Review on Verious Type of Welding Process

Home , Upset welding, Welding defect

International Journal For Technological Research In Engineering Volume 3, Issue 3, November-2015 ISSN (Online): 2347 - 4718

REVIEW ON VERIOUS TYPE OF WELDING PROCESS

Onkar Patel1, Prakash Kumar Sen2, Gopal Sahu3, Ritesh Sharma4, Shailendra Bohidar5 1Student, Mechanical Engineering, Kirodimal Institute of Technology, Raigarh (C.G.) 2,3,4,5Lecturer, Mechanical Engineering, Kirodimal Institute of Technology, Raigarh (C.G.)

ABSTRACT: In manufacturing process two part are joint is  Friction welding necessary where welding is generally use. Welding is a  Cold presser welding permanent joint process in this paper discuss in welding  Spot welding process there type and its defect and safety process.  Seam welding Key word- welding pressure arc.  Projection welding  Upset but welding I. INTRODUCTION  Flash but welding Welding often done by melting the work pieces and filler  Percussion welding material is added to form a pool of molten material that cools to become a strong joint, with the pressure, sometimes used 2.2 Non presser welding (fusion welding)-in this type of in conjunction with heat, or by itself, to produce the weld. welding process of joining two piece of metal by application The history of joining metals goes back several millennia, of heat the two parts to be joined are placed together heated with the earliest examples of welding from the bronze Age to molten state often with the addition of filler metal until and the Iron Age in Europe and the Middle East [1]Welding they melt and solidify on cooling . in this welding , the technology which is a high productive and practical joining material at the joint is heated to molten state and then method is widely used in modern manufacturing industry allowed to solidify Such as shipbuilding, automobile, bridge, and pressure vessel  Gas welding industry [2]. Welding, the fusing of the surfaces of two work pieces to form one, is a precise, reliable, cost-effective, and  Termite welding high- method for joining materials. No other technique is as  Electric arc welding widely used by manufacturers to join metals and alloys  1.carbon are welding efficiently and to add value to their products. Most of the  metal arc welding familiar objects in modern society, from buildings and  submerged arc welding bridges, to vehicles, computers, and medical devices, could  plasma arc welding not be produced without the use of welding. goes well  atomic hydrogen welding beyond the bounds of its simple description. Welding today  inert gas welding – is applied to a wide variety of materials and products, using  tungsten ins welding (TIG) such advanced technologies as lasers and plasma arcs. The  metallic inert gas welding (MIG) future of welding holds even greater promise as methods are devised for joining dissimilar and non-metallic materials, and for creating products of innovative shapes and III. FUSION WELDING designs.[3]Welding is a process of permanent joining two Fusing two or more bars together by bringing them to a high materials (usually metals) through localised coalescence heat in a forge, and applying pressure to the area being fused resulting from a suitable combination of temperature, by hammer blows. Forge welding is used in several pressure and metallurgical conditions. Depending upon the circumstances: to produce a smooth transition of adjoining combination of temperature and pressure from a high elements; to secure several elements into a bundle (i.e. temperature with no pressure to a high pressure with low leaves, grapes, acorns, basket twist); to join a bundle to temperature, a wide range of welding processes has been another element; to close the ends of a single bar shaped in a developed. ring, oval, or rectangular shape (as in a frame); to join mild steel to high carbon steel (as in an axe bit); or to laminate II. TYPES OF WELDING several bars together to form a billet (as in Damascus There are two type of welding laminate).[5] presser welding non presser welding IV. RESISTANCE WELDING 2.1 presses welding – in this type of welding process pieces Resistance welding is the most commonly used method for of metals are to be joined to a plastic state and then forced joining steel sheets. No filler metal is needed and the heat together by external pressure no fillere material is used in this required for the weld pool is created by means of resistance method plastic welding may be classifieds follows- when a high welding current is directed through the welded work-pieces. An electro-conductive contact surface is  Blacksmiths forge welding created between the work pieces by pressing them together.  Resistance welding

International Journal For Technological Research In Engineering Volume 3, Issue 3, November-2015 ISSN (Online): 2347 - 4718

Contact is made using the shape of either the welded surfaces VII. SPOT WELDING of the work pieces or the shape of the electrodes. Spot welding is the most commonly used form of resistance welding. Usually it is used to weld various sheet metals with V. FRICTION WELDING reduced thickness. The weld is discontinued and limited to Friction welding is a solid state welding process that allows one or more spots, with the work pieces usually overlapped. joining of specific material combinations which are It is produced by the generation of heat and pressure, without considered unweldable by conventional techniques. In order filler metal, in a localized area[11] to produce a friction weld, the two components are forced to rotate against each other (friction phase), thereby generating VIII. PROJECTION WELDING heat at the interface. Once the desired upset length or process Projection welding is an electric resistance welding process time has been reached, the rubbing motion stops (braking that uses small projections, embossments, or intersections on phase), the pressure rises (swelling time) and the components one or both components of the weld to localize the heat and are pressed against each other (forging phase) until they are pressure. By doing so, weld current and force is focused into cooled down. The main variables in friction welding are the the small area of the projection, and heat is obtained from the rotational speed, the axial forces during the friction and resistance to the flow of the welding current. Due to this forging phases, and the welding time. The typical heat, the projections collapse and the parts are weld relationship of these characteristics is shown in Fig. 2 which together.[12] illustrates a direct drive friction welding process[6] IX. RESISTENCE BUT WELDING Resistance butt welding is a welding technique that produces coalescence simultaneously over the entire area of abutting surfaces or progressively along a joint, by the heat obtained from resistance to electric current through the area where those surfaces are in contact[13]. Pressure is applied before heating is started and is maintained throughout the heating period. The equipment used for upset welding is very similar to that used for flase . It can be used only if the parts to be welded are equal in cross-sectional area

Fig. -1: Variation of the welding parameters with time in X. GAS WELDING direct drive friction welding.[7] Gas metal arc welding (GMAW) process is an important component in many industrial operations. The GMA welding VI. COLD PRESSER WELDING parameters like welding current, welding speed, arc voltage Cold pressure welding is the establishment of an atom-to- are the most important factors affecting the quality, atom bond between the two pieces to be joined through productivity and cost of welding joint. Weld bead geometry intimate contact between oxide-free areas achieved under directly affects the cost of welding[14] pressure and without the formation of liquid phase. In order to develop this bond, surface films have to be removed or at least reduced in amount. Surface films fall into two categories: - Oxide film: All metals except gold possess an oxide film at room temperature. In most metals the oxide film reaches a limiting thickness in the range 20-100 angstroms at room temperature. - Contaminant film: This film consists of a thin layer of moisture and greases. The best technique, which has proved to be successful in reducing these films, is a combination of chemical and mechanical cleaning. Then, the welding method contains two stages. The first stage of welding involves the formation of overlapped oxide-free metallic areas; this is controlled by: (a) difference on a micro scale of the local plastic strain occurring on matching opposite faces of the weld interface, (b) relative hardness of the metal and its oxide film, and (c) mechanical properties of the oxide. The second stage involves: (a) plastic flow of the metal to the over-lapped areas; stress at which this can take place is in fluent by the stacking fault energy of the metal, and (b) some relative shear displacement at the points where metal cleaned of oxide comes into contact; this is influenced Fig.2. gas welding by surface roughness [8,9,10]

International Journal For Technological Research In Engineering Volume 3, Issue 3, November-2015 ISSN (Online): 2347 - 4718

XI. THERMITE WELDING operator must then wait for a few minutes before returning to Exothermic reactions between a metal and a metal oxide. work between metallic elements (intermetallic), and the combustion of metals (metal oxidation reactions) are extremely useful sources of energy production and material synthesis for numerous applications. For example, the thermite welding process was first demonstrated in 1898 and continues to be the most frequently used method for the field welding of rail road track[15,16]Other applications for thermite reactions include termite torches for underwater and atmospheric cutting and perforation electronic hardware destruct devices; additives to propellants and explosives for increased performance; pyrotechnic switches; airbag gas generator materials; reactive fragments; high- temperature- stable igniters; free-standing insert able heat sources; devices Fig.4. Electric arc welding to breech ordnance cases to relieve pressure during fuel fires; and methods of producing alumina liners in situ for pipes[17] A WELDER B ELECTRODE HOLDER C ELECTRODE D EARTH CABLE E ELOCTED HOLDER F SWITH G POWER CABLE I CLAME

XIII. WELDING DEFECT Welding defect are excessive condition, that are outside the parameter of the required weld the defect will compromise the stability and function of the weld welding defect occur in weldments due to improper welding procedure or due to random causes. With proper care these defect can be prevented in most cases The defect commonly occurring can be classified into there main categories 1.Dimention defects 2. structural discontinuities 3. inadequate properties Important welding defect- 1. weld crack Fig.3. THERMITE WELDING 2. porosity 3. undercut XII. ELECTRIC ARC WELDING 4. inclusion Electrical arc welding is the procedure used to join two metal 5. distortion parts, taking advantage of the heat developed by the electric 6. slag inclusion arc that forms between an electrode (metal filler) and the 7. incomplete fusion material to be welded. The welding arc may be powered by an alternating current generator machine (welder). This XIV. SAFTEY PROCESS IN WELDING welding machine is basically a single-phase static Before any welding is conducted outside of a designated transformer suitable for melting RUTILE (sliding) acid welding area, a responsible individual must inspect the area electrodes. Alkaline electrodes may also be melted by and identify precautions to be taken preferably on a written alternating current if these condor open-circuit voltage is Hot Works permit. Fire extinguishers must be ready for greater than 70 V The welding current is continuously immediate use. A fire watch lasting at least 30 minutes after regulated (magnetic dispersion) by turning the hand wheel on the welding or cutting operations is required if more than a the outside of the machine, which makes it possible to select minor fire might develop. All combustibles must be moved the current value, indicated on a special graded scale, with 35 feet away or properly protected or shielded. the utmost precision. To prevent the service capacities from Prohibited areas for welding include: being exceeded, all of our machines are fitted with an  Areas unauthorized by management automatic overload protection which cuts of the power  Areas where sprinklers are impaired supply (intermittent use) in the event of an overload. The  Areas in explosive atmospheres

International Journal For Technological Research In Engineering Volume 3, Issue 3, November-2015 ISSN (Online): 2347 - 4718

 Areas near storage of large quantities of readily 1957, volume 1, number 3, pages 117-135. ignitable material [9] Tylecote, R. F. Pressure Welding in Practice, Welding Technology-British Welding Journal, XV. SAFTEY IN WELDING March 1957, volume 4, number 3, pages 113-119. 15.1. Good housekeeping-good housekeeping, especially the [10] Mohamed, H. A., Washburn, J. Mechanism of removal of combustible materials, is essential. Solid State Pressure Welding, Welding Journal, 15.2. Gas-if you can smell gas – don’t light any gas torches 1975, volume 54, number 9, pages 302-310. or use electric welding equipment, but don’t rely wholly on [11] EWF/IAB-WWW.EWF be copy right2007 your sense of smell to warn you. [12] © 2013 Artech Welders Private Limited. All Rights 15.3. Eye protection-wear eye protection and cover bare skin. Reserved. be aware that: arc flash can occur through the side of the eye [13] Resistance but welding esab.com. Retrieved 2014- arc flash can cause ‘sunburn’ on exposed skin. 02-25. 15.4. Hot surfaces-mark hot surfaces as such. better still, [14] INSTITUTE OF TECHNOLOGY, NIRMA assume everything is hot. UNIVERSITY, AHMEDABAD – 382 481, 08-10 First aid-in addition to standard training, first-aiders in DECEMBER, 2011 welding situations should know about the symptoms of [15] E. Moin, The Current Status of Field Welding of electric shock, arc flash and the consequences of exposure to Rail, Railway TrackStruct., October 1988. heated coatings on metals (e.g. when galvanised metal is [16] A. A. Shidlovskiy, Principles of Pyrotechnics, welded) Mashinostroyeniye Press, 1964. [17] I SAND95-2448C eddfigt6qI7-To be presented at XVI. CONCLUSION the 32"d AIANASMEISAEIASEE Joint Propulsion In industry and every manufacturing welding process is Conference,Lake Buena Vista, FL, July 1-3, 1996 important roll there are two type of joint permanent and detachable joint. Welding is a permanent joint in this day electric arc welding is generally use in manufacturing process welding defect are prevention with materials free Frome dirt and correctly prepared .use the correct tool, equipment and setting correct storage of electrode and also follow the safety process in welding work

REFERANCE [1] R.Waterfield, 1986; Herodotus. The Histories; Publisher: Oxford University Press) [2] Jiangchao Wang, Ninshu Ma, H. Murakawa, Shijian Yuan, 2011; Prediction and Measurementof Welding Distortion of a Spherical Structure Assembled from Multi Thin Plates; Materials & Design; pg. 4728-4737) [3] InternationalOPEN ACCESS Journal Of Modern Engineering Research (IJMER)| IJMER| ISSN: 2249–6645 | Vol. 4| Iss. 1| Jan.2014|105 [4] U. NAVY, "Underwater Cutting and Welding Manual," Naval Sea Systems Command, USA, 2002. [5] CO N T ROL L ED HA N D FO RG I N G10 HAMMER’S BLOW By Dan Nauman Illustrations by Tom LatanéPhotos by Dan NaumanLesson Number 10– Forge Welding [6] REVIEW Friction welding – critical assessment of literature. , M. Graz.University of Technology : Institute of Materials, Minerals and Mining, 10 09 , 2007, pp. 738-759 [7] Bart Derynck, Dries Bonte.Ontwikkelen van een wrijvingslasmachine voor het verbinden van ongelijksoortige materialen. Universiteit Gent : s.n., 2010. [8] Tylecote, R. F. Investigations on Pressure Welding, Welding Research-British Welding Journal, March