Knowledge about Welding Process

Contents :
• Definitions
• History of welding
• Types Of Welding Processes
• Welding Nomenclature ,Symbols and Terminology
• Types Of Welds
• Types Of Joints
• Welding positions
• Description Of widely used processes i.e.
• SMAW (Shielded Metal Arc Welding)
• GTAW (Gas Tungsten Arc Welding)
• ERW (Electric Resistance Welding)
• Codes & Standards
What is Welding ??
Welding 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 is used for making permanent joints.
Welding is a material joining process in which two or more parts
are joined together at their contacting surfaces by a suitable
application of heat and/or pressure.
• In some welding process a filler material is added to facilitate
coalescence.
• Welding is most commonly associated with metallic parts but
for plastics also it is used.
It is used in the manufacture of Railway, automobile bodies,
aircraft frames, railway wagons, machine frames, structural works,
tanks, furniture, boilers, general repair work and ship building.
What is History of Welding ??
Welding was used in the construction of the iron pillar
in Delhi India, erected about 310 AD and weighing
5.4 metric tons.
Until the end of the 19th century, the only welding
process was forge welding, which blacksmiths had used
for centuries to join iron and steel by heating and
hammering them.
Arc welding and oxy-fuel welding were among the first
processes to develop late in the century, and resistance
welding followed soon after.
What is History of Welding ??
Welding, was transformed during the 19th century. In 1802,
Russian scientist Vasily Petrov discovered the electric arc and
subsequently proposed its possible practical applications,
including welding.

From this many other forms, including current forms, have

been born including:
• Carbon arc welding
• Alternating current welding
• Resistance welding
• Oxyfuel welding

World War I and World War II caused a major surge in the

use of welding processes, with the various military powers
attempting to determine which of the several new welding
processes would be best.
What is History of Welding ??
• Thermit Welding (1903) • Flux Cored Wire with CO 2 Shielding (1954)
• Cellulosic Electrodes (1918) • Electron Beam Welding (1954)
• Arc Stud Welding (1918) • Constricted Arc (Plasma) for Cutting (1955)
• Seam Welding of Tubes (1922) • Friction Welding (1956)
• Mechanical Flash Welder for Joining • Plasma Arc Welding (1957)
Rails(1924) • Electro Gas Welding (1957)
• Extruded Coating for MMAW Electrodes (1926) • Short Circuit Transfer for Low Current, Low
• Submerged Arc Welding (1935) Voltage Welding with CO 2 Shielding (1957)
• Air Arc Gouging (1939)
• Vacuum Diffusion Welding (1959)
• Explosive Welding (1960)
• Inert Gas Tungsten Arc (TIG) Welding (1941)
• Laser Beam Welding (1961)
• Iron Powder Electrodes with High Recovery
• High Power CO2 Laser Beam Welding (1964)
(1944)
• All welded ‘ Liberty ' ships failure in 1942, gave
• Inert Gas Metal Arc (MIG) Welding (1948) a big jolt to application of welding. However, it
• Electro Slag Welding (1951) had drawn attention to fracture problem in
welded structures
How is it done ??
Often done by melting the work pieces and adding a filler material to
form a pool of molten material (the weld pool) that cools to become a
strong joint.
Pressure sometimes used in conjunction with heat, or by itself, to
produce the weld.
Welding is process of joining similar metals by the application of heat
with or without the application of pressure and addition of filler
material. It is broadly classified into plastic & fusion welding.
Fusion Welding : In the Fusion welding, material at joint is heated to a
molten state and allowed to solidify.
Plastic Welding : The type of welding in which the pieces of metals to
be joined are heated to a plastic state and then forged together by
external pressure is called plastic welding.
What is similar to welding?
Shouldering and brazing, which involve melting a lower-melting-point
material between the work pieces to form a bond between them,
without melting the work pieces.
Types of welding??
Welding

Fusion Welding Pressure Welding Friction Welding

Homogeneous Heterogeneous
Welding Welding

Electric Resistance welding

Soldering Brazing
Gas welding
Gas metal arc welding (MIG) (GMAW)
Electro slag welding

High energy beam Gas tungsten arc welding (TIG) (GTAW)

Electric arc welding Shielded metal arc welding -Stick

Brazing
It is a low temperature joining process. It is performed
at temperatures above 4490C (840º F) and it generally
affords strengths comparable to those of the metal
which it joins. It is low temperature in that it is done
below the melting point of the base metal. It is
achieved by diffusion without fusion (melting) of the
base.
Brazing can be classified as
• Torch brazing
• Dip brazing
• Furnace brazing
• Induction brazing
Brazing :
Advantages:
• Dissimilar metals which cannot be welded can be
joined by brazing
• Very thin metals can be joined
• Metals with different thickness can be joined easily
• In brazing thermal stresses are not produced in the
work piece. Hence there is no distortion
• Using this process, carbides tips are brazed on the
steel tool holders

Disadvantages :
• Brazed joints have lesser strength compared to
welding.
• Joint preparation cost is more.
• Can be used for thin sheet metal sections.
Shouldering :
It is a low temperature joining process. It is
performed at temperatures below 449 0C (840ºF) for
joining.
Soldering is used for,
• Sealing, as in automotive radiators or tin
cans
• Electrical Connections
• Joining thermally sensitive components
• Joining dissimilar metals
How is it done ??
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 ELECTRODE COATING

Fusion Welding Principles : CORE WIRE

• Base metal is melted WELDING ATMOSPHERE

ARC STREAM
• Filler metal may be added ARC POOL
SOLIDIFIED SLAG
• Heat is supplied by various means PENETRATION
DEPTH

• Oxyacetylene gas WELD

• Electric Arc
BASE METAL
• Plasma Arc
• Laser
Classification of welding processes:
(i). Arc welding
• Carbon arc (iv)Thermit Welding
• Metal arc
• Metal inert gas (v) Solid State Welding
• Tungsten inert gas • Friction
• Plasma arc • Ultrasonic
• Submerged arc • Diffusion
• Electro-slag • Explosive
(ii). Gas Welding (vi) Newer Welding
• Oxy-acetylene • Electron-beam
• Air-acetylene • Laser
• Oxy-hydrogen (vii) Related Process
(iii). Resistance Welding • Oxy-acetylene cutting
•Butt • Arc cutting
•Spot • Hard facing
•Seam • Brazing
•Projection • Soldering
•Percussion
Arc Welding :
• Uses an electric arc to coalesces metals
• Arc welding is the most common method of welding
metals
• Electricity travels from electrode to base metal to
ground
Equipment :
• A welding generator (D.C.) or Transformer (A.C.)
• Two cables- one for work and one for electrode
• Electrode holder
• Electrode
• Protective shield
• Gloves
• Wire brush
• Chipping hammer
• Goggles
Arc Welding :
Advantage :
• Most efficient way to join metals
• Lowest-cost joining method
• Affords lighter weight through better utilization of materials
• Joins all commercial metals
• Provides design flexibility
Limitations
• Manually applied, therefore high labor cost.
• Need high energy causing danger
• Not convenient for disassembly.
• Defects are hard to detect at joints.
Comparison of A.C. and D.C. Arc
welding :
Alternating Current (from Transformer) : Direct Current (from Generator) :
• More efficiency • Less efficiency
• Power consumption less • Power consumption more
• Cost of equipment is less • Cost of equipment is more
• Higher voltage – Hence not safe • Low voltage – Safer operation
• Not suitable for welding non ferrous metals • Suitable for both ferrous non ferrous metals
• Not preferred for welding thin sections • Preferred for welding thin sections
• Any terminal can be connected to the work • Positive terminal connected to the work
or electrode • Negative terminal connected to the
electrode
Shielded Metal Arc (Stick) Welding :
• An electric arc is generated between a coated electrode and the parent metal
• The coated electrode carries the electric current to form the arc, produces a gas to control
the atmosphere and provides filler metal for the weld bead
• Electric current may be AC or DC. If the current is DC, the polarity will affect the weld size
and application
Process :
• Intense heat at the arc melts the tip of the electrode
• Tiny drops of metal enter the arc stream and are deposited on the parent metal
• As molten metal is deposited, a slag forms over the bead which serves as an insulation
against air contaminants during cooling
• After a weld ‘pass’ is allowed the cool, the oxide layer is removed by a chipping hammer and
then cleaned with a wire brush before the next pass.
Gas Metal Arc Welding / Metal Inert Gas (MIG or
GMAW) :
• MIG welding is gas shielded metal arc welding process using
the heat of an electric arc between a continuously fed,
consumable electrode wire and material is to be welded.
Metal is transferred through a protected arc column of inert
gas to the work.
• A wire of copper coated mild steel is fed continuously from
a reel through a gun with a melting rate upto 5 min/min.
• Current through wire ranges from 100 to 400 amp
depending upon the diameter of wire.
• CO2 is principally used apart from argon or organ helium
mixture as shielding gas.
• Welding machine is a DC constant voltage machine.
• Uses a consumable electrode (filler wire made of the base
metal)
MIG Welding : Benefits and Applications :
Benefits :
There are various benefits of MIG welding, which is why it is the most popular welding process
used in the professional field.
Speed – The process is semi-automatic, and hence, there are few stops and starts. Therefore,
the deposition rate is high leading to the high speed of welding.
Easy Operation – MIG welding is the easiest welding process as it is semi-automatic, and even
beginners can do it without much skill.
Versatile – The process is applicable to most of the metal, starting from steel and nickel to
different metal alloys.
Better Visibility – Most of the process is hands-free, and you get better visibility of the weld
pool and weld formation. As there is less intervention, weld joints are clean and consistent.
Greater Penetration – With a better weld pool formation due to heating and melting of
materials, the materials can mix better, and the weld formation is uniform with greater
penetration of the material.
MIG Welding : Benefits and Applications
Application :
MIG welding is perfect for welding large and thick materials with speed and adjustability.
Welding Pipe – Welding pipes are thick, and hence, MIG welding fits the best. All the different
types of pipes for regular and industrial applications can be welded with MIG welding.
Railways Industry – MIG welding finds a wide range of applications in railroad track building and
joining. Even repairing the worn-out track and locomotive can be done with this welding
process.
Regular Repairing – MIG welding is widely used in all repairing works where welding plays a
major role. As a matter of fact, it is perfect for large-scale welding, thanks to its speed.
Apart from these, from steel structure building and repairing to the automotive and home
improvement industry, all rely on MIG welding.
Tungsten Inert Gas or Gas Tungsten Arc Welding (TIG
or GTAW) :
• Tungsten electrode acts as a cathode
• A plasma is produced between the tungsten cathode and the
base metal which heats the base metal to its melting point
• Filler metal (rod) can be added to the weld pool as filler
material
• The weld area is protected from atmospheric through inert
shielding gas i.e. Argon
• TIG welding is a rather manual process, and hence, the
welder needs enough experience for perfection. TUNGSTEN
ELECTRODE
(CATHODE)

++ ++
---
BASE METAL (ANODE)
TIG Welding: Benefits and Applications
There are various benefits of TIG welding, which is why it is the most preferred welding process by
experienced welders.
Neat Weld Joint – Out of all the welding techniques, TIG welding ensures the best result as the final
output is neat, clean, and precise. Therefore, the appearance of the weld joint is going to be far
better than any other process. It is highly useful in the professional field where the joint should not
disturb the aesthetic value of the object.
Compatibility and Durability – TIG welding is applicable on a variety of metals, starting from
aluminum and magnesium to steel, nickel, copper, and even gold. As far as durability is concerned,
TIG weld joints are surely highly long-lasting, which is always desirable.
All Position Welding – TIG welding lets the welders weld the base metal in any position. Whether it
is flat, horizontal, vertical, or overhead position, you can weld it in any confined area without any
issue.
Clean Process – There is no spark and spatter generated in the process. This is because there is no
extra consumption of filler material, and you only add the filler material when needed. As a matter
of fact, the process does not generate too much smoke or fume if the base metal is clean. Moreover,
this process doesn’t require flux or slag.
One Shielding Gas – There is no need for scratching your head about which shielding gas to be
used based on filler material or base metal. This is because one shielding gas is enough for all
applications, which happens to be Argon.
Application :
TIG welding is perfect for welding small and thin materials with precision and accuracy.
Automotive Industry – As the weld joints are neat and clean, TIG welding finds a wide range of
applications in the automotive industry. Moreover, the joints are strong and durable, and they
do not break due to regular wear and tear.
Aerospace Industry – As the weld joints can be done precisely with TIG welding, the aerospace
industry relies on it for all welding jobs. Apart from strength, the aesthetic value is also taken
care of in TIG welding. Besides, aerospace projects involve the usage of the aluminum body
where TIG welding acts the best.
Manufacturing Industry – TIG welding finds a considerable application in the manufacturing
industry, especially in areas where welder does not get much space for welding. Apart from that,
regular repairing can also be done where durability is the priority.
Similarities between MIG and TIG welding –
There are only a handful of similarities between MIG and TIG welding.
Arc Welding – Both MIG and TIG are arc welding as an electric arc forms between the electrode
and the workpiece.
Bare Electrode – Both the processes use a bare electrode. This means there is no application of
flux-coated electrodes. Hence, there is no spatter formation and less after-process cleaning.
Shielding Gas – Both processes use a shielding gas to protect the welded part from reacting with
elements in the air.
Conductive Metals – You can weld only conductive metals using MIG and TIG welding. This is
because the base metal has to conduct the arc to heat it up and melt.
Differences between MIG and TIG welding :
Parameters MIG Welding TIG Welding
Equipment Used Welding gun, welding power supply, consumable wire electrode, Welding torch, constant-current power supply, non-
and active shielding gas. consumable electrode, and inert shielding gas.
Electrode Type Uses a consumable electrode that is continuously fed during the Uses a non-consumable electrode that stays intact
process. throughout the process.
Electrode Material Material selection depends on the base material Tungsten
Power Supply Uses constant voltage direct power supply Uses constant-current welding power supply
Shielding Gas A mixture of active and inert gas. An inert gas, specifically Argon.
Polarity Uses Direct Current Electrode Positive(DCEP) Polarity for faster Uses Direct Current Electrode Negative(DCEN) Polarity for
deposition rate. the greater lifespan of the electrode.
Filler Material Requirement No additional filler material required as the electrode already May need to supply filler material external, if needed.
has it.
Wire Feeding Need continuous wire feeding. No need of wire feeding.
Speed Fast Slow
Working Position Works in a certain position only. Can work in any position.
Filler Deposition Rate High Low
Spatter Some spatter produced. No spatter produced.
Skill Requirement Basic skills and experience are enough. Requires highly skilled welders with some experience.
Weld Bead Appearance Not so good and uniform. Neat and clean appearance.
Suitability Suitable for homogeneous welding. Suitable for autogenous welding though can be used for
homo and heterogeneous welding.
Submerged Arc Welding (SAW) :
In submerged arc welding, coalescence is produced by the heat of an
arc between a bare metal electrode and the work surface. The arc is
shielded by a blanket of granular, fusible flux. The tip of the
electrode and the welding zone are surrounded and shielded by the
molten flux and a layer of unused flux in the granular state. In this
process, there is no visible evidence of the passage of current
between the electrode and the work surface. This eliminates the
sparks, spatter, and smoke ordinarily seen in other arc welding
processes. Fumes are still produced, but not in quantities generated
by other processes.
Shielded Metal Arc Welding (SMAW) :
is a manual arc welding process that uses a consumable electrode
coated in flux. Current in the form of either AC or DC from a welding
power supply, is used to form an electric arc between the electrode
and the metals to be joined. As the weld is laid, the flux coating of
the electrode disintegrates, giving off vapors that serve as a
Shielding gas and providing a layer of slag, both of which protect the
weldment from air entrapment and slag prevent sudden cooling
Gas Welding :
• Sound weld is obtained by selecting proper size of flame, filler material
and method of moving torch
• The temperature generated during the process is 3300°c.
• When the metal is fused, oxygen from the atmosphere and the torch
combines with molten metal and forms oxides, results defective weld.
• Fluxes are added to the welded metal to remove oxides
• Common fluxes used are made of sodium, potassium. Lithium and borax.
• Flux can be applied as paste, powder, liquid, solid coating or gas.
Types of Gas Welding Technique :
Two types of welding techniques which we are using –
1. Forehand / Forward / Push / Leftward Welding Technique
2. Backhand / Backward / Pull / Rightward Welding Technique
 Forehand Welding Backhand Welding
In forward welding, the flame or electrode is In backwards welding, the flame or electrode is
pointed towards the direction of weld pointed away from the direction of weld
progression. progression.
Here the torch is inclined at an obtuse angle Here the torch is inclined at an acute angle
(usually 135° – 150°) with the feed vector. (usually 30° – 45°) with the feed vector.
The torch is situated above the deposited weld The torch does not remain above the weld bead,
bead (puddle). rather it remains above the unfilled root gap.
Filler metal is applied ahead of the torch. Filler metal is applied behind the torch.
Pre-heating of the base metals takes place No pre-heating occurs here.
automatically in forehand technique. Leftward or Forward Technique
No post-heating occurs here. Backhand welding technique facilitates post- (Forehand)
heating of the deposited weld bead.
The weld joint is subjected to undesired Post-heating allows the joint to be continuously
residual stress. annealed that helps relieving the residual stress.
Pre-heating offers a faster torch feeding rate, Torch feeding rate usually slow due to lack of
which helps in improving productivity. pre-heating.
It increases the filler deposition rate but It assists in achieving deeper penetration,
cannot fetch deeper penetration. though filler deposition rate is slow.
Tendency of spatter formation is more with Backhand welding technique creates
forehand technique. comparatively less spatter.
This technique offers good visibility to the The weld zone has poor visibility.
welder. Rightward or Backward Technique
It is preferred for joining thin plates (usually up It is preferred for joining thicker plates.
to 3.0 mm without edge preparation).
Gas Welding Equipment's :
1. Gas Cylinders
• Pressure
Oxygen – 125 kg/cm2
Acetylene – 16 kg/cm2
2. Regulators
• Working pressure of oxygen 1 kg/cm2
• Working pressure of acetylene 0.15 kg/cm2
• Working pressure varies depends upon the
thickness of the work pieces
welded.
3. Pressure Gauges
4. Hoses
5. Welding torch
6. Check valve
7. Non return valve
Types of Gas Welding flames :
• Oxygen is turned on, flame immediately changes into a long
white inner area (Feather) surrounded by a transparent blue
envelope is called Carburizing flame (30000c)
• Addition of little more oxygen give a bright whitish cone
surrounded by the transparent blue envelope is called Neutral
flame (It has a balance of fuel gas and oxygen) (3200 0c)
Example - Used for welding steels, aluminium, copper and
cast iron
• If more oxygen is added, the cone becomes darker and more
pointed, while the envelope becomes shorter and more fierce is
called Oxidizing flame. Has the highest temperature about
34000c
Example - Used for welding brass and brazing operation
Three basic types of oxyacetylene flames used in oxyfuel-gas
welding and cutting operations:
(a) Neutral flame; (b) Oxidizing flame; (c)Carburizing or reducing
flame.
Gas Cutting :
• Ferrous metal is heated in to red hot condition and a jet of pure
oxygen is projected onto the surface, which rapidly oxidizes
• Oxides having lower melting point than the metal, melt and are
blown away by the force of the jet, to make a cut
• Fast and efficient method of cutting steel to a high degree of
accuracy
• Torch is different from welding
• Cutting torch has preheat orifice and one central orifice for
oxygen jet
• PIERCING and GOUGING are two important operations
• Piercing, used to cut a hole at the centre of the plate or away
from the edge of the plate
• Gouging, to cut a groove into the steel surface
Oxy Acetylene welding:
• Flame formed by burning a mix of acetylene (C 2H2) and
oxygen TORCH TIP 2300 deg F

• Fusion of metal is achieved by passing the inner cone of the

Inner Cone: 5000-6300 Combustion Envelope 3800
flame over the metal deg F deg F

• Oxyacetylene can also be used for cutting metals

Ultrasonic welding:
Ultrasonic welding (USW) is a solid-state welding process that
produces a weld by local application of high-frequency
vibratory energy while the work pieces are held together
under pressure.
Plasma Arc Cutting (PAC) :
In plasma arc cutting, the metal is cut by melting a localized area
with a constricted arc and removing the molten material with a
high velocity jet of hot, ionized gas.
Welding Positions:

INCREASING DIFFICULTY

FLAT

HORIZONTAL
OVERHEAD

VERTICAL
Welding Defects:
1. Undercuts/Overlaps

2. Grain Growth
A wide T will exist between base metal and HAZ. Preheating and cooling methods will affect the brittleness of the
metal in this region
3. Blowholes
Are cavities caused by gas entrapment during the solidification of the weld puddle. Prevented by proper weld
technique (even temperature and speed)
4. Inclusions
Impurities or foreign substances which are forced into the weld puddle during the welding process. Has the same
effect as a crack. Prevented by proper technique/cleanliness.
5. Segregation
Condition where some regions of the metal are enriched with an alloy ingredient and others aren’t. Can be
prevented by proper heat treatment and cooling.
6. Porosity
The formation of tiny pinholes generated by atmospheric contamination. Prevented by keeping a protective shield
over the molten weld puddle.
Welding Defects:
Defect Description Causes Pictures

The depth of the weld is less than Excessive heat

specifications. Excessive speed

The weld metal is not completely Incorrect angle

fused to base metal or passes are not Incorrect manipulation
completely fused. Insufficient heat

Weld material flows over, but is not Slow speed

fused with the base metal.

Weld bead does not extend to the Low heat/Long arc

desired depth. Incorrect joint design
Small indentions in the surface of the Excessive gas in the weld zone.
weld Moisture
Rust
Dirt

Small voids throughout the weld Accelerated cooling

material.

Usually visible cracks on the surface or Accelerated cooling

through the weld Constrained joint
Small weld volume

Cracks in the transition zone between Induced hydrogen

the weld and base metal Incompatible electrode or wire
Accelerated cooling

Misshapen and/or uneven ripples Inconstant speed

Incorrect manipulation
Incorrect welder settings
Residual Stresses :

Rapid heating and cooling results in thermal stresses detrimental to joint strength.

Prevention :
• Edge Preparation/Alignment – beveled edges and space between components to allow movement
• Control of heat input – skip or intermittent weld technique
• Preheating – reduces expansion/contraction forces (alloys) and removes moisture from the surface
• Peening – help metal stretch as it cools by hitting with a hammer. Use with care since it may work
harden the metal
• Heat Treatment – “soak” the metal at a high temperature to relieve stresses
• Jigs and Fixtures – prevent distortion by holding metal fixed
• Number of Passes – the fewer the better.
Generalized Welding Symbol :
The Field Weld Symbol is a guide for installation. Shipyards normally do not use it, except in modular
construction.
FAR SIDE DETAILS Field weld symbol
Weld Geometry

Electrode D L1-L2 Weld all-around

for pipes, etc.
Material D L1-L2
ARROW SIDE DETAILS D = Weld Depth (usually equal to plate thickness)
L1 = Weld Length
L2 = Distance between centers for stitched welds

1/2

1/2

Geometry symbol
for V-groove
1/2” 1/2”
Welding Positions:
Welding Positions:
Joint Designs :

BUTT JOINT STRAP JOINT Plug/Slot Weld FILLET JOINT

CORNER JOINT

LAP JOINT Spot / Seam Weld

Open Corner Joint

Edge Weld
Weld Symbols in Designs (Butt Joints):

BUTT JOINT
Backing
Weld Symbols in Designs (Fillet Joints):

FILLET JOINT
Weld Symbols in Designs (Corner Joints):

CORNER JOINT
Weldability of a Metal :
• Metallurgical Capacity
Parent metal will join with the weld metal without formation of deleterious constituents or alloys
• Mechanical Soundness
Joint will be free from discontinuities, gas porosity, shrinkage, slag, or cracks
• Serviceability
Weld is able to perform under varying conditions or service (e.g., extreme temperatures, corrosive
environments, fatigue, high pressures, etc.)
Weld Metal Protection :
• During fusion welding, the molten metal in the weld “puddle” is susceptible to oxidation
• Must protect weld puddle (arc pool) from the atmosphere
• Methods
• Weld Fluxes
• Inert Gases
• Vacuum
Weld Fluxes & Inert Gases:
Typical fluxes :
• SiO2, TiO2, FeO, MgO, Al2O3
• Produces a gaseous shield to prevent contamination
• Act as scavengers to reduce oxides
• Add alloying elements to the weld
• Influence shape of weld bead during solidification
Inert Gases :
• Argon, Helium, Nitrogen and Carbon dioxide
• Form a protective envelope around the weld area
• Used in -
• MIG
• TIG
• Shield Metal Arc
Electric Resistance welding (ERW) :
Using heat from electric resistance to the flow of a current passing between the faying surface of two
parts held together under pressure.

Types of Electric Resistance welding :

• Electric spot welding
• Electric seam welding
• Electric percussion welding
• Electric projection welding
• Electric Butt Welding
Welding testing methods:
Destructive method : Non Destructive method :
• Chisel hammer testing (ERW) • Radiography (X-Ray)
• UTM testing • Magnetic particle Inspection
• Penetration testing (Etching test) • Penetrant testing Inspection
• Alternet bending test • Ultrasonic testing
• Fillet weld break testing • Eddy current testing
• Impact testing • Leakage testing (for vessels)
Vaccum:
• Produce high-quality welds
• Used in electron beam welding
• Nuclear/special metal applications
• Titanium (Ti), zirconium (Zr) and hafnium (Hf)
• Reduces impurities by a factor of 20 versus other methods
• Expensive and time-consuming

Safe Practices :
Welders need protection from:
• Arc’s rays
• Welding fumes
• Sparks
• Contact with hot metal
Welding Applications:

Automobile