Joining Techniques in Ship Building

Lecture-I
Introduction-Definition ,Historical back ground
and classification
 Welding definition
•Welding is the process of joining two similar or
dissimilar metallic components with the
application of heat, with or without the application
of pressure and with or without the use of filler
metal.
• If no filler metal is used during welding then it is
termed as ‘Autogenous Welding Process'.
•Heat may be obtained by chemical reaction,
electric arc, electrical resistance, frictional heat,
sound and light energy.
 Historical background of Welding
• During Bronze Age, parts were joined by forge
welding to produce tools, weapons and
ornaments etc,.

• The welding methods remained more or less

unchanged until the dawn of the 19th century.

• In the 19th century, major breakthroughs in

welding were made.
• In 1800, “Damascus Sword”-Layers of metal
forge welded to high strength.
 Historical background of Welding
• Again in 1800, - a battery operated tool which
could produce an arc between carbon
electrodes was invented. This tool was
extensively used in welding of metals.

• Acetylene was discovered in 1836 and was

soon utilized by the welding industry.

• In 1877, the possibility of electric resistance

welding was recognized.
 Historical background of Welding
• In 1881, the heat generated from an
arc was utilized for welding of
metals.
• In 1889, the concept of coated
electrodes was developed (Shielded
Arc Weld-SMAW).
• During the 1890's, one of the most
popular welding methods was carbon
arc welding.
 Historical background of Welding
• A number of other welding processes were
developed during 1900 such as seam
welding, spot welding, flash butt welding,
and projection welding.

• Coated metal electrode was first introduced in

1900. A coating of lime helped the arc to be much
more stable.

• Stick electrodes became a popular welding

tool around this time as well.
 Historical background of Welding
• In 1903 , oxy – acetylene welding became feasible
in Europe.

• In 1919, the alternating current was invented.

However, alternating current was first
commercially utilized by the welding industry only
in the 1930's.

• After the end of World War I, the American

Welding Society was established. The aim of the
society was the advancement of welding
processes.
 Historical background of Welding
•Automatic welding was first introduced in
1920. Several types of electrodes were also
developed during this decade.

• Welding found its place in ship building

around 1920 and presently all welded ships are
widely used. Similarly submarines are also
produced by welding.
 Historical background of Welding

•In 1930,the New York Navy Yard developed stud

welding. Stud welding was increasingly used for
the construction industry and also for
shipbuilding.
• In Shipbuilding industries, the stud welding
process was replaced by the more advanced
submerged arc welding.
 Historical background of Welding
• A new type of welding called seamless welding
was developed in 1941.
• The gas shielded metal arc welding or GTAW was
another significant milestone in the history of
welding which was developed in 1948.
• The CO2 welding process was popularized in 1953
as it was comparatively economical. Soon,
electrode wires of smaller diameter were
launched. This made welding of thin materials
more convenient.
 Historical background of Welding
• There were several advancements in the welding
industry during the 1960‘s for examples, Electro
slag welding, Plasma arc welding, electron beam
welding.
• Laser was originally developed in Bell Telephone
Laboratories but it is now being used for various
kinds of welding work.
 Historical background of Welding
•Some of the recent developments in the welding
industry include the friction welding process and
laser welding.

•Ships were produced earlier by riveting before

welding was introduced. Over ten million rivets
were used in ‘Queen Mary' ship which required
skills and massive organization for riveting but
welding would have allowed the semiskilled/
unskilled labor and the principle of pre-fabrication.
 Historical background of Welding
•All welded ‘ Liberty ' ships failure in 1942, gave a
big jolt to application of welding. However, it had
drawn attention to fracture problem in welded
structures.
Importance of Welding in Ship Building
1.Water tightness
2.Apperanace
3.Resistance-operational efficiency
4.Strength
5.Weight reduction
6.Easy to repair
7.Hull Protection
8.Less manpower and smooth operation
9.All position and methods
10.Quality of weld-welder and welding procedure
qualification.
 Importance of Welding
• Why is welding important?
– Many of the things we use need to be welded.
 Importance of Welding-Cont….

•Welding is used for making permanent

joints.
•It is used in the manufacture of automobile
bodies, aircraft frames, railway wagons,
machine frames, structural works, tanks,
furniture, boilers, general repair work and
ship building.
Why Welding is Important

– Welded components become a single entity

-Usually the most economical way to join
components in terms of material usage and
fabrication costs
– Mechanical fastening usually requires additional
hardware components (e.g., screws and nuts) and
geometric alterations of the parts assembled
– Welding can be accomplished "in the field"
Limitations & Drawbacks of Welding
• Most welding operations are performed manually
and are expensive in terms of labor cost
• Most welding processes utilize high energy and are
inherently dangerous
• Welded joints do not allow for convenient
disassembly
• Welded joints can have quality defects that are
difficult to detect
 Classification of welding
• Welding processes can be classified based on
following criteria;
• Welding with or without filler material.
• Source of energy of welding.
• Arc and Non-arc welding.
• Fusion and Pressure welding.
 TYPES
• Plastic Welding or Pressure Welding
The piece of metal to be joined are heated to a
plastic state and forced together by external
pressure, Ex. Resistance welding
• Fusion Welding or Non-Pressure Welding
The material at the joint is heated to a molten
state and allowed to solidify, Ex. Gas welding,
Arc welding
 Classification of welding processes:
(i). Arc welding
• Carbon arc
(iv)Thermit Welding
• Metal arc
(v)Solid State Welding
• Metal inert gas
Friction
• Tungsten inert gas
Ultrasonic
• Plasma arc
Diffusion
• Submerged arc
Explosive
• Electro-slag
(vi)Newer Welding
(ii). Gas Welding
Electron-beam
• Oxy-acetylene
Laser
• Air-acetylene
(vii)Related Process
• Oxy-hydrogen
Oxy-acetylene cutting
(iii). Resistance Welding
Arc cutting
• Butt
Hard facing
• Spot
Brazing
• Seam
Soldering
• Projection