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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.
– 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.
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
• Metal arc
• Metal inert gas
• Tungsten inert gas
• Plasma arc
• Submerged arc
• Electro-slag
(ii). Gas Welding
• Oxy-acetylene
• Air-acetylene
• Oxy-hydrogen
(iii). Resistance Welding
• Butt
• Spot
• Seam
• Projection
• Percussion
• Arc welding
• Equipments:
• 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 Equipments
• Metal arc welding
• Arc Welding
• Carbon Arc Welding
• Arc welding
Advantages
– 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)
More efficiency
Power consumption less
Cost of equipment is less
Higher voltage – hence not safe
Not suitable for welding non ferrous metals
Not preferred for welding thin sections
Any terminal can be connected to the work or electrode
• Comparison of A.C. and D.C. arc welding
Direct Current (from Generator)
Less efficiency
Power consumption more
Cost of equipment is more
Low voltage – safer operation
suitable for both ferrous non ferrous metals preferred for welding thin sections Positive terminal connected to the work Negative terminal connected to the electrode
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 33000c
• 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.
GAS WELDING EQUIPMENT...
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
Oxy-Acetylene welding
TYPES OF 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) (32000c)
• 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
• 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; © 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
GAS CUTTING…
Weld joints
Brazing and Soldering
Brazing
It is a low temperature joining process. It is performed at temperatures above 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
Advantages& Disadvantages
Advantages
• Dissimilar metals which canot 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
Soldering
• It is a low temperature joining process. It is performed at temperatures below 840ºF for joining.
• Soldering is used for,
• Sealing, as in automotive radiators or tin cans
• Electrical Connections
• Joining thermally sensitive components
• Joining dissimilar metals

WELDING TRANSFORMER
 RESISTANCE WELDING TRANSFORMERS
 ARC WELDING TRANSFORMERS
 SPOT WELDING TRANSFORMERS
 BUTT WELDING TRANSFORMERS
RESISTANCE WELDING TRANSFORMERS
Resistance welding involves the controlling of electrical currents ranging from as low as 1000 amperes to has high as 250,000 amperes. The voltage that is required across the work piece to deliver this level of current is only around one volt. Resistance welding is an electromechanical process that is used to assemble metallic parts. A basic understanding of the electrical and mechanical components of the process will provide the foundation for developing control algorithms that benefit the users of this assembly method. It is a good practice to design welding tools beginning at the requirements of the weld nugget and progressing outwards to the controls
ARC WELDING TRANSFORMERS
Product Profile
 The Arc Welding Transformer, SH30, is very effective for speedy production, structural work, machine building and fabrications, filling jobs, worn-out machine parts repair and in arc cutting jobs. Design features: modern look, novel design concept; epoxy power coated body for long life and coil varnishing by vacuum pressurized impregnating varnishing system.
Technical Specifications
 Nominal current output: 300 amps; primary voltage: 380 to 415; frequency: 50 Hz; maximum continuous hand welding current at 60% duty cycle: 300 amps, etc.
ARC WELDING TRANSFORMERS
The Arc Welding Transformers are extensively used nowadays as power source for most of the manual arc welding jobs in light, medium & heavy structural, machine building & fabrication works. Transformer designs are backed by the latest technology to give the best-cost effectiveness with portable, sturdy construction. These appear attractive and negligible in maintenance. Welding current regulation by moving core magnetic shunt design & adequate open circuit voltage for all general purpose AC and AC/DC electrodes.
Features of Arc Welding Transformers
 Combines excellent welding characteristics with high reliability.
 Stepless, smooth and infinitely variable current by latest moving core design.
 Compact size and robust construction.
 Easily maneuverable from place to place.
 Available in Copper or Aluminium winding.

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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.
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.
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
Metal arc
Metal inert gas
Tungsten inert gas
Plasma arc
Submerged arc
Electro-slag
(ii). Gas Welding
Oxy-acetylene
Air-acetylene
Oxy-hydrogen
(iii). Resistance Welding
Butt
Spot
Seam
Projection
Percussion
Arc welding
Equipments:
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 Equipments
Metal arc welding
Arc Welding
Carbon Arc Welding
Arc welding
Advantages
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)
More efficiency
Power consumption less
Cost of equipment is less
Higher voltage – hence not safe
Not suitable for welding non ferrous metals
Not preferred for welding thin sections
Any terminal can be connected to the work or electrode
Comparison of A.C. and D.C. arc welding
Direct Current (from Generator)
Less efficiency
Power consumption more
Cost of equipment is more
Low voltage – safer operation
suitable for both ferrous non ferrous metals
preferred for welding thin sections
Positive terminal connected to the work
Negative terminal connected to the electrode
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 33000c
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.
GAS WELDING EQUIPMENT...
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
Oxy-Acetylene welding
TYPES OF 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) (32000c)
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
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; © 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
GAS CUTTING…
Weld joints
Brazing and Soldering
Brazing
It is a low temperature joining process. It is performed at temperatures above 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
Advantages & Disadvantages
Advantages
Dissimilar metals which canot 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
Soldering
It is a low temperature joining process. It is performed at temperatures below 840ºF for joining.
Soldering is used for,
Sealing, as in automotive radiators or tin cans
Electrical Connections
Joining thermally sensitive components
Joining dissimilar metals