4.

WELDING PROCESS Compiled by 1

4.1 Introduction: -
➢ Welding is a fabrication process in which two or more metal work pieces are joined permanently to form single component
➢ Welding is carried out by heating the edges of the work pieces to suitable temperature and then fused together with or without application
of pressure
➢ Since a slight gap exists between the edges of the work pieces, a filler metal is used to supply the additional material to fill the gap. The
filler metal is melted in the gap, combines with the molten metal of the work piece and upon solidification forms an integral part of the
weld. But welding can also be carried out without use of filler material is called autogenous weld.
4.2 Principles of welding:-
• The first known principle of welding is the hammering the pieces together while they are in hot condition
• Welding process is carried out by heating the edges of work pieces to a suitable temperature. On heating the materials softens
sufficiently so that the surfaces fuse together with or without application of pressure(force)
• The bonding force holds the atoms, ions or molecules together in a solid. This effective bonding is achieved only when the surfaces to be
joined are clean, smooth and fit each other exactly and free from dust, rust, oil, grease etc,.
4.3 Classification of welding: - Welding process can be broadly classified in to two categories 1. Fusion welding 2. Solid state welding
➢ Fusion welding is a process in which joining is accomplished by melting (fusion) the base metal and with or without filler metal.
➢ Solid state welding is a process in which joining is accomplished by heat and pressure, but no melting of base metals occurs and no filler
metal is added.
I. Fusion Welding II. Solid State Welding
1) Gas welding: - 1.) Forge welding
a) Oxy-acetylene welding 2.) Cold welding
b) Oxy- hydrogen welding 3.) Roll welding
2) Arc welding: - 4.) Hot press welding
a) Manual metal arc welding (MMAW) 5.) Diffusion welding
b) Metallic inert gas welding (MIG) Consumable electrode 6.) Explosive welding
c) Submerged arc welding (SAW) 7.) Friction welding
d) Tungsten inert gas welding (TIG) Non consumable electrode 8.) Frictions stir welding
e) Plasma arc welding (PAW) 9.) Ultrasonic welding
f) Electro slag welding (ESW)
g) Stud arc welding
3) Resistance welding:-
a) Spot welding
b) Seam welding
c) Flash butt welding
d) Projection welding
4) Thermo-chemical welding:-
a) Thermit welding
b) Atomic hydrogen welding
5) Radiant energy welding:-
a) Laser welding
b) Electron beam welding
4.41Oxy-acetylene gas welding: ➢ It is a fusion welding process in which the work pieces are
joined by the heat of a strong flame generated by combustion
of oxygen and acetylene
➢ The equipment consists of one O2 Cylinder at high pressure
and other C2H2 Cylinder. Pressure regulators fitted on the
respective cylinders to regulate the pressure of the gas flowing
from the cylinders to the welding torch as per the requirements
➢ The welding torch is used to mix both oxygen and acetylene
gas in required proportion and ignited at the welding torch tip
➢ When a mixture of C2H2+O2 ignited at the welding torch tip,
generates a flame temperature of 3200°C-3500°C which is
sufficient enough to melt and fuse the work piece metals
➢ Since a light gap usually exists between the two work pieces, a
filler material may be used to supply additional material to
fill the gap
➢ The molten metal of filler metal combines with molten metal of
work piece and upon solidification form a single piece of metal

Advantages:-
1. Process is simple and inexpensive
2. No skilled labor is required
3. Temperature of the flame can be controlled easily
4. The equipment is used for welding, cutting, brazing and soldering

Limitations:-
1. Acetylene gas is slightly costlier
2. Not suitable for thick and high melting point metals
3. Refractory metals like Tungsten and Molybdenum etc. and reactive metals like Titanium & Zirconium, etc,. cannot be gas welded
4. Acetylene gas is highly explosive and hence precautions should be taken during its storage and welding

4.42 Types of Oxy-Acetylene gas welding flames:-

1. Neutral flame: - oxygen and acetylene are mixed in equal proportions. All the carbon supplied by acetylene (C2H2) is being combustion
completely. The flame has inner whitish cone surrounded by outer sharp blue flame. The temperature of neutral flame is around
3260°C. The flame does not produce chemical change in molten metal of weld and hence the name neutral flame. Neutral flame is
used for welding mild steel, cast iron, aluminum, copper etc,.
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2. Oxidizing flame: - it is characterized by excess of oxygen. All the carbon

supplied by acetylene (C2H2) is being combustion completely. The flame has
inner whitish short cone surrounded by outer bright color flame. The
temperature of the oxidizing flame is 3500°C.This flame oxidizes the molten
weld pool and hence the name oxidizing flame. This flame not used for welding
steel as it oxidizes the steel. Oxidizing flame is used for welding Brass.
3. Carburizing flame (Reducing flame):- it is characterized by excess of
acetylene. All the carbon supplied by acetylene (C2H2) is not being
combustion completely. This flame has greenish acetylene feather between
inner cone and the outer envelope. The temperature of the reducing flame is
around 3065°C. Reducing flame is used for surfacing hardening, welding
Monel (Ni-Cu alloy), brazing and soldering .Carburizing flame should not be
employed for welding steel as unconsumed carbon may be introduced into the
weld to produce hard and brittle deposit.

4.43 Oxy fuel gas cutting:-

➢ Oxy fuel gas cutting process is used to cut steel plates up to 4” thick.
➢ The difference between oxy fuel welding and cutting is the torch and the
amount of oxygen used
➢ The cutting torch has tube (cutting tip) with orifice in center through which
oxygen passes at high pressure to cut the metal
➢ Cutting tips are made of copper, similar to welding tips. Externally the cutting
tip appears larger.

4.44 Alternative gases for Oxy fuel welding:-

1. Methyl-Acetylene-Propadiene (MAPP) 2.Hydrogen 3.Propylene 4.Propane 5.Natural gas
4.45 Oxy fuel Gas welding safety:-
1. Welder should wear proper personnel protective equipment (PPE) like leather welding gloves, leather welding apron, leather welding jacket,
leather welding trousers and shoes
2. Welder should protect eye and face by wearing welding mask, welding goggles, nose mask etc,.
3. Proper handling and storage of both oxygen and acetylene cylinders is essential to prevent fire accidents
4. Any leakages at hoses, joints, valves and torch should be avoided
5. Adequate ventilation and good working environment should have during welding process
6. Fire extinguisher should be located before any welding begins
7. Fire shields should be provided to prevent sparks escaping from welding area
4.46 Brazing:-
➢ Brazing is a method of joining similar or dissimilar metals by means of filler metal whose melting temperature is above 450°C and
below the melting point of the base metal.
➢ The filler metal is called spelter is non ferrous metal or an alloy. Copper & copper alloys, silver & silver alloys and aluminum &
aluminum alloys are most widely used filler materials.
➢ The most common type of flux used in brazing is borax. The main functions of flux are 1.) Wetting and cleaning of the surfaces to be
joined 2.) Prevent oxidation of base metal during heating 3.) Allow molten filler metal to flow through the gap by capillary action 4.)
Dissolve the metal oxides.
➢ In operation, the surfaces to be joined are cleaned thoroughly in order to remove dirt, grease and other oxides. After cleaning, flux is
applied at the joint. The base metals are broadly heated by oxy acetylene - carburizing flame. The filler metal is applied between the joint,
which melts and flow due to capillary action. Upon cooling the filler metal gets solidify and forms strong joint.
Advantages:
1. Much heat is not involved in the process and hence low thermal distortion and residual stresses in the joint
2. Dissimilar metals can be joined
Limitations:-
1. Flux residues must be removed after brazing, otherwise which may cause corrosion
2. Large and thick sections cannot be brazed efficiently
3. Relatively expensive filler materials. 4. Strength of joint is less compare to arc welding joint.
4.47 Soldering:-
➢ Soldering is a method of joining similar or dissimilar metals by means of filler metal whose melting temperature is below 450°C.
➢ The filler metal is called solder is an alloy of tin and lead in various proportions
➢ The most common type of flux used in soldering is rosin-alcohol, zinc chloride and aniline phosphate. The main functions of flux are
1.) Wetting and cleaning of the surfaces to be joined 2.) Prevent oxidation of base metal during heating 3.) Allow molten filler metal to flow
through the gap by capillary action 4.) Dissolve the metal oxides.
➢ In operation, the surfaces to be joined are cleaned thoroughly in order to remove dirt, grease and other oxides. After cleaning flux is
applied at the joint. The base metals are broadly heated by oxy acetylene - carburizing flame. The filler metal is applied between the joint,
which melts and flow due to capillary action. Upon cooling the filler metal gets solidify and forms joint.
Advantages: -
1. Low temperature process and hence low thermal distortion and residual stresses in the joint
2. Dissimilar metals can be joined easily
3. Thin parts can be joined
Limitations: - 3
1. Flux residues should be removed after soldering, otherwise which causes corrosion
2. Thick parts cannot be joined efficiently
3. Strength of joint is low and cannot be used at high temperature applications
4.46 Comparison between Brazing and Soldering:-
1. Melting point of filler metal in brazing is above 450°C, where as melting point of filler metal in soldering is below 450°C.
2. Filler metal used in brazing is called spelter , where as filler metal used in soldering is called solder
3. Strength of joint obtained in brazing is high, where as strength of joint obtained in soldering is low
4. Brazing is slightly costlier, where as soldering is comparatively cheaper
5. Brazed joints with stand high temperature applications, where as soldered joints does not with stand high temperature applications
ARC WELDING
4.50 Manual metal arc welding (MMAW) or Shielded Metal Arc Welding (SMAW) or Flux shielded metal arc welding (FSMAW):-

• Flux shielded metal arc welding is

a process in which the work pieces
are joined by the heat obtained
from electrode arc struck between
a consumable flux coated electrode
and the work piece.
• Large diameter electrodes with
high current are used for welding
thicker plates and vice versa.

Operational procedure steps:-

1. The edges of work pieces to be joined are cleaned and ground properly. An electrode is connected to one pole of power supply and the work
piece is connected to other pole of power supply. Either AC or DC is used as power supply.
2. In operation, the arc is struck by touching the tip of electrode on the work piece and instantaneously the electrode is moved back by small
distance of 2-4 mm such that the arc is still remains in between the electrode and the work piece
3. The high heat at the tip of the arc melts the work piece metal forming a small molten metal pool. At the same time the tip of the electrode
also melts.
4. The molten metal of the electrode mixes with molten metal of work piece fills the joint to form a single piece of metal.
5. The electrode is moved along the surface to be welded to complete the joint.
6. The arc is extinguished (stopped) by increasing the gap between electrode and the work piece.
Electrode: - The electrode is made of metallic wire of same composition of work piece material. Electrode is coated with flux material like TiO2 ,
CaCO3, CaF2, Cellulose, iron oxide, Iron powder etc, which gives off gases at high temperature. The benefits of flux coating are
• Prevents oxidation of the molten metal by providing shielding gas
• Improve arc ignition and stabilization of the arc
• The flux reacts with oxides, impurities and forms slag.
• The slag floats and covers the top portion of weld metal and thereby prevents it from rapid cooling and brittleness of welded joint.
Advantages:-

1. The process is simple and in expensive. Hence suitable for shop works and field works
2. Eliminates skilled labor
3. The process dominates other welding process in maintenance and repair industry
4. Used for welding ferrous and a few non ferrous metals like aluminum, nickel, copper alloys etc,.
Limitations:-
1. Weld time is low, since the consumable electrode must be replaced frequently
2. Weld spatter, poor fusion, shallow penetration and cracks are a few major problems associated with the process. However by proper
welding practice, they can be minimized
Applications: - Ship building, bridge construction, building construction, boiler and pressure vessel fabrication, repair and maintenance work.
4.51 Metallic inert gas welding (MIG):-
➢ It is a welding process in which work pieces are joined together by the heat obtained from an electric arc struck between consumable
uncoated electrode and work piece in the presence of inert gas atmosphere.
➢ The consumable uncoated electrode act as a filler metal to fill the gap between the work pieces
Operational procedure steps:-
1. MIG welding equipment consists of welding torch(in which uncoated consumable electrode in the form of wire is held and guided through
welding torch), an inert gas cylinder and DC power source. The electrode material is same chemical composition of work piece metal. Its
diameter varies from 0.7 to 2.4 mm. The electrode is fed continuously at a constant rate through feed rollers driven by electric motor
2. MIG makes use of shielding gas to prevent oxidization of molten weld pool. Mixture of argon and carbon dioxide in the ratio of 75:25 is
commonly used. The shielding gas flows from the cylinder through the electrode holder and then impinges the work piece
3. Electrode is connected to positive pole of DC power source and the work piece is connected to negative pole of DC supply. This results
faster melting of electrode, which increases weld penetration and welding speed
4. In operation the work pieces to be weld are cleaned to remove dust, grease, oil, rust, oxides etc, to get sound weld.
5. The control switch provided on the welding torch is switched on to initiate the electric power, shielding gas and the wire feed.
6. An arc is struck by touching electrode tip with the work piece and instantaneously the electrode is separated from the work piece by a
small distance of 1.5 to 3mm so that the arc still remains between electrode and work piece.
7. The high intensity of arc melts the work piece metal and electrode.
8. The molten metal of the electrode mixes with molten metal of work piece fills the joint to form a single piece of metal.
9. The welding torch is moved along the joint to complete the weld.
10. The arc is extinguished (stopped) by increasing the gap between electrode and the work piece
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Advantageous, limitations and applications:-
Advantageous:-
1. Fast and economical
2. The electrode and inert gas is automatically fed and
hence reduce the burden on operator and helps him to
concentrate on the arc
3. Weld deposition rate is high due to automatic electrode
wire feed
4. No flux used. Hence no slag formation and clean weld
5. Thin and thick metals can be welded
6. Process can be automated
Limitations:-
1. Equipment is costlier
2. Dross and porosity weld defects quality problem in the
process. However extensive edge preparation can
eliminate this defect
Applications:- used extensively in sheet metal and
automobile industries.
4.52 Tungsten inert gas welding (TIG):-

➢ In TIG welding , the work pieces are joined together by heat

obtained from the electric arc struck between non consumable
tungsten electrode and the work piece in the presence of inert gas
➢ An inert gas is a non reactive gas used in chemical synthesis,
chemical analysis or preservation of reactive materials. The non
reactivity of Inert gas is due to the outer most shell is completely
filled with electrons. A few inert gases include: helium, argon, xenon,
neon, nitrogen and krypton

Operational procedure steps:-

1. TIG welding equipment consists of welding torch in which non consumable tungsten electrode is held rigidly in the collet, inert gas
cylinder and DC power source. Inert gas protects the molten weld pool form atmospheric contamination
2. In operation, the work pieces to be joined are cleaned to remove dirt, rust, grease, oil, oxides etc, to get sound weld
3. The welding current and inert gas supply is switched on. An electric arc is struck between non consumable bare tungsten electrode and
work piece, and instantaneously the electrode is separated from the work piece by a small distance of 1.5-3 mm such that the arc still
remains between the electrode and the work piece
4. The high intensity of the arc melts the work piece metal and filler rod metal. The molten filler rod metal mixes with molten metal of work
piece fills the joint to form a single piece of metal.
5. The welding torch is moved along the joint to complete the weld. The arc is extinguished by widening the gap between electrode and work
Advantageous:-
1. Suitable for thin metals
2. Strong and high quality joints are obtained due to presence of inert gas
3. No flux used. Hence, no slag formation. This results is clean weld joints
Disadvantageous:-
1. TIG is the most difficult process to the operator as with one hand he should maintain the arc stability and with other hand he should feed
filler metal rod
2. Skilled operator is required
3. Process is slower
4. Not suitable for thick metal
Applications: - stainless steel fabrication, aerospace industries, refrigerators, air conditioners, chemical plants etc,.
4.53 Submerged arc welding (SAW):-

Submerge arc welding:-

➢ It is a welding process in which work pieces are joined
together by the heat obtained from an electric arc struck
between consumable uncoated electrode and work piece.
➢ The consumable bare electrode act as a filler metal to fill
the gap between the work pieces.
➢ The arc is struck under the layer of granulated flux
and hence the name submerged arc welding process.

Operational procedure steps:-

1. The equipment consists of D.C power source, welding head (carrying a bare consumable electrode) and flux container.
2. The flux container remains ahead of the electrode, stores and drops the granulated flux on the joint to be welded. The flux may contain
oxides of calcium, silicon, magnesium, aluminum or manganese. The flux shields and protects oxidization of molten weld pool.
3. The uncoated electrode wire is fed continuously through the feed rollers.
4. Welding current is switched on. An arc is struck between electrode and the work piece under the layer of flux. The high intensity of arc
melts the electrode and the work piece metal forming a molten weld pool. At the same time, a portion of the flux melts and reacts with the
molten weld pool to form a slag. The slag floats on the surface providing thermal insulation and prevents oxidation of molten weld pool.
5. The welding head is moved along the joint to be welded. The electrode and flux is fed continuously till the welding is completed.
Advantages:- 5
1. Weld deposition rate is high due to continuous wire feed. Hence single pass welds can be made in thick plates
2. Less smoke, as the flux hides the arc. Hence improved working conditions
3. No chance of spatter of molten metal, as the flux hides the arc.
4. Welded joint is very clean, smooth & good quality.
Limitations:-
1. Difficult to judge the welding progress due to the arc is invisible and beneath the flux
2. The process to be carried out only in flat position, because of difficult to put flux in vertical position.
3. Need for extensive flux handling.
4. Plates of lesser thickness (<5mm) cannot be welded due to risk of burn through.
Applications: - fabrication of pressure vessels, pen stocks, boilers etc,.
4.54 Plasma arc welding (PAW):-

➢ Plasma is the fourth state of the matter. The other more common states of matter are solid, liquid and gas as shown in fig
➢ When a jet of air is ionized (super heated)by an electric arc, it becomes plasma.
Operational procedure steps: -

1. PAW consists of welding torch in which non consumable tungsten electrode is fixed in the collet, compressed air supply( plasma gas),
shielding gas(inert gas) supply and power source
2. An electric arc is struck between non consumable tungsten electrode and the work piece. The heat developed by the arc ionizes (super
heating) the inert gas to plasma gas. The temperature of the plasma arc is 28000°C. The shielding gas flows the outside of the plasma gas
and protects the molten weld metal from oxidization.
3. The torch is moved along the joint to be welded. The plasma gas, shielding gas and power supply is switched off after the welding process
is completed
Advantageous: - 1. Excellent weld quality 2. Good arc stability 3. Better penetration control 4. Can be used to weld any metals
Disadvantageous: - 1. High equipment cost 2. Large torch size restricts to access in some joints
Applications: - Aero space industry, welding high melting point metals, titanium metals and nickel alloys.

RESISTANCE WELDING
4.55 Spot welding: -
• Spot welding is a resistance welding process in which work pieces are joined by the heat
obtained from the resistance offered by the work piece to the flow of electric current and
under application of external pressure
• The two work pieces are cleaned to remove dirt, oil, grease, rust or other oxides to
obtain sound weld
• The work pieces are placed one above other under copper electrodes which are
connected to secondary circuit of step down transformer.
• In operation the welding current is switched ON. As the current passes through the
electrodes to the work pieces, heat is generated at the point of contact of work pieces
• As the temperature is in the order of 800-930°C, and as a result melts the work piece
locally at the contact point to form spot weld
• In order to obtain strong weld, external force is applied to the work piece through the
electrodes by means of piston-cylinder arrangement

Advantages: - 1. No filler metal is required 2. High production rates 3. Suitable for automation 4. Deformation of work piece less 5. Clean weld
Disadvantages: - 1. Weld strength is significantly less 2. Silver and copper are difficult to weld due to high thermal conductivity
Applications: - sheet metal fabrication in automobile industries, metal furniture and appliances.
4.56 Projection welding: - 6
1. Projection welding is a resistance welding process in which work
pieces are joined by heat obtained due to the resistance of the work
piece to the flow of electric current trough them. The resulting welds
are localized at predetermined points by projections or embossments
2. The work piece to be welded are cleaned to remove dirt, oil, grease,
rust and other oxides to get sound weld
3. The work pieces are overlapped and placed in between two flat large
size electrodes and held firmly with force
4. Welding current is switched on, and maximum heat is generated at
the point of projections
5. This heat soften and deforms the work piece plastically under the
external force and thereby forming spot weld

Advantages:-
1. Multiple welds can be made at single operation
2. Welding current and pressure required is less
3. No filler metal, flux and hence clean weld
Disadvantages:-
1. Costly equipment
2. Projections cannot be made in thin work pieces and cannot with stand under electrode pressure
Applications: - welding of special nuts having projections on the face to be welded on assembly, welding part of refrigerators, refrigerator racks,
grills etc,.
4.57 Seam welding: -
1. Seam welding is a resistance welding process in which work pieces are
joined by heat obtained from the electrical resistance of the work pieces
due to flow of current through them.
2. It is similar to spot welding process, but instead of pointed electrodes,
mechanically driven wheel shape electrodes are used to produce
continuous weld
3. The work pieces to be welded are cleaned to remove dirt, oil, grease, rust
or any other oxides to obtain sound weld
4. The work pieces are overlapped and placed between two wheel shaped
copper electrodes which are connected to secondary circuit of step down
transformer

5. The electrodes wheels are driven mechanically with the work piece passing in between them and the pressure applied by electrodes
6. Welding current is passed to the work piece at series of intervals which heat and melt the work piece at point of contact to form series of
spot welds
Advantages:-
1. A continuous overlapping weld produced by the process makes it suitable for joining liquid or gas tight containers and vessels
2. Filler metal, flux is not required and hence clean weld is obtained
Disadvantages:-
1. Requires complex control system to generate series of electrical pulses with respect to travel speed of electrodes
2. Difficult to weld metals having thickness more than 3mm
Applications:- used to fabricate liquid or gas tight containers or vessels such as gasoline tanks, automobile mufflers and heat exchangers
THERMO-CHEMICAL WELDING
4.58 Thermit welding:-
Operational procedure steps: -

1. Thermit welding is a fusion welding process in which the work

pieces are joined by the heat obtained from a chemical reaction of
Thermit mixture.
2. The thermit mixture is a mixture of iron oxide and aluminum
powder, and when this mixture is brought to ignition temperature
of 1200°C, reactions takes place producing molten iron and
slag(Al2O3) releasing enormous amount of heat
3Fe3O4 + 8Al 9Fe + 4Al2O3 + Heat
3. The molten metal (Fe) thus obtained is poured into the gap
between two work pieces. The molten metal melts the work piece
edges and fusion takes place. Upon solidification the slag is
removed and weld joint is cleaned

Advantages:-
1. The process is suitable in remote areas where power supply and welding equipment cannot be arranged
2. Very large heavy sections can be welded
3. Making a fast weld
4. Provides a reasonably strong weld
Disadvantages:-
1. Only ferrous metals can be welded
2. Process consume more time for preparation of mold cavity and finishing of weld
Applications: - welding of rail way track sections, repair and welding of large forging and castings, joining of large wires and pipes etc,.
 RADIANT ENERGY WELDING
4.59 Electron beam welding: - 7

Operational procedure steps: -

EBM is a radiant energy welding process in which work pieces are joined
by heat obtained from a concentrated high velocity electron beam
impinging on the surfaces to be joined

1. The system consists of electron gun and a vacuum chamber inside

which the work pieces to be joined is placed. The electronic gun emits
and accelerates the beam of electrons and focuses on the work pieces
2. The highly accelerated electrons hit the base metal and penetrate
slightly below the base surface. The kinetic energy of the electrons
converted into heat energy
3. The succession of electrons striking at the same place causes the
work piece metal to melt and fuse together

Advantages:-
1. Any metals, including zirconium, beryllium or tungsten can be easily welded
2. High quality welds, as the operation is carried out in vacuum
3. Concentrated beam minimizes the distortion of parts
4. Shielding gas, flux or filler metal is not required
5. Heat affected zone is less
Disadvantages:-
1. Equipment is costly
2. Extensive joint preparation is required
3. Vacuum chamber size tend to limit the size of the work piece to be welded
4. Not suitable for high carbon steels due to sudden cooling of weld
Applications: - electronic industries, automotive and aircraft industries where high quality of weld is primary factor
4.60 Laser beam welding (LBW):-
• Laser beam welding is a radiant energy welding process in which work pieces are joined by heat obtained from concentrated
monochromatic and coherent light beam impinging upon the work pieces to be joined
• The term LASER stands for Light Amplification by Stimulated Emission of Radiation. The LASER has the following properties
1. The light is monochromatic (single wave length)
2. The light is coherent( waves exactly in phase with one other)
3. The light is extremely intense
4. The light is highly collimated ( travel very long distance of about 3/4th million kilometers without any deviation)

Operation procedure steps:-

1. The laser beam equipment consists of ruby crystal with both ends parallel
to each other. Ruby is aluminum oxide(Al2O3) with chromium dispersed
throughout it
2. Top end face of the ruby crystal is highly silvered so that it reflects 100%
incident light. In order to tap out the laser output the bottom end face of
the ruby crystal is partially silvered and a small hole through which the
laser light emerges
3. The ruby crystal is surrounded by flash lamp which converts electrical
energy into flash light energy
4. The intense flash light energy excites the chromium atoms present in
ruby crystal to higher energy level and produce intense beam of light is
emitted
5. This stimulated emission of light is focused through the lens on the work
piece produces enormous amount of heat to melt and weld the joint

Advantages:-
1. Similar and dissimilar metals can be welded easily
2. High welding precision and location of welding spots
3. Heat affected zone is very small and suitable for heat sensitive components
4. Clean weld joints. No smoke, no flux and filler metal is needed
Disadvantages:-
1. Equipment cost is high
2. Rapid cooling rate causes cracks in high carbon steels
3. Slow welding speed(25-250 mm/min)
Applications: - widely used in electronic industries and automobile industries