Primary Manufacturing Process (ME403)

Topic- Arc Welding (including process parameters) and its application

Prepared by:

KRISHNA PRAKASH
4th Semester
Mechanical Engineering
Roll-100

ACADEMY OF TECHNOLOGY
AEDCONAGAR, HOOGHLY – 712121
WEST BENGAL, INDIA
ABSTRACT:- In this term paper we would discuss in details about the arc welding process, its
applications, role in the industrial world along with its advantages and disadvantages. Various
parameters about arc welding process has also been covered.

KEYWORDS:- Arc Welding, Electrode, AC & DC power source, arc stability, arc blow,
welding, brazing, soldering, DCSP, DCRP etc.

INTRODUCTION:- Welding is a process of joining two similar or dissimilar metals by the

application of heat/pressure or both. In welding, generation of heat by an electric arc is one of the
most efficient methods. The electric arc welding process makes use of the heat produced by the
electric arc to fusion weld metallic process. This is one of the most widely used electric arc to
fusion weld-metallic process.
BODY:-
Principal of Arc: An arc is generated between two conductors of electricity, cathode and
anode (considering DC), when they are touched to establish the flow of current and then
separated by a small distance. An arc is a sustained electric discharge through the ionised gas
column called plasma between the two electrodes.

Equipment of Arc welding: The main requirement in an arc welding setup is the source of
electric power. They are essentially of two types (a) Alternating current machines- It consists of a
Transformer and a motor engine driven alternator. (b) Direct current machines: It also has the
same parts as of AC machine, the only extra requirement is a DC rectifier.
A transformer is used in AC arc welding process because it has higher efficiency and a less
maintenance cost. Also there is no noise in operation of welding transformer. In dc arc welding a
rectifier or a generator is used to supply the required dc power. In the rectifier type, the power
supply is first stepped down by means of a transformer to the required voltage and then silicon
controlled rectifiers(SCR) is used to convert ac to dc. The other type is a dc generator, which is
running on a induction motor running on ac or an oil engine. This combination is less efficient,
more expensive and noisy in operation.
Electrodes: The electrode used for providing heat input in arc welding are of the two types,
the consumable and the non-consumable electrode. In case of a consumable electrode, the
electrode melts with by the heat produced from the arc. The molten metal from the electrode and
that obtained from the base metal gets intimately mixed under the arc and provides the necessary
joint after solidification. Since, the electrode continuously melts it also acts ass the filler rod to
provide the filler metal to the joint. It is also possible to use non-consumable electrodes made of
carbon, graphite or tungsten. The carbon and graphite electrodes are only used in dc welding.
A consumable electrode used in welding can be either bare or coated. The coated electrode also
called stick electrode is used for manual arc welding process.
 Coatings on the electrode: The coatings on an electrode serve a number of purposes.
Some of them are discussed as follows:
 The coatings give off inert gases such as carbon dioxide under the arc heat, which shields
the molten metal pool and protects it from atmospheric oxygen, hydrogen and nitrogen
pick-up, thus reducing contamination of the weld metal.
 The coating provides flux to the molten metal pool, which mixed with oxides and other
impurities forms a slag. This slag protects the welded part from the atmospheric air and
moisture.
 Some elements which are also required for stabilization of arc are also added in these
coatings. The coatings are different for dc and ac welding.
 Strength and physical properties of the weld metal also increases due to these coatings.
 Rate of solidification is also dependent on the coatings of the electrode.

Coding of electrodes: The covered electrode to be used for manual metal arc
welding are standardized for various base materials. The coding are used for marking
the electrodes as per the relevant Indian Standards. The corresponding code is given on
each packet of electrode. As per IS 815 electrodes are designated with letters and digits.

PXXXXXXS

Prefix (P) is either E or R which indicates solid extruded (E) or reinforced extruded (R)
Electrode.
1st digit – Indicates type of coating.
2nd digit – Indicates weld positions in which electrode can be used.
3rd digit – Indicates welding current conditions.
4th and 5th digit – Indicate UTS and YS of all weld metal.
6th digit – Requirement of minimum % elongation and absorbed energy in charpy V-
notch impact test of weld metal.
Suffix (s) – P – Deep penetration electrode
H – Hydrogen controlled electrode
J, K and L – Amount of metal recovery in case of iron powder electrode
Suffix (s) are optional and may or may not be given if not applicable.

Stability of Arc: All those welding processes (SMAW, PAW, GTAW) in which electrode is
expected to emit free electrons required for easy arc initiation and their stability, selection of
polarity affects the arc stability. Shielded metal arc welding using covered electrode having low
ionization potential elements provide better stable arc stability with DCEN than DCEP. However,
SMA welding with DCEP gives smoother metal transfer. Similarly, in case of GTAW welding,
tungsten electrode is expected to emit electrons for providing stable arc and therefore DCEN is
commonly used except when clearing action is receded in case of reactive metals e.g. Al, Mg, Ti.
 Arc Blow: Arc Blow is basically a deflection of a welding arc from its intended path i.e. axis of
the electrode. Deflection of arc during welding reduces the control over the handling of molten
metal by making it difficult to apply the molten metal at right place. A severe arc blow increases
the spattering which in turn decreases the deposition efficiency of the welding process. According
to the direction of deflection of arc with respect to welding direction, an arc blow may termed as
be forward or backward arc blow. Deflection of arc ahead of the weld pool in direction of the
welding is called forward arc blow and that in reverse direction is called backward arc blow.

Welding without arc blow Arc blow in dc arc welding

Comparison of AC and DC arc welding

Comparison between Welding, soldering and brazing:-

Welding
Weld joints are the strongest joints used
to bear the loads.
Temperature required is 3800 degree
centigrade in welding joints.
Work piece to be joined needs to be
heated till their melting points.
Mechanical properties of base metal
may change at the joint due to heating
and cooling
Heat cost is involved and high skill level
is required
Heat treatment is generally required to
eliminate undesirable effects of welding
Soldering
Soldering joints are the weakest joint
out of the three.
Temperature required is up to 450
degree centigrade in soldering joints.
Heating of the work piece is not
required.
No change in mechanical properties
after joining.
Less expensive and skill
requirements are very low.
No heat treatment is required.
Brazing
Brazing are weaker than welded
joints but stronger than soldering
joints.
Temperature may go up to 600
degree centigrade ion brazing joints.
Work piece are heated but not upto
their melting point.
May change in mechanical properties
of the joint but it is almost negligible.
Cost involved and the skill
requirements are in between other
two.
No heat treatment is required after
brazing.
Limitations of Arc welding: Some of the disadvantages of the electric arc welding are as follows:
 Higher introductory setup cost.
 Higher maintenance cost because of additional electrical equipment.
 Lower efficiency, more waste is generally during arc welding than many other types.
 High skill level- operators of arc welding projects need a high level of skill and training,
not all professionals have this.
 It can be tough to do arc welding in thin materials.

Duty Cycle:- Duty cycle is a welding equipment specification which defines the number of
minutes within a 10 minutes period during which a given welder can safely produce a particular
welding current. For e.g. a 150 amps welder within a 30 % duty cycle must be rested for at least
7 minutes after a 3 minutes of continuous welding.
Reverse Polarity (DCRP):- The arc welding leads are arranged so that the electrode is positive
pole and the base metal is the negative pole in the arc circuit. The decision to use the DCRP
depends on a number of variable including the material to be welded, the position of the weld
and the electrode being used.
Straight Polarity (DCSP):- The arc welding leads are arranged so that the electrode is the
negative pole and the base metal is the positive pole. In general, DCSP will provide shallow
penetration in comparison to DCRP.

CONCLUSION:- Though, electric arc welding have some disadvantages but it is one of the
most common welding process used in industries. There are many factors on which the efficiency
the welding depends. Melting of metal followed by its solidification takes place in this welding.

REFERENCES:-
 Manufacturing Technology volume- 1 by P N Rao, 3rd Edition, TMH Publication.
 A text book on welding technology by O. P. Khanna, 2nd Edition, Dhanpat Rai
Publication.
 A text book on welding technology by P. C. Sharma, 7th Edition, S Chand Publication.