History of Arc Welding

Arc welding dates back to the late 1800s First developed following the invention of AC

electricity Pioneered when a man was welding with a bare metal rod on iron, the sparks from the welding caught a stack of newspapers on fire near him and while welding, he noticed that his welds started looking a lot better. The reason for this was the smoke took the oxygen out of his welding environment and decreased porosity.

What is Arc Welding?

The fusing of two or more pieces of

metal together by using the heat produced from an electric arc welding machine.

Basics of Arc Welding

The arc is struck between the electrode

and the metal. It then heats the metal to a melting point. The electrode is then removed, breaking the arc between the electrode and the metal. This allows the molten metal to freeze or solidify.

How an arc is formed?

The arc is like a flame

of intense heat that is generated as the electrical current passes through a highly resistant air gap.

Welding Processes
SMAW (Shielded Metal Arc Welding)
GMAW (Gas Metal Arc Welding)

GTAW (Gas Tungsten Arc Welding)

Oxygen/ Fuel Welding

SMAW
Also referred to as Stick Welding Used for everything from pipeline

welding, farm repair and complex fabrication. Uses a stick shaped electrode. Can weld: steel, cast iron, stainless steel, etc.

Examples of SMAW Welds

GMAW
Also referred to as MIG welding Uses a shield gas and a continuous wire

electrode Used for all types of fabrication Great for thin metals up to Excellent speed of deposition Used for metals such as: steel, aluminum and stainless steel.

GMAW Welds

MIG Welding Benefits

All position capability Higher deposition rates than

SMAW Less operator skill required Long welds can be made without starts and stops Minimal post weld cleaning is required

GTAW
Also referred to as TIG Welding

Uses a shield gas, a nonconsumable tungsten electrode and a hand fed filler rod
Excellent for welding thin metals, pipeline welding and exotic metals Highly skilled labor needed for this process

GTAW Welding Benefits

Superior quality welds Welds can be made with or without filler metal Precise control of welding variables (heat) Free of spatter Low distortion

Types of SMAW Machines

AC Welding Machine
Most common type found in homes, farms, etc. Good for farm repairs, light jobs. Low cost

DC Welding Machines
Often generator

type machines Diesel or gasoline engine driven Portable Expensive

AC/DC Welders
Can weld in AC

or DC polarity Less expensive than DC machine Quieter than DC machine

Oxygen/ Fuel Welding

Utilizes oxygen and a fuel gas to

heat metal until it is in a molten state and fuse multiple pieces of metal together. Can be used with or without a filler rod. Great for brazing dissimilar metals together. Older technology that can be replaced by GTAW

Resistance Welding
Developed in the early 1900s A process in which the heat required for welding is

produced by means of electrical resistance across the two components

RW does not requiring the following:
Consumable electrodes

Shield gases
Flux

Resistance Spot Welding

RSW uses the tips of two opposing solid cylindrical electrodes Pressure is applied to the lap joint until the current is turned off

in order to obtain a strong weld

Fig: (a) Sequence in the resistance spot welding

Resistance Spot Welding

Surfaces should be clean Accurate control of and timing of electric current and of pressure are

essential in resistance welding

Fig: b)Cross-section of a spot weld,showing the weld nugget and the indentation of the electrode on the sheet surfaces.This is one of the most commonly used process in sheet-metal fabrication and in automotivebody assembly

Resistance Seam Welding

RSEM is modification of spot welding wherein the electrodes are

replaced by rotating wheels or rollers

The electrically conducting rollers produce a spot weld RSEM can produce a continuous seam & joint that is liquid and gas tight

Fig : (a) Seam-Welding Process in which rotating rolls act as electrode (b) Overlapping spots in a seam weld. (c) Roll spot weld (d) Resistance-welded gasoline tank

Resistance Projection Welding

RPW is developed by

introducing high electrical resistance at a joint by embossing one or more projections on the surface to be welded
Weld nuggets are

similar to spot welding

Fig: a) Resistance projection Welding b)A welded bracket c) & d) Projection welding of nuts r threaded hosses and stack

Resistance Projection Welding

The electrodes exert pressure to compress the

projections
Nuts and bolts can be welded to sheet and

plate by this process

Metal baskets, oven grills, and shopping carts can be made by RPW

Flash Welding
Heat is generated from the arc as the ends as the two members

contacts An axial force is applied at a controlled rate Weld is formed in plastic deformation

Fig : (a)Flash-welding process for end-to end welding of solid rods or tubular parts (b) & (c) Typical parts made by flash welding (d)Design Guidelines for flash welding

Stud Welding

Small part or a threaded rod or hanger serves as a electrode Also called as Stud arc welding Prevent oxidation to concentrate the heat generation Portable stud-welding is also available

Fig:The sequence of operation in stud welding,which is used for welding bars threaded rods and various fasteners onto metal plates

Arc Welding PPE