ADVANCEDWELDINGTECHNIQUESIN

MANUFACTURINGINDUSTRY4.0
ProjectsubmittedinpartialfulfillmentoftherequirementsfortheDegreeof

Diploma
In

Mechanical Engineering
By
 Somnath Ghosh - D222303184
 Ankan Shyam - D222303175
 Sekh Aman - D232404507
 Soumyadip Mallick - D232404517
 Arjun Bhakta - D222303194
 Ankur Samanta – D232404504
 Srinjit Dutta - D202102114
 Ritush Roy – D222303159

Under the Guidance of

SATYAJIT ROY

Dr.B.C.RoyPolytechnic,Durgapur-06,WestBengalinINDIA
 Dr. B. C. Roy Polytechnic, Durgapur-06, West Bengal in INDIA

Certificate
This is to certify that the project entitled "ENERGY SCENARIO IN INDIA" submitted
by SOMNATH GHOSH, ANKAN SHYAM, SEKH AMAN, SOUMYDIP MALLIC,
ARJUN BHAKTA, ANKUR SAMANTA, RITUSH ROY, and SRINJIT DUTTA have
been carried out under my supervision in partial fulfillment of the requirements for the
Degree of Diploma in Mechanical Engineering during session 2022-2025 and 2023-
2025 in the department of Mechanical Engineering, Dr. B. C. Roy Polytechnic, and
Durgapur.

Satyajit Roy
Lecturer of Mechanical Engineering Department,
Dr. B. C. Roy Polytechnic

Mr. Chirodip Pal

HOD, Lecturer of Mechanical Engineering Department,
Dr. B. C. Roy Polytechnic
 Dr. B. C. Roy Polytechnic, Durgapur, West Bengal in INDIA

Certificate Approval

The forgoing project is hereby approved to be creditable of an engineering subject carried

out and presented in a manner satisfactory to warrant its acceptance as a prerequisite to
the degree for which it has submitted, it is understood that by this approval the
undersigned do not necessarily endorse or approve any statement made, opinion expressed
or conclusion drawn from therein but approved the thesis only for the purpose for which it
is submitted.

Committee on final
Examination for
evaluationofthe project
 Dr. B.C. Roy Polytechnic, Durgapur-06, West Bengal in INDIA

Acknowledgement

This dissertation would not have been possible without the guidance and the help of several
individual who in one way or another contributed and extended their valuable guidance and
support in the preparation and completion of this study.
Firstly, and fore mostly we want to express my sincere gratitude and thank gratefully to my
supervisor Satyajit Roy, Lecturer of the Mechanical Engineering Department, Dr. B. C.
Roy Polytechnic, Durgapur, West Bengal, India for his unreserved help, motivation,
enthusiasm and constant guidance to finish my project step by step. Under his supervision I
successfully overcame many adversities and learned a lot. I extend my deep sense of
obligation and honor to him for his inspiring discussions, kind co-operation and constant
encouragement throughout period of my project work which has been influential in the
success of project and thanks of Mr. Chirodip Pal, HOD of Mechanical Engineering
Department for supporting us to complete our project.
Last but not least, we would like to pay high regards to my parents, my friends and the
omnipresent God for giving me strength in all the critical situations and supporting me
spiritually throughout my life.

Somnath Ghosh - Ankan Shyam - Sekh Aman -

D222303184 D222303175 D232404507

Soumyadip Mallick - Arjun Bhakta - Ankur Samanta –

D232404517 D222303194 D232404504

Ritush Roy – Srinjit Dutta -

D222303159 D202102114
 Abstract
Today most of the industries are trying to make improvement in their production processes
as well as relevant machinery to improve the productivity along with the automation.
Conventionally, the metal joining process used to be carried out using fasteners and rivets.
Since the advancements in technology, the metal joining process is now performed via
welding. Because welding affects the mechanical properties, the importance of welding
parameters to determine the mechanical properties of welded plates is considered.
Manufacturing (Welding and casting) and machining processes (Turning and Boring) are
such operations which are most frequently used in small- and large-scale industries. Most
of the industries use the conventional methods which are very time consuming process, less
accurate and includes higher labor cost, and ultimately leads to less productivity. So, there
is a scope to develop the machine for various operations which would overcome all the
problems faced by the conventional process. So industry 4.0 tries to introduce advancement
in welding process by modifying the conventional one. In our thesis we try to project
different welding technique used in current industry scenario and market size of welding
industry.
 Contents
CHAPTER TOPIC NAME PAGE NO.
Abstract
Chapter1 Introduction and Literature review
1
1.1 Introduction
1
1.2 Literature review
1
Chapter 2 Objective 1
Chapter 3 Different types of welding processes 1 to 18
Chapter 4 Advanced welding techniques 19
Chapter 5 Future scope of work 20
Chapter 6 References 21 to 22

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1. INTRODUCTION AND LITERATUREREVIEW:
1.1 Introduction: -

Resistance welding, invented in 1877 by Elisha Thomson, was accepted long before arc welding for spot and
seam joining of sheet. Butt welding for chain making and joining bars and rods was developed during the 1920s.
In the 1940s the tungsten-inert gas process, using a no consumable tungsten electrode to perform fusion welds,
was introduced. In 1948 a new gas-shielded process utilized a wire electrode that was consumed in the weld.
More recently, electron-beam welding, laser welding, and several solid-phase processes such as diffusion
bonding, friction welding, and ultrasonic joining have been developed [1][5].
Welding is the technique of uniting two or more metals, either similar or dissimilar, by heating them to a certain
temperature, either with or without the use of flux, filler material, or pressure.
Electric arcs (for arc welding), gas combustion (for gas welding), electrical resistance (for resistance welding),
or black Smith's fire (for forge welding) can all provide heat. The composition and melting point of the filler
material are comparable to those of the base metal. The purpose of the filler rod is to create a circular, oval, or
fillet, to fill the space between joints, and to supply the additional material. It also serves to compensate for losses
incurred during the welding process [1][2][5].

Definition: - The fabrication technique of welding combines materials, typically metals or Thermoplastics, by
melting the components together at a high temperature and letting them cool, which creates fusion. Common
substitute techniques include solid-state welding techniques that bind without melting, such as pressure, cold
welding, and diffusion bonding, and solvent welding (of thermoplastics), which uses solvents to melt materials
being bonded without heat. Metal welding differs from lower temperature bonding methods like brazing and
soldering, which require the flow of a filler metal to establish their bonds rather than melting the base metal
(parent metal) [3][5][6].

Type of welding:-

1. Arc Welding
Arc welding is a process that uses an electric current to create an arc that generates intense heat to join pieces
of metal together. It's a common welding method used in many industries, including construction,
shipbuilding, and aerospace. Types of arc welding.

 SMAW (Shielded Metal Arc Welding or Stick Welding)

Shielded metal arc welding (SMAW) is a welding process in which coalescence of metals is produced
by heat from an electric arc maintained between the tip of a consumable electrode and the surface of
the base material in the joint being welded [5]. The impact of changing the welding current and speed
on mechanical properties such as hardness and tensile strength values were reviewed to show the
behavior of low carbon, mild carbon and stainless-steel joints. The results show that varying the
welding parameters greatly affected mechanical properties of different steel joints. Mainly, the current
caused the higher hardness values which would require further heat treatment to prevent brittle failure
[6] [7].

1
 Mild Steel (MS) is the economical form of steel offering suitable mechanical properties for various
applications. It is hard, weld-able and durable, but it rusts easily. It contains 0.29% carbon and can be
magnetized easily. It is widely used in structural work and in automotive industries [7].
Low-Carbon Steel has a 0.16–0.29% carbon content and is widely used. It has low tensile strength but
high ductility which makes it excellent for welding and machining. It cannot be hardened by
performing heat treatment, instead cold working is used [7].
Stainless-Steel is an iron-alloy which comprises of at least 11% chromium which prevents the material
from rusting and makes it more heat-resistant. It is a hard and ductile. The chromium forms a layer of
oxide on the steel surface called the “passive layer”. This layer makes the surface resistant to
corrosion. Thus, greater chromium content will increase the anti-corrosion properties of stainless steel
[7].
Parameters are Welding speed is the rate of distance covered by an electrode along the seam by
increasing the speed and maintaining arc voltage, the width of welding bead will be reduced. As a
result optimum point at which penetration of weld will peruse maximum and going beyond this
optimum point will decrease the penetration. This study examined the effects of welding speed and
current on the mechanical characteristics of joints. Numerous experiments were conducted in order to
conduct the analysis on specimens that have been steel-welded [7].

 GMAW (Gas Metal Arc Welding or MIG welding)

Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert gas (MIG) and
metal active gas (MAG) is a welding process in which an electric arc forms between a consumable
MIG wire electrode and the work piece metal(s), which heats the work piece metal(s), causing them
to fuse (melt and join) [6].
Mild Steel MIG welding works incredibly well on mild steel, creating strong, clean welds with little
spatter. Large projects can benefit from the welding process's quick deposition rates.
To avoid oxidation and guarantee weld quality, a range of shielding gases are employed, including
CO2 or a combination of argon and CO2 [6].
Carbon Steel MIG welding produces strong, long-lasting welds on carbon steel, just like it does on
mild steel. Higher carbon content, however, may make the material more brittle, necessitating
careful heat input control and, in certain situations, preheating [6]
Aluminum one of the most used methods for welding aluminum is MIG welding. The material's high
thermal conductivity necessitates careful consideration of heat input because it can cause
deformation and overheating. For aluminum, a shielding gas mixture of argon and helium is
frequently utilized to improve arc stability and penetration. The metal being welded is taken into

2
 consideration when choosing aluminum filler rods. [6] [5]
Nickel Alloys in order to prevent contamination during MIG welding of nickel-based alloys such as
Inconel or Montel, particular filler materials and shielding gases must be used, particularly when
welding high-temperature resistant alloys. For shielding, argon or argon-helium combinations are
frequently utilized. [6] [7]
Cast Iron its brittleness and propensity to fracture when heated, MIG welding cast iron is more
challenging. To ensure a solid bond and prevent cracking, the cast iron must frequently be preheated
and the proper filler material—typically a nickel-based filler—must be employed. To reduce the
amount of tension on the weld, the cooling rate should also be managed. [6] [5]

 GTAW (Gas Tungsten Arc Welding or TIG Welding)

Tungsten Inert Gas (TIG) welding, also known as Gas Tungsten Arc Welding (GTAW) is an arc
welding process that produces the weld with a non-consumable tungsten electrode. Tungsten inert
gas (TIG) welding became an overnight success in the 1940s for joining magnesium and aluminum.
[4] [7] [10]
Stainless steel because GTAW can create strong, corrosion-resistant welds, it works especially well
on stainless steel. Because the method preserves the base metal's chemical integrity, it is perfect for
use in the chemical, pharmaceutical, and food processing sectors. [4] [7] [10]
Aluminum TIG welding is frequently utilized for aluminum, particularly in applications that call for a
high level of strength and visual appeal. Alternating current (AC) ensures a clean weld by assisting
in the removal of the aluminum oxide layer. For thicker parts, preheating can be required to enhance
penetration. [4] [7] [10]
Carbon Steel while GTAW can be used for carbon steel, it is less common than other methods like
MIG welding. It provides good control over the heat input, which is beneficial for thin materials.
Proper filler material (like ER70S-2) is essential to ensure good weld quality. [4] [7] [10]
Copper and Copper Alloys GTAW can be used for welding copper, but it requires careful control of
heat to prevent excessive melting. Filler materials like ERCu or ERCuSi are often used. [4] [7] [10]

3
  SAW (Submerged Arc Welding)
Submerged Arc Welding (SAW) is a type of welding process that uses an electric arc to create a
bond between metal work pieces. Unlike other welding techniques, SAW is characterized by the arc
being submerged under a layer of granular flux, which provides several benefits to the process. [8]
[12]
Carbon Steels structural steel SAW is frequently utilized in the development of buildings, bridges,
and other substantial constructions. It is effective in welding thick structural steel parts because of
its deep penetration and high deposition rate. Pressure Vessels SAW is used to fabricate pressure
vessels, such as tanks and boilers, where exceptional strength and dependability are essential. [8]
[12]
Steels with low alloy content pipeline construction because of its great productivity and capacity to
consistently produce welds under a variety of field situations, SAW is perfect for welding pipelines.
Offshore platforms SAW is used in the construction of offshore platforms, where it can withstand
harsh marine environments and provide durable welds. [8] [12]
Stainless Steels equipment for chemical processing in the chemical industry, where corrosion
resistance is crucial, SAW is utilized in the fabrication of tanks, pipes, and other equipment. [8] [12]
Alloys based on nickel parts for aircraft when welding high-temperature components in aerospace
applications, where strength and oxidation resistance are crucial, SAW is utilized. [8] [12]

 FCAW (Flux Cored ARC Welding)

Flux-cored arc welding (FCAW or FCA) is a semi-automatic or automatic arc welding process.
FCAW requires a continuously-fed consumable tubular electrode containing a flux and a constant-
voltage or, less commonly, a constant-current welding power supply. An externally supplied
shielding gas is sometimes used, but often the flux itself is relied upon to generate the necessary
protection from the atmosphere, producing both gaseous protection and liquid slag protecting the
weld. [13] [8] [12]
Carbon Steel its rapid penetration and deposition rates make it ideal for welding. Able to
successfully weld polluted surfaces, including those with mill scale or rust. [13] [8] [12]
Stainless Steel certain flux-cored wires made for stainless steel can be used with FCAW. Creates
robust welds that are resistant to corrosion. [13] [8] [12]
Cast Iron suitable for repairs and fabrication, though care must be taken to manage heat input to
avoid cracking. Flux-cored wires can help in achieving good fusion and strength. [13] [8] [12]

4
  PAW (Plasma Arc Welding)
Plasma Arc Welding (PAW) is a welding process that uses a plasma arc to melt and join metals. It is
similar to Gas Tungsten Arc Welding (GTAW or TIG), but with some key differences. In PAW, the
welding arc is formed between a tungsten electrode and the work piece, and the arc is constricted
through a nozzle, creating a highly focused and intense heat source. [15] [16]
Stainless Steele PAW works well for welding a variety of stainless steel grades, including thick-
section and thin-gauge materials. It provides excellent welding and exact control. [15] [16]
Aluminum PAW is well-suited for welding aluminum alloys, especially those that are difficult to
weld with other processes. It provides deep penetration and minimizes porosity. [15] [16]
Titanium alloys, which are frequently utilized in the aerospace and medical sectors, can be welded
using PAW. It reduces the chance of contamination and provides exceptional weld quality. [15]
[16]
Copper and Copper Alloys brass, bronze, and other copper alloys may be welded using PAW. It
produces excellent welds with favorable mechanical characteristics. [15] [16]
Nickel Alloys PAW is used to weld nickel alloys, which are often used in high-temperature and
corrosive environments. It offers excellent weld quality and resistance to corrosion. [15] [16]
Exotic Alloys a range of exotic alloys, including those utilized in nuclear and aerospace applications,
may be welded using PAW. It offers precise control and high-quality welds. [15] [16]

 Carbon Arc Welding

Carbon arc welding (CAW) is a welding process that uses an electric arc to join metals together.
The process involves heating the metals with an arc between a non-consumable carbon electrode
and the metal being welded. The arc can produce temperatures of over 3,000 °C, which causes the
metals to bond together. [15] [18] [21]
Steel Although carbon contamination can be an issue with CAW, particularly for high-strength steels,
it can be used to weld a variety of steel varieties. [15] [18] [21]
Cast Iron Because CAW can quickly melt the metal at high temperatures, it is a good choice for
welding cast iron. [15] [18] [21]
Non-ferrous Metals Copper and aluminum are examples of non-ferrous metals that can be welded
using CAW, but caution must be exercised to prevent oxidation and excessive heat input. [15] [18]
[21]

5
  Stud Welding
Stud Welding is a specialized welding process used to attach a metal stud (a short, cylindrical metal
part) to a work piece, typically a base metal, through the use of heat generated by an electric arc.
The process is widely used in manufacturing industries, particularly in applications where a strong,
permanent attachment is required without needing to access both sides of the base material. [5] [7]
Stud Welding Steels stud welding is an option for mild and stainless steels. Because it works well
with drawn arc stud welding and capacitor discharge stud welding, steel is generally excellent for
use as a stud and base material. Preheating is typically necessary when using medium or high carbon
steels (those with carbon equivalents more than 0.25 percent) in order to prevent cracking. Low
carbon mild steel weld studs for drawn arc and capacitor discharge stud welding are available from
Taylor Stud welding because of their superior quality. On client request, corrosive and acid
Resistant materials as well as heat-resistant steel grades are also offered. Regarding the many kinds
of weld studs, we provide mild and stainless steel studs that are threaded, unthreaded, and internally
threaded. These studs work with a variety of steel bases. [5] [7]
Stud Welding Aluminum Another very practical material for stud welding is aluminum. Aluminum
studs and aluminum base materials go hand in hand. Although each is ideally coupled with studs of
the aluminum alloy material, this is true for both pure aluminum and aluminum alloy base materials.
Aluminum alloy (AlMg3) CD weld studs are available from Taylor Stud welding. Both threaded
and unthreaded versions of our aluminum CD studs are available. In addition, we manufacture
aluminum non-ferrous studs up to 12 mm in diameter for DA stud welding procedures upon request.
[5] [7]
Stud Welding Brass For stud welding applications, lead-free brass can be utilized with mild steel,
stainless steel, or brass weld studs. Only brass should be stud welded utilizing the capacitor
discharge method. Both threaded and unthreaded brass CD weld studs are available from Taylor
Stud Welding. Lead-free copper and lead-free brass can be used as basis materials for brass CD
studs. [5] [7]
Stud Welding Copper If you want to have no markings, copper base stud welding materials work
best with brass weld studs. Although light marking may occur, mild steel and stainless steel studs
are also alternatives. Capacitor discharge stud welding is the best method for stud welding copper
because of its fast speed and high thermal conductivity. When it comes to stud welding across a
variety of sectors, we always aim to satisfy our clients' expectations. Every customer has different
needs, and we can help them choose the best stud welding systems, arc welding kinds, and studs for
their needs. You can contact us to learn more about our goods, and we will be happy to offer
guidance. [5] [7]

2. Oxy fuel Gas Welding

Oxy-fuel gas welding, also known as oxyacetylene welding or gas welding, is a welding process that uses a
combination of oxygen and fuel gases to melt and fuse metals together. It's one of the oldest welding

6
 methods and is often used in construction, metalworking, and automotive repair. [3] [10] [11]
Mild Steel: Oxy-acetylene welding produces strong, ductile welds that are ideal for mild steel. Controlling
the flame is necessary to prevent oxidation and excessive heat input, which can cause distortion. [3] [10]
[11]
High-Carbon Steel: To avoid hardening and cracking, high-carbon steel must be welded with careful
flame control. To reduce oxidation, a neutral flame is typically utilized. [3] [10] [11]
Stainless Steel: Because stainless steel is more prone to oxidation and heat deformation, oxy-acetylene
welding is a more difficult process. For stainless steel, TIG welding is frequently chosen. [3] [10] [11]
Aluminum: Because of its high heat conductivity and oxidation susceptibility, aluminum is not a good
candidate for oxy-acetylene welding. Aluminum is best welded using TIG or MIG. [3] [10] [11]

3. Electron beam welding

Electron Beam Welding (EBW) is a high-precision welding process that uses a focused beam of high-
velocity electrons to melt and join materials. It is a type of fusion welding, which means the materials are
melted at the joint to form a bond. The process is carried out in a vacuum or controlled atmosphere to
prevent contamination, as the electron beam can be influenced by gases and particles in the air. [2] [5]
Ferrous Metals: Steel and cast iron are two examples of ferrous metals that EBW is excellent at welding.
It can provide ductile, robust welds with little deformation. [2] [5]
Non-Ferrous Metals: Non-ferrous metals such as titanium, copper, and aluminum may also be welded
using EBW. To prevent porosity and cracking, however, the welding settings must be carefully controlled.
[2] [5]
Dissimilar Metals: Unlike other welding techniques, EBW may be used to connect dissimilar metals like
Steel and aluminum. [2] [5]
Heat-Treated Metals: Heat-treated metals may be welded with EBW without sacrificing their mechanical
qualities. [2] [5]

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4. Laser beam welding
Aster Beam Welding (LBW) is a high-precision welding process that uses a concentrated laser beam as the
heat source to melt and join materials. The laser provides a focused, intense heat that can create deep welds
with minimal heat input and distortion. This process is used for a wide variety of materials and thicknesses,
offering advantages in speed, precision, and automation. [5] [7] [23]
Carbon and mild steels have high-strength, flawless joints and excellent weld ability. Porosity and
cracking in high-carbon steels as a result of fast cooling are potential problems. For high-carbon grades,
preheating and post-weld heat treatments could be necessary. [5] [7] [23]
Stainless steels produce excellent welds with less deformation. Keeps corrosion resistance intact when the
right shielding gas, such argon, is utilized. Some grades may become sensitized, which might result in the
precipitation of chromium carbide. [5] [7] [23]
Aluminum may be welded successfully, although careful parameter control is needed to prevent
deformation and overheating. Produces robust joints, but in order to avoid strength loss, the heat input
needs to be controlled. Produces a crisp weld that requires little post-weld polishing. [5] [7] [23]

5. Termite Welding
Thermite Welding (TW) is a type of welding process that uses a chemical reaction between metal powders
to generate heat, which is then used to melt and join two work pieces. The key feature of thermite welding
is the exothermic reaction that occurs when metal powder, typically aluminum powder, reacts with metal
oxides (usually iron oxide), producing an intense amount of heat that reaches temperatures over 2,500°C
(4,500°F). This heat is sufficient to melt the base material and form a strong bond once it solidifies. [6] [9]
[17]
Steel and Iron Because of the high temperatures attained during the reaction, high strength thermite
welding creates a strong link between steel and iron, producing a weld that is frequently stronger than the
base materials. Zone Affected by Heat (HAZ) The extreme heat may change the iron or steel's
microstructure, which might have an impact on its mechanical qualities in the HAZ. Uses often used to
weld rails in railway construction, guaranteeing dependability and durability under high loads. [6] [9] [17]
Copper conductors can be joined via thermite welding, which produces a weld with exceptional electrical
conductivity. In order to confine the molten copper that flows around the conductors to make a solid
junction, the method frequently uses graphite molds. The resultant weld is appropriate for electrical
applications due to its strong corrosion resistance. [6] [9] [17]
Metals Alloyed By adding alloying materials during the thermite process, the weld's characteristics may
be modified to satisfy certain needs, including greater strength or better resistance to wear. For the weld to
have the appropriate qualities, the thermite mixture's composition needs to be properly regulated. [6] [9]
[17]

8
6. Electro slag welding
Electro slag Welding (ESW) is a high-heat, high-productivity welding process primarily used for welding
thick, heavy materials, particularly in vertical or overhead positions. The process involves melting both the
base material and a filler metal using the heat generated by a molten slag pool. The molten slag acts as both
the heat source and a protective layer for the weld, making this process ideal for welding large sections
with minimal distortion and high-quality welds. [13] [20]
Carbon Steel ESW offers strong welds and deep penetration, making it especially useful for welding thick
portions of carbon steel. Mechanical characteristics may be impacted by microstructure changes in the
HAZ. To reduce negative consequences, welding settings must be well controlled. Frequently utilized in
structural applications requiring great strength, including beams and girders. [13] [20]
Low alloy steels can be joined with ESW while retaining their strength and durability. To prevent
brittleness, the cooling rate must be carefully managed. The method is appropriate for crucial applications
in pipelines and pressure vessels because it may yield high-quality welds with few flaws. [13] [20]
Stainless steel the corrosion-resistant qualities of stainless steel may be maintained by using ESW to weld
it. To prevent sensitization, which might result in corrosion, the heat input must be managed. In situations
where appearance counts, including food processing or architectural features, the method can yield visually
beautiful welds. [13] [20]
Cast iron is fragile and prone to cracking when heated to high temperatures, ESW is often not advised for
use with it. Alternative welding techniques are frequently used, such as preheating and the use of certain
filler materials. Preheating is necessary when doing ESW on cast iron in order to avoid cracking and lessen
thermal shock. [13] [20]

Some of the pressure welding processes are:

1. Resistance Welding
Resistance welding is a process that joins two metals together by applying pressure and passing an electric

9
 current through them. The heat generated melts the metals at the joint, fusing them together. [3] [10] [13]
Steel Resistance welding produces strong, long-lasting welds and is quite effective on steel. Effective heat
production at the weld contact is facilitated by steel's high electrical resistance. [3] [10] [13]
Stainless Steel Because of its lower electrical resistivity and higher heat conductivity than carbon steel,
stainless steel need careful control over the welding settings, even though it may be resistance welded. [3]
[10] [13]
Aluminum because of its high thermal conductivity and quick heat dissipation, resistance welding presents
difficulties for aluminum. Nonetheless, high-quality welds may be produced with certain methods and tools.
[3] [10] [13]
Copper Like aluminum, copper is difficult to concentrate heat at the weld joint due to its high thermal
conductivity. To overcome this obstacle, specialized electrodes and welding methods are needed. [3] [10]
[13]
Titanium Because of its high reactivity and propensity to develop oxide layers, which can impede the
creation of a sound weld, titanium is typically not a good candidate for resistance welding. [3] [10] [13]

 Spot Welding
Spot Welding is a type of resistance welding process that is commonly used to join two or more metal
sheets by applying heat and pressure to specific points, creating a small, localized weld at each point.
It is widely used in industries such as automotive manufacturing, where large volumes of sheet metal
parts need to be welded together quickly and efficiently. Spot welding is a fast and cost-effective
method for creating strong, reliable welds in thin metal sheets. [9] [12] [23]
Poor-carbon steel Because of its poor thermal conductivity, which enables effective heat concentration
at the weld joint, this material is ideal for spot welding. [9] [12] [23]
Mild steel Spot welding is an easy way to weld mild steel, just like it is with low-carbon steel. [9] [12]
[23]
Stainless steel although stainless steel may be spot welded, its greater electrical resistivity and thermal
conductivity than mild steel necessitate careful welding parameter modification. [9] [12] [23]
Aluminum although it may also be welded, aluminum poses difficulties because of its high heat
conductivity and tendency to produce oxide layers. High-quality welds need certain welding
conditions and procedures. [9] [12] [23]
Different metals it might be more difficult to spot weld different metals. It is essential to carefully
evaluate the welding settings, material qualities, and any metallurgical problems. [9] [12] [23]

10
  Seam Welding
Seam welding is the most expanded technique for on-line welding as a continuous process to ensure
coil-to-coil assembly at the entry of continuous annealing lines and galvanizing lines. This is a
resistance welding technique that requires an overlap of the two extremities of the coils so one can be
joined to another. [15] [21]
Low-Carbon Steel good electrical conductivity and mild heat conductivity make it ideal for seam
welding. Creates continuous, robust welds. Excessive distortion can be avoided with easily regulated
heat input. [15] [21]
Stainless Steel has increased electrical resistance and poorer thermal conductivity, necessitating
precision heat management. May experience oxidation and discoloration; post-weld cleaning or
shielding gas can lessen these effects. Welds are robust and resistant to corrosion. [15] [21]
Aluminum its strong heat conductivity and propensity to develop oxides make it difficult to seam weld.
To get good results, special methods and electrode materials are frequently used. [15] [21]

 Projection Welding
Projection welding is a form of resistance welding which uses pressure and electrical current to join
two or more metal parts that have been designed to meet at one or more specific points with the
maximum amount of contact. [9] [12] [22]
Steel Mild steel, low-carbon steel, and high-strength steel are all often subjected to projection welding.
High strength, strong electrical conductivity, and the capacity to work with different thicknesses are
among its benefits. [9] [12] [22]
Aluminum Because of its low melting point and strong heat conductivity, aluminum may be projection
welded, but the welding settings must be carefully controlled. Successful welds depend on accurate
current and pressure settings as well as a well-designed projection. [9] [12] [22]
Stainless Steel because of its greater resistance to heat flow, stainless steel can be difficult to project
weld. To obtain high-quality welds, careful consideration of electrode pressure, welding duration, and

11
 projection design is required. [9] [12] [22]
Copper due of its high heat conductivity, copper can be challenging to project weld. However, sound
welds may be achieved, particularly for thinner portions, with the right technique and parameter
modifications. [9] [12] [22]

 Flash Welding
Flash Welding is a type of resistance welding process in which two metal pieces are joined by applying
heat generated through resistance to electric current, along with pressure. The key feature of flash
welding is that it involves creating a controlled flash of molten metal at the interface between the two
work pieces before applying pressure to forge the joint. This process is commonly used to weld metals
like steel, aluminum, and copper, particularly for applications involving large sections or parts with
high strength requirements. [5] [17]
Low-carbon steels because of their very simple microstructure, low-carbon steels are very wieldable.
Flash welding produces robust joints with few flaws. Rarely is preheating or a certain pace of
cooling required may be necessary. [5] [17]
High-carbon and alloy steels these materials may experience brittleness or cracking due to the higher
carbon content and alloying elements. Careful control of the heating and cooling cycles is necessary
to avoid defects like martensitic transformation or carbide precipitation. [5] [17]
Stainless steels but extra care must be taken to avoid chromium carbide precipitation, which can lead
to intergranular corrosion. It may be necessary to use post-weld heat treatments or shielding gasses.
[5] [17]
Aluminum because of their high heat conductivity and tendency to develop oxide layers, aluminum
and its alloys are more difficult to flash weld. Accurate parameter control and surface preparation
are crucial. [5] [17]
Copper and its alloys high conductivity requires high current during welding. Flash welding can
produce good joints, but softening in the heat-affected zone (HAZ) might reduce joint strength. [5]
[17]

12
  Upset Welding
Upset Welding is a type of resistance welding process that involves the joining of two metal pieces
by applying pressure and heat generated by electrical resistance. It is a variation of the resistance
welding process, where the material at the welding interface is heated by passing an electric current
through it. The key feature of upset welding is that the two metal pieces are "upset" or squeezed
together under pressure after heating, causing them to fuse. [9] [17]
Carbon Steels upset welding is frequently used to connect carbon steels, especially in the construction
and automotive sectors. It creates welds with high mechanical qualities that are robust and long-
lasting. [9] [17]
Stainless Steels although upset welding may be used to effectively weld stainless steels, oxidation and
intergranular corrosion must be avoided by carefully controlling the welding settings. [9] [17]
Aluminum Alloys upset welding is suitable for joining aluminum alloys, but it is important to control
the welding parameters to avoid excessive melting and porosity. [9] [17]
Copper Alloys Although upset welding may be used to weld copper and its alloys, the high thermal
conductivity of these materials might make it challenging to reach the necessary welding temperature.
[9] [17]
Titanium Alloys although titanium alloys may be joined via upset welding, extra care must be taken to
avoid contaminating the weld zone due to titanium's strong reactivity with oxygen and nitrogen. [9]
[17]

 Percussion Welding
Percussion Welding is a resistance welding process that involves the joining of metal parts by applying
high-pressure electrical current in short, rapid pulses. The process is called "percussion" welding
because the energy is delivered in a quick, controlled pulse (like a "percussive" strike) to produce a

13
 strong weld. It is typically used for welding small parts, components, or assemblies where precision
and speed are essential. [9] [12] [23]
Ferrous Metals steel, iron, and other ferrous metals are excellent candidates for percussion welding. It
preserves the qualities of the material by producing clean, robust welds with little heat-affected
zones (HAZ). [9] [12] [23]
Non-Ferrous Metals Copper, brass, and aluminum are among the non-ferrous metals that it can weld.
However, elements like surface preparation and material thickness might affect the quality of the
weld. [9] [12] [23]
Dissimilar Metals percussion welding's capacity to fuse disparate metals together is one of its key
benefits. It may forge solid connections between metals with dissimilar characteristics, such copper
and steel or stainless steel and aluminum. [9] [12] [23]

2. Diffusion welding (DFW)

Diffusion Welding (DFW) is a solid-state welding process in which two metal surfaces are joined together
by the application of heat and pressure over a period of time, causing the atoms of the materials to diffuse
across the interface and bond without reaching the melting point. This process relies on atomic diffusion,
which occurs at temperatures typically between 0.3 and 0.7 of the melting point of the materials being
joined. Diffusion welding is often used to create high-strength joints between materials that would be
difficult to weld using conventional methods, such as dissimilar metals or high-performance alloys. [6] [7]
Carbon, alloy, and stainless steels: Create strong metallurgical connections. At high temperatures,
microstructural changes take place, such as grain expansion. Hardness and corrosion resistance may be
impacted by the diffusion of alloying elements. [6] [7]
Titanium: Because DFW maintains the material's superior mechanical qualities and corrosion resistance, it
is frequently used to combine titanium alloys. [6] [7]
Nickel Alloys: Because DFW preserves the strength and creep resistance of nickel-based super alloys, it
may be used to connect them in high-temperature applications. [6] [7]

14
3. Friction welding (FRW)
Friction Welding (FRW) is a solid-state welding process that joins two work pieces by generating heat
through mechanical friction. This heat is generated by the relative motion between the two pieces, which is
then used to create a strong bond without melting the material. The process relies on the combination of
heat from friction and pressure to forge the pieces together. Friction welding is often used for joining
dissimilar metals, thermoplastics, and other materials that may be difficult to weld using traditional
methods. [3] [7] [19]
Steels: FRW is frequently used to connect many kinds of steel, such as stainless steel, alloy steel, and
carbon steel. It creates ductile, robust joints with little heat-affected areas. [3] [7] [19]

Cast iron: Cast iron components can be joined using FRW, however porosity and cracking must be
prevented by carefully controlling the welding settings. [3] [7] [19]
Aluminum: FRW produces strong, corrosion-resistant connections when used to link aluminum alloys.
Controlling the welding conditions is crucial, though, to prevent melting and excessive heat input. [3] [7]
[19]
Copper: Although FRW may be used to connect copper and copper alloys, certain methods may be needed
to avoid porosity and oxidation. [3] [7] [19]
Titanium: Although titanium alloys may be joined by FRW, it is essential to regulate the welding settings
to prevent embrittlement and mechanical property loss. [3] [7] [19]

4. Ultrasonic welding (USW)

Ultrasonic Welding (USW) is a solid-state welding process that uses high-frequency ultrasonic vibrations to
create heat and bond materials together. This process is often used to join thermoplastics or thin metal parts,

15
 but it can also be applied to other materials. The ultrasonic vibrations cause localized friction at the interface
between the work pieces, generating heat that softens or melts the materials, allowing them to fuse together.
[5] [8] [20]
Copper and Aluminum: In USW, these metals are most frequently utilized. High-frequency vibrations
produced by the process heat up and distort the metal surfaces, creating a solid metallurgical bond. USW's
excellent malleability and thermal conductivity make it perfect for connecting copper and aluminum. [5] [8]
[20]
Steel: In general, USW is not appropriate for welding thick steel pieces. Nonetheless, thin steel sheets,
especially those coated with non-ferrous metals, can be joined using it. [5] [8] [20]

5. Cold Pressure Welding

Cold Pressure Welding (CPW) is a solid-state welding process that joins two materials without the
application of heat. Instead, it relies on the application of high pressure to cause plastic deformation at the
interface of the materials, resulting in atomic bonding between them. The process is carried out at or near
room temperature, and it is often used for joining metals or metallic components that would otherwise be
difficult to weld using traditional heat-based methods. [2] [7] [16]
Aluminum: Cold pressure welding is widely used for joining aluminum wires, especially in the electronics
industry. It's particularly valuable for joining dissimilar aluminum alloys, which can be challenging with
traditional welding methods. [2] [7] [16]
Copper: Another metal that works well for cold pressure welding is copper. It is frequently utilized in
electrical applications because of its high conductivity, which makes it perfect for forging dependable and
robust connections. [2] [7] [16]
Gold: Gold is highly ductile and malleable, making it an excellent candidate for cold pressure welding.
It's commonly used in jewelry making and electronic components. [2] [7] [16]
Silver: Similar to gold, silver is also highly ductile and can be easily cold pressure welded.
It's used in various applications, including electrical contacts and jewelry. [2] [7] [16]

16
6. Forge welding
Forge welding is a process that involves heating two pieces of metal before hammering, pressing or rolling
them together to create a joint. Originally developed in the middle Ages, it is one of the oldest known
methods for joining metals and is an essential skill for blacksmiths. [10] [17]
Steel and Iron: Forge welding works very well with wrought iron and other kinds of steel. The procedure
can result in ductile, robust joints. The mechanical qualities of the weld can be improved by refining the
grain structure by heat and mechanical manipulation. [10] [17]
Aluminum: Because of its strong heat conductivity and lower melting point, forge welding aluminum is
more difficult. Accurate temperature management is necessary. Strong joints can be created if done
properly, however poor bonding and oxidation can result from incorrect heating. [10] [17]
Copper: Although it is possible to forge weld copper, careful temperature control is necessary to prevent
melting. Although too much heat might produce grain development and weaken the material, the procedure
can result in a fine-grained structure. [10] [17]
Nickel and Nickel Alloys: High temperatures and cautious handling are necessary to prevent oxidation
while forge welding nickel and its alloys. The mechanical qualities can be improved by the procedure,
although the weld quality may be impacted by contaminants. [10] [17]
Bronze and Brass: Bronze and brass can be forge-welded, although careful temperature control is
necessary to prevent melting. Strong joints may be produced by the method, however unfavorable phase
shifts may result from overheating. [10] [17]

7. Explosion welding (EXW)

Explosion Welding (EXW) is a solid-state welding process that uses the energy from an explosive charge to
create a strong, metallurgical bond between two materials. The process involves the detonation of an
explosive charge to propel one work piece at high velocity into contact with another work piece. The intense

17
 force generated by the explosion causes plastic deformation at the interface, resulting in the bonding of
the two materials without melting. This process is commonly used for joining dissimilar metals,
particularly those with large differences in physical properties, such as copper to steel or aluminum to
steel. [18] [21][23]
Copper: Because of its exceptional ductility and conductivity, EXW is especially well suited for copper.
Strong joints may be produced by the method with little heat input. The resulting connection maintains
copper's inherent qualities, resulting in great thermal and electrical conductivity. [18] [21] [23]
Aluminum: By taking use of its lightweight and corrosion-resistant qualities, EXW can successfully
connect aluminum to other metals, despite the fact that it is difficult. The procedure helps prevent melting,
which can cause aluminum to oxidize and lose its strength. [18] [21] [23]
Steel: EXW works well for attaching different kinds of steel, such as carbon and stainless steels, to other
metals. The steel's mechanical integrity is preserved while a solid bond is formed by the explosive process.
Nickel and Nickel Alloys: EXW is capable of efficiently bonding nickel and its alloys, creating robust
connections that are impervious to heat and corrosion. The procedure improves nickel's mechanical
qualities, enabling it to be used in demanding applications. [18] [21] [23]

18
 Application:-

 Welding pipes and tubes, where it can produce strong, reliable joints with minimal human intervention.
 Ideal for thin materials and complex geometries, laser welding is widely used in automotive and electronics
manufacturing.
 TIG welding is often used in applications requiring high-quality welds, such as in aerospace and food
processing industries.
 This process allows for continuous welding, making it efficient for large-scale production.
 This technique is particularly useful for aluminum and is gaining traction in the aerospace and
transportation industries.
 Automated systems can operate in hazardous environments, reducing the risk to human workers and
improving overall safety.
 Hybrid techniques can improve weld quality and reduce production times, making them suitable for
complex application

ADVANTAGES:
 Small in size.
 Cost is less compared to other welding machine.
 Due to portable ability it is easily handled.

DISADVANTAGES:
 Not so effective for very hard materials.
 Feed should be given intermittently.
 Overload should be avoided.

APPLICATIONS:
There are many different uses of welding machines. Some of the areas where it finds
Applications are:
 Automobile industry
 Automotive manufacturing
 Metal working
 Shipbuilding
 Fabrication
 Casting

19
 FUTURE SCOPE OF WORK
Advanced welding techniques are widely used in industries for high-precision applications, but they are
also prone to specific defects that can compromise the integrity of welded joints. Understanding these
defects and their causes is crucial for quality assurance and improved performance. Here's an overview:
Defects in Advanced Welding Techniques:
1. Lack of Fusion
2. Porosity
3. Cracking
4. Distortion
5. Incomplete Penetration
6. Spatter
7. Undercutting
8. Weld Contamination
9. Oxidation

20
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