WTP Group 6 Presentation

BATANGAS STATE UNIVERISTY
THE NATIONAL ENGINEERING UNIVERSITY

ALANGILAN CAMPUS
MECHANICAL ENGINEERING DEPARTMENT
METAL JOINING
PROCESSES,
WELDING DEFECTS
AND INSPECTION
Presentation by Group 6
ALANGILAN CAMPUS
METAL JOINING
PROCESS
WHAT IS METAL
JOINING PROCESS?
WHAT IS METAL
JOING PROCESS?
Process use for joining materials.

Metal joining processes are a set of
techniques used to join two or
more metal pieces together to form
a single, unified structure.
WHAT IS METAL
JOING PROCESS?
With that, different methods of
metal joining are employed based
on the specific requirements of a
project, the type of metals involved,
and the desired characteristics of
the joint.
TYPES OF METAL
JOINING PROCESS
1. WELDING
Fusion Welding
Arc Welding
Gas Welding / Oxyfuel Gas Welding
Electron Beam Welding
Laser Beam Welding
Thermit Welding
Solid State Welding
TYPES OF METAL
JOINING PROCESS
2. Barzing
3. Soldering
4. Adhesive Bonding
5. Mechanical Fastening Riveting
LOGO HERE
WELDING
Welding is a metal joining

process that involves the fusion
of two or more pieces of metal
to create a strong, permanent
bond.
LOGO HERE
WELDING
This process is widely used in
various industries, including
manufacturing, construction,
automotive, aerospace, and
more.
The primary goal of welding is to
join metals together to form a
single, continuous structure.
COMMON WELDING
METHODS
FUSION WELDING
Fusion welding is a category of
welding processes that joins two
or more pieces of metal by
melting their edges and fusing
them together without the use
of a filler material.
COMMON WELDING
METHODS
FUSION WELDING
Fusion welding processes are
known for their ability to create
strong and high-quality welds,
particularly when the base
metals being joined have similar
properties.
TYPES OF FUSION
WELDING
ARC WELDING
It is the process that joins two
pieces of metal by using
electricity to create an intense
heat source known as an
"electric arc."
TYPES OF FUSION
WELDING
ARC WELDING
This arc generates enough heat
to melt the edges of the metal
pieces, and when the melted
metal cools, it forms a strong
bond, effectively fusing the two
parts together.
TYPES OF FUSION
WELDING
RESISTANCE WELDING
It is the process that joins two
pieces of metal by using
electrical resistance to create
heat at the joint.
It's like holding the two metal
pieces together and passing an
electric current through them.
TYPES OF FUSION
WELDING
RESISTANCE WELDING
It is similar to holding two metal
pieces tightly together and using
electricity to make them so hot
that they stick together as they
cool down.
TYPES OF FUSION
WELDING
RESISTANCE WELDING
This method is commonly used
in manufacturing, particularly in
applications where a strong and
efficient bond is needed.
TYPES OF FUSION
WELDING
GAS WELDING/ OXYFUEL GAS
WELDING
Gas welding, also known as
oxyfuel gas welding, is a welding
process that uses the heat
generated by the combustion of
a mixture of fuel gas and oxygen
to melt and join metals.
TYPES OF FUSION
WELDING
WELDING
Gas welding is often used for
welding and cutting metals in
various applications, such as in
metal fabrication, repair work,
and metal sculpture.
TYPES OF FUSION
WELDING
WELDING
It is known for its portability and
flexibility but is less common in
industrial applications compared
to other welding methods like
arc welding.
TYPES OF FUSION
WELDING
ELECTRON BEAM WELDING
Electron beam welding is a high-
tech welding process that uses a
concentrated beam of electrons
to join two pieces of metal.
TYPES OF FUSION
WELDING
In electron beam welding, a
highly focused beam of fast-
moving electrons is generated.
These electrons have a lot of
energy.
TYPES OF FUSION
WELDING
The electron beam is directed at
the point where the two metal
pieces need to be joined. When
the electrons strike the metal,
their energy is converted into
heat.
TYPES OF FUSION
WELDING
Electron beam welding is like
using a super-focused beam of
energy to melt and fuse metal
pieces together. It's a precise
and high-energy welding method
used in industries that demand
extremely accurate and strong
welds.
TYPES OF FUSION
WELDING
LASER BEAM WELDING
Laser beam welding is a welding
process that uses a concentrated
beam of high-intensity light,
known as a laser, to join two
pieces of metal.
TYPES OF FUSION
WELDING
LASER BEAM WELDING
The laser beam is directed at the
point where the two metal
pieces need to be joined. When
the laser light hits the metal, it
gets converted into heat.
COMMON WELDING
METHODS
THERMITE WELDING
Thermite welding is a metal
joining process that uses a
chemical reaction to create very
high temperatures for welding.
COMMON WELDING
METHODS
THERMITE WELDING
A special mixture, called thermit,
is prepared. It typically consists
of a metal powder, like
aluminum, and a metal oxide,
such as iron oxide (rust). The
mixture is usually ignited by a
spark or flame.
COMMON WELDING
METHODS
THERMITE WELDING
When the thermite mixture
ignites, it undergoes a chemical
reaction that releases an
enormous amount of heat. This
heat is so intense that it can
reach temperatures exceeding
4,000 degrees Fahrenheit (2,200
degrees Celsius).
COMMON WELDING
METHODS
THERMITE WELDING
Thermite welding is often used
to join railway tracks, repair
large metal structures, and
connect heavy steel components
in construction and industry.
LOGO HERE
BRAZING
Brazing is a metal joining process
that uses a filler metal (often
referred to as brazing alloy) to create
a strong and permanent bond
between two or more metal pieces.
This process is typically conducted at
temperatures lower than the
melting points of the base metals,
making it distinct from welding,
where the base metals themselves
are melted.
LOGO HERE
BRAZING
Brazing is commonly used in
applications where high joint
strength is needed and where the
base metals may have different
melting points, making traditional
welding less practical.
It is often used in industries such as
aerospace, automotive, and
plumbing for joining a wide range of
materials, including steel, copper,
and aluminum.
LOGO HERE
SOLDERING
Soldering is a metal joining process
that uses a lower-melting-point
metal alloy, known as solder, to
create a connection between two or
more metal parts.
Unlike welding, soldering doesn't
melt the base metals; instead, it
fuses them together with the molten
solder.
LOGO HERE
SOLDERING
Soldering is commonly used in

various applications, including
electronics, plumbing, jewelry
making, and stained glass work.
LOGO HERE
ADHESIVE
BONDING
Adhesive bonding is a metal joining
process that uses adhesive
materials, such as glues, epoxies, or
other bonding agents, to create a
strong and permanent bond
between two or more metal parts.
Unlike traditional welding or
soldering, adhesive bonding doesn't
rely on melting or fusing the base
metals.
LOGO HERE
ADHESIVE
BONDING
Adhesive bonding is commonly used
in a wide range of industries,
including automotive, aerospace,
construction, and electronics.
Adhesive bonding is also
appreciated for its flexibility, as it
can bond materials with different
shapes and sizes.
LOGO HERE
MECHANICAL
FASTENING
Mechanical fastening is a metal
joining process that involves using
mechanical devices, such as screws,
bolts, nuts, rivets, pins, or clips, to
connect two or more metal parts
together.
This method does not rely on
melting, gluing, or chemical bonding;
instead, it creates a connection
through physical mechanisms.
LOGO HERE
MECHANICAL
FASTENING
Mechanical fastening is widely used
in various applications, from
assembling machinery and vehicles
to building structures and furniture.
It's also suitable for joining materials
that may not be easily bonded using
other methods, such as welding or
adhesive bonding.
LOGO HERE
RIVETING
Riveting is a metal joining process
that involves using rivets, which are
cylindrical metal pins, to create a
permanent and strong connection
between two or more metal parts.
Riveting is a mechanical fastening
method that doesn't rely on melting
or adhesives.
LOGO HERE
RIVETING
Riveting is commonly used in
applications where a strong,
vibration-resistant, and long-lasting
connection is needed, such as in the
construction of bridges, buildings,
aircraft, and various metal
structures.
ALANGILAN CAMPUS
WELDING
INSPECTION,
DEFECTS AND
TESTING
WHAT ARE WELDING
INSPECTION AND
TESTS?
WHAT ARE WELDING
INSPECTIONS AND
TESTS?
Weld inspection is the process of

inspecting welds for quality,
strength, safety, and a variety of
other relevant characteristics.
WHAT ARE WELDING
INSPECTIONS AND
TESTS?
A weld inspection involves
experienced professionals
performing a series of quality
assurance checks before, during,
and after the welding process to
ensure that the fabrication is as
safe and secure as feasible.
WHAT ARE WELDING
INSPECTIONS AND
TESTS?
Weld testing is performed to
determine the structural integrity
of welds. It is constructed on test
components designed for
destructive testing.
WHAT ARE WELDING
INSPECTIONS AND
TESTS?
Weld testing is performed to
ensure that the welding technique
is under control. Even if it is not
required by standards, weld testing
allows welders to check and
improve their own skills.
DIFFERENT INSPECTION
AND TESTING METHODS
NON-DESTRUCTIVE METHOD
Welding NDT, or Non-Destructive
Method is the use of non-destructive
testing to inspect a weld. Inspectors
evaluate whether a weld is strong or
has possible faults that could
undermine its integrity by using non-
destructive weld testing equipment.
TYPES OF NON-
DESTRUCTIVE METHOD
VISUAL INSPECTION
This method involves visually
examining the weld for any visible
defects such as cracks, porosity, or
incomplete fusion. It is a simple
and cost-effective method but may
not detect internal defects.
TYPES OF NON-
DESTRUCTIVE METHOD
RADIOGRAPHIC TESTING
This method uses X-rays or gamma
rays to create an image of the weld.
It can detect internal defects such as
cracks, voids, or inclusions.
Radiographic testing is commonly
used for critical welds or when
internal defects are a concern.
TYPES OF NON-
DESTRUCTIVE METHOD
ULTRASONIC TESTING
Ultrasonic waves are used to detect
defects in the weld. The waves are
sent through the weld, and any
changes in the wave pattern indicate
the presence of defects. Ultrasonic
testing is effective for detecting
internal defects and is commonly
used for thicker welds.
TYPES OF NON-
DESTRUCTIVE METHOD
MAGNETIC PARTICLE TESTING

This method uses magnetic fields
and iron particles to detect surface
and near-surface defects. The iron
particles are applied to the weld, and
any magnetic leakage caused by
defects is detected. Magnetic particle
testing is commonly used for
ferromagnetic materials.
TYPES OF NON-
DESTRUCTIVE METHOD
EDDY CURRENT TESTING

Eddy Current Testing uses
electromagnetism to detect surface-
breaking and slightly sub-surface
flaws in materials. It's especially
useful for identifying defects near
the surface of the weld.
TYPES OF NON-
DESTRUCTIVE METHOD
DYE PENETRANT TESTING

This method involves applying a
liquid dye to the weld, which
penetrates any surface defects. After
a certain time, the excess dye is
removed, and a developer is applied
to make the defects visible. Dye
penetrant testing is effective for
detecting surface defects.
DIFFERENT INSPECTION
AND TESTING METHODS
DESTRUCTIVE WELD TESTING

It involves the physical destruction of
a finished weld in order to assess its
strength and features. The testing
technique is carried out to
comprehend a specimen's material
behavior, strength, welded joint
quality, and welder skill.
TYPES OF DESTRUCTIVE
METHOD
MACRO ETCH TESTING

It is a useful technique for finding
macroscopic defects in metallic
materials. Surface cracks, porosity,
and other discontinuities that may
influence the material's integrity and
performance can be shown using
this method.
METHOD
FILLET WELD BREAK TEST

It determines the soundness of fillet
welds. The entire sample is
examined for root penetration
throughout this mechanical testing
method. Tension is applied to the
unwelded side of the sample using
an arbor press, testing machine, or
hammer.
METHOD
TRANSVERSE TENSION TEST

It is applied to a test specimen that is
extracted in the transverse direction
or across a sample of an item such
as a plate or pipe. Transverse tensile
strength, yield strength, proof stress,
elongation, and area reduction are
all measured in this test.
METHOD
GUIDED BEND TEST

A sample of the weld is bent to a
specific angle to assess its ductility
and the presence of defects. This
test is used to determine the weld's
ability to withstand bending stresses.
WHAT IS WELDING
DEFECT?
WHAT IS WELDING
DEFECT?
Welding defects are flaws that

develop during the various welding
procedures. Welding defects
develop for a variety of reasons.
DIFFERENT WELDING
DEFECTS
LACK OF FUSION
Lack of fusion happens when there is
inadequate bonding between the weld
metal and the base material. It can be
caused by factors like improper heat
input, incorrect welding technique, or
dirty base metal surfaces. If not treated,
lack of fusion can lead to weak and
unreliable welds.
DIFFERENT WELDING
DEFECTS
POROSITY
Porosity is a common welding defect
caused by the presence of gas pockets in
the weld metal. It can occur due to
factors like improper shielding gas,
contaminated base metal, or incorrect
welding parameters. If not treated,
porosity can weaken the weld joint and
reduce its strength.
DIFFERENT WELDING
DEFECTS
CRACKS
Cracks in welds can occur due to various
reasons, such as high cooling rates,
excessive stress, or improper welding
techniques. They can be categorized into
different types like hot cracks, cold
cracks, or solidification cracks. If not
treated, cracks can compromise the
integrity of the weld joint and increase
the risk of failure.
DIFFERENT WELDING
DEFECTS
UNDERCUT
Undercut is a groove-like depression
along the weld toe or weld face. It is
typically caused by excessive heat input
or improper welding technique. If not
treated, undercut can reduce the cross-
sectional area of the weld joint, leading
to a weaker connection.
DIFFERENT WELDING
DEFECTS
UNDERFILL
It is a longitudinal continuous or
intermittent area in a weld's surface that
is below the neighboring surface of the
parent metal due to insufficient weld
metal deposition. This is external and
clearly detectable through visual
inspection.
DIFFERENT WELDING
DEFECTS
MISALIGNMENT
Misalignment, often known as HiLo, is
the disparity between the internal
and/or external heights of two pipes.
Poor alignment results in a weaker weld
that is less able to withstand high fatigue
conditions.
DIFFERENT WELDING
DEFECTS
BURN-THROUGH
Burn-through occurs when the weld
penetrates deep enough to reach the
weld root. Essentially, you melt the full
thickness of the base metal. This is why
burn-through is often referred to as
melt-through. As a result, it appears as a
hole in the completed weld joint.
DIFFERENT WELDING
DEFECTS
INCLUSION
An inclusion is a solid foreign substance
that becomes entrapped during the
welding process. It can be a metallic
inclusion (tungsten, copper, or another
metal) or a slag inclusion (linear, solitary,
or clustered).
DIFFERENT WELDING
DEFECTS
SPATTER
It is usually caused by the amperage-
voltage relationship. This is common
when the welding voltage is too low or
the amperage is too high for a particular
wire and gas combination. The arc is too
cold in this case to keep the wire and
pool molten, resulting in a stubbing
action on the wire.
COMMON CAUSES OF
WELDING DEFECTS
IMPROPER WELDING PARAMETERS
Incorrect settings for welding current,
voltage, or travel speed can lead to
defects such as lack of fusion, excessive
penetration, or undercutting.
COMMON CAUSES OF
WELDING DEFECTS
POOR JOINT PREPARATION
Inadequate cleaning or improper bevel
angles can result in poor weld quality
and defects such as lack of fusion or
incomplete penetration.
COMMON CAUSES OF
WELDING DEFECTS
CONTAMINATION
Presence of moisture, oil, grease, or
other contaminants on the welding
surface can lead to defects such as
porosity or lack of fusion.
COMMON CAUSES OF
WELDING DEFECTS
INADEQUATE SHIELDING GAS
Insufficient or improper shielding gas
can cause defects such as porosity or
excessive spatter.
COMMON CAUSES OF
WELDING DEFECTS
IMPROPER WELDING TECHNIQUE
Improper welding technique, such as
incorrect electrode angle or travel
speed, can result in defects such as
undercutting or lack of fusion.
EFFECTS OF UNTREATED
WELDING DEFECTS
REDUCED STRENGTH
Welding defects can weaken the weld
joint, reducing its load-carrying capacity
and overall strength. This can increase
the risk of failure or structural collapse.
WELDING DEFECTS
INCREASED VULNERABILITY TO FATIGUE
Defects like cracks or lack of fusion can
create stress concentration points,
making the weld joint more susceptible
to fatigue failure under cyclic loading
conditions.
WELDING DEFECTS
IMPAIRED STRUCTURAL INTEGRITY
Welding defects can compromise the
structural integrity of the welded
components, leading to potential safety
hazards or operational issues.
WELDING DEFECTS
DECREASED SERVICE LIFE
Untreated welding defects can
accelerate the deterioration of the weld
joint, reducing its service life and
requiring more frequent repairs or
replacements.
GROUP MEMBERS
MAGBOO, MARTINEZ, MASILANG,

MARFA, CHARLS MATIRA,
GLORIOUS JAMES
JOAN T. VHINCENT D. MARLON A.
CARL G. HEYDRIAN J.
THANK YOU
FOR LISTENING

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BATANGAS STATE UNIVERISTY

THE NATIONAL ENGINEERING UNIVERSITY

Process use for joining materials.

Welding is a metal joining

Soldering is commonly used in

Weld inspection is the process of

MAGNETIC PARTICLE TESTING

EDDY CURRENT TESTING

DYE PENETRANT TESTING

DESTRUCTIVE WELD TESTING

MACRO ETCH TESTING

FILLET WELD BREAK TEST

TRANSVERSE TENSION TEST

GUIDED BEND TEST

Welding defects are flaws that

MAGBOO, MARTINEZ, MASILANG,

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