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Introduction To Welding Processes
Introduction To Welding Processes
Introduction To Welding Processes
1.
General
An arc is created when an electrical discharge occurs across the gap between an
2.
Heat Input
energy is the amount of heat generated in the welding arc per unit length of weld.
Heat Input = Arc Energy x Thermal Efficiency Factor
Welding position and the process have a major influence on the travel speed that can
be used.
For manual and semi-automatic welding the following are general principles:
Vertical-up progression tends to give the highest heat input because there is a
need to weave
Vertical-down welding tends to give the lowest heat input
Horizontal-vertical welding is a relatively low heat input welding position because
heat input.
Typical heat input values in the range ~1.0 to ~3.5kJ/mm.
3.
Amperage too low: Poor fusion or penetration, irregular weld bead shape,
slag inclusion unstable arc, arc stumble, porosity, potential arc strikes.
Amperage too high: Excessive penetration, burn through, undercut, spatter.
3.3 Polarity
Determines whether most of the arc energy (the heat) is concentrated at the
electrode surface or at the surface of the parent material.
4.
An open circuit voltage (OCV) to initiate the arc, between 50 and 90v.
Welding voltage to maintain the arc during welding, between 20 and 30v
There is a relationship between the arc voltage and the current flowing through
the welding circuit that depends on the electrical characteristics
This is the preferred type of power source for manual welding (MMA and manual
TIG).
Arc voltage is controlled by the arc length
too long the arc will extinguish
too short the electrode may stub into the weld pool
Large changes in arc voltage give only small change in current, 10v = 5 amps
An open circuit voltage (OCV) to initiate the arc, between 50 and 90v.
A suitable current range, typically 30-350 amps
A constant welding current. The arc length may change during welding
Preferred type of power source for welding processes that have a wire feeder
pre-set value.
Small changes in arc voltage give only large change in current