE MELTING RANGE IN WHICH MATERIAL IS MIXTURE OF

LIQUID AND SOLID PHASES.

TEMPERATURE AT WHICH MELTING BEGINS SOLIDUS

TEMPERATURE AT WHICH MELTING COMPLETE LIQUIDUS

 DEFINITIONS
ALLOYS

MOST METALS IN COMMON USE ARE IN THE FORM OF ALLOY

SUBSTITUTIONAL SOLID SOLUTION
INTERSTITIAL SOLID SOLUTION
INTER-METALLIC COMPOUND

PHASE EACH GROUPING WITH ITS OWN

CRYSTALLINE STRUCTURE

MICROSTRUCTURE OVERALL ARRANGEMENT OF GRAINS,

GRAIN BOUNDARIES & PHASES PRESENT
IN ALLOY
 SOLID SOLUTIONS

INTERSTITIAL SOLID
SUBSTITUTIONAL SOLID
SOLUTION
SOLUTION
 EQUILIBRIUM PHASE DIAGRAM OF Cu Ni ALLOY

MELTING TEMPERATURE OF Ni = 1452O C

1500 MELTING TEMPERATURE OF Cu = 1083O C B
1452O C
LIQUID
1400
P
TEMPERATURE C
O

LIQUID + SOLID
1300

X Z Y
1200

SOLID
Q
1100
1083 A
1000
Ni % 0 25 50 75 100

Cu % 100 75 50 25 0
 COOLING CURVE OF A PUR IRON

1537
LIQUID
1500

IRON (B.C.C.)
C

1400
O
TEMPERATURE

1200
IRON (F.C.C.)

910

900
IRON (F.C.C.)

TIME
 PERCENTAGE OF CARBON

ALLOY % OF CARBON
WROUGHT IRON No Carbon ( < 0.08%)
LOW CARBON STEELS 0.15 % Carbon (Max)
0.25 - 1.5 % Manganese
MILD STEEL 0.15 - 0.29 % Carbon

MEDIUM CARBON STEEL 0.25 - 0.50 % Carbon

0.60 - 1.65 % Manganese
HIGH CARBON STEELS 0.50 - 1.03 % Carbon
0.30 - 1.00% Manganese
LOW ALLOY STEELS 0.29 % Carbon (Max.)
Total Metal Alloys <= 2.0 %
CAST IRON 2.1 % Carbon
 IRON CARBON EQUILIBRIUM DIAGRAM

1537 +L
1492 L (LIQUID)
1400
+
+L
(AUSTENITE) E L + Fe3C
A
TEMPERATURE OC

1125

EUTECTIC
+
910 + Fe3C
E
723
C
PEARLITE CEMENTITE
(EUTECTOID)
+ Fe3C
(FERRITE)
FERRITE CEMENTITE
+ PEARLITE + PEARLITE

C% 0 0.83 2.00 4.3 6.67

STEEL CAST IRON

MICROSTRUCTURE OF PHASES OF
CARBON STEEL
 MICROSTRUCTURE

MICROSTRUCTURE REFERS OF THE MICROSCOPIC DESCRIPTION

OF THE INDIVIDUAL CONSTITUENTS OF A MATERIAL. THE LENGTH
SCALE IS 100-1 MICROMETER, WELL ABOVE THE ATOMIC LEVELS.

IN METALS OR OTHER HOMOGENOUS MATERIALS, THIS IMPLIES A

UNIFORM MICROSTRUCTURE,

IN ALLOYS, SEDIMENTARY ROCKS AND BIOLOGICAL MATTER THE

MICROSTRUCTURE CONTAINS ALL THE INFORMATION REGARDING
THE DISTRIBUTION OF THE INDIVIDUAL CONSTITUENTS WITHIN
THE MATERIAL.
 MICROSTRUCTURE
FERRITE

STATE OCCURENCE REMARKS

- IRON WITH CEMENTITE IN LOW

CARBON STEEL & IN
IT IS ALMOST PURE IRON

WROUGHT IRON VERY SMALL AMOUNT OF

DISSOLVED CARBON

SOFT, DUCTILE & WEAK

 MICROSTRUCTURE
AUSTENITE

STATE OCCURENCE REMARKS

- IRON WITH (UP IN CARBON STEEL, IT IS IT EXISTS AT 723O C TO 1400O C
TO 2%) CARBON IN NOT PRESENT AT
SOLID SOLUTION ROOM TEMPERATURE VERY SOFT & DUCTILE
FOR HEAT TREATMENT, STEELS
BROUGHT IN THIS STATE.
ROLLING & FORGING ARE DONE
IN THIS STATE.
 MICROSTRUCTURE
CEMENTITE

STATE OCCURENCE REMARKS

Fe3C ALONG WITH FERRITE IN HARD & BRITTLE

STEELS.

IMPORTANT CONSTITUENTS IT PRESENCE IN STEELS

OF WHITE CAST IRON & ALONG WITH FERRITE MAKES
TOOL STEEL THEM TOUGH, HARD &
STRONG
 MICROSTRUCTURE
PEARLITE

STATE OCCURENCE REMARKS

ALTERNATIVE CHIEF CONSTITUENTS OF SOFTER & MORE DUCTILE

LAYERS OF ANNEALED, NORMALIZED & THAN CEMENTITE
FERRITE & EUTECTOID STEEL
CEMENTITE
HARDER & STRONGER
THAN FERRITE
 MICROSTRUCTURE
MARTENSITE

STATE OCCURENCE REMARKS

FORCED SOLUTION IN HARDENED STEEL HARD & BRITTLE.
OF CARBON IN IRON
VERY LITTLE DUCTILITY
 BRINELL HARDNESS NUMBER

120
160
200
240
280
320
360
ELONGATION, PERCENTAGE

5
10
15
20
30

25

0.0
0.1
PIPE BOILER PLATES, SHEET STEEL, RIVETS, BOLTS,

STRUCTURAL STEEL, COLD

0.2
FORGINGS ROLL STEEL
MILD STEEL
VERY MILD &

0.3
MACHINE PARTS,
AXLES, SHAFTS ,

0.4
STEEL CASTINGS
ELONGATION

0.5
LOW & MEDIUM
CARBON STEEL
HYPOEUTECTOID STEEL

0.6
TENSILE

WOOD WORKING TOOLS,

0.7
STRENGTH

BAND SAW

0.8
SPRINGS, METAL DIES, LATHE

0.9
WORKING TOOLS, TOOLS, ROCK
WIRES & CABLES DRILL

PERCENTAGE, CARBON
1.0
EUTECTOID STEEL

1.1
1.2 KNIVES, SAW, FILES,
RAZORS, DIES, BALL
BEARING, WIRE DRAWING
1.3

DIES
HYPEREUTECTOID STEEL

HIGH CARBON STEEL

HARDNESS

1.4
1.5
1.6
1.7
15
30
45
60
75
90
120
EEFECT OF CARBON CONTENT ON ELONGATION, HARDNESS AND TENSILE STRENGTH OF STEEL

TENSILE STRENGTH Kg / mm2

A SCHEMATIC VIEW OF A POWER PLANT
 QUANTUM OF WELDING
IN
A POWER PLANT (2* 500 MW)

AREA OF WELDING QUANTUM OF WELDING

(NO. OF JOINTS)
STRUCTURAL WELDING > 10,000 Nos
(SG, TG, CHP, ETC) PLATE MATERIAL PLATE THICKNESS (t)
MILD STEEL 60 mm t 6 mm
(IS 2062)

PIPE WELDING > 10,000 Nos

PIPE MATERIAL PIPE THK (t) PIPE OD
mm mm
CARBON STEEL 100 t 6 25 d 400

ALLOY STEEL 100 t 6 25 d 400

STAINLESS 20 t 6 25 d 200
STEEL
 INTRODUCTION TO WELDING

WELDING INVOLVES MORE SCIENCES & VARIABLES

THAN ANY OTHER INDUSTRIAL PROCESS

IT IS A COMPLEX PROCESS

NUMEROUS EXAMPLES OF STRUCTURES / EQUIPMENT

WHERE WELDING IS INVOLVED

WORLD TALLEST BUILDING

MOON ROCKET ENGINE
NUCLEAR REACTORS
POWER PLANTS
AUTOMOBILE ETC.
 INTRODUCTION TO WELDING
WELDING IS THE MOST EOCONOMIC & EFFICIENT WAY TO
MAKE PERMANENT JOINT IN METALS

EXCESS METAL TO
MAKE RIVETTED JOINT

WELDED JOINT

EOCONOMICAL
MORE STRENGTH
 INTRODUCTION TO WELDING
WELDING IS THE MOST EOCONOMIC & EFFICIENT WAY TO
MAKE PERMANENT JOINT IN METALS
ECONOMICAL WELDED JOINT

EXCESS METAL TO MAKE

SLEEVE JOINT IN PIPE LINE
 INTRODUCTION TO WELDING
WELDING IS THE BEST WAY TO PROTECT AND CONSERVE
MATERIALS BY PROTECTING THEIR SURFACE WITH SPECIAL
METAL OVERLAYS

OVERLAID PART IN CINDER

CRUSHER ROLL

SPECIAL ALLOYS DEPOSITED ON BASE METAL TO PROVIDE

CORROSION - RESISTANT SURFACES
HARD SURFACING OVERLAYS TO MAKE WEAR RESISTANT SURFACES
 INTRODUCTION TO WELDING

THERE ARE MANY WAYS TO MAKE A WELD

ARC WELDING MOST POPULAR

IDENTIFIED WITH SPARK

SOME WELDING DO NOT CAUSE SPARK

PROCESSES

IN SOME CASES NO ELECTRICITY

WELDING HAS BECOME COMPLEX & TECHNICAL

IT REQUIRES CONSIDERABLE KNOWLEDGE TO SELECT

THE PROPER WELDING PROCESS
 INTRODUCTION TO WELDING

ADVANTAGES OF WELDING

LOWEST COST JOINING METHOD

AFFORD LIGHTER WEIGHT THROUGH BETTER UTILIZATION
OF MATERIALS
JOIN ALL COMMERCIAL METALS
CAN BE USED ANYWHERE
PROVIDE DESIGN FLEXIBILITY

LIMITATIONS

SOME WELDING DEPENDS ON HUMAN FACTOR

IT OFTEN REQUIRES INTERNAL INSPECTION
 INTRODUCTION TO WELDING
ALL METALS COMMERCIALLY USED FOR STRUCTURAL OR
STRENGTH PARTS ARE WELDABLE.

SOME METALS EASY TO WELD.

SOME METALS DIFFICULT TO WELD.

REQUIRES SPECIAL PROCEDURES
& TECHNIQUES.

WELDABILITY

THE CAPACITY OF MATERIALS TO BE WELDED UNDER THE IMPOSED

FABRICATION CONDITIONS INTO A SPECIFIC SUITABLY DESIGNED
STRUCTURE AND TO PERFORM SATISFACTORILY IN THE INTENDED
SERVICE.
 WELDING HISTORICAL DEVELOPMENT

EARLIEST EXAMPLES OF WELDING

BRONZE AGE SMALL GOLD CIRCULAR BOXES MADE

BY PRESSURE WELDING LAP JOINT
ESTIMATED 2000 YRS. AGO
PRESENTLY ON EXHIBIT AT NATIONAL
MUSEUM IN DUBLIN, IRELAND

IRON AGE EGYPTIANS LEARNED TO WELD PIECES

OF IRON TOGETHER

TOOLS FOUND - 1000 B.C.

EXHIBIT IN BRITISH MUSEUM IN LONDON

 WELDING HISTORICAL DEVELOPMENT
MIDDLE AGE BLACKSMITHING WAS DEVELOPED.
IRON WELDED BY HAMMERING.
IRON PILLAR OF DELHI - 310 A.D.
MADE OF IRON BILLETS WELDED
TOGETHER
IT IS 7.6 m TALL, TOP DIA 300 mm
BOTTOM DIA 400 mm
TOTAL WT. = 5.4 MT
SOME EXAMPLES IN EUROPE

19th CENTURY WELDING WHAT WE KNOW TODAY

INVENTED

1836 DISCOVERY OF ACETYLENE -

EDMUND DAVY OF ENGLAND
MID 19th CENTURY ELECTRIC GENERATOR INVENTED
 WELDING HISTORICAL DEVELOPMENT
LATE 19TH GAS WELDING & CUTTING DEVELOPED
CENTURY

RESISTANCE WELDING BECAME

PRACTICAL JOINING PROCESS

1890 ARC WELDING USING METAL ELECTRODE

1900 COATED ELECTRODE INTRODUCED

1920 AUTOMATIC WELDING INTRODUCED
CONCEPT OF GTAW REFINED
1930 STUD WELDING
1948 GAS SHIELDED METAL ARC WELDING
1957 PLASMA ARC WELDING,ELECTRON BEAM
1958 ELECTROSLAG WELDING
LATEST LASER BEAM WELDING
 DEFINITIONS
WELDING PROCESSES & GROUPING

PROCESS

A DISTINCTIVE PROGRESSIVE ACTION OR SERIES OF ACTION

INVOLVED IN THE COURSE OF PRODUCING A BASIC TYPE OF
RESULT

AWS HAS GROUPED THE PROCESSES TOGETHER ACCORDING TO

MODE OF HEAT TRANSFER AS PRIMARY CONSIDERATION.

SECONDARY FACTOR IS INFLUENCE OF CAPILLARY ATTRACTION

IT DISTINGUISHES BRAZING, SOLDERING FROM ARC WELDING,

GAS WELDING OR RESISTANCE WELDING
AWS MASTER CHART OF WELDING & ALLIED PROCESSES

ARC
WELDING
SOLID STATE (AW)
WELDING BRAZING
(SSW) (B)

SOLDERING WELDING OTHER

(S) PROCESSES WELDING

OXYFUEL
RESISTANCE GAS
WELDING WELDING
(RW) (OFW)
AWS MASTER CHART OF WELDING & ALLIED PROCESSES

THERMAL ADHESIVE
ALLIED
SPRAYING BONDING
PROCESSES
(THSP) (ABD)

OXYGEN THERMAL ARC

CUTTING CUTTING CUTTING
(OC) (TC) (AC)

OTHER
CUTTING
POPULAR WELDING PROCESSES & LETTER DESIGNATIONS

GROUP WELDING PROCESS DESIGN.

ARC CARBON ARC CAW
WELDING ELECTRO GAS EGW
FLUX - CORED ARC FCAW
GAS METAL ARC GMAW
PLASMA ARC PAW
SHIELDED METAL ARC SMAW
STUD ARC SW
SUBMERGED ARC SAW

OXYFUEL OXYACETYLENE WELDING OAW

GAS OXYHYDROGEN WELDING OHW
WELDING

RESISTANCE FLASH WELDING FW

WELDING PROJECTION WELDING RPW
SEAM WELDING RSEW
SPOT WELDING RSW
UPSET WELDING UW
POPULAR WELDING PROCESSES & LETTER DESIGNATIONS
GROUP WELDING PROCESS DESIGN.
SOLID STATE COLD WELDING CW
WELDING DIFFUSION WELDING DFW
EXPLOSION WELDING EXW
FORGE WELDING FOW
FRICTION WELDING FRW
HOT PRESSURE WELDING HPW
ROLL WELDING ROW
ULTRASONIC WELDING UW

OTHER ELECTRON BEAM EBW

WELDING ELECTROSLAG ESW
PROCESSES FLOW FLOW
INDUCTION IW
LASER BEAM LBW
PERCUSSION PEW
THERMIT TW
 METHODS OF APPLYING WELDING

MANUAL
WELDING WITH TORCH, GUN OR ELECTRODE
HOLDER HELD AND MANIPULATED BY HAND.

SEMI AUTOMATIC
MANUAL WELDING WITH EQUIPMENT THAT
AUTOMATICALLY CONTROLS ONE OR MORE OF
WELDING CONDITIONS.
 METHODS OF APPLYING WELDING
MECHANISED
WELDING WITH EQUIPMENT THAT REQUIRES
MANUAL ADJUSTMENT OF THE EQUIPMENT
CONTROLS IN RESPONSE TO VISUAL
OPERATION OF THE WELDING WITH THE TORCH
MOUNTED GUN OR ELECTRODE HOLDER HELD
BY A MECHANICAL DEVICE.

AUTOMATIC
NO MANUAL ADJUSTMENT OF THE EQUIPMENT
CONTROLS
 METHODS OF APPLYING WELDING
ARC WELDING MANUAL SEMI MECHANIZED AUTOMATIC
ELEMENTS/FUNCTION AUTOMATIC
Start & maintain the Person Machine Machine Machine
arc
Feeds the Electrode Person Machine Machine Machine
into the arc
Control the heat for Person Person Machine Machine
proper penetration

Moves the arc along Person Person Machine Machine

the joint (travels)

Guide the arc along Person Person Person Machine

the joint prearrange
d path
Manipulates the torch Person Person Person Machine
to direct the arc

Corrects the arc to Person Person Person Does not

overcome deviations correct
 METHODS OF APPLYING WELDING

WELDING OR CUTTING MANUAL SEMI MECHANIZED AUTOMATIC

PROCESS AUTOMATIC
GAS METAL ARC Not Most Used Popular
possible Popular
FLUX CORED ARC Not Most Used Popular
possible Popular
GAS TUNGUSTEN Most Possible - Used Used
ARC Popular rare

PLASMA ARC Popular Not Used Used Used

SUBMERGED ARC Not Little Used Most Popular

possible Popular

SHIELDED METAL Most Not Used Not Used Not Used

ARC Popular

OXYFUEL GAS Most Not Used Little Used Little Used

Popular
 FUNDAMENTALS OF WELDING
DEFINITIONS
To understand welding, it is necessary To be familiar with
the basic terms used by the industry.

WELDING
A joining process that produces coalescence of
materials by heating them 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 metal

It is used to make welds.

 FUNDAMENTALS OF WELDING
WELD
A localized coalescence of metals or non-metals
produced either by heating materials to the
welding temperature, with or without application
of pressure, or by the application of pressure
alone and with or without the use of filler metal.

COALESCENCE

Coalescence means the growing together or

growth into one body of materials being welded.
 FUNDAMENTALS OF WELDING
WELDMENT

An assembly, whose component parts are joined by welding.

Can be made of many or few metal parts

May contain metals of different Compositions,

Pieces may be in the form of sheet, plate, pipe etc.

Example - All welded ship,

A skyscraper,
Bicycle frame, etc.
 FUNDAMENTALS OF WELDING

JOINT
Junction of members or the edges of members
that are to be joined or have been joined

FIVE BASIC TYPES OF THE JOINT

BUTT JOINT
Two parts in approximately the same plane
 FUNDAMENTALS OF WELDING
CORNER JOINT Two parts located approx.
at right angle to each other

T - JOINT
Parts approximately at
right angles in the form of T
 FUNDAMENTALS OF WELDING
LAP JOINT Between overlapping parts
in parallel plane

EDGE JOINT
Between the edge of two or
more parallel parts.
 FUNDAMENTALS OF WELDING
DIFFERENT TYPES OF WELDS
They are best described by their shapes

FILLET WELD
A weld of approximately triangular cross - section
joining two surfaces approximately at right angle to
each other.
 FUNDAMENTALS OF WELDING

GROOVE WELD A weld made in the groove

between two members joined.

FLANGE WELD Primarily used for light gauge

or sheet metal joint
 DIFFERENT TYPES OF WELDS
TYPE OF WELD SYMBOL FIGURE
FILLET WELD MOST
POPULAR
CAN BE SINGLE /DOUBLE

PLUG OR SLOT WELD

USED WITH PREPARED HOLE

PLUG WELD ROUND HOLE

SLOT WELD ELONGATED HOLE

SPOT OR PROJECTION WELD

USED WITH OUT PREPARED HOLE
USE ARC OR RESISTANCE
 DIFFERENT TYPES OF WELDS
TYPE OF WELD SYMBOL FIGURE
SEAM WELD
CONTINUOUS, USE ARC OR
RESISTANCE

GROOVE WELD MOST

POPULAR
CAN BE SINGLE OR DOUBLE
HAVE MANY VARIATIONS

BACK OR BACKING WELD

BEAD TYPE BACK OR BACKING
WELD OF SINGLE GROOVE WELD
 DIFFERENT TYPES OF WELDS
TYPE OF WELD SYMBOL FIGURE
SURFACE WELD
SURFACE BUILD UP BY WELDING

FLANGE WELD
USED FOR LIGHT GAGE METAL
JOINTS

STUD WELD
SPECIAL APPLICATION
WELDING PROCESS
 JOINT EDGE PREPARATION

Why is edge preparation done?

TO PROVIDE ACCESS TO JOINT INTERIOR

HELP IN PROPER FUSION

How the edge preparation done ?

BY FLAME CUTTING
PLASMA ARC CUTTING
GRINDING
EDGE SHAPES

Square Edge Shape

Single - Bevel Edge Shape

Double - Bevel Edge Shape

Single - J Groove Edge Shape

Double - J Groove Edge Shape

EDGE PREPARATION TERMINOLOGY

GROOVE ANGLE
BEVEL DEPTH

BEVEL ANGLE

ROOT FACE SIZE

ROOT OPENING

V - GROOVE JOINT
 SELECTION OF JOINT PREPARATION

What determines which joint preparation geometry to

use?

Kind of joint loads (Tension, Compression, etc)

Level of Joint Loading
Static or Dynamic loading
Thickness & Type of Metal Joined
Welding Position
One side/ both sides access to the weld
Skills of the welders
 PARTS OF THE GROOVE WELD

TERMS USED TO DESCRIBE THE PARTS OF A

GROOVE WELD

LEG OR SIZE OF THE WELD

FACE

TOE

REINFORCEMENT

ROOT PENETRATION
 GROOVE WELD

FACE REINFORCEMENT

TOE TOE

DEPTH OF FUSION
WELD SIZE FUSION
(leg) FACE
FUSION ZONE

ROOT
REINFORCEMENT
WELD INTERFACE
ROOT
 PARTS OF THE FILLET WELD

TERMS USED TO DESCRIBE THE PARTS OF A

FILLET WELD

LEG OR SIZE OF THE WELD

FACE

TOE

REINFORCEMENT

ROOT PENETRATION

ACTUAL THROAT & THEORETICAL THROAT

 FILLET WELD

TOE

WELD INTERFACE

ACTUAL THROAT

WELD THEORETICAL THROAT

SIZE
(Leg)
TOE

ROOT
WELD FUSION FACE

DEPTH OF FUSION

FUSION ZONE
 WELDING TERMINOLOGY
AXIS OF THE WELD
AN IMAGINARY LINE DRAWN PARALLEL TO THE WELD
BEAD THROUGH THE CENTER OF THE WELD.

TRAVEL ANGLE
SMALLEST ANGLE FORMED BETWEEN THE
ELECTRODE AND THE AXIS OF THE WELD

WORK ANGLE
THE SMALLEST ANGLE FORMED BY A PLANE, DEFINED
BY THE ELECTRODE AND THE AXIS OF THE WELD, AND
THE WORK PIECE.
 WELDING TERMINOLOGY

PUSH ANGLE DURING FOREHAND WELDING

TRAVEL ANGLE, WHEN THE ELECTRODE IS POINTING
TOWARDS THE DIRECTION OF WELD PROGRESSION

DRAG ANGLE DURING BACKHAND WELDING

TRAVEL ANGLE, WHEN THE ELECTRODE IS POINTING
AWAY FROM THE DIRECTION OF WELD PROGRESSION
WELDING TERMINOLOGY
 WELDING POSITIONS
FLAT POSITION 1G HORIZONTAL POSITION 2G

PLATE - VERTICAL
AXIS OF WELD - HORIZONTAL

PLATE & AXIS OF WELD - HORIZONTAL

FLAT POSITION 3G OVERHEAD POSITION 4G

PLATE - VERTICAL
PLATE & AXIS OF WELD - HORIZONTAL
AXIS OF WELD - VERTICAL

WELDING POSITIONS FOR GROOVE WELD :- PLATE

 WELDING POSITIONS
FLAT POSITION 1F HORIZONTAL POSITION 2F

AXIS OF WELD
HORIZONTAL

AXIS OF WELD
HORIZONTAL

VERTICAL POSITION 3F OVERHEAD POSITION 4F

AXIS OF WELD
VERTICAL

AXIS OF WELD
HORIZONTAL

WELDING POSITIONS FOR FILLET WELD :- PLATE

 WELDING POSITIONS
PIPE POSITION PIPE POSITION
FLAT 1G HORIZONTAL 2G

AXIS OF CYLINDER
VERTICAL

AXIS OF CYLINDER HORIZONTAL

PIPE SHALL BE TURNED WHILE WELDING

PIPE POSITION PIPE POSITION 6G

HORIZONTAL FIXED 5G

V
450 50

AXIS OF PIPE
AT 450
AXIS OF CYLINDER HORIZONTAL
PIPE SHALL NOT BE TURNED OR
ROLLED WHILE WELDING H

WELDING POSITIONS FOR GROOVE WELD :- PIPE

 WELD SYMBOLS

GROOVE WELD

FILLET SCARF V BEVEL U J FLARE V FLARE -

BEVEL
 WELD SYMBOLS

FILLET PLUG STUD SPOT SEAM BACK SUR- EDGE

OR OR OR FACING
SLOT PROJECTION BACKING
 WELDING SYMBOL
FINISH SYMBOL GROOVE ANGLE; INCLUDED OF
COUNTERSUNK IN PLUG WELD
GROOVE WELD SIZE
ROOT OPENING;
DEPTH OF FILLING LENGTH OF THE
CONTOUR SYMBOL WELD
F IN PLUG WELD
DEPTH OF BEVEL;
SIZE OR SRENGTH OF PITCH OF THE
CERTAIN WELDS WELD
A
SPECIFICATION;
PROCESS OR
R FIELD
SYMBOL
WELD

OTHER REFERENCE

S (E) L-P WELD ALL AROUND

SYMBOL
T

(N) REFERENCE LINE

TAIL (MAY BE
OMMITTED WHEN NO. OF SPOT, SEAM, STUD,
REFERENCE IS NOT ARROW CONNECTING
PLUG,SLOT OR PROJECTION REFERENCE LINE TO
USED.) WELD ARROW SIDE OF THE
ELEMENTS IN THIS AREA REMAIN AS MEMBER OR ARROW SIDE
WELD SYMBOLS OF THE JOINT
SHOWN WHEN TAIL AND ARROW ARE
REVERESED

WELD SYMBOLS SHALL BE CONTAINED

WITH IN LENGTH OF REFERENCE LINE
WELDING SYMBOL - EXAMPLES

DESIRED WELD LEFT SIDE VIEW FRONT VIEW

ARROW SIDE V - GROOVE WELD SYMBOL

DESIRED WELD LEFT SIDE VIEW FRONT VIEW

OTHER SIDE V - GROOVE WELD SYMBOL

DESIRED WELD LEFT SIDE VIEW FRONT VIEW

BOTH SIDE V - GROOVE WELD SYMBOL

 WELDING SYMBOL - EXAMPLES

OTHER SIDE
OTHER SIDE
ARROW SIDE
ARROW SIDE
ARROW SIDE
ARROW SIDE

OTHER SIDE OTHER SIDE

OTHER SIDE

ARROW SIDE

OTHER SIDE
 WELDING SYMBOL - EXAMPLES
ARROW SIDE

OTHER SIDE
SYMBOL
WELD CROSS SECTION

ARROW SIDE

OTHER SIDE
WELD CROSS SECTION SYMBOL

OTHER SIDE ARROW SIDE

SYMBOL
WELD CROSS SECTION

ARROW SIDE

OTHER SIDE

WELD CROSS SECTION SYMBOL

 WELDING SYMBOL - EXAMPLES
ARROW SIDE

OTHER SIDE
SYMBOL
WELD CROSS SECTION

ARROW SIDE

OTHER SIDE
WELD CROSS SECTION SYMBOL

OTHER SIDE ARROW SIDE

SYMBOL
WELD CROSS SECTION

ARROW SIDE

OTHER SIDE

WELD CROSS SECTION SYMBOL

 WELDING SYMBOL - EXAMPLES
4 4
2-4

2 2 2

4 4
2-4

2 2 2

LENGTH AND PITCH OF CHAIN INTERMITTENT WELD

WELDING SYMBOL - EXAMPLES

DESIRED WELD SYMBOL

ENTIRE SURFACE BUILD UP BY WELDING

 SHIELDED METAL ARC WELDING

AWS DESIGNATION SMAW

COMMON NAMES ARC WELDING, STICK WELDING,

STICK ELECTRODE WELDING

DEFINITION

AN ARC WELDING PROCESS WITH AN ARC BETWEEN A

COVERED ELECTRODE AND THE WELD POOL. SHIELDING IS
DONE FROM THE DECOMPOSITION OF THE ELECTRODE
COVRERING, WITHOUT THE APPLICATION OF PRESSURE
AND WITH FILLER METAL FROM ELECTRODE.
 SHIELDED METAL ARC WELDING
EQUIPMENT SET-UP

WELDING POWER SUPPLY UNIT

ELECTRODE HOLDER, LEAD & ITS TERMINAL
GROUND CLAMP, LEAD & ITS TERMINALS
WELDING ELECTRODES
 SHIELDED METAL ARC WELDING
HOW DOES THE SMAW PROCESS WORK ?

SMAW is a manual process.

ELECTRIC CIRCUIT is established between the Welding

Power Supply, Electrode, Arc, Work

Electrons flowing through the gap between electrode

and the work - produces an ARC

Arc furnishes HEAT to melt both electrode & base metal

TEMPERATURE within arc > 3300o C

Tiny Globules of metal forms at the tip of electrode

SHIELDED METAL ARC WELDING
METAL TRANSFER IN SMAW

BY GRAVITY

BY GAS EXPANSION

BY ELECTROMAGNETIC FORCES

BY SURFACE TENSION
 SHIELDED METAL ARC WELDING

ELECTRODE IS COATED WITH FLUX

HEAT CAUSES FLUX COMBUSTION & DECOMPOSITION

GASEOUS SHIELD TO PROTECT TIP, WORK & MOLTEN POOL

 SHIELDED METAL ARC WELDING

FLUX CONTAIN METAL POWDER TO

PROVIDE ADDITIONAL HEAT

INCREASE DEPOSITION RATE
ENHANCE WELD PROPERTIES
 METALS WELDABLE BY SMAW
BASE METAL WELDABLE BY SMAW
ALUMINIUM POSSIBLE BUT NOT POPULAR
BRONZE WELDABLE
COPPER POSSIBLE BUT NOT POPULAR
COPPER NICKEL WELDABLE
CAST & MALLEABLE IRON WELDABLE
WROUGHT IRON WELDABLE
INCONEL WELDABLE
NICKEL WELDABLE
MONEL WELDABLE
LOW CARBON STEEL WELDABLE
LOW ALLOY STEEL WELDABLE
HIGH & MEDIUM CARBON STEEL WELDABLE
ALLOY STEEL WELDABLE
STAINLESS STEEL WELDABLE
SHIELDED METAL ARC WELDING

Range of Thickness 3.2 mm to 200 mm

Range of Current 25 - 600 Amp

Open Circuit Voltage 50 - 100 Volts

Voltage Across Arc 17 - 40 Volts

 SHIELDED METAL ARC WELDING

-
+

POLARITY CONNECTION OF CHARACTERISTICS

ELECTRODE WORK PIECE
STRAIGHT NEGATIVE POSITIVE MORE HEAT LIBERATED IN
POLARITY NEGATIVE POLE

ELECTRODE MELTS OFF FASTER

ALSO CALLED
ELECTRODE NEGATIVE
(DCEN)
 SHIELDED METAL ARC WELDING

+
-

POLARITY CONNECTION OF CHARACTERISTICS

ELECTRODE WORK PIECE
REVERSE POSITIVE NEGATIVE RESULTS IN DEEPER
POLARITY PENETRATION

ALSO CALLED
ELECTRODE POSITIVE
(DCEP)
 SHIELDED METAL ARC WELDING

Type of Currents AC
DCEN or DCSP
DCEP or DCRP

DCEN AC DCEP

EFFECT OF WELD BEAD PENETRATION AT

SAME WELDING CURRENT
 SHIELDED METAL ARC WELDING
ADVANTAGES

LOW COST EQUIPMENT

CAN WELD MANY DIFFERENT METAL

RELATIVELY PORTABLE & USEFUL IN CONFINED SPACE

WELD CAN BE PERFORMED IN ANY POSITION

SAME EQUIPMENT WELD VARIOUS THICKNESS

 SHIELDED METAL ARC WELDING

DISADVANTAGES

NOT SUITABLE FOR THK < 2 MM

LOW OPERATOR DUTY CYCLE & OVERALL DEPOSITION RATE

NOT ALL ELECTRODE CAN BE USED

MORE CHANCES OF DEFECT BECAUSE OF FREQUENT START

STOP
 GAS METAL ARC WELDING

AWS DESIGNATION GMAW

COMMON NAMES MIG
WIRE FEED WELDING

DEFINITION

AN ARC WELDING PROCESS THAT USES AN ARC BETWEEN

CONTINUOUS FILLER METAL ELECTRODE AND THE WELD
POOL. SHIELDING IS DONE FROM AN EXTERNALLY
SUPPLIED GAS AND WITHOUT THE APPLICATION OF
PRESSURE.
 GAS METAL ARC WELDING
EQUIPMENT SET-UP

WELDING POWER SUPPLY UNIT WIRE FEEDER

PRESSURE REGULATOR (FOR SHIELDING GASES) WELDING GUN

COMPRESSED GAS CYLINDERS

 GAS METAL ARC WELDING
HOW DOES THE GMAW PROCESS WORK ?

TRIGGER TURNS ON WELDING POWER SUPPLY.

ARC BETWEEN ELECTRODE WIRE & WORK

ARC FURNISHES HEAT TO MELT BOTH THE ELECTRODE WIRE

TIP & BASE METAL

WIRE FEEDING MECHANISM

ELECTRONICALLY OPERATED VALVE, REGULATOR, OPENS &

FEEDS SHIELDING GAS

WELDER CAN MANIPULATE THE GUN & LAY DOWN THE WELD
IN DESIRED PATTERN
 GAS METAL ARC WELDING
Applications

What metals can GMAW weld ?

Aluminum
Carbon Steel
Copper
Low Alloy Steels
Magnesium
Nickel
Stainless Steels
Titanium

Thickness Range 0.13 mm & above

 GAS METAL ARC WELDING
Joint Design

GMAW & SMAW

Same Joint Design
For Maximum Economy & Efficiency,
Groove Weld should be modified.
600 450

SMAW GMAW
 GAS METAL ARC WELDING

Shielding Gas
What gases are commonly used for GMAW shielding ?
Ar + CO2
Ar
Ar + He
Ar + O2
CO2
He
He + Ar + CO2
CO2 is commonly used on Mild Steel for Min. Cost
75% CO2 + 25% Ar used for general Welding of CS
& Low AS
 GAS METAL ARC WELDING
Welding Variables

Major Welding Variables affecting penetration, bead shape &

Weld Quality
Always DCRP polarity
Arc Voltage
Electrode Diameter
Electrode Extension
Electrode Orientation
Shielding Gas
Travel Speed
Welding Current
Wire Feed Rate
 GAS TUNGSTEN ARC WELDING

AWS DESIGNATION GTAW

COMMON NAMES TIG WELDING
HELIARC (DURING DEVELOPMENT)
WIG (WOLFRAM INERT GAS)
( IN EUROPE)
WOLFRAM GERMAN NAME OF TUNGSTEN
DEFINITION

AN ARC WELDING PROCESS THAT USES AN ARC BETWEEN

A TUNGSTEN ELECTRODE (NON-CONSUMABLE) AND THE
WELD POOL. SHIELDING IS DONE FROM AN EXTERNALLY
SUPPLIED GAS AND WITHOUT THE APPLICATION OF
PRESSURE. FILLER METAL MAY OR MAY NOT USED.
 GAS TUNGSTEN ARC WELDING
EQUIPMENT SET-UP

WELDING POWER SUPPLY UNIT PRESSURE REGULATOR FOR SHIELDING GAS

TUNGSTEN ELECTRODE COMPRESSED AIR CYLINDERS
GTAW TORCH & ASSOCIATED CABLES
 GAS TUNGSTEN ARC WELDING
How does the GTAW process work ?

CONTINUOUS ARC BETWEEN

ELECTRODE WIRE & WORK

INTENSE HEAT OF THE ARC -

APPROX. 5500O C

IT MELTS BOTH THE FILLER

WIRE TIP & BASE METAL

INERT GAS IS SUPPLIED THROUGH THE TORCH

ON THINNER METALS, EDGE JOINT & FLANGE JOINT - NO FILLER IS ADDED

LESS SPATTER, LITTLE OR NO SMOKE

 METALS WELDABLE BY GTAW
BASE METAL WELDABLE BY GTAW
ALUMINIUM WELDABLE
BRONZE WELDABLE
COPPER WELDABLE
COPPER NICKEL WELDABLE
CAST & MALLEABLE IRON POSSIBLE, BUT NOT POPULAR
WROUGHT IRON POSSIBLE, BUT NOT POPULAR
INCONEL WELDABLE
NICKEL WELDABLE
MONEL WELDABLE
LOW CARBON STEEL WELDABLE
LOW ALLOY STEEL WELDABLE
HIGH & MEDIUM CARBON STEEL WELDABLE
ALLOY STEEL WELDABLE
STAINLESS STEEL WELDABLE
 GAS TUNGSTEN ARC WELDING

Range of Thickness 0.13 mm to 51 mm

Range of Current 1 - 1000 Amp
Range of Voltage 10 - 40 Volts

Shape of the Arc Inverted Funnel

Polarity Used DCEN

DCEP
AC
 GAS TUNGSTEN ARC WELDING
Since the arc temperature is well above the melting point
of the tungsten GTAW Electrode, Why doesnt the
electrode melt ?

Very Small amount of electrode does melt & ends up in

the weld.

The electrode resists melting because

Tungsten is having Highest Melting Point of all

metals - 3420 o C
Tungsten has High Thermal Conductivity
Torch Collets are designed to remove heat from
the electrodes
 GAS TUNGSTEN ARC WELDING

ELECTRODE

+ - + - + -
+ - + - + -
+ - + - + -

WORK PIECE

DCEN DCEP AC
HEAT 70% AT WORK END 30% AT WORK END 50% AT WORK END
BALANCE
30% AT ELECTRODE 70% AT ELECTRODE 50% AT ELECTRODE

PENETRATION DEEP, NARROW SHALLOW, WIDE MEDIUM

 GAS TUNGSTEN ARC WELDING

Shielding Gas
What gases are commonly used for GTAW shielding ?
Helium - 99.99 % purity (minimum)
Argon - 99.95 % purity (minimum)

Joint Design

More or less same as SMAW

 GAS TUNGSTEN ARC WELDING

Welding Variables

Major Welding Variables affecting penetration, bead

shape & Weld Quality
Arc polarity
Arc Current
Size of part to be welded
Thermal Conductivity of the part
Shielding Gas
Travel Speed
 GAS TUNGSTEN ARC WELDING
ADVANTAGES

HIGH QUALITY WELD IN ALMOST ALL METALS & ALLOYS.

VERY LITTLE, IF ANY, POST WELD CLEANING IS REQUIRED.
VERY LITTLE OR NO SPATTER
WELDING CAN BE PERFORMED IN ALL POSITIONS
REDUCTION OF SMOKE & FUEL
NO SLAG PRODUCED

JOINS DISSIMILAR METALS

 GAS TUNGSTEN ARC WELDING
DISADVANTAGES

REQUIREMENT OF HIGHER SKILL

LOWER DEPOSITION RATE

EQUIPMENT MORE COMPLEX & EXPENSIVE

 GAS TUNGSTEN ARC WELDING
INDUSTRIAL USE AND TYPICAL APPLICATIONS

AIRCRAFT INDUSTRY

SPACE VEHICLE - SHELL WELDING

STRUCTURE WELDING
WELDING INVOLVED IN VARIOUS TANKS
THOUSANDS OF METER OF TUBING
INVOLVED IN ROCKET ENGINE.

SMALL DIAMETER THIN WALL TUBING

ROOT PASS WELDING IN PIPING
WELDING OF THIN MATERIAL - VIRTUALLY EVERY INDUSTRY
REPAIR OF TOOLS & DIES
REPAIR ALUMINUM & MAGNESIUM PARTS
REPAIR OF HIGHLY CRITICAL ITEM.