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
1
Student, Mechanical Engineering, Kirodimal Institute of Technology, Raigarh (C.G.)
2,3,4,5
Lecturer, Mechanical Engineering, Kirodimal Institute of Technology, Raigarh (C.G.)
ABSTRACT: In manufacturing process two part are joint is
necessary where welding is generally use. Welding is a
permanent joint process in this paper discuss in welding
process there type and its defect and safety process.
Key word- welding pressure arc.
I. INTRODUCTION
Welding often done by melting the work pieces and filler
material is added to form a pool of molten material that cools
to become a strong joint, with the pressure, sometimes used
in conjunction with heat, or by itself, to produce the weld.
The history of joining metals goes back several millennia,
with the earliest examples of welding from the bronze Age
and the Iron Age in Europe and the Middle East [1]Welding
technology which is a high productive and practical joining
method is widely used in modern manufacturing industry
Such as shipbuilding, automobile, bridge, and pressure vessel
industry [2]. Welding, the fusing of the surfaces of two work
pieces to form one, is a precise, reliable, cost-effective, and
high- method for joining materials. No other technique is as
widely used by manufacturers to join metals and alloys
efficiently and to add value to their products. Most of the
familiar objects in modern society, from buildings and
bridges, to vehicles, computers, and medical devices, could
not be produced without the use of welding. goes well
beyond the bounds of its simple description. Welding today
is applied to a wide variety of materials and products, using
such advanced technologies as lasers and plasma arcs. The
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
designs.[3]Welding is a process of permanent joining two
materials (usually metals) through localised coalescence
resulting from a suitable combination of temperature,
pressure and metallurgical conditions. Depending upon the
combination of temperature and pressure from a high
temperature with no pressure to a high pressure with low
temperature, a wide range of welding processes has been
developed.
II. TYPES OF WELDING
There are two type of welding
presser welding
non presser welding
2.1 presses welding – in this type of welding process pieces
of metals are to be joined to a plastic state and then forced
together by external pressure no fillere material is used in this
method plastic welding may be classifieds follows Blacksmiths forge welding
 Resistance welding
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







Friction welding
Cold presser welding
Spot welding
Seam welding
Projection welding
Upset but welding
Flash but welding
Percussion welding
2.2 Non presser welding (fusion welding)-in this type of
welding process of joining two piece of metal by application
of heat the two parts to be joined are placed together heated
to molten state often with the addition of filler metal until
they melt and solidify on cooling . in this welding , the
material at the joint is heated to molten state and then
allowed to solidify
 Gas welding
 Termite welding
 Electric arc welding
 1.carbon are welding
 metal arc welding
 submerged arc welding
 plasma arc welding
 atomic hydrogen welding
 inert gas welding –
 tungsten ins welding (TIG)
 metallic inert gas welding (MIG)
III. FUSION WELDING
Fusing two or more bars together by bringing them to a high
heat in a forge, and applying pressure to the area being fused
by hammer blows. Forge welding is used in several
circumstances: to produce a smooth transition of adjoining
elements; to secure several elements into a bundle (i.e.
leaves, grapes, acorns, basket twist); to join a bundle to
another element; to close the ends of a single bar shaped in a
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
several bars together to form a billet (as in Damascus
laminate).[5]
IV. RESISTANCE WELDING
Resistance welding is the most commonly used method for
joining steel sheets. No filler metal is needed and the heat
required for the weld pool is created by means of resistance
when a high welding current is directed through the welded
work-pieces. An electro-conductive contact surface is
created between the work pieces by pressing them together.
Copyright 2015.All rights reserved.
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International Journal For Technological Research In Engineering
Volume 3, Issue 3, November-2015
Contact is made using the shape of either the welded surfaces
of the work pieces or the shape of the electrodes.
V. FRICTION WELDING
Friction welding is a solid state welding process that allows
joining of specific material combinations which are
considered unweldable by conventional techniques. In order
to produce a friction weld, the two components are forced to
rotate against each other (friction phase), thereby generating
heat at the interface. Once the desired upset length or process
time has been reached, the rubbing motion stops (braking
phase), the pressure rises (swelling time) and the components
are pressed against each other (forging phase) until they are
cooled down. The main variables in friction welding are the
rotational speed, the axial forces during the friction and
forging phases, and the welding time. The typical
relationship of these characteristics is shown in Fig. 2 which
illustrates a direct drive friction welding process[6]
ISSN (Online): 2347 - 4718
VII. SPOT WELDING
Spot welding is the most commonly used form of resistance
welding. Usually it is used to weld various sheet metals with
reduced thickness. The weld is discontinued and limited to
one or more spots, with the work pieces usually overlapped.
It is produced by the generation of heat and pressure, without
filler metal, in a localized area[11]
VIII. PROJECTION WELDING
Projection welding is an electric resistance welding process
that uses small projections, embossments, or intersections on
one or both components of the weld to localize the heat and
pressure. By doing so, weld current and force is focused into
the small area of the projection, and heat is obtained from the
resistance to the flow of the welding current. Due to this
heat, the projections collapse and the parts are weld
together.[12]
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
direct drive friction welding.[7]
VI. COLD PRESSER WELDING
Cold pressure welding is the establishment of an atom-toatom bond between the two pieces to be joined through
intimate contact between oxide-free areas achieved under
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
by surface roughness [8,9,10]
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X. GAS WELDING
Gas metal arc welding (GMAW) process is an important
component in many industrial operations. The GMA welding
parameters like welding current, welding speed, arc voltage
are the most important factors affecting the quality,
productivity and cost of welding joint. Weld bead geometry
directly affects the cost of welding[14]
Copyright 2015.All rights reserved.
Fig.2. gas welding
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International Journal For Technological Research In Engineering
Volume 3, Issue 3, November-2015
XI. THERMITE WELDING
Exothermic reactions between a metal and a metal oxide.
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- temperaturestable igniters; free-standing insert able heat sources; devices
to breech ordnance cases to relieve pressure during fuel fires;
and methods of producing alumina liners in situ for pipes[17]
Fig.3. THERMITE WELDING
XII. ELECTRIC ARC WELDING
Electrical arc welding is the procedure used to join two metal
parts, taking advantage of the heat developed by the electric
arc that forms between an electrode (metal filler) and the
material to be welded. The welding arc may be powered by
an alternating current generator machine (welder). This
welding machine is basically a single-phase static
transformer suitable for melting RUTILE (sliding) acid
electrodes. Alkaline electrodes may also be melted by
alternating current if these condor open-circuit voltage is
greater than 70 V The welding current is continuously
regulated (magnetic dispersion) by turning the hand wheel on
the outside of the machine, which makes it possible to select
the current value, indicated on a special graded scale, with
the utmost precision. To prevent the service capacities from
being exceeded, all of our machines are fitted with an
automatic overload protection which cuts of the power
supply (intermittent use) in the event of an overload. The
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ISSN (Online): 2347 - 4718
operator must then wait for a few minutes before returning to
work
Fig.4. Electric arc welding
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 defect1. weld crack
2. porosity
3. undercut
4. inclusion
5. distortion
6. slag inclusion
7. incomplete fusion
XIV. SAFTEY PROCESS IN WELDING
Before any welding is conducted outside of a designated
welding area, a responsible individual must inspect the area
and identify precautions to be taken preferably on a written
Hot Works permit. Fire extinguishers must be ready for
immediate use. A fire watch lasting at least 30 minutes after
the welding or cutting operations is required if more than a
minor fire might develop. All combustibles must be moved
35 feet away or properly protected or shielded.
Prohibited areas for welding include:
 Areas unauthorized by management
 Areas where sprinklers are impaired
 Areas in explosive atmospheres
Copyright 2015.All rights reserved.
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International Journal For Technological Research In Engineering
Volume 3, Issue 3, November-2015

Areas near storage of large quantities of readily
ignitable material
XV. SAFTEY IN WELDING
15.1. Good housekeeping-good housekeeping, especially the
removal of combustible materials, is essential.
15.2. Gas-if you can smell gas – don’t light any gas torches
or use electric welding equipment, but don’t rely wholly on
your sense of smell to warn you.
15.3. Eye protection-wear eye protection and cover bare skin.
be aware that: arc flash can occur through the side of the eye
arc flash can cause ‘sunburn’ on exposed skin.
15.4. Hot surfaces-mark hot surfaces as such. better still,
assume everything is hot.
First aid-in addition to standard training, first-aiders in
welding situations should know about the symptoms of
electric shock, arc flash and the consequences of exposure to
heated coatings on metals (e.g. when galvanised metal is
welded)
XVI. CONCLUSION
In industry and every manufacturing welding process is
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
ISSN (Online): 2347 - 4718
1957, volume 1, number 3, pages 117-135.
[9] Tylecote, R. F. Pressure Welding in Practice,
Welding Technology-British Welding Journal,
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[10] Mohamed, H. A., Washburn, J. Mechanism of
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[11] EWF/IAB-WWW.EWF be copy right2007
[12] © 2013 Artech Welders Private Limited. All Rights
Reserved.
[13] Resistance but welding esab.com. Retrieved 201402-25.
[14] INSTITUTE OF TECHNOLOGY, NIRMA
UNIVERSITY, AHMEDABAD – 382 481, 08-10
DECEMBER, 2011
[15] E. Moin, The Current Status of Field Welding of
Rail, Railway TrackStruct., October 1988.
[16] A. A. Shidlovskiy, Principles of Pyrotechnics,
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[17] I SAND95-2448C eddfigt6qI7-To be presented at
the 32"d AIANASMEISAEIASEE Joint Propulsion
Conference,Lake Buena Vista, FL, July 1-3, 1996
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