Unit 2: Joining Processes

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Sections

Quick Formula Reference
Heat Input
H = (V × I × 60) / S
Arc Power
P = V × I
Welding Speed
S = L / T
Practice Problems
50+ ProblemsJoining Processes
1

Introduction to Welding

Section 1 of 7

3D Welding Process Visualization

Experience welding processes in interactive 3D. See the arc formation, weld pool, and metal joining in real-time.

ARC Welding Process
Click play to start welding
Fusion Welding

Metal is heated to molten state and allowed to solidify

No pressure applied
Filler metal used
Examples: Arc, Gas welding
Pressure Welding

Metal heated to plastic state and pressed together

Pressure applied
No filler material
Examples: Resistance welding
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Construction
Building frames
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Automotive
Car assembly
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Shipbuilding
Hull construction
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Aerospace
Aircraft frames
Welding Fundamentals - Exam Guide

Welding Classification & Theory

Heat Sources in Welding:
  • • Electric Arc: 4000-6000°C, most common
  • • Gas Flame: 3200°C (oxy-acetylene)
  • • Resistance Heating: I²R losses
  • • Electron Beam: 10,000°C+, vacuum required
  • • Laser: Concentrated energy, precise control
Weld Joint Types:
  • • Butt Joint: End-to-end joining, full penetration
  • • Lap Joint: Overlapping plates, fillet welds
  • • T-Joint: Perpendicular joining, corner welds
  • • Corner Joint: L-shaped configuration
  • • Edge Joint: Parallel edges joined

Critical Formulas & Calculations

Heat Input: H = (V × I × 60) / S (J/mm)
Arc Power: P = V × I (Watts)
Welding Speed: S = L / T (mm/min)
Deposition Rate: DR = (I × DE) / 1000 (kg/hr)
Thermal Efficiency: η = Heat in weld / Total heat input

Exam Questions & Solutions

Q: Calculate heat input for: V=25V, I=150A, Speed=5mm/s
A: H = (25 × 150 × 60) / (5 × 60) = 750 J/mm
Q: Why is shielding gas necessary in welding?
A: Prevents oxidation, controls arc characteristics, affects penetration and bead shape
⚡Welding Basics Quiz
1/2

What is the main difference between fusion and pressure welding?

Score: 0/0
Section Summary
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Key Concept
Introduction to Welding
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Industry Application
Construction & Manufacturing
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Safety Focus
Protective Equipment