S0ME SAFETY TIPS BEFORE WELDING

1. All inflammable materials near the vicinity should be removed.

2. Wear protective gear (welding gloves, mask, apron, etc.)
3. Fire extinguisher should always be kept ready in case of emergency.
4. Welding place should have proper ventilation to avoid accumulation
of toxic materials.
5. Parts other than those that are being welded should be removed so
that they will not be affected by the heating process.
6. New or unauthorized persons should not be allowed to operate the
machines.
7. Welder may use woolen clothing rather cotton, as cotton will easily
catch fire.
WELDING - is a process of joining two metals together by means of heat by the use
of a filler material.
- It is either by GAS or ARC welding

GAS WELDING – Oxygen-Acetylene welding.

ARC WELDING – Electric Welding.

ELECTRIC WELDING
-AC (Alternating Current)
-DC (Direct Current)

POLARITIES OF DC WELDING
DC + Reverse Polarity REP ( REVERSE ELECTRODE POSITIVE)
DC - Straight Polarity SEN ( STRAIGHT ELECTRODE NEGATIVE)
Good Welds are Dependent on Five Techniques

1. Correct Amperage Setting

2. Correct Arc Length / Gap
3. Correct Rod / Electrode Selection ALWAYS USE NOVA™ ELECTRODES
4. Correct Travel Speed
5. Welding Rods / Electrodes that have been stored and maintained properly.
PROCESSES OF WELDING

GTAW (TIG) GAS TUNGSTEN ARC WELDING (TUNGSTEN INERT GAS)

FCAW FLUX CORED ARC WELDING

SAW SUBMERGED ARC WELDING

SMAW SHIELDED METAL ARC WELDING

 CORE WIRE

GASEOUS SHIELD
FLUX COATING

SLAG

WELD DEPOSIT

DEPTH OF ARC GAP = CORE WIRE DIAMETER

PENETRATION
MOLTEN POOL
ARC STREAM

BASE METAL
Production and Fabrication Welding Use Ordinary Welding Electrodes such as:

AWS – American Welding Standard

Example:

E 60 1 1 70 18
E 60 1 2 90 18
E 60 1 3 110 18

Flux Coating

Position (all position except vertical down)

Approximate Tensile 60 X 1000 = 60,000 psi

 BASE METAL CLASSIFICATION

STEEL - is an addition of Iron (Fe) + Carbon (C)

- If Carbon (C) Content reaches 0.05%

Low Carbon Steel If Carbon Content is below 0.20%

Medium Carbon Steel If Carbon Content is between 0.20% - 0.50%
High Carbon Steel If Carbon Content is above 0.50%

Low Alloy Steel If Alloy Content is below 3%

Medium Alloy Steel If Alloy Content is between 3% - 5%
High Alloy Steel If Alloy Content is above 5%
CLASSES OF STEEL

1. CARBON ( C) STEEL
2. NICKEL (Ni) STEEL
3. CHROMIUM-NICKEL STEEL (Cr-Ni)
4. CHROMIUM-MOLYBDENUM STEEL (Cr-Mo)
5. CHROMIUM STEEL (Cr)
6. CHROMIUM-VANADIUM STEEL (Cr-V)
7. XXXXX
8. TUNGSTEN STEEL – (W)
9. SILICON-MANGANESE STEEL (Si-Mn)

SAE SOCIETY OF AUTOMOTIVE ENGINEERS BOTH HAVE THE SAME

AISI AMERICAN IRON AND STEEL INSTITUTE NUMBERING STANDARD
 SAE/AISI

APPROXIMATE TENSILE STRENGTH (PSI) = 40,000 PSI

10 + 30 = 40 x 1000 = 40,000 PSI

1 0 3 0

CLASS OF STEEL PERCENT CARBON

(Carbon Steel) (0.3% Carbon)

PERCENT ALLOY
( 0% Alloy)

SUMMARY:
CARBON STEEL
0 % ALLOYING ELEMENT
0.30% CARBON
APPROXIMATE TENSILE STRENGTH = 40,000 PSI
 SAE/AISI

APPROXIMATE TENSILE STRENGTH (PSI) = 83,000 PSI

43 + 40 = 83 x 1000 = 83,000 PSI

4 3 4 0

CLASS OF STEEL PERCENT CARBON

(Chrome-Moly Steel (Cr-Mo)) (0.4% Carbon)

PERCENT ALLOY
( 3% Alloy)

SUMMARY:
CHROMIUM-MOLYBDENUM STEEL (Cr-Mo)
3 % ALLOYING ELEMENT
0.40% CARBON
APPROXIMATE TENSILE STRENGTH = 83,000 PSI
PRODUCT CHROMIUM NICKEL HIGH TEMP. HIGH TENSILE
NSS 309L 24 12 2ND CHOICE 2ND CHOICE
NSS 310 25 20 1ST CHOICE 3RD CHOICE
NSS 312 29 9 3RD CHOICE 1ST CHOICE

Chromium - hard, sharp, tough, corrosion resistance

Nickel - soft, malleable, resist high temperature

NOVA NSS 312 – First choice for PROBLEM STEEL WELDING

- Tensile Strength- 840 N/sq. mm (121, 800 psi)

NOVA NSS 309L

NOVA NSS 310 Highly recommended for use as a buffer layer prior
NOVA NSS 312 to hardfacing/hardsurfacing
 HEAT AFFECTED ZONE

60 ⁰
MAXIMUM

1
5 7
3 4
8 6
2

CLOCKING METHOD
OF INTERMITTENT
AND SKIP WELDING
CHARCOAL
2.5 ft – 3 ft

MARTENSITE STRUCTURE
 EFFECTS OF ALLOYING ELEMENTS
Carbon (C) – hard, gives strenght, responds to heat, brittle.
Nickel (Ni)- soft, can resist high temperature, resist corrosion.
It improves toughness when added to chromium.
Molybdenum (Mo) – slippery, can resist strong acids, acts also as
stabilizer. In small amounts molybdenum improves certain
metallurgical properties of alloy steels, such as deep hardening and
toughness.
Chromium (Cr) – hard, tough, gives strength, sharp, resist corrosion,
high temperature resistant. High chromium raises the hardening
temperature of the tool steel. It improves the wear resistant of steels.
Silicon (Si) – deoxidizer and improves the hot forming properties of
the steel. In combination with certain alloying elements the silicon
content is sometimes raised up to about 2 percent for increasing
the strength and toughness of steels to sustain shock loads.
 EFFECTS OF ALLOYING ELEMENTS
Manganese (Mn) – In smaller amounts. To about 0.60 percent,
manganese is added for reducing brittleness and to improve
forgeability. Larger amount of manganese improve hardenability,
permitting oil quenching for non-alloyed carbon steels, thus
reducing deformation.
Tungsten (W) – This is one of the important alloying elements of tool
steels particularly because of two valuable properties; it improves
“hot hardiness” that is, the resistance of the steel to the softening
effect of elevated temperature, and it also forms hard, abrasion
resistant carbides, thus improving the wear properties of tool steels.
Vanadium (V) – Contributes to the refinement of the carbide
structure and thus improves the forgeability of alloy tool steels. A very
strong tendency to form a hard carbide, which improves both the
hardness and the wear properties of tool steels
(causes low grindability).
 CAST IRON - is an addition of Iron (Fe) + Carbon (C) + Silicon (Si)
If Carbon (C) content reaches 1.5%
TYPES OF CAST IRON
Name Carbon Silicon Manganese Phosphorous Magnesium Nickel Tensile Elongation Hardness Uses
(C) (Si) (Mn) (P) (Mg) (Ni) Strength Brinell
(ksi) Scale

Grey Cast 3.4 1.8 0.5 0 0 0 25 0.5 180 Engine

Iron cylinder
blocks,
flywheels,
gears,
machine-
tool bases
White 3.4 0.7 0.6 0 0 0 25 0 450 Bearing
Cast Iron surfaces

Malleable 2.5 1 0.55 0 0 0 52 12 130 Axle

Iron Bearings,
Track
wheels,
automotiv
e
crankshaft
Ductile or 3.4 0 0.4 0.1 0.06 1.0 70 18 170 Gears,
Nodular camshafts
Iron crankshaft

Ductile or Cast -do- -do- -do- -do- -do- 135 5 310 -do-
nodular (quench
)
 NOVA NCI 20

CORE WIRE (91-97.3% NICKEL)

ADDED WITH
FLUX COATING ( REM – RARE EARTH MATERIAL )

CAN WELD BRASS, BRONZE, COPPER, CAST IRON,

CAST STEEL,STAINLESS STEEL AND GALVANIZED

OTHER BRANDS

CORE WIRE (81% NICKEL)

FLUX COATING SOME OF THE NICKEL CONTENT

IS ADDED HERE
 Approximately 12 inches
Reddish Yellow Color

Low Carbon

Medium Carbon Cast Iron

Cast Iron

High Carbon

Long Yellowish Spark

Low Carbon
Steel
Medium Carbon
Steel

High Carbon

Stars means steel with

Chromium content
Cast Iron – Dull Sound
Low Carbon

Steel – High Pitch Sound

Steel Medium Carbon (Tagingting)
Knock test
High Carbon
 Stainless Steel – is an addition of Iron (Fe) + Chromium (Cr)
If Chromium (Cr) content reaches 11.5%
Stainless Steel must have 2-3% molybdenum content for strong acid resistance.

Most Commonly used Stainless Steel:

300 SERIES - Austenitic Type

- Non-Magnetic
- Chromium-Nickel Austenitic Steels (ie. 301, 302, 303, 304,
305, 308, 309, 310, 314, 315, 316, 317, 318, 321, 347, 348

400 SERIES – Martensitic 11.5-17% Cr

- Straight Chromium (No Nickel Content)
- Magnetic, Can be Air Hardened.
- Commonly used in kitchen wares such as knife, spoon,
fork, frying pan, etc.
- Example: 410, 416, 418, 420
- FERRITIC 17-27% Cr
- Magnetic, Non-Hardennable
- Example: 430, 442, 446

In many cases, the 400 SERIES Steel are Joined with a 300 SERIES Electrodes (309, 310)
because of the Non-hardening aspect of the 300 SERIES weld deposit.
TENSILE STRENGTH HARDNESS

Ideal Point Hardness: 45 HRC

(approximately 450 BHN )

Note: Above 45 HRC start

Non-machinable

0 0

TENSILE STRENGTH/HARDNESS RELATIVITY DIAGRAM

 GAS WELDING – OXYGEN/ACETYLENE WELDING

THREE TYPES OF FLAMES:

1. NEUTRAL FLAME

1 PART ACETYLENE:1 PART OXYGEN

2. CARBURIZING FLAME

3 PARTS ACETYLENE:1 PART OXYGEN

3. OXIDIZING FLAME

EXCESS OXYGEN