WELDING TECHNOLOGY

WELDING
ENGR. JOGNO
WEEK 3-4

I. WELDING IV. HOW WELDING WORKS

 A critical construction-related activity that is  A welding gun or torch melts a specific part of the
generally used for binding materials together parent metal.
through the application of heat.  This process, conducted using high heat (typically
 It is a fabrication process that involves the usage with the addition of filler material), creates a
of heat, pressure, or both to fuse two parts. molten metal pool so that it is easy to join a new
metal part to it.
II. FUNDAMENTAL PRINCIPLES OF WELDING  Instead of heat, pressure is also used to weld
 Welding involves a high skill level and practical metals together (pressure welding) depending on
knowledge of subjects like physics, chemistry, and the type and thickness of the material.
metallurgy.
 Welding is generally done on metals but is also KINDS OF WELDING
used for fusing wood or thermoplastic parts.
 A completed joint is a weld joint or weldment. METAL  In most cases, using pressure and
 The parts fused are the parent material, while the WELDING heat together over the base
material used to help form this weld joint is the material enables quick and efficient
filler material. metal welding.
 Welding involves bonding the same type of
material (metal and metal, or wood and wood) PLASTIC  In plastic welding, the surfaces are
using heat welding, pressure welding, or both. WELDING first prepared, followed by heat and
 Welders add metal to the welded joint to
pressure application. After this, the
strengthen the weldment, while a shielding gas
materials are cooled.
like carbon dioxide protects the joint from
contamination through natural elements.
 Different metals react in different ways, depending WOOD  Welding wood involves subjecting
on their physical, mechanical, and chemical WELDING the materials to pressure before
properties. using the same heat that the linear
 Heat can alter the strength, ductility, and friction movement creates.
malleability of metal. Welding can straighten out a
warped piece of metal by applying adequate heat.
 Welding involves the heating and cooling of the V. TYPES AND PROCESSES OF WELDING
metal – there is no other chemical reaction
involved. However, the weld becomes weak if ● STICK WELDING (SMAW)
oxygen reacts with the molten metal. Using ○ Commonly referred to as stick welding,
protective gases around the weld pool prevents involves using welding rods or sticks.
oxygen and other contaminants from damaging ○ The stick consists of the filler material and
the joint. flux
 Extreme heat can alter the crystalline structure ○ Used across construction, shipbuilding, field
and weaken any metal. repair, mining, manufacturing, and
aerospace.
III. ADVANTAGES OF WELDING ○ This type of welding is affordable.
 The technique creates a permanent weld and is
excellent for the fusion of two materials. ● GAS METAL ARC WELDING (GMAW)
 Using the right filler metal ensures strength and ○ Commonly referred to as stick welding,
durability, producing long-lasting weld joints. involves using welding rods or sticks.
 In terms of costs, this method is quite economical ○ The stick consists of the filler material and
in terms of materials, fabrication, and equipment. flux
 The process is versatile and flexible – used ○ Used across construction, shipbuilding, field
indoors as well as outdoors. repair, mining, manufacturing, and
 Welded joints look good, smooth, and polished in aerospace.
terms of appearance. ○ This type of welding is affordable.
 One of the fastest methods in terms of the speed ● FLUX-CORED ARC WELDING (FCAW)
of fabrication. ○ Just like MIG welding, FCAW is great for
 The technique creates a permanent weld and is outdoor welding work and general repairs.
excellent for the fusion of two materials. ○ This technique finds its application in
 Using the right filler metal ensures strength and industrial welding, manufacturing, pipeline
durability, producing long-lasting weld joints. repairs, shipbuilding, and manufacturing.
 In terms of costs, this method is quite economical ○ The difference between MIG and FCAW is
in terms of materials, fabrication, and equipment. that the latter uses a tubular filler wire that
 The process is versatile and flexible – used contains the flux.
indoors as well as outdoors.
 Welded joints look good, smooth, and polished in ● TUNSTEN INSERT GAS WELDING (TIG)
terms of appearance. ○ This particular type of welding uses a non-
 One of the fastest methods in terms of the speed consumable electrode that consists of
of fabrication. tungsten to produce the arc.
WELDING TECHNOLOGY

WELDING
ENGR. JOGNO
WEEK 3-4

○ Creates a clean, smooth, and superior SMAW/STICK WELDING

quality weld. Industries like art, automotive, MACHINE
and aerospace use gas tungsten arc
welding.
● SUBMERGED ARC WELDING (SAW)
○ SAW is a welding method that uses flux but
is different from FCAW because the process
happens under a blanket of granular flux.
○ This is one of the safest types of welding PROFESSIONAL
because it creates lesser welding fumes and WELDING MACHINE &
ultraviolet light. PLASMA
○ SAW is the preferred welding technique in
vessel construction, industrial
manufacturing, and structural construction.
● HYPERBARIC WELDING
○ This is a process that welders use
underwater. The wet welding technique
utilizes stick welding, where the flux
produces bubbles that act as a shield to TIG WELDING MACHINE
prevent the welder from being electrocuted.

Some other important and often-used welding

processes and techniques include:

MIG WELDING MACHINE

VI. DIFFERENT EQUIPMENTS USED IN WELDING

 Welding is a specialized job that requires you to
have a variety of essential tools, including (but not GAS WELDING MACHINE
restricted to) the following equipment:

ELECTRO SLAG
WELDING MACHINE
VII. TYPICAL TYPES OF WELDING MACHINES

TYPES OF WELDING MACHINES

SMAW/STIC WELDING
MACHINE
ELECTRO GAS MACHINE
WELDING TECHNOLOGY

WELDING
ENGR. JOGNO
WEEK 3-4

VIII. FOUR BASIC WELDING POSITIONS  Bend Test

 Fillet and groove welds are performed in these o Bend testing is performed to check the
basic positions: strength and durability of the weld when
1. Flat a certain amount of pressure or force is
2. Horizontal applied to it. It determines the quality of
the weld, the degree of penetration, and
3. Vertical the fusion to the base metal.
4. Overhead  This procedure aims to check the discontinuities in
the welds. It helps to find the amount of pressure
that the weld can bear before it breaks or
fractures. Three different types of bend tests are
used, namely jig, free bend, and backbend.
o
 NICK BREAK TEST
o Nick break tests are used to determine
the internal defects of the weld, such as
gas pockets, poor fusion, slag
inclusions, oxidation, or burnt metal.
o A piece of the welded butt joint is placed
between the two supports and pressure
is applied.
o A big blow is applied to it using a
hammer that causes it to fracture. You
can then perform your analysis and
check for the defects such as inclusions
or gas pockets
 NON-DESTRUCTIVE
o Non-destructive testing is a part of weld
testing that doesn't damage the material
being tested. It involves investigating the
material under the subject by studying
its properties.
o A great benefit of this method is that it
saves time and money for companies as
material damage caused by other
IX. WELD TEST testing methods can be costly.
 The welding procedure and its quality is o The following examples of non-
dependent on ensuring that every step is done destructive welding testing:
correctly. It is a technical task that requires proper
certification, safety regulations, and training. NON-DESTRUCTIVE WELDING TESTING
 Any damage to the welding part can be costly and
VISULA  In most cases, using pressure and
might cause permanent structural damages to the
INPECTION heat together over the base
final product.
material enables quick and efficient
 Weld testing is a procedure used to check the
metal welding.
quality and standard of welding.
 It is a necessary process to ensure that the
LIQUID OR  In plastic welding, the surfaces are
welding is suitable for a specific purpose.
DYE first prepared, followed by heat and
X. TYPES OF WELD TEST PENETRANT pressure application. After this, the
INSPECTION materials are cooled.
 Visual Inspection of the Weld
o The basic method of checking the WOOD  Welding wood involves subjecting
quality of a weld is to inspect it for any WELDING the materials to pressure before
flaws visually. using the same heat that the linear
o Look for any cracks, beads, bends, friction movement creates.
craters, excessive reinforcements, or
other flaws and inform any concerned
authorities about it.  MACROTECH TEST
o Visual inspection is a basic step, and if o
the weld fails it, it means that it is not up  LEAK TEST IN PIPE WELDING
to mark and needs to be re-welded. o
Thus, it will not be sent off for further .
tests if it fails in this initial test. 4. Non-Destructive Testing
WELDING TECHNOLOGY

WELDING
ENGR. JOGNO
WEEK 3-4

Non-destructive testing is a part of weld testing that doesn't primary coil. The change in primary coil current flow is
damage the material being tested. It involves investigating detected. The amount of the current change represents the
the material under the subject by studying its properties. effect of a discontinuity causing the distortion in the
It uses various scientific techniques to evaluate the secondary field.
material's strength, durability, and other properties to make it This method is used to detect weld defects deep into the
suitable for a certain job. A great benefit of this method is metal. Depths of up to 25 mm are possible depending on the
that it saves time and money for companies as material metal being tested and the speed of at which the alternating
damage caused by other testing methods can be costly. current changes (its frequency).
The following examples of non-destructive welding testing: This is the favoured approach for testing steel tank floors
a) Visual Inspection and walls. A crawling scanner is sent across the surface and
This method uses a qualified and trained observer watching changes in the eddy current are shown on a monitoring
the weld as the welder is working. The observer watches the screen. Where evidence of a discontinuity is found the spot
weld pool and the cooling metal. They typically look for is marked and then a more thorough local examination is
inclusions, undercutting (the weld height is below the parent conducted with other NDT equipment to quantify the defect.
metal height), depth of weld penetration and certainty of e. Ultrasonic Inspection
bonding to the parent metal. High frequency sound waves are sent into a metal using an
When a non-complying defect is observed the spot is emitting probe. If the waves encounter a discontinuity they
marked. At the end of the weld run the defect is ground out bounce off it and return to the probe where they are
and the weld is remade to the required quality detected. The size and location of the discontinuity are
b) Liquid or Dye Penetrant Inspection displayed on a monitoring screen.
As the name suggests a colouring agent is used to detect The method cannot be used for surface and near surface
weld defects. This method will only find surface cracks and faults. A dead-zone occurs just below the contact point of the
surface discontinuities. The weld surface is thoroughly probe. To insure proper acoustic connection between the
cleaned of scale and splatter (but not shot blasted as it will probe and metal surface a liquid coupling agent, like grease,
close over the defects). A detergent wash is used to remove is used between the two. The test surface is required to be
dirt, a pickling paste is used to remove paint or grease and a smooth enough for the coupling agent to maintain contact
degreaser or solvent is applied to remove oil. Only a clean between probe and metal. Where the weld is peaked too
metal surface is acceptable. high a different technique is required that uses reflected
The system normally comes in two spray cans – one is the sound to check for discontinuities.
penetrant and the other is the developer. The penetrant is The sizes of defects that can be detected depend on the
sprayed over the weld and capillary action draws it into any wavelength of the sound. As a rule the defect has to be half
minute surface cracks. The penetrant on the surface is the wavelength to be detectable. Different metals have
wiped off and the penetrant in the cracks remains wet. After different wavelengths for the same sound frequency. In steel
a short dwell time the developer is sprayed over the weld. at 2 MHz, defects of 1.5 mm are detectable.
The developer acts to draw-out the penetrant dye from the f. Acoustic Emission Monitoring
cracks and so changes colour. It behaves like blotting paper Acoustic emissions are stress waves produced by sudden
and magnifies the presence of the crack. movement in stressed materials. When a material is placed
c. Magnetic Particle Inspection under load it deforms ever so slightly. Internal movements
This method uses changes in a magnetic field to detect produced by the deformation create sounds that travel
surface and just-below surface discontinuities. When a through the structure. These sounds can be detected and
magnetic field is interrupted by a defect, the field distorts the source of the movement located. Once the source is
around the defect. Powdered magnetic filings placed in the found other NDT techniques are used to quantify the
field can show this distortion. This method is only usable for movement and any presence of discontinuities.
ferro-magnetic (iron based magnetic) metals. This method is often used on existing large structures, such
When used to test welds the magnetic field is produced as tanks and pressure vessels, as it is fast and low cost.
either by placing metal prods on each side of the weld and Fixed sensors are located on the structure and typically
introducing a low electric current through the metal or by placed every 1 to 6 meters apart. The structure is ‘loaded’ in
placing the metal part into a magnetic field. Magnetic fields rising, step-wise fashion and the acoustic emissions
are induced into the part by the external magnetic field. recorded on a display monitor. The loading is varied or held
Once the magnetic field is established a few powdered, constant for a period of time and the changes in acoustic
coloured metal particles are placed on the part. The pattern emissions indicate if the structure is continuing to move
created by the powder in the magnetic field is inspected for internally.
field distortions. The particles may be used wet (in a By factoring-in the metal’s sound velocity, the emission point
suspension of kerosene) or dry depending on the parts can be located by triangulation with good accuracy.
location and the purpose of the examination. Background noise can interfere with results. This problem
d. Eddy Current Inspection can be overcome by stopping the noise at its source, by
The principle of operation is the detection of changed electric filtering it out using the electronics within the monitoring
current flow in a coil of electric wire. Alternating electric equipment or by use a different measuring frequency to the
current flow through a coil creates a fluctuating magnetic noise frequency.
field around the coil. If the magnetic field is brought close to g. Industrial Radiography
conducting metal, eddy electrical currents develop in the Radiographic inspection is based on the absorption of
metal. The eddy currents in turn set up a magnetic field in radiation by materials of different density. In the engineering
opposition to the coil’s primary field. industry X-rays or gamma rays are used. It is an expensive
Any fluctuations in the secondary magnetic field due to process but penetrates almost all materials to great depths.
distortions also change the strength of the primary field, The radiation source is put on one side of the weld being
which in turn change the electrical current flow through the tested and the detecting ‘photographic’ film is placed on the
WELDING TECHNOLOGY

WELDING
ENGR. JOGNO
WEEK 3-4

other side of the weld. As radiation passes through the weld

discontinuities act as density reducers allowing more
radiation through them. The high level of radiation shows up
as a darker colour on the film.
Because the image created on the film is a ‘shadow’ it can
be affected by factors such as changes in subject thickness,
radiation scatter, geometric factors influencing radiation,
source positioning, exposure times and film quality.
5. Macroetch Test
This one is useful for fillet welds and helps identify the fusion
to the roof and its sidewalls. It reveals any problems if there
is any lack of fusion on the groove welds. A limitation in this
type of testing is that it checks the fusion and the penetration
on one spot only.
LEAK TEST IN PIPE WELDING
A leak testing in welding is done to makes sure that no gas
leaks out from small holes and defects in the pipe. The test
is done by first passing air or high pressure gas through the
pipes.
The pipes are them submerged under water. If there are
leaks present in the pipe, there would be bubbles on the
water. The position of the leaks can also be determined by
the position of the bubbles of water. There are times when a
liquid penetrate is also used to determine leaks.
The liquid penetrate works as a marker for the leaks in the
pipe. If the welding pipe is handling sensitive gas then the
specific gas detectors can be used to detect leakage of
those gasses in the air.
Non destructive inspection and quality control can be used to
check for leak in welding pipes. This way the safety of
the welding system is maintained.

CUTTING SPEED
● The relative speed between the cutting tool and
workpiece is expressed in meters per minute.