Fusion-Welding Processes

CHAPTER 7-1

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 27-1

General Characteristics of Fusion Welding Processes

TABLE 27.1
Joining process Shielded metal-arc Submerged arc Gas metal-arc Gas tungsten-arc Flux-cored arc Oxyfuel Operation Manual Automatic Semiautomatic or automatic Manual or automatic Semiautomatic or automatic Manual Advantage Portable and flexible High deposition Most metals Most metals High deposition Portable and flexible Most metals Skill level required High Low to medium Low to high Low to high Low to high High Medium to high Welding position All Flat and horizontal All All All All All Current type ac, dc ac, dc dc ac, dc dc Distortion 1 to 2 1 to 2 2 to 3 2 to 3 1 to 3 2 to 4 3 to 5
*

Cost of equipment Low Medium Medium to high Medium Medium Low High

Electron-beam, Semiautomatic Laser-beam or automatic * 1, highest; 5, lowest.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 27-2

Oxyacetylene Flames Used in Welding

Figure 27.1 Three basic types of oxyacetylene flames used in oxyfuel-gas welding and cutting operations: (a) neutral flame; (b) oxidizing flame; (c) carburizing, or reducing, flame. The gas mixture in (a) is basically equal volumes of oxygen and acetylene.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 27-3

Torch Used in Oxyacetylene Welding

Figure 27.2 (a) General view of and (b) cross-section of a torch used in oxyacetylene welding. The acetylene valve is opened first; the gas is lit with a spark lighter or a pilot light; then the oxygen valve is opened and the flame adjusted. (c) Basic equipment used in oxyfuel-gas welding. To ensure correct connections, all threads on acetylene fittings are left-handed, whereas those for oxygen are right-handed. Oxygen regulators are usually painted green, acetylene regulators red.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 27-4

Shielded Metal-Arc Welding

Figure 27.4 Schematic illustration of the shielded metal-arc welding process. About 50% of all large-scale industrial welding operations use this process.

Figure 27.5 Schematic illustration of the shielded metal-arc welding operations (also known as stick welding, because the electrode is in the shape of a stick).

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 27-5

Multiple Pass Deep Weld

Figure 27.6 A deep weld showing the buildup sequence of individual weld beads.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 27-6

Submerged-Arc Welding

Figure 27.7 Schematic illustration of the submerged-arc welding process and equipment. The unfused flux is recovered and reused. Source: American Welding Society.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 27-7

Gas Metal-Arc Welding

Figure 27.8 Schematic illustration of the gas metal-arc welding process, formerly known as MIG (for metal inert gas) welding.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 27-8

Equipment Used in Gas Metal-Arc Welding

Figure 27.9 Basic equipment used in gas metal-arc welding operations. Source: American Welding Society.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 27-9

Flux-Cored Arc-Welding
Figure 27.10 Schematic illustration of the flux-cored arc-welding process. This operation is similar to gas metal-arc welding, showing in Fig. 27.8.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 27-10

Equipment for Electroslag Welding

Figure 27.12 Equipment used for electroslag welding operations. Source: American Welding Society.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 27-11

Designations for Mild Steel Coated Electrodes

TABLE 27.2 The prefix E designates arc welding electrode. The first two digits of four-digit numbers and the first three digits of five-digit numbers indicate minimum tensile strength: E60XX 60,000 psi minimum tensile strength E70XX 70,000 psi minimum tensile strength E110XX 110,000 psi minimum tensile strength The next-to-last digit indicates position: EXX1X All positions EXX2X Flat position and horizontal fillets The last two digits together indicate the type of covering and the current to be used. The suffix (Example: EXXXX-A1) indicates the approximate alloy in the weld deposit: A1 0.5% Mo B1 0.5% Cr, 0.5% Mo B2 1.25% Cr, 0.5% Mo B3 2.25% Cr, 1% Mo B4 2% Cr, 0.5% Mo B5 0.5% Cr, 1% Mo C1 2.5% Ni C2 3.25% Ni C3 1% Ni, 0.35% Mo, 0.15% Cr D1 and D2 0.250.45% Mo, 1.75% Mn G 0.5% min. Ni, 0.3% min. Cr, 0.2% min. Mo, 0.1%min. V, 1% min. Mn (only one element required)

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 27-12

Gas Tungsten-Arc Welding

Figure 27.13 The gas tungsten-arc welding process, formerly known as TIG (for tungsten inert gas) welding.

Figure 27.14 Equipment for gas tungsten-arc welding operations. Source: American Welding Society.
Kalpakjian Schmid Manufacturing Engineering and Technology 2001 Prentice-Hall Page 27-13

Plasma-Arc Welding

Figure 27.15 Two types of plasma-arc welding processes: (a) transferred, (b) nontransferred. Deep and narrow welds can be made by this process at high welding speeds.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 27-14

Comparison of Laser-Beam and Tungsten-Arc Welding

Figure 27.16 Comparison of the size of weld beads in (a) electron-beam or laser-beam welding to that in (b) conventional (tungsten-arc) welding. Source: American Welding Society, Welding Handbook (8th ed.), 1991.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 27-15

Example of Laser Welding

Figure 27.17 Laser welding of razor blades.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 27-16

Flame Cutting and Drag Lines

Figure 27.18 (a) Flame cutting of steel plate with an oxyacetylene torch, and a crosssection of the torch nozzle. (b) Cross-section of a flame-cut plate showing drag lines.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 27-17

Summary
Electrode Electrode Extruded coating flux Gas shielding Molten metal Granulated Powder Electrode

Molten metal

Molten metal

metal-arc welding
Consumable Electrode (filler)

Shielded metal-arc welding

Submerged arc welding

Gas flow control taps

Inert gas Molten metal

TIG
Oxygen gas Acetylene gas Outer envelope

Inner cone Filler

Non-consumable Electrode

Inert gas Filler wire

Fig 6.3 Gas welding using Oxyacetylene torch.

A B

TIG
2001 Prentice-Hall Page 27-18

Kalpakjian Schmid Manufacturing Engineering and Technology

Simple butt joint Simple butt joint (Thick plate)

Single V joint Single V joint (thick plate 4-30mm)

Double V joint Double V joint (thick plate 20-25mm)

Single U joint Single J joint (thick plate >25mm)

(b)

(a)

(a) Welding joints

Kalpakjian Schmid Manufacturing Engineering and Technology

(b) Welding applications.

2001 Prentice-Hall

Page 27-19

W ( power) K R I t
2
Where, K: constant less than 1 related to heat losses. I : Current. R: Resistance of ionized air gap. t : Welding time.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 27-20