WELDING

Welding is a process of permanent joint production by formation of

interatomic bonds origination between the parts being joined.

Welding methods

Welding by fusion Welding by pressure

– Electric arc welding – Cold welding

– Gas welding – Friction welding
– Plasma welding – Ultrasonic welding

Plasma welding Friction welding

 WELDING
Electric arc welding

U, V

а b

Scheme of direct current Static volt-ampere arc characteristic (а);

welding arc: 1 – electrode; 2 – base metal; external characteristics of current sources for welding (b)
3 – bath of liquid metal; 4 – arc column

The welding arc is a powerful stable electric discharge burning between

electrodes in the atmosphere of ionised gases and vaporised metals.
WELDING: Electric arc welding

Manual metal-arc welding

circuit diagram:
1 – A.C. mains supply;
2 – neutral;
3 – live;
4 – fused switch;
5 – primary cables;
6 – current control;
7 – welding set;
8 – welding cable;
9 – electrode holder;
10 – electrode;
11 – work-piece;
12 – work support;
13 – return current cable;
14 and 15 – earth

Diameter of electrode d is chosen depending

on welded metal thickness:
where s is the thickness of welded metal, mm.
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Electric arc welding

2–

Automatic submerged arc welding (SAW):

1 – sliding conductor ; 2 – feeder; 3 – welding wire; 4 – liquid slag; 5 –layer of flux; 6 – slag crust;
7 – welded seam; 8 – basic metal; 9 – pool of liquid metal; 10 – arc zone

Advantages of the process:

– the most productive way of welding;
– high quality of a seam;
– low production cost of 1 m of seam;
– welding metal up to 20 mm thickness for one pass without cutting of edges.
Application: in serial and mass production, such as manufacturing of boilers, tanks, ship hulls, bridge beams,
welded pipes with a direct and a spiral seam, wheels.
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Resistance welding

Resistance butt welding (RW):

1 – current supply clips; 2 – billets; 3 – Flash welding (FW)
motionless plate; 4 – mobile plate; 5 –guide; 6 –
welding transformer; 7 – flexible buses

Advantages of the process:

– cleaning of surfaces is not necessary;
– welding parts of a complex section and with the different shape of the section;
– dissimilar metals can be welded.
Application: welding of rings, wheels, the end tool (drills, mills, taps), rods, rails, reinforcement, pipes.