WELDING

Classification of welding processes. Principles of

Oxy-acetylene gas welding. A.C metal arc
welding, resistance welding, submerged arc
welding, tungsten inert gas welding, metal inert
gas welding, plasma arc welding, thermit welding,
electron beam welding, laser beam welding,
defects in welding, soldering and brazing.

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DEPT. OF MECHANICAL

RESISTANCE WELDING
When Electric current flows through a wire, it
generates heat due to resistance offered by
the metal of the wire to the flow of electrons.
In Resistance Welding, the heat required for
welding is produced by means of the
electrical resistance between the two
members to be joined.
A force/pressure is always applied before,
during and after the application of current to
join the metal pieces.
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DEPT. OF MECHANICAL

RESISTANCE WELDING
The heat generated in resistance welding is
given by,
H = I2Rtk
Where,

H = Heat generated in joules (watt sec)

I = Currents in amperes
R = Resistance in ohms
t = time of current flow in seconds
k = constant to account for losses due to
radiation & conduction.
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DEPT. OF MECHANICAL

RESISTANCE WELDING
The various resistance welding
process are,
Resistance Spot Welding
Resistance Seam Welding
LAP JOINTS
Resistance projection Welding
Upset Welding
Flash butt Welding
M.SARAVANA KUMAR
BUTT
JOINTS
12/1/15

DEPT. OF MECHANICAL

RESISTANCE WELDING
Resistance Welding Process depends on
the following factor.
Welding Current
Welding pressure
Time of application (cycle time)

Weld Time
Squeeze or forge time
Hold Time
Off Time

Contact area of electrodes

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DEPT. OF MECHANICAL

RESISTANCE SPOT WELDING

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DEPT. OF MECHANICAL

APPLICATIONS
Fabricating sheet-metal products.
Attaching handles to stainless-steel
cookware
Automobile bodies.

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DEPT. OF MECHANICAL

RESISTANCE SPOT WELDING

ADVANTAGES

DISADVANTAGES

High Production Rate

Economical Process.
Most Suitable for
Sheet Metal Products.
Small heat affected
area

Suitable for thin

sheets only.
High Equipment Cost.

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DEPT. OF MECHANICAL

RESISTANCE SEAM
WELDING

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DEPT. OF MECHANICAL

RESISTANCE SEAM
WELDING
PRINCIPLE:
At Low Voltage, High Current flowing through
the joint generates larger amount of heat
due to High Contact Resistance, Which
causes Melting of Joint and further fusion of
metals.
Resistance Seam Welding is the process in
which the Adjoining Metal Surfaces are joined
together by the heat obtained from
Resistance to the current flow, thus forming
welded seam between them.
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DEPT. OF MECHANICAL

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RESISTANCE SEAM
WELDING
APPLICATIONS
Pressure tanks
Oil Switches
Refrigerators
Evaporators
Condensers
Aircraft tanks

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DEPT. OF MECHANICAL

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RESISTANCE PROJECTION
WELDING

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DEPT. OF MECHANICAL

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RESISTANCE PROJECTION
WELDING
ADVANTAGE

DISADVANTAGE

Welding
occurs
Uniformly.
Different metals with
Different
Thickness
can be welded.
Process is Economical
for
large
scale
production

Projections cannot be
made
in
Thin
Workpiece
For proper welding all
projections must be of
same height

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DEPT. OF MECHANICAL

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RESISTANCE BUTT WELDING

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DEPT. OF MECHANICAL

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RESISTANCE FLASH
WELDING

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DEPT. OF MECHANICAL

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FLASH WELDING
The parts to be welded are clamped
to the electrodes as in butt welding.
But the voltage is applied before the
parts are butted together.
As the parts touches each other, the
arc is established which continues as
long as parts advance at correct
speed.
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DEPT. OF MECHANICAL

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FLASH WELDING
When the welding temperature is
reached, the speed of travel is
increased, the power is switched off
and weld is upset.
The metal forced-out(impurities) as a
result of upsetting action is called
Flash.
Used in automobile construction on
the body, axles, wheels, frames.
Welding
of
motor
frames,
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DEPT. OF MECHANICAL

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LASER BEAM WELDING

LASER LIGHT AMPLIFICATION BY
SIMULATION EMISSION OF RADIATION
LASER is a Concentrated Beam of
Coherent Monochromatic Radiation.
It is used when Thin and Precise weld
is Preferred.
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GENERATION OF LASER LIGHT

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LASER BEAM
WELDING
The LASER welding
System Comprise the
following:
Electrical Storage Unit
Capacitor bank
Triggering device
Flash tube that is
wrapped with a wire
Lasing material.
Focusing lens
mechanism
Work table
( operatable in three
axes X,Y and Z)
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ADVANTAGES
This process can be used to weld
dissimilar metals with widely varying
physical properties.
Metals with relatively high electrical
resistance and parts of considerably
different sizes and mass can be
welded.
Weld can be made with a high
degree of precision & at minimum
thickness.
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ADVANTAGES
LASER Welding holds thermal
distortion and shrinkage to a
minimum.
High depth-to-width ratio of weld.
Welding can be done in inaccessible
locations.
Welds can be made in air or with
shielding gas.
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DISADVANTAGE
High energy losses.
High equipment cost ( but not as
high as for electron beam welding).
Maximum joint thickness that can be
welded by the laser beam is limited.
Rays generated through laser are
harmful to the human body
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