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By M Ibrahim Khan

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We find that the electrode burn off rate changes rapidly with change in current. Thus we should have a power source which can accomodate these large changes in the 41 Welding Science burn-off rates. For a small change in voltage, there should be a large change in current. Special power-sources have been designed for this purpose. 8 mm dia 200 100 Arc unstable 0 2 4 6 8 10 12 Wire feed speed m/min 14 Fig. 5 Wire feed rate Vs current for three electrodes in CO2 welding • Some welding power sources are designed to give a flat volt-ampere characteristics as shown in Fig.

Values of heat utilization may vary from 20 to 85 percent. Efficiency of heat utilization is usually low for GTAW, intermediate for SMAW and high for SAW. • With higher travel speeds the efficiency of heat transfer in the fusion zone is increased. Thus for the same arc energy input, the volume of fused metal increases as travel speed is increased. 2 Resistance Welding • The resistance welding process employ a combination of force and heat to produce a weld between the workpieces. 8) where H = heat generated, in Joules (watt.

Butt weld Force Force High frequency current Fig. 4 SOLID PHASE WELDING This group of welding processes uses pressure and heat (below the melting temperature) to produce coalescence between the pieces to be joined without the use of filler metal. The processes under this category include: Diffusion Bonding, Cold Welding, Explosive Welding, Friction Welding, High Frequency Pressure Welding, Forge Welding, Hammer Welding, Ultrasonic Welding, etc. The important ones will now be discussed. 1 Friction Welding Friction heat between two sliding/rotating surfaces is employed in this process to form a joint.

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