533262 MANUFACTURING

PROCESS LABORATORY
FUNDAMENTAL OF ARC WELDING PART I
TOPICS
• Objectives of Study
• Theory of Arc Welding
• Welding Machine and Equipment
• Steps of Arc Welding
• Quality of Weld Line
• Arc length
• Electric current
• Travel speed
• Welding angle

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OBJECTIVES OF STUDY
1. To understand a process of arc welding
2. To understand factors that affect to the quality of weld line

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THEORY OF ARC WELDING
• Arc welding is the process of joining two metal workpieces together
using a flux-covered electrode which is melted in an “electric arc” and
becomes a fused part of the pieces being welded.
• It is a type of welding that uses a welding power supply to create an
electric arc between a metal stick (electrode) and the base material to
melt the metals at the point of contact. Arc welders can use either
direct (DC) or alternating (AC) current, and consumable or non-
consumable electrodes.

Welding workpiece
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 What is Arc?
• Arc happens when electrons move through
space (between two conductors) in the same
direction, leading to spark discharges

The arc or spark in real life

Natural lightning Sparking wires

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Law of Conservation of Energy
• The arc welding process is a process in which heat energy is obtained
from electrical energy
• Formula for converting electrical energy to heat energy

H = I RT 2

• H is the amount of heat produced in ‘Joules’

• I is the amount of current passing in ‘Amps’
• R is the resistance of medium in ‘Ohms’
• is the time during which the current flows (in second)
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Example
• If a welder takes 2 minutes to complete an 8 centimeters long weld.
He keeps the voltage at 24 volts and the current 120 amps. What is
your heat input?

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Basic Arc Welding Circuit Diagram

Arc welding electrode or Rod or stick

Reference: Antonini 2014 8

Electrode Welding

Electrode wire
(Metal)

Electrode coating
(Flux)
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Arc Welding Process
• The melted flux covers the molten metal
in the weld zone. Flux materials are
chosen so that the density of the melted
flux/slag is lower than that of the metal
being welded so that the flux floats to the
very top of the weld puddle and leaves
pure or nearly pure metal to solidify
below
• The flux cover also helps thermally
insulate the weld and reduce the cooling
Reference: Antonini 2014 rate

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WELDING MACHINE AND EQUIPMENT
• Welding is a hazardous workplace activity that exposes workers to
health and safety risks. To get the high quality of a workpiece
together with the safety of workers. It is therefore important to use
the equipment correctly.
• There are 4 types of equipment in the arc welding process
1. Safety equipment
2. Cleaning equipment
3. Welding accessories
4. Welding machine

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Safety Equipment
• Leather apron
• Leather sleeves
Hand screens Helmet
• Leather gloves
• Industrial safety shoes
• Hand screens or helmet

Industrial safety shoes

Leather sleeves
Leather gloves
Leather apron 12
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Cleaning Equipment
• Wire brushing
• Hammer
• Chisel Hammer

Wire brushing
Chisel 14
Welding Accessories
• Electrode-holder Electrode-holder

• Earth Clamp
• Welding cables/leads

Earth Clamp

Welding cables/leads

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Welding Machine
• Some arc welding machines provide
AC/DC output, leading to easily use in
the different situation

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STEPS OF ARC WELDING
1. Wearing proper safety gear
2. Setting up your work area
3. Securing your workpiece
4. Striking the arc
5. Correct rod position and movement
6. Cleaning your workpiece

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Defects in Arc Welding Process

Welding Spatter Porosity

narrow
wide
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QUALITY OF WELD LINE
• There are 4 factors that affect to quality of weld line.
1. Arc length
2. Electric current
3. Travel speed
4. Welding angle degree
• The quality of the finished weld depends almost entirely upon their proper
selection and control.

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Arc Length
• The arc length or called arc gap, is the
distance between the part that has to be
welded and the electrode tip.
• The arc length depends on the arc
stability, the weld current and the
concentricity of the part.
• The task of the commercial welder here
is to keep the electrode at a certain
Reference: Lincoln Electric 2020
distance from the surface so that there
is enough place to avoid stubbing out.

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The effect from arc length
• Arc length is too short: This weld was laid with the end of the rod
covered by the molten slag. The surface of the weld is uneven where
it has been dragged along by the rod, and the weld will be low on
power and contain slag inclusions.
• Arc length is correct: A normal arc weld. The weld has a consistent
profile and minimal spatter.
• Arc length is too long: Too great a distance between the rod and the
work will increase the voltage resulting in a flat and wide weld with a
great deal of spatter. It also makes the arc unstable, and the slag will
be difficult to remove from the edges of the weld. Sectioning this
weld reveals undercutting to the left side.

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The effect from arc length (Continued)

Reference: https://www.mig-welding.co.uk/arc-welding-faults.htm
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Electric Current
• In the case, as the arc current is reduced, so the tip of the welding
wires will operate at a lower level, giving a narrower weld with less
penetration than a higher arc current would give under the same
speed condition.
• With high arc current, the wire tip operates at a high level, allowing
the metal to spread out, giving the wider weld with deep penetration.
It also allows the fusing of slightly more flux than in the former case.

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The effect from electric current

Reference: https://www.mig-welding.co.uk/arc-welding-faults.htm
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Travel Speed
• Weld size and shape are affected by travel speed. Any increase in
travel speed will reduce weld size and produce a narrower weld bead.
Penetration is also affected by travel speed, an increase over normal
settings will give a proportionate decrease in depth of penetration.

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Reference: https://www.mig-welding.co.uk/arc-welding-faults.htm
Welding Angle Degree
• During the welding process, a welder
should hold the rod at a 10° to 15°
angle in the direction you are pushing
the weld.
• Note that an excessive rod lead angle
will also increase the arc length.
• Welding at a “bad angle” can thus
cause inadequate welds to form, which
may in turn be poor as well as porous.
Reference: https://weldingtroop.com/welding-defects-how-to-prevent/

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