The document provides information on various welding processes including submerged arc welding, hyperbaric welding, and stud welding. Submerged arc welding involves an electric arc formed between an electrode and workpiece under a covering layer of flux. It allows for high deposition rates and quality welds. Hyperbaric welding is performed inside a pressurized chamber and allows for underwater welding. Stud welding uses an electric arc to instantly weld metal stud fasteners to workpieces for permanent bonding.

1. PRESENTATION
ON
WELDING PROCESSES
GUIDED BY:- PROF. HITESH PATEL
MANUFACTURING PROCESS-2
SUBMITTED BY:
HIMANSHI GUPTA(140120119057) / ME / A2
PRACHI SHARMA(140120119216) / ME / A2
(2141908)
GA N D H IN A GA R IN STITU TE OF
TEC H N OLOGY

3. 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.

4. TYPES OF WELDING
 PLASTIC WELDING OR PRESSURE WELDING:
• The piece of metal to be joined are heated to a plastic state and forced
together by external pressure
• Example: Resistance welding
 FUSION WELDING OR NON-PRESSURE WELDING:
• The material at the joint is heated to a molten state and allowed to
solidify
• Example: Gas welding, Arc welding

5. CLASSIFICATION OF WELDING PROCESSES

6. CHARACTERISTICS OF WELDING
a) Deposition rate
b) Deposition efficiency
c) Operation factor
d) Penetration
e) Welding speed
f) Heat input
g) Power density

7. SUBMERGED ARC WELDING

8. INTRODUCTION
• Submerged arc welding (SAW) is a method in which the heat required
to fuse the metal is generated by an arc formed by an electric current
passing between the electrode and the workpiece.
• There is no visible arc and no sparks, spatter or fume.
• The electrode may be a solid or cored wire or a strip.
• SAW is normally a mechanised process.

9. WORKING
• The submerged arc welding flux feeds through the hopper tube and
continuously distributes itself over the seam a short distance ahead
of the welding zone.
• The wire feed mechanism begins to feed the welding into the joint at
a controlled rate.
• An electric arc is established as the current flows between the
electrode and the work.
• The carriage is started(manually or automatically) to travel along the
seam.

10. SET UP
• Current: The total welding current can
range between 100 and 3600 amps.
• Wires in one molten pool: From 1 to 6.
• Voltage: 20-50 volts.
• Speed: 30-350 cm/min.
• Deposition rate: 2-100 kg/hr.

11. ADVANTAGES
• High quality
• Little risk of undercut and porosity
• No spatter
• Very little risk of lack of fusion due to deep and safe penetration
• High deposition rate
• High thermal efficiency
• No radiation
• High welding speeds are possible

12. LIMITATIONS
• Precise joint preparation required
• No observation of arc and process during welding is possible
• High operational effort
• It can not be used for plates less than 5mm thickness
• Flux is subjected to contamination and adsorption of moisture
• Solidification cracking
• Irregular wire feed

13. APPLICATIONS
This welding method can be used for:-
• Fabrication of Boiler Pressure Vessel.
• Railroad tank cars.
• Structural shapes and cylinders.
• Circular welds.
• Beam Production.
• Ship Building.
• Circumferential welding in wind tower fabrication.
• Longitudinal pipe welding.

14. HYPERBARIC WELDING

15. INTRODUCTION
• A chamber is created near the area to be welded and the
welder does the job by staying inside the chamber
• It produces high quality weld joints
• The gas-tungsten arc welding process is used mostly for pipe
works
• Gas metal arc welding is the best process for this welding

16. WORKING
• It is carried out in chamber sealed around the structure to be welded
• The chamber is filled with a gas at the prevailing pressure, to push
water back
• The welder fitted with breathing mask and other protective devices on
the pipe line
• Mask filled with a breathable mixture of helium and oxygen in the
habitat
• The area under the floor of the habitat is open to water, so hyper baric
welding is termed as “HABITATWELDING”.

17. ADVANTAGES
• Better diver safety
• Better quality welds
• No build up of hydrogen and oxygen pockets
• Allows for heat treatment before and after welding
• Non destructive testing
• Surface monitoring possible

18. DISADVANTAGES
• Requires large, complex equipment
• Chamber has to be fabricated differently for different applications
• Cost is very high and increases with depth
• More energy requirement
• Shark attack or other sealife attack
• Drowning
• Explosion from gas pockets

19. APPLICATIONS
• Offshore construction for tapping sea resources
• Temporary repair work caused by ships collisions or unexpected
accidents
• Salvaging vessels sunk in the sea
• Repair and maintenance of ships
• Construction of large ships beyond the capacity of existing docks.
• Repair and maintenance of underwater pipelines.

20. STUD WELDING

21. INTRODUCTION
• Stud welding is a high-speed metal fastening process in which a metal
fastener can be applied by a welding arc to another piece of metal.
• Weld studs come in a variety of designs and shapes for a wide range of
applications.
• A weld stud can be end-joined to a metal work piece instantaneously
for a high quality, high strength permanent bond.
• The base metal and the welded fastener do not need to be the same
material.
• Stud welding is less expensive than other fastening methods.

22. SET UP
The equipment required for stud welding is composed of the
following:
• A direct current Power Supply
• A Controller
• A Weld Gun
• Cables to tie the system components and base metal together
In most systems, the power supply and controller are combined as one
component called the "Welder".

23. ARC STUD WELDING
• Arc Stud Welding is generally used to weld large diameter fasteners to
rougher and thicker base metals.

24. CAPACITOR DISCHARGE STUD WELDING
• Capacitor Discharge Stud Welding is generally used to weld smaller
diameter fasteners to thin base metals.

25. APPLICATIONS
• Weld Studs fasteners are used in a wide variety of industries:
• Aerospace
• Appliances
• Automotive
• Construction
• Electronics
• Forging Process
• Insulation Installation
• Offshore
• Petrochemical
• Shipbuilding
• Toys
• Transportation

26. THANK YOU 