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Welding Processes Overview

Welding is a crucial fabrication process used to join materials through fusion, classified into fusion, pressure, and solid-state welding methods, each with unique applications and limitations. Key welding techniques include gas welding, manual metal arc welding, and various continuous welding processes like MIG and TIG, which enhance efficiency in manufacturing. Electrodes used in arc welding are coated with flux to stabilize the arc, protect the weld pool, and may introduce alloying elements.

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12 views5 pages

Welding Processes Overview

Welding is a crucial fabrication process used to join materials through fusion, classified into fusion, pressure, and solid-state welding methods, each with unique applications and limitations. Key welding techniques include gas welding, manual metal arc welding, and various continuous welding processes like MIG and TIG, which enhance efficiency in manufacturing. Electrodes used in arc welding are coated with flux to stabilize the arc, protect the weld pool, and may introduce alloying elements.

Uploaded by

Harshitha
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Welding Processes Overview

General Survey and Classification of Welding Processes

Welding is a fabrication process used to join materials, usually metals or thermoplastics, by causing fusion. It

is an essential manufacturing process in various industries including construction, automotive, shipbuilding,

and aerospace.

Welding processes are classified into:

1. Fusion Welding (no pressure, uses heat):

- Gas Welding

- Arc Welding (MIG, TIG, SMAW)

- Thermit Welding

- Electron Beam and Laser Welding

2. Pressure Welding (with or without heat):

- Forge Welding

- Resistance Welding (Spot, Seam, Projection)

- Friction Welding

- Ultrasonic Welding

3. Solid-State Welding:

- Cold Welding

- Diffusion Welding

- Explosion Welding

Each method has its own applications, advantages, and limitations depending on the materials and joint

requirements.
Welding Processes Overview

Conventional Gas Welding and Cutting

Gas welding is one of the oldest and most versatile welding methods. It typically uses a mixture of oxygen

and acetylene gases to create a flame hot enough to melt metals.

- Equipment: Gas cylinders, regulators, hoses, torch.

- Types: Oxy-acetylene welding is most common.

- Cutting: Oxy-fuel cutting uses oxygen to oxidize and remove molten metal.

- Applications: Used in sheet metal, plumbing, and repair work.

- Advantages: Portable, low cost, simple setup.


Welding Processes Overview

Manual Metal Arc Welding (MMAW)

Also known as Shielded Metal Arc Welding (SMAW), it is a manual arc welding process that uses a

consumable electrode coated in flux to lay the weld.

- Equipment: Power supply, electrode holder, ground clamp, electrodes.

- Procedure: Electric arc forms between the electrode and base metal, melting both and forming a weld pool.

- Advantages: Low cost, portable, works in outdoor conditions.

- Limitations: Slower, requires skill, slag must be removed.


Welding Processes Overview

Electrode Coverings and Their Functions

Electrodes in arc welding are coated with flux that performs several functions:

- Stabilizes the arc.

- Shields the molten weld pool from atmospheric contamination.

- Forms a slag cover to protect and shape the weld.

- May introduce alloying elements.

Types of electrode coverings include:

- Cellulosic: Deep penetration, fast-freezing.

- Rutile: Smooth arc, easy slag removal.

- Basic: For high-strength steels, less hydrogen.


Welding Processes Overview

Continuous Welding Processes Based on the Above

Continuous welding processes are automated or semi-automated systems used for large-scale and repetitive

production tasks.

Examples include:

- Submerged Arc Welding (SAW): Uses a continuous wire feed and granular flux.

- Metal Inert Gas Welding (MIG): Continuous wire electrode with shielding gas.

- Tungsten Inert Gas Welding (TIG): Non-consumable electrode with filler rod.

- Resistance Seam Welding: For long continuous welds in sheet metals.

These processes increase efficiency, speed, and weld consistency in manufacturing.

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