1. PPE During Welding?

Take Away of Lecture 2. What is Welding?

3. Difference between Welding & Brazing?
4. Types of Welding Process?
5. Welding processes as per KBI scope?
6. Definition of TIG , MIG & Resistance Welding.
7. Difference Between MIG & MAG ?
8. Shielding Gas Purpose & Types.
9. Fusion Gas effect on Weld Penetration & Fusion
10. Types of weld joint
11. Common Welding Symbol
12. Pre & Post Inspection of weld joint
13. Common NDT technique- VT, DP,MT,RT
14. Overview of ISO 15085 .
PPE (Personal Protection Equipment)
During Welding
 What is Welding?
As per AWS
“Welding is a joining process in which two metals/thermoplastic joined
with each other with or without application of heat ,with or without
application of pressure ,with or without use of filler metal”.
 Difference between Welding & Brazing
Sr No Welding Brazing

1. Material is heated above recrystallization Material is not heated above recrystallization temperature
temperature
2. Base Material melting occurs. Base Material doesn’t melt.
3. Welding typically involves Temperature over Brazing typically involves Temperature upto 450 deg C.
450 deg C.

4.
Types of Welding Process
Welding processes as per KBI Scope
• GTAW(TIG)
• GMAW(MIG)
• Resistance Welding(Spot Type)
GTAW(TIG)
• GTAW- Gas Tungsten Arc Welding
• TIG-Tungsten Inert Gas
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 a shielding gas (usually an inert gas such as argon),
and a filler metal is normally used.
 GMAW(MIG)
Gas metal arc welding (GMAW) is a fusion welding process, which uses an
electrical arc as the source of energy that causes the metal fusion to occur.
The electrode used in gas metal arc welding is also the filler metal
consumable. An external shielding gas is used to protect the molten weld
puddle.
GMAW Variants
GMAW have Two Variants:-

1.MIG (Metal Inert Gas)

2.MAG (Metal Active Gas)

Difference Between these:-

Sr No MIG(Metal Inert Gas) MAG(Metal Active Gas)

1 Shielding Gas is inert gas e.g Ar, Helium etc. Shielding gas is mixture of active gas and inert gas or only
active gas.
2 Cannot alter weld bead properties. Disintegrated elements can diffuse into weld properties.
 Resistance Welding
Resistance Welding is a thermo-electric process where heat is
generated at the interface of the parts to be joined by passing an
electrical current through them or a precisely controlled time and under
a controlled pressure (also called force
The general heat generation formula for resistance welding is:
Heat = I2 x R x t
I- Current in Amp
R- Electric Resistance of W/P
t-Weld Time
SPOT Resistance Welding Cycle
What is purpose of shielding gas in welding?
Shielding are mainly used to protect the molten metal from the contamination
and oxidation caused by these harmful gases in the atmosphere.
Type of Welds
1. Groove Weld
2. Fillet Weld
3. Plug Weld
4. Seam Weld
5. Spot Weld
Pre & Post Inspection of weld joint
Pre inspection of weld joint
Weld Zone Terms
Weld zone
Face
A B
Weld Fusion
metal zone
Heat
Affected
Zone Weld
Junction

C Root
D
A, B, C & D = Weld Toes
Fillet Weld Dimension
a = Design / Theoretical
throat thickness
s = Actual throat thickness

b = Horizontal leg length

c
c = Vertical leg length
e.g
Leg length = 6mm
Design Throat = 6mm x 0.7
a Design Throat = 4.2mm
b s
The leg length should be approximately equal to the
material thickness
The design throat thickness is 0.7 of the leg length
Common Welding Symbol
Welding Position

Flat: PA / 1G:
Flat PA / 1F
Vertical upwards
PF / 3G

Horizontal vertical:
PB / 2F: Horizontal vertical:
PC / 2G:

Overhead Vertical downwards

Horizontal overhead PE / 4G PG / 3G
PD / 4F
Welding Position

PF / 5G PG / 5G
PA / 1G
Weld: Flat Weld: Vertical upwards Weld: Vertical Downwards
Pipe: rotated Pipe: Fixed Pipe: Fixed
Axis: Horizontal Axis: Horizontal Axis: Horizontal
45o

PC / 2G H-LO 45 / 6G
Weld: Horizontal vertical Weld: Upwards
Pipe: Fixed Pipe: Fixed
Axis: Vertical Axis: Inclined
Common Welding Defect/Discontinuity
• Crack
• LoF (Lack of Fusion)
• LoP (Lack of Penetration)
• Undercut
• Porosity
• Underfill
Crack
Sr No Cause Remedy
1 Wrong Consumable Use Right Electrode/Wire

2 Wrong procedure Qualify Procedure

3 Improper Preheat Preheat Uniformly

LoF (Lack of Fusion)
Sr No Cause Remedy
1 Improper Current Use Right Current

2 Wrong Electrode Angle Train/Qualify welder

3 Improper bead placement Train/Qualify welder to place proper welding
LoP (Lack of Penetration)
Sr No Cause Remedy
1 Excess Root Face Use Correct Root Face

2 Inadequate Root Opening Use Correct Root Opening

3 Oversize Electrode Use Correct Size Electrode

4 Imprpoer Bead Placement Correct Bead Placement

Undercut
Sr No Cause Remedy
1 Excessive Current Use Correct Welding Current

2 Excessive Voltage Use Correct Welding Voltage

3 High Travel Speed Use Correct Welding Speed

4 Improper Bead Placement Correct Bead Placement

Porosity
Sr No Cause Remedy
1 Wet Surface of Base Material Make it Dry
2 Paint or Rusted Surface of Base Material Claen the Base Metal Material Prior to Welding
3 High Velocity Air/Storm Isolate the Welding Area from High Velocity Air/Storm
Underfill
Sr No Cause Remedy
1 Low Welding Current Use Correct Welding Current

2 Excessive Voltage Use Correct Welding Voltage

3 High Travel Speed Use Correct Welding Speed

4 Improper Bead Placement Correct Bead Placement

Post Inspection of weld joint
1. VT
2. DPT (https://www.youtube.com/watch?v=1Qrm0bQro1U)
3. MACRO
4. MT
5. RT
6. UT
ISO 15085

This standard deals with welding steel and aluminum alloys including castings.
Sr Class Component
No
1 CL1 bogies (headstocks, sole bars, cross bearers, bogie frames); underframes (extensions, sole
bars, cross bearers, assembly) , brake equipment (magnetic track brake, brake rods, brake
triangles, brake cylinders,brake cross beams etc.
2 CL2 sliding doors in vehicles including runways, internal parts of passenger coaches (partitions,
walls, doors, paneling) etc.
3 CL3 window frames , ventilation grilles etc

4 CL4 Design ,bought and assembled etc.