Welding process is "a materials joining

process which produces coalescence of

materials by heating them to suitable
temperatures with or without the
application of pressure or by the
application of pressure alone and with
or without the use of filler material".
 Welding Joint design
Welding processes
Shielding gases
Welding consumables and equipment
 Industrial application & raw material
Atmospheric conditions
Depending on medium
On the quality of weld
Productivity
Welding Economics
 Manual metal arc welding (MMAW)/SMAW

Gas metal active welding (GMAW/MIG)

Submerged arc Welding (SAW)

 Rutile: This type of electrodes are made of
titanium dioxide (Ti02).

Basic: This type of electrodes are made of

lime coating, they are very hygroscopic in
nature.

Cellulose: This type of electrodes are made of

up with cellulose, produces a large amount of
hydrogen, typically 30 to 45ml
hydrogen/100gm weld metal
 Voltage The electrical potential or pressure that causes
current to flow
Measured in Volts

Current The movement of charged particles in a specific

direction
Measured in Amps
DC+
DC -
Polarity
DC- (Direct Current
Electrode Negative)
DC+ (Direct Current
Electrode Positive) AC
AC (Alternating Current)
 Changes of State and Chemical Reactions
During the welding process the metal changes states or
forms.

What are the states of matter?

Solid
Liquid
Gas
Plasma
 Changes of State and Chemical Reactions
So what changes of state occur during welding?
Initially the metal is a solid
When the arc starts the solid is converted into a liquid
Some of the liquid is converted into a gas vapor
When the arc stops the liquid cools to form a solid
again this is the newly formed weld joint

Solid Liquid Solid

(gas vapor)
Raw material & electrodes specification recommended
for SMAW PROCESS
Steel Specification Recommended Electrodes used
electrodes as per in
AWS D1.1 PEB/structural
steel

ASTM A 572-Gr-50 E-7015,E-7016,E- E-7018

7018,E-7028
ASTM A 572-Gr-55 -DO- -DO-

ASTM A 572-Gr-42 -DO- -DO-

IS 2062 Fe 410, 490 -DO- & E-6013 -DO-

 Advantages
Versatility - readily applied to a variety of applications and a wide choice
of electrodes
Relative simplicity and portability of equipment
Low cost
Adaptable to confined spaces and remote locations
Suitable for out-of-position welding

Disadvantages:
Not as productive as continuous wire processes
Likely to be more costly to deposit a given quantity of metal
Frequent stop/starts to change electrode
Relatively high metal wastage (electrode stubs)
Current limits are lower than for continuous or automatic
processes (reduces deposition rate) & improper shielding
Submerged Arc Welding (SAW)
Conrac butt weld Machine - Conrac twin arc fillet weld
1,Wire Dia,2mm Machine-1,Wire Dia-2mm
Zing gong butt weld machine-1 Zing gong twin arc fillet weld
Wire Dia,2mm Machine-1,Wire Dia,2mm
Zing gong butt weld machine- Zing gong twin arc fillet weld
2 Wire Dia,2mm Machine-2,Wire Dia,1.6mm
Conrac butt weld Machine - Conrac twin arc fillet weld
1,Wire Dia,2mm Machine-1,Wire Dia-2mm
 Plates

Angles

Channels

Beams
 Dimensional

Visual inspection

Chemical analysis

Destructive testing

Non destructive testing

 Wire brush cleaning

Sand Blasting

Pickling or Acid cleaning

Flame cleaning