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Welding- Short Notes ( Key properties and Applications )

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Subhadeepta Sahoo
Subhadeepta Sahoo

The document discusses various welding techniques including DCSP arc welding, DCRP arc welding, constant current welding, constant voltage welding, TIG welding, MIG welding, plasma arc welding, submerged arc welding, gas welding, thermite welding, atomic hydrogen welding, spot welding, seam welding, projection welding, flash welding, electroslag welding, explosive welding, ultrasonic welding, forge welding, diffusion welding, electron beam welding, laser beam welding, brazing, and soldering. It provides details on their uses, parameters like current and thickness of materials welded, advantages, and applications in different industries.

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DCSP(Arcwelding): Usedfor weldingof highthicknessandhighmeltingpointmaterials. Welddepositionrate isless. DCRP(ArcWelding): Usedfor lessthicknessandlowmeltingpointmaterials. Welddepositionrate ismore. >>Penetration:DCSP> AC> DCRP Constantcurrenttype welding: UsedinManual Arc WeldingTechnique. Constantvoltage type welding: UsedinAutomaticArcWeldingTechnique. >>Arc BlowhappensinDCarc weldingnotinAC. ReducingArcBlow: >> Provide some extramaterial atthe beginningandatthe end of material knownasTab in andTab out. >> Reduce the intensityof currentatthe beginningandatthe endof w/p. Material for flux Coating: >> De-oxidisingelement:graphite,alumina,ferrosilicon,ferro-manganese. >> Slagformation compound:ironoxide,silicondi-oxide,titaniumoxide,silicaflourandCalcium fluoride. >> Arc stabiliser:Sodiumoxide,calciumoxide,potassiumsilicate. >> Alloyingelements:chromium, nickel,Co,Vanadium. >> Gas formingcompound:cellulose,calcium carbonate. TungstenInertGas Welding: Uses:Weldingof Al,Mg and itsalloyinautomobile,aerospace andchemical industry. Generallyusedforlessthan5mmthicknessmaterial. Metal Inert Gas Welding(DropTransfer): Uses:Weldingof Al,Mg and itsalloyinautomobile,aerospace andchemical industry. Generallyusedformore than5mm thicknessmaterial. Current= 150-400A
PlasmaArc Welding: Maximumtemp.= 11000 Celsius,Current=120-150A. Uses:Weldingof Ti,Ni,Co, Mo and itsalloyinaerospace, jetengine,turbinebladesetc. Highm/p and highthicknessmaterialcanbe welded. Penetrationismore andweldingspeedismore. SubmergedArcWelding( Canbe usedin flatpositiononly): Current=200-2000A. Uses:Weldingof highthicknessplate inship building,fabricationof pressure vesselsanddomesticLPG cylinders. Penetrationismore andweldingspeedismore. Gas Welding: Neutral flame:weldingof lowandmediumcarbonandmildsteel,castiron,aluminiumanditsalloy. OxidisingFlame:Weldingof Cu,Zn,Brass etc. CarburizingFlame:Highcarbonsteel,Nickel basedalloy. Thermite Welding: Uses:Repairworkshop,railwayrail,weldingof large size plate,brokencasting. AtomicHydrogenwelding: Uses:Weldingof tool steel anddie steel,repairworkshop,cuttingtool anddies.4000 celsius. Ac powersupplyisusedbecause of uniformheatsupply. SpotWelding: Current:10000 50000A Cu electrode isuseddue tolowresistance andhighthermal conductivity. Uses:Lap joiningof twosheetsinautomobile bodiesandrefrigerationbody. Seamwelding: Uses:Fabricationof fuel tanks,radiatorsandmufflerusedinradiatorpipes. weldingspeedismore. ProjectionWelding: Uses:Joiningof threadedscrewandnutsto sheetmaterial,fabricationof grillsandmeshes. More numberof nuggetcan be producedina single cycle.
FlashWelding: Uses:Joiningof objectendtoend whichare made of highC steel,low Csteel,alloyedsteel andAl and itsalloys( 5-25mm diameteronly) ElectroslagWelding: DCRP isused. Current= 1000A. thickness=50-250mm. Uses:Joiningof highthicknessobjectedge toedge verticallyinshipbuilding,fabricationof pressframes and rollingmill stands. Explosive Welding: Uses : Claddingof objectstoincrease corrosive resistance,joiningof dissimilarmaterial. UltrasonicWelding: Uses:Fabricationof diodesandtriodes,keysetc. F = 20-60KHz. Thickness< 1-2mm.HAZ doesntappearhere. Forge Welding: Uses:Generallyusedinagriculture applicationforjoiningof object. Accuracy isless.Increasedstrength. DiffusionWelding: Accuracy and strengthisveryhigh. TO maximize oxide formationandtoincrease the surface finishthisprocesswill be carriedoutin vacuum. Uses:Fabricationof composite laminates. ElectronBeamwelding: Voltage=40 120 kV No oxide isformeddue tovacuumcondition.Penetrationismaximum.Anodeiscalledannularanode. Uses:Joiningof Titanium,Ba,StainlessSteel,WandColumbium.Inspace craft,aerospace,nuclear powerplantandmissiles.
Laser BeamWelding: EnergygeneratedislessthanEBW. Depthof penetrationandweldingspeedishigh. Uses:joiningof Al,Ti and superAlloysinaerospace andelectronicsindustries. Brazing/ Soldering: Fillermaterial islead+tinalloy>> soldering.(<427 Celsius) Fillermaterial isCualloy( Cu+Zn, Cu + Al,Cu + Ag) >> brazing.(>427 Celsius) Uses:Joiningof materialstoproduce leakproof jointslike inradiatorbodies,pipesusedinwatersupply. Joiningof cuttingtool tipsmade upof tungstencarbide(brazewelding). >> Mildsteel > Cast Iron> Cu > Al (Weldability)

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Welding- Short Notes ( Key properties and Applications )

  • 1. DCSP(Arcwelding): Usedfor weldingof highthicknessandhighmeltingpointmaterials. Welddepositionrate isless. DCRP(ArcWelding): Usedfor lessthicknessandlowmeltingpointmaterials. Welddepositionrate ismore. >>Penetration:DCSP> AC> DCRP Constantcurrenttype welding: UsedinManual Arc WeldingTechnique. Constantvoltage type welding: UsedinAutomaticArcWeldingTechnique. >>Arc BlowhappensinDCarc weldingnotinAC. ReducingArcBlow: >> Provide some extramaterial atthe beginningandatthe end of material knownasTab in andTab out. >> Reduce the intensityof currentatthe beginningandatthe endof w/p. Material for flux Coating: >> De-oxidisingelement:graphite,alumina,ferrosilicon,ferro-manganese. >> Slagformation compound:ironoxide,silicondi-oxide,titaniumoxide,silicaflourandCalcium fluoride. >> Arc stabiliser:Sodiumoxide,calciumoxide,potassiumsilicate. >> Alloyingelements:chromium, nickel,Co,Vanadium. >> Gas formingcompound:cellulose,calcium carbonate. TungstenInertGas Welding: Uses:Weldingof Al,Mg and itsalloyinautomobile,aerospace andchemical industry. Generallyusedforlessthan5mmthicknessmaterial. Metal Inert Gas Welding(DropTransfer): Uses:Weldingof Al,Mg and itsalloyinautomobile,aerospace andchemical industry. Generallyusedformore than5mm thicknessmaterial. Current= 150-400A
  • 2. PlasmaArc Welding: Maximumtemp.= 11000 Celsius,Current=120-150A. Uses:Weldingof Ti,Ni,Co, Mo and itsalloyinaerospace, jetengine,turbinebladesetc. Highm/p and highthicknessmaterialcanbe welded. Penetrationismore andweldingspeedismore. SubmergedArcWelding( Canbe usedin flatpositiononly): Current=200-2000A. Uses:Weldingof highthicknessplate inship building,fabricationof pressure vesselsanddomesticLPG cylinders. Penetrationismore andweldingspeedismore. Gas Welding: Neutral flame:weldingof lowandmediumcarbonandmildsteel,castiron,aluminiumanditsalloy. OxidisingFlame:Weldingof Cu,Zn,Brass etc. CarburizingFlame:Highcarbonsteel,Nickel basedalloy. Thermite Welding: Uses:Repairworkshop,railwayrail,weldingof large size plate,brokencasting. AtomicHydrogenwelding: Uses:Weldingof tool steel anddie steel,repairworkshop,cuttingtool anddies.4000 celsius. Ac powersupplyisusedbecause of uniformheatsupply. SpotWelding: Current:10000 50000A Cu electrode isuseddue tolowresistance andhighthermal conductivity. Uses:Lap joiningof twosheetsinautomobile bodiesandrefrigerationbody. Seamwelding: Uses:Fabricationof fuel tanks,radiatorsandmufflerusedinradiatorpipes. weldingspeedismore. ProjectionWelding: Uses:Joiningof threadedscrewandnutsto sheetmaterial,fabricationof grillsandmeshes. More numberof nuggetcan be producedina single cycle.
  • 3. FlashWelding: Uses:Joiningof objectendtoend whichare made of highC steel,low Csteel,alloyedsteel andAl and itsalloys( 5-25mm diameteronly) ElectroslagWelding: DCRP isused. Current= 1000A. thickness=50-250mm. Uses:Joiningof highthicknessobjectedge toedge verticallyinshipbuilding,fabricationof pressframes and rollingmill stands. Explosive Welding: Uses : Claddingof objectstoincrease corrosive resistance,joiningof dissimilarmaterial. UltrasonicWelding: Uses:Fabricationof diodesandtriodes,keysetc. F = 20-60KHz. Thickness< 1-2mm.HAZ doesntappearhere. Forge Welding: Uses:Generallyusedinagriculture applicationforjoiningof object. Accuracy isless.Increasedstrength. DiffusionWelding: Accuracy and strengthisveryhigh. TO maximize oxide formationandtoincrease the surface finishthisprocesswill be carriedoutin vacuum. Uses:Fabricationof composite laminates. ElectronBeamwelding: Voltage=40 120 kV No oxide isformeddue tovacuumcondition.Penetrationismaximum.Anodeiscalledannularanode. Uses:Joiningof Titanium,Ba,StainlessSteel,WandColumbium.Inspace craft,aerospace,nuclear powerplantandmissiles.
  • 4. Laser BeamWelding: EnergygeneratedislessthanEBW. Depthof penetrationandweldingspeedishigh. Uses:joiningof Al,Ti and superAlloysinaerospace andelectronicsindustries. Brazing/ Soldering: Fillermaterial islead+tinalloy>> soldering.(<427 Celsius) Fillermaterial isCualloy( Cu+Zn, Cu + Al,Cu + Ag) >> brazing.(>427 Celsius) Uses:Joiningof materialstoproduce leakproof jointslike inradiatorbodies,pipesusedinwatersupply. Joiningof cuttingtool tipsmade upof tungstencarbide(brazewelding). >> Mildsteel > Cast Iron> Cu > Al (Weldability)