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How do you join two metals of the different materials together for any production requirement? It is done by a process called welding. Welding is done by heating the material to its melting point under the application of pressure. We use different types of welding for different applications.

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Electric welding power sets: The Welding power sets may be different types and they can be selected depending upon the nature of the available power supply either AC Welding sets or DC Welding sets.

Pure weld can be produced if this procedure is carried out in a high vacuum without the use of electrodes, gases, or filler metal. In addition, a strong vacuum is kept around the cathode (of the filament). In order to prevent burning up and to produce an ongoing stable beam. Without a vacuum, the electron would strike the tiny components in the atmosphere, lowering their velocity and decreasing their capacity for heating.

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Welding Cables: The main function of welding cables is to carry current through the welding process. To connect the electrode and workpiece to the welding power supply, two electrode cables are required. Rubber insulation is required for these wires, which also require a routine inspection to ensure optimum welding performance.

This can be avoided by using coated electrodes, which produce more complete ionization in the arc stream even though the current passes through zero. The welding transformers may be of the air- or oil-cooled types. In the transformer welding set for AC welding, the main and secondary windings are linked in series with a choke coil or reactor to control the current flow.

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The jaws of the electrode used to retain it in the holder must be completely shielded from thermal and electric shocks. Electric holders need to be robust mechanically.

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The process typically involves directing a beam of radiant energy onto the surface of the workpiece, causing it to heat and fuse the material together, creating a strong bond.This method is often used in high-speed welding applications, such as for welding thin-walled tubes and small components, due to its high accuracy, repeatability, and efficiency.

In welding, there are different methods. On the basis of the different sources, welding can be classified as shown in the chart below.

After the chipping hammer has finished its work, a wire brush, which is formed of stiff steel wire encased in a layer of wood, removes any leftover slag materials and cleans the weld. To protect the welder from hot particles, thermal shocks, etc., protective clothing (such as an apron, gloves, etc.) is required.

This article focuses on Electric welding. We will discuss its types; Electron beam and Laser beam type in detail. The information in this article helps you extensively in your SSC JE Electrical and GATE Electrical preparation journey.

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Resistance welding is a fast and efficient welding process that produces strong, durable joints. It is particularly well-suited for welding thin materials, as well as mass production and high-volume applications. The process is highly controllable, ensuring consistent quality and reducing the need for post-weld processing.

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Chipping Hammer and wire Brush: A chisel-shaped tool called a chipping hammer is used to scrape off the slag that has formed over the molten weld.

The electrons released from the cathode have high kinetic energy and are moving at high speed in the vacuum of \(10^{-3}\ to \ 10^{-5}\) mm Hg, The material or workpiece releases its KE as heat in the substance to be heated when the fast-moving electrons impact. The metal is melted with this heat.

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This article concludes all the information related to Electric Welding, which helps to propel your preparation for various AE/JE examinations. To boost up your preparation, you should test yourself through a series of Mock Tests for Electrical Engineering Exams. You can check the syllabus for the AE/JE exam. You can visit the Testbook app to keep yourself updated with all the exam-oriented information related to the upcoming examinations, including GATE Electrical and AE/JE Electrical exam

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It is described as a method of uniting two pieces of metal in which heat is produced at the place welding in order to melt the junction.

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The meaning of laser is (light amplification stimulated emission of radiation). By concentrating monochromatic light into intensely focused beams and directing them onto the weld zone, metal parts are joined.

Electric Arc Welding is a welding process that uses an electric arc to produce heat and melt metal, which is then cooled to form a solid joint. It is a popular welding method used in many industries due to its high welding speed, versatility, and cost-effectiveness.

Radiant energy welding is a type of welding process that uses radiant energy in the form of electromagnetic waves, such as infrared, ultraviolet, or visible light, to provide heat for welding.

An electrode is a metal wire or rod that is either completely bare or uniformly covered in flux. Current for welding is carried by the electrode. The electrode's contact end must be spotless before being inserted into the electrode holder, which creates an arc at the other end. The following are the categories under arc welding electrodes:

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AC Welding set: Under the conditions of an AC supply being accessible, single-phase or three-phase step-down transformers are frequently employed in AC welding setups. These transformers supply welding operations with low voltage, in the range of 80–100 V. Since the AC supply passes through zero twice for each cycle, the welding arc would extinguish twice.

The workpiece melts under the heat produced by the laser beam, completing the weld. The laser's welding capabilities are comparable to those of an electron beam. Aluminum, carbon steel, low-alloy steel, and other materials all, can be welded using a laser beam.

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Electric welding is a type of welding process that uses electricity to produce heat and melt metal. The process typically involves two electrodes, a welding machine, and a filler material, which is added to join the two metal parts.

It is one of the electric welding procedures in which the heat required to carry out the welding operation is obtained through the heat caused by an electron bombardment. A constant stream of electrons is produced between the material to be heated and the cathode of the electron-producing material during the electron bombardment heating process.

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Rectifier set : The Rectifier set is a thyristor control electronic circuit or device, that converts AC to DC supply. The transformer output is fed, as a power supply to the rectifier set. The rectifier consists of silicon diodes or metal plates coated with selenium compounds. This allows a unidirectional current. The set is reliable and can be controlled instantly, but the price is too expensive. Some of the beneficial arcing properties of DC welding are thought to combine with rectifier-type welders. Along with those of welding transformers, for simple arc initiation, and to minimize losses. In this case, adjusting the transformer output can be used to regulate the DC voltage.

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The thick xenon material that makes up the flash tube delivers tremendous power levels for a very limited time. When the bulb is used in this way, it effectively transforms electrical energy into light energy. Next, the laser is turned on. The focusing lens directs the laser beam from the flash tube to the workpiece after it has passed through the lens.

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The schematic diagram for laser welding is shown here. The flash tube in the system is built to produce thousands of flashes per second. Electrical energy is delivered into the flash tube through the trigger wire when the capacitor bank is triggered.

Welding generator: A DC generator is driven by a primer mover (electric motor or diesel engine) which produces DC current. The differential compound DC generator is called as a welding generator.

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There are several types of electric welding, including arc welding, resistance welding, and plasma arc welding. The choice of the welding process depends on the type of metal, the thickness of the parts, and the desired outcome of the welding job.

This procedure is carried out without the use of a shielding gas or pressure. Although the laser beam is unidirectional and extremely powerful, it can be focussed and bent in the same way as a regular light beam. By adjusting the lenses, mirrors, and distance from the workpiece, the laser beam's focus can be adjusted.

To demonstrate the drop in electron velocity, the procedure should thus be carried out in the vacuum. Because of this procedure, vacuum electron beam welding is given as another name for this process. The power obtained from the electron beam is given by