Arc Welding
2022
Presented By:
Seif Wagdy (Team Leader) 19p8234
Mohamed Amr 19P3989
Ahmed Rafaat 19P4258
Kirollos Naguib 19P3989
Mina Tawfik 19P9641
Sandy Zakria 19P9258
Moemen Youssef 18P8394
Supervised By:
Dr. Ramadan El-Gamasy
Eng. Bassem Tarek
1. Introduction
Welding is widely used all over the world in most industrial fields, and it has
many types according to the type of material, its size, and types of resources
available. And here is the difference between Welding Types.
1.1. Spot Welding
For example, spot welding is a type of electric
resistance welding used to weld various sheet metal
products, through a process in which contacting metal
surface points are joined by the heat obtained from
resistance to electric current.
1.2. Arc Welding
Arc welding is a welding process that is used to join
metal to metal by using electricity to create enough
heat to melt metal, and the melted metals when cool
result in a binding of the metals.
1.3. Gas Welding
Gas welding is a welding process done by burning fuel gases with the help of
oxygen which forms a concentrated flame of high temperature. This flame
directly strikes the weld area and melts the weld surface and filler material.
The melted part of welding plates diffused in one another and create a weld
joint after cooling.
2. Fusion Welding
Fusion welding is a type of welding that depends on melting to join metals of
similar properties. Due to the high-temperature phase transitions inherent to
these processes, a heat-affected zone is created in the material. Fusion
welding is used in the manufacture of many everyday items including
airplanes, cars, and structures. A large community uses both arc and flame
contact welding to create artwork. Fusion welding has many types, such as
Electrical Arc welding, laser beam, induction, oxyacetylene, and solid reactant.
In this report, we will discuss arc welding and its types and flames in detail.
3. Arc Welding
Arc welding is a type of welding that uses a welding power supply to create an
electric arc between a metal stick (electrode) and the base material to melt
the metals at the point of contact. The welding area is usually protected by
some type of shielding gas, vapor, or slag. Arc welding processes may be
manual, semi-automatic, or fully automated.
It has several methods whether they are done using a consumable electrode
(like SMAW, SAW, MIG), or a non-consumable electrode (like TIG, PAW).
3.1. Consumable electrode
Electrodes are used in electric arc welding processes. the electrode is used to
produce the electric arc between the electrode and the metals to be welded
together, generating the heat with which to melt the base metals. Consumable
electrodes become part of the weld. The electrode serves as the filler metal
and melts along with the metals to be welded together. the consumable
electrode is the filler metal welding rod and contains a flux that is used to
produce a barrier to protect the weld from any contamination.
3.1.1. Arc welding processes that employ a consumable electrode:
• Shielded Metal Arc Welding (SMAW)
• Gas Metal Arc Welding (GMAW) (both MIG and MAG)
• Flux-cored arc welding (FCAW)
• Submerged arc welding (SAW)
• Electroslag welding (ESW), Electro-gas welding (EGW)
3.2. Non-consumable electrode
A non-consumable electrode does not meltdown on the weld pool. It remains
intact throughout the welding. The non-consumable electrode does not supply
filler. Thus, filler material is required to supply separately.
3.2.1. Arc welding processes that employ a non-consumable electrode:
• Gas Tungsten Arc Welding (GTAW) or Tungsten Inert Gas (TIG) Welding
• Atomic Hydrogen Welding (AHW)
• Carbon Arc Welding (CAW)
4. Tig Welding
4.1. Definition
It is a gas tungsten arc welding. it uses tungsten as an electrode (added with 1-
2% thorium and zircon. Which improves electron emission and arc stability)
that is non-consumable Electrode holder is used to fix it. Instead of flux, an
inert gas is supplied from a cylinder and passes through the nozzle to protect
the welding zone. It surrounds the arc from the atmosphere and makes a
defect-free weld also it protects the tungsten electrode. The filler material may
or may not be used. Mostly DCSP (straight polarity. Electrode to w/p electron
flow) is used. Because DCRP melts the tungsten. Used to weld steel, aluminum,
CI, stainless steel, nickel-based alloy, copper-based alloy, and low alloy steels
Used up to thickness of 6.5mm.
4.2. Advantages
• No flux
• Speed welding
• Used in both ferrous and non-ferrous welding
• High-quality welding
• No weld cleaning is necessary
4.3. Disadvantages
• High cost
• Slow process
• A separated filler rod is required
4.4. Applications
• Welding of sheet metal and thinner sections
• Precision welding in aircraft, chemical and instrumental industries.
5. MIG Welding
5.1. Definition
It Is a process where a continuously fed metal electrode (Wire) contacts the
base metal and produces heat. The arc is shielded by an inert gas. MIG
electrode is a metal wire, fed through the gun by the wire feeder and
measured its diameter. MIG welding requires a shielding gas to protect the
weld puddle; shielding gas is usuallyCO2, argon, or a mixture of both. The MIG
process is performed using DCEP (Direct Current Electrode Positive).
Alternating current is never used for MIG.
5.2. Advantages
• No flux is used so no need to clean.
• Produce very high-quality weld
• Weld zone is visible
• No possibility of cracks.
• There is no frequent change of electrode, so it is more efficient.
• Easily automated.
5.3. Disadvantages:
• Weld surface must be clean and free from oil, grease, and paint.
• On site welding is a difficult one.
• Difficult to weld in small corners
• Equipment is costly
• Less portable one
5.4. Applications:
• Used for most types of sheet metal welding
• Fabrication of pressure vessels and steel structures
• Automotive industry and home improvement industry
6. Conclusion
In conclusion, arc welding with its several methods is very important and
widely used all over the world in different industries as it provides strong
welding seams that are needed in many applications from joining construction
structural steel to joining oil and gas service pipes. But safety precautions
should be considered before and while using them as the generated electric
arc can cause severe damage to the working personnel. It’s also a not very
environment friendly technique of due to the harmful gasses produced.
