Fusion Welding Process

Overview

Fusion welding processes- Fusion welding is a joining process that uses fusion of the base metal to make the weld. The three main type of the fusion welding are as follows:

1. Gas Welding :
Oxyacetylene welding (OAW)

2. Arc Welding :
Shielded metal arc welding (SMAW)
Gas-tungsten arc welding (GTAW)
Plasma arc welding (PAW)
Gas-metal arc welding (GMAW)
Flux-cored arc welding (FCAW)
Submerged arc welding (SAW)
Electroslag arc welding (ESW)

3. High-energy beam welding :
Electron beam welding (EBW)
Laser beam welding (LBW)

Since there is no arc involved in in the electroslag welding process, it is not exactly an arc welding process. For convenience of discussion, it is grouped with arc welding processes.

Electroslag strip Cladding

Fusion Welding

(REF.- Welding Metallurgy, Second Edition. Sindo Kou Copyright 􀂶 2003 John Wiley & Sons, Inc. ISBN: 0-471-43491-4)

Comments

Electroslag Welding (ESW)

ELECTROSLAG WELDING The Process :- Electroslag welding (ESW) is a process that melts and joins metals by heating them with a pool of molten slag held between the metals and continuously feeding a filler wire electrode into it, as shown in Figure. The weld pool is covered with molten slag and moves upward as welding progresses. A pair of water-cooled copper shoes, one in the front of the workpiece and one behind it, keeps the weld pool and the molten slag from breaking out. Similar to SAW , the molten slag in ESW protects the weld metal from air and refines it. Strictly speaking, however, ESW is not an arc welding process, because the arc exists only during the initiation period of the process, that is, when the arc heats up the flux and melts it. The arc is then extinguished, and the resistance heating generated by the electric current passing through the slag keeps it molten. In order to make heating more uniform, the electrode is often oscillated, especially when welding thicker...

Flux-Core Arc Welding (FCAW)

FLUX-CORE ARC WELDING (FCAW) The Process:- Flux-core arc welding (FCAW) is similar to GMAW , as shown in Figure a. However, as shown in Figure b, the wire electrode is flux cored rather than solid; that is, the electrode is a metal tube with flux wrapped inside. The functions of the flux are similar to those of the electrode covering in SMAW , including protecting the molten metal from air. The use of additional shielding gas is optional. Flux-Core Arc Welding (FCAW) (a) overall process (b) welding area enlarged Advantages of FCAW:- High deposition rates Deeper penetration than SMAW High quality welds Less pre-cleaning than GMAW Slag covering helps with out-of-position welds Self-shielded FCAW is draft tolerant Disadvantages of FCAW:- Slag must be removed Higher fume generation than GMAW and SAW Spatter Equipment is more expensive and complex than SMAW FCAW wire is more expensive Types of continuous wire electrodes:- Read ...

Gas–Tungsten arc welding (GTAW)

GTAW The Process Gas–tungsten arc welding (GTAW) is a process that melts and joins metals by heating them with an arc established between a non consumable tungsten electrode and the metals, as shown in Figure. The torch holding the tungsten electrode is connected to a shielding gas cylinder as well as one terminal of the power source, as shown in Figure a . The tungsten electrode is usually in contact with a water-cooled copper tube, called the contact tube, as shown in Figure b , which is connected to the welding cable (cable 1) from the terminal. This allows both the welding current from the power source to enter the electrode and the electrode to be cooled to prevent overheating.The workpiece is connected to the other terminal of the power source through a different cable (cable 2). The shielding gas goes through the torch body and is directed by a nozzle toward the weld pool to protect it from the air. Protection fro...

Welding

Search This Blog