Republic of the Philippines

DEPARTMENT OF EDUCATION
Region I
Pangasinan Division II

Luciano Millan National High School

Asingan,Pangasinan

MODULE 7
IN

SMAW NC II-GRADE 12

Setup Welding Equipment

Common Competencies

Prepared By: Checked /Validated By:

Wilmer J. Directo Evangeline A. Mariano

SHS- Teacher II Asst. Principal II

Approved By:

Jose S. Venenciano
Principal IV
 Program/Course Shielded Metal Arc Welding (SMAW) NC II
Unit of Competency Set up welding Equipment
Module Title Set up welding Equipment

Learning Outcome 1: Set up welding machine

INTRODUCTION

This unit covers the skills, knowledge and attitudes in preparing equipment
for welding.

PRE-TEST

Multiple Choice

Directions: Read and analyze the statement carefully. Choose the best answer and write the letter
only in your answer sheet.

1. Is a welding process that creates an electric arc between an automatically fed wire electrode
and the work piece. The arc heat melts the parent metal and filler wire.
a. GMAW b. SMAW c. SAW d. GTAW
2. Is a welding process that creates an electric arc between an automatically fed, hollow wire
filled with flux and the work piece.
a. FCAW b. SAW c. GTAW d. GTAW
3. A supply of flux material is introduced around the arc to contribute to the welding
operation, exclude atmospheric gases from the weld zone and form a slag over the
cooling weld.
a. SAW b. FAW c. GTAW d. SMAW
4. Is a welding process that creates an electric arc between a non-consumable tungsten
electrode and the work piece.
a. SAW b. FAW c. GTAW d. SMAW
5. Welding process has three type of polarity, the first is Alternating Current (AC), Direct
Current Revers Polarity (DCRP), and Direct Current Straight Polarity (DCSP).
a. SAW b. FAW c. GTAW d. SMAW
6. Is unsuitable for use as the welding current as the voltage is too high and
the amperage too low.
a. Main supply b. Direct Current c. Alternating current d. Polarity
7. These stationary machines require mains current to operate.
a. AC transformers b. Transformer rectifiers c. AC motor generator d. Inventer
8. These stationary machines provide AC/DC welding current from an AC main by means of a
rectifier.
a. AC transformers b. Transformer rectifiers c. AC motor generator d. Inventer
9. Compared to other machines of similar current capacity they are compact, lightweight and
provide a smooth DC output.
a. AC transformers b. Transformer rectifiers c. Inventer d. AC motor generator
10. An AC electric motor and a DC generator are built on a common shaft.
a. AC transformers b. Transformer rectifiers c. Inventer d. AC motor generator
Introduction
All arc welding processes have a few basic requirements for their operation. They must

have a safe voltage available that is sufficient for the operator to get the arc started and be
maintained. They also require sufficient amperage to provide the heat for melting ofthe parent metal
and filler material.

Arc welding processes have been a popular and widely applied method of welding for

many years. They offer sound and reliable weld, simple operation and low capital cost.

Arc welding process overview

There are a lot of arc welding processes used in the metal fabrication and welding industries.
Some of these are commonly used and others are used in specialist applications. This section
introduces some of the most commonly used arc welding processes; which are:

1. Shielded metal arc welding (SMAW)

2. gas metal arc welding (GMAW)
3. flux cored arc welding (FCAW)
4. submerged arc welding (SAW)
5. gas tungsten arc welding (GTAW).

The Shielded Metal Arc Welding process has three type of polarity, the first is Alternating Current
(AC), Direct Current Revers Polarity (DCRP), and Direct Current Straight Polarity (DCSP). For
machine type, SMAW has three kinds current that is machine direct current (DC), the machine with
alternating current (AC), machines with a combination of direct current (DC) and alternating current
(AC). You can look proceshe American Welding Society (AWS) numbering system can tell a welder quite a bit
about a specific stick electrode including what application it works best in and how it should be used to maximize
performance. With that in mind, let's take a look at the system and how it works.

Shielded Metal Arc Welding Process (Wikipedia)

SMAW Welding can use for anything weld joint or welding position. Otherside we use this process for
underwater welding, but the tools must be complete again suitable for underwater welding procedure.
If we do not follow the procedure then can cause our accident, for example, electric shock or other
accident types.

Advantages and Disadvantages SMAW Welding:

Advantages Shielded Metal Arc Welding:

 Can use to welding for all type joint.

 SMAW can use all welding position.
 We do not need gas for shielding the molten weld metal.
 Do not need much preparation before welding.

Disadvantages Shielded Metal Arc Welding:

 We must clean the slag after welding process is done.

 There are spatters.
 One electrode just can produce weld metal around ten to fifteen centimeters.
 The speed can not fast because we must change the electrode.

Gas metal arc welding (GMAW)

is a welding process that creates an electric arc between an automatically fed wire electrode
and the work piece. The arc heat melts the parent metal and filler wire. A supply of shielding gas that
excludes atmospheric gases from the weld zone is introduced around the arc. The GMAW welding
process needs a suitable and constant voltage power source (DC), a wire feed unit, consumable wire
electrodes, a shielding gas supply, a welding gun, a work clamp and leads.

GMAW equipment is not as cheap as MMAW and requires some skill to set up
properly. A good operator can use the GMAW process to weld most materials in most
welding positions.
Typical uses for the GMAW process include:
1. Light/heavy fabrication
2. General engineering
3. Most materials and thicknesses
Flux-cored arc welding (FCAW)
FCAW is a welding process that creates an electric arc between an automatically fed, hollow
wire filled with flux and the work piece. The arc heat melts the parent metal, filler wire and flux. The
flux may also add additional material or elements and breaks down in the arc to produce a gaseous
shield that excludes atmospheric gases from the weld zone. An optional supply of shielding gas may
be introduced around the arc.
 The FCAW welding process needs a suitable and constant voltage power source (DC),
wire feed unit, consumable flux-filled electrodes, an optional shielding gas supply, a
welding gun, a work clamp and leads.
FCAW equipment is generally more robust than GMAW plant and requires some skill to
set up properly. The process may be self shielding or gas shielded.
Typical uses for the FCAW process include:
1. Heavy fabrication
2. General engineering.

Submerged arc welding (SAW)

SAW is a welding process that creates an electric arc between an automatically fed
wire electrode and the work piece. The arc heat melts the parent metal and filler wire.
A supply of flux material is introduced around the arc to contribute to the welding
operation, exclude atmospheric gases from the weld zone and form a slag over the
cooling weld.
The SAW welding process needs a heavy duty power source (DC), a wire feed unit,
wire electrodes, flux and a flux delivery system, a power head unit, a welding gun, a
work clamp and leads.

SAW equipment is heavy and specialised and generally produces high quality welds on
steel products.
Typical uses for the SAW process include:
• heavy/fabrication
• flat butt and fillet welds only.
Gas tungsten arc welding (GTAW)
GTAW is a welding process that creates an electric arc between a non-consumable tungsten
electrode and the work piece. The arc heat melts the parent metal. A supply of inert shielding that
excludes atmospheric gases from the weld zone gas is introduced around the arc. Filler wire may be
introduced into the weld area. The GTAW welding process needs a suitable and constant current
power source (AC or DC), tungsten electrodes, an inert shielding gas supply, a welding torch, a work
clamp and leads.

The GTAW equipment process requires some skill to set up properly and a good
operator can produce high quality welds on nearly all materials.
Typical uses for the GTAW process include:
1. Light fabrication
2. General engineering
3. Root runs, pipe work.
GTAW welds most materials and thicknesses (carbon steel, aluminium, stainless ,steel etc).
There are other welding processes used in the metal fabrication industry that are not covered in this
text. These are:
1. electric resistance welding (ERW)
2. electro slag welding (ESW)
3. laser welding (LW)
4. fuel gas welding (FGW).
Fuel gas welding is covered in greater depth in gas welding theory.

Selecting a welding power source

The choice of machine depends on three major factors:
1. the type of work the machine is required to do
2. the operating conditions – field or site work, shop work, available power
3. the type of welding required, with regard to specific operating conditions, for the least cost.
There are six basic machine types commonly available:
1. AC transformers
2. transformer rectifiers
3. inverters
4. motor generators
5. independently driven generators
6. engine driven generators.
AC transformers
These stationary machines require mains current to operate. They are cheap to buy and maintain
and electrically efficient, but offer limited control of the welding current and restricted electrode
choice.

Transformer rectifiers
These stationary machines provide AC/DC welding current from an AC main by means of a rectifier.
They offer quiet, efficient operation with virtually no moving parts. These machines are commonly
used for GTAW and GMAW

Inverters

Inverters also require mains primary current. Compared to other machines of similar current
capacity they are compact, lightweight and provide a smooth DC output. They are commonly used as
MMAW, GMAW and GTAW machines.

AC motor generators

AC motor generator An AC electric motor and a DC generator are built on a common shaft. The AC
motor turns the shaft and direct current is produced in the generator section, and output to the
welding terminals. These machines offer smooth current with a choice of polarity and OCV. Small
machines (typically to 300 A) are commonly used for MMAW and larger machines are commonly
used to provide current for SAW.
Independently driven generator

These machines are normally purchased where a power take off (PTO) is available, such as
those on a truck, tractor or 4WD. A welding current is then available wherever the host vehicle can
go. Often this type of machine has a power pack built in to provide power for other devices such as
lights, drills and grinders.

Engine-driven generator
These machines are DC generators or AC alternators with electronic control coupled
to a diesel or petrol internal combustion engine. They are extremely portable, and
are commonly used for site construction work. These machines are equipped with
governors to maintain constant engine speed and idling devices to reduce engine
speed when welding is not in progress. Most machines are water-cooled, but machines
with air-cooled engines are available for light duty use. Initial maintenance costs of
these machines is high. Diesel engines cost more than petrol engines, but are more
economical to run and maintain.
Polarity

The electrical circuit that forms when you turn on the welding machine has a negative and a
positive pole. This property is called polarity.

Polarity is extremely important in welding because choosing the right polarity is what affects
the strength and quality of the weld. With the wrong polarity, you could get lots of spatter,
bad penetration, and lose control of your welding arc.

AC- stands for alternating current,

-the direction of the flow alternates
DC- stands for direct current. In AC current, the direction of the flow alternates, while there is only
one direction in DC. Therefore, welding machines and electrodes that have the DC label have
constant polarity, while AC labels mean that the polarity changes.

Three different types of polarity are used in welding.

1.Direct current straight polarity

This occurs when the electrode is made negative, and the plates are positive. As a result, the
electrons flow from the electrode tip to base plates.
2.Direct current reverse polarity
This occurs when the electrode is made positive, and the plates are negative. The electrons then
flow in the reverse direction from the base plates to the electrode.
3.Alternating current polarity
If the power source provides an AC current, then both straight and reverse polarity will occur one
after the other in each cycle. For half the cycle, the electrode will be negative, and hence the base
plates are positive. In the other half, the base plates will be negative and the electrode, positive. The
number of cycles that occur within a second depends on the frequency of the supply.

Direct Current Electrode Positive (DCEP) polarity in arc welding

With a direct current (DC) power supply, if the electrode is connected to the positive terminal and
the base plates to the negative terminal, it is termed as Direct Current Electrode Positive – or
Reverse Polarity.
Direct Current Electrode Negative (DCEN) polarity
In stark contrast to DCEP, when the electrode is connected to the negative terminal and the base
plates to the positive one, it is termed Direct Current Electrode Negative – or Straight Polarity.
Electrons flow from the electrode to the base plates.
Alternating current polarity
AC Polarity offers advantages of both DCEP and DCEN since both are occurring in a cycle, but only to
some extent.
AC polarity offers moderate arc cleaning action and is compatible with most electrode types, but not
all. It allows for better fusion and metal penetration and is suitable for a wide range of plate
thicknesses.
 Program/Course Shielded Metal Arc Welding (SMAW) NC-1
Unit of Competency Set up welding Equipment
Module Title Set up welding Equipment

Learning Outcome 2: Set up welding accessories

This unit covers the skills, knowledge and attitudes in Set up welding accessories in
welding.

PRE-TEST

Multiple Choice

Directions: Read and analyze the statement carefully. Choose the best answer and write the letter
only in your answer sheet.

1. The prefix "E" designates.

a. Electron b. Electrode c. Electrode holder d. Electricity
2. Connects the current from welding machine to electrode which we use to weld the base
metal.
a. Electron b. Electrode cable c. Electrode holder d. Electricity
3. Cable has a function for connecting current from machine to base metal, after that base
metal and electrode touch then will welding process is happening.
a. Massa cable b. Electrode cable c. Electrode holder d. Earth clamp
4. Is a clamping device for holding the electrode securely in any position.
a. Massa cable b. Electrode cable c. Electrode holder d. Earth
clamp
5. The symbol E-6013; 60 means
a. Welding position b. Power supply c. Tensile strength d. Flux coating
6. The third digit in the symbol E-6013; 1 stands for
a. Tensile strength b. Welding position c. Flux coating d. Power supply
7. The third digit in the symbol E-6027; 2 stands for
a. Horizontal position b. Flat position c. Flat and horizontal position d. All position
8. It has a deep, penetrating arc and is often the first choice for repair or maintenance work
when DC is unavailable.
a. E-6011 b. E-6010 c. E- 7018 d. E-6013
9. To connect the machine to the base metal.
a. Massa cable b. Electrode cable c. Electrode holder d. Earth clamp
10. As a filler metal, after the welding process finish then the electrode will change be weld
metal.
a. Electron b. Electrode c. Electrode holder d. Electricity

Shielded metal arc welding machine parts and procedure:

SMAW machine parts:

1.Machine
Shielded Metal Arc Welding machine is the main parts of this process, because without
machine certainly, we cannot do welding process.
 2.Electrode Cable
The function Electrode cable connects the current from welding machine to electrode which
we use to weld the base metal.

3.Massa Cable
Massa Cable has a function for connecting current from machine to base metal, after that
base metal and electrode touch then will welding process is happening.

4.Welding Power Source

Have to function for supply current from electrical source to welding machine.

5.Current Control
For control current output which uses for the welding process, big or little the current
dependent form type or thickness of material (base metal).

6. Electrode holder, commonly called a stinger, is a clamping device for holding the electrode
securely in any position. The welding cable attaches to the holder through the hollow
insulated handle. The design of the electrode holder permits quick and easy electrode
exchange. Two general types of electrode holders are in use: insulated and noninsulated.
The noninsulated holders are not recommended because they are subject to accidental
short circuiting if bumped against the work- piece during welding. For safety reasons, try
to ensure the use of only insulated stingers on the jobsite.
Electrode holders are made in different sizes, and manufacturers have their own
system of designation. Each holder is designed for use within a specified range of
electrode diameters and welding current. You require a larger holder when welding with
a
machine having a 300- ampere rating than when welding with a 100-ampere machine. If the
holder is too small, it will overheat.
 7. Earth Cramp
To connect the machine to the base metal.

8. Switch
For on or off the welding machine.
9. Electrode
As a filler metal, after the welding process finish then the electrode will change be weld metal.
The electrode has a flux which the function is to protect steel melting when the welding
process takes place.

ELECTRODES

In general, all electrodes are classified into five main groups:

1. Mild steel
2. High-carbon steel
3. Special alloy steel
4. Cast iron
5. Nonferrous
The widest range of arc welding is done with electrodes in the mild steel group.
Electrodes are manufactured for use in specific positions and for many different
types of metal. They also are specially designed to use with ac or dc welding
machines. Some manufacturer's electrodes work identically on either ac or dc,
while others are best suited for flat-position welding. Another type is made
primarily for vertical and overhead welding, and some can be used in any position.
As you can see, electrode selection depends on many variables.
Types of Electrodes
Electrodes are classified as either bare or shielded. The original bare electrodes
were exactly as their name implied-bare. Today, they have a light covering, but
even with this improvement they are rarely used because of their limitations.
They are difficult to weld with, produce brittle welds, and have low strength. Just
about all welding is done with shielded electrodes.

The shielded electrode has a heavy coating of several chemicals, such as

cellulose, titania sodium, low- hydrogen sodium, or iron powder. Each of the
chemicals in the coating serves a particular function in the welding process. In
general, their main purposes are to induce easier arc starting, stabilize the arc,
improve weld appearance and penetration, reduce spatter, and protect

The prefix "E" designates an arc welding electrode. The first two digits of a 4-digit number and the
first three digits of 5-digit number indicate minimum tensile strength. For example, E6010 is a 60,000
psi tensile strength electrode while E10018 designates a 100,000 psi tensile strength electrode.
E 60 1 10
Electrode Tensile Strength Position Type of Coating and Current
The next to last digit indicates position. The "1" designates an all position electrode, "2" is for flat
and horizontal positions only; while "4" indicates an electrode that can be used for flat, horizontal,
vertical down and overhead. The last 2 digits taken together indicate the type of coating and the
correct polarity or current to use. See chart below:

As a welder, there are certain electrodes that you will most likely see and use time and time again as
you go about your daily operations. A DC machine produces a smoother arc. DC rated electrodes will
only run on a DC welding machine. Electrodes which are rated for AC welding are more forgiving and
can also be used with a DC machine. Here are some of the most common electrodes and how they
are typically used:
E6010
DC only and designed for putting the root bead on the inside of a piece of pipe, this is the most
penetrating arc of all. It is tops to dig through rust, oil, paint or dirt. It is an all-position electrode
that beginning welders usually find extremely difficult, but is loved by pipeline welders
worldwide
E6011
This electrode is used for all-position AC welding or for welding on rusty, dirty, less-than-new
metal. It has a deep, penetrating arc and is often the first choice for repair or maintenance work
when DC is unavailable.
E6013
This all-position, AC electrode is used for welding clean, new sheet metal. Its soft arc has
minimal spatter, moderate penetration and an easy-to-clean slag.
E7018
A low-hydrogen, usually DC, all-position electrode used when quality is an issue or for hard-to-
weld metals. It has the capability of producing more uniform weld metal, which has better
impact properties at temperatures below zero.
E7024
Typically used to make a large weld down hand with AC in plate that is at least ¼" thick, but
more commonly used for plate that is ½" and up.
Other Electrodes
Although not nearly as common, an electrode may have additional numbers after it such as
E8018-B2H4R. In this case, the "B2" indicates chemical composition of the weld metal deposit.
The "H4" is the diffusible hydrogen designator, which indicates the maximum diffusible
hydrogen level obtained with the product. And "R" stands for the moisture resistant designator
to indicate the electrode's ability to meet specific low moisture pickup limits under controlled
humidification tests.
Electrode Selection Guide
 Program/Course Shielded Metal Arc Welding (SMAW) NC-1
Unit of Competency Set up welding Equipment
Module Title Set up welding Equipment

Learning Outcome 3: Set up welding positioners, jigs and fixtures

This unit covers the skills, knowledge and attitudes in Set up welding positioners, jigs and
fixtures

PRE-TEST

Multiple Choice

Directions: Read and analyze the statement carefully. Choose the best answer and write the letter
only in your answer sheet.

1. A work-holding device that holds, supports, and locates the workpiece and guides the one or
more
tools to perform a specific operation.

a. Jig b. Fixtures c. Jigs and Fixtures d. Plate Jig

2. The work holding device, which holds, supports and locates the workpiece but not guides the
cutting tool to perform a specific operation.
 a. Jig b. Fixtures c. Jigs and Fixtures d. Plate Jig
3. Are used to reduce the nonproductive time of any mass production process.

a. Jig b. Fixtures c. Jigs and Fixtures d. Plate Jig

4. Is commonly applied with fuel gas torches or electrical resistance heaters.
a. Pre heating b. Heat treatment c. Jigs and Fixtures d. Plate Jig
5. Is an operation that is both time consuming and costly.
a. Pre heating b. Heat treatment c. Jigs and Fixtures d. Plate Jig
6. This consists of heating a metal to a high temperature, where recrystallization and/or a phase
transformation take place, and then cooling slowly, often in the heat treatment furnace.
a. Pre heating b. Heat treatment c. Annealing d. Normalizing
7. This is a heat treatment that is carried out only on ferritic steels.
a. Pre heating b. Heat treatment c. Annealing d. Normalizing
8. This comprises a rapid cool from a high temperature.
a. Quenching b. Tempering c. Annealing d. Normalizing
9. A heat treatment carried out on ferritic steels at a relatively low temperature, below the lower
transformation temperature; in a conventional structural carbon steel this would be in the
region of
600-650°C.
a. Quenching b. Tempering c. Annealing d. Normalizing
10. A low temperature heat treatment designed to produce the correct size and distribution of
precipitates, thereby increasing the yield and tensile strength.
a. Ageing or Precipitation hardening b. Tempering c. Annealing d. Normalizing

Jigs and Fixtures

JIG
A jig is a work-holding device that holds, supports, and locates the workpiece and guides the one
or more tools to perform a specific operation.

In other words, this can also be defined as, used for holding the tools and also guiding the cutting
tools.

The main purpose of a jig is to provide repeatability, accuracy, and interchangeability in the
manufacturing of products.

Some important points to remember about Jigs:

 It is used in uni-dimensional machining processes like drilling, tapping, and reaming, etc.

 This system is found to be light and has a complex shape.

 Gauge blocks are not necessary and the cost of jigs is higher.

 Jigs are not fixed to the machine table until a large operation has to be performed.

Fixtures
Fixtures are the work holding device, which holds, supports and locates the workpiece but not
guides the cutting tool to perform a specific operation.

In other words, the fixtures are only the work holding device that holds, supports and locates the
workpiece in the desired position to perform any operation.

The main purpose of the fixtures is to hold and locate the workpiece during any machining
operation and to provide repeatability, accuracy, and interchangeability in the manufacturing of
products.

Some important points about fixtures:

 Fixtures are used in multi-dimensional machining like milling, grinding, turning, etc.

 This system found to be heavy in weight, have simple designing.

 Gauge blocks provided for effective handling and the cost is average.

 Fixtures are having specific tools that use particularly in the milling machine, shapers and
slotting machines.

 Fixtures are fixed to the machine table.

Jigs vs Fixtures:

Both the jigs and the fixtures are used to reduce the nonproductive time of any mass production
process.

The jig is used for guiding the cutting tool (like a drill bit), and for doing so, jigs have components like
a bush, which comes in contact with the cutting tool.

On the other hand, a fixture never comes into direct contact with the cutting tool.

Fixtures assure the position and alignment of the work pieces for getting the required machining
operation done.
hese are the factores should be considered before designing a jig or fixture:

 Study of the component.

 Study of locating elements.

 Type and capacity of the machine

 Loading and unloading arrangement.

 Clamping arrangement.

 Study of power devices for operating and clamping element and also a safety arrangement
device.

 The clearance between a jig and the component.

 Study of tool guiding, cutter setting elements, rigidity and vibration problems.

 Fool-proofing arrangement.

 Study of ejecting devices, table fixing arrangement, and the indexing device.

 Swarf removal arrangement.

Types of Jigs and Fixtures:

There are several types of Jigs and Fixtures available in the market. Also, you can create a Jig and
Fixture by yourself to do an operation easily. it is up to you. Although these are some available Jigs
and Fixtures in the market.

TYPES OF JIGS

 Template jig

 Plate jig

 Diameter jig

 Channel jig

 Ring jig

 Box jig

 Leaf jig

 Angle plate jig

 Indexing jig

 Trunion jig

Types of Fixtures:

These are some Fixtures available in the market:

 Plate fixture
  Angle plate fixture

 Vise-jaw fixture

 Indexing fixture

 Multistation fixture

 Profile fixture

Why should we use Jigs and Fixtures?

Let's see some advantages of Jigs and fixtures:

 It eliminates the setting time required before machining.

 It increases the machining accuracy and also increases production capacity.

 Requires less skilled operation.

 They reduce the production cost.

 Increases machine and labor utilization.

 They simplify the work handling.

 Increases the quality of production in the industry.

 They enable the quick setting of a tool and the proper positioning of the work.

Although there are so many advantages by using Jigs and Fixtures, but also there are some
disadvantages too.

Disadvantages of Jigs and Fixtures:

 Can wear away over time.

 Another one is the high initial set up costs (and time).

 And can use a lot of material and be bulky.

Applications of Jigs and Fixtures:

There are various fields where we can use Jigs and Fixtures and those are:

 Mass production of automobile parts.

 Inspection of parts in continuous production in manufacturing industries.

 Cutting the ingots in the steel plant.

 In the refrigeration industry.

 Pump assembling process

 For drilling the flanges and drilling holes to any required angles.

 For multi-spindle machining.

 Jigs used for mass drilling, reaming and tapping.

  For guiding the tools for machining contours.

 Fixtures used for milling, mass turning, and grinding operations.

The Material used for Jigs and Fixtures:

These are the following material is used for making Jigs and Fixtures:

 Grey cast iron

 Hardened steel

 Carbide

 Plastic

 Epoxy resins

 Low melt alloy steels

 Stainless steel

 Bronze

Conclusion:

Jigs and Fixture is an essential element in Manufacturing Technology. There are several factors you
should consider to make jig and fixtures. By using these you can save a couple of production time.

Why is preheat sometimes required before welding?

Preheating the steel to be welded slows the cooling rate in the weld area. This may be
necessary to avoid cracking of the weld metal or heat affected zone.

The need for preheat increases with steel thickness, weld restraint, the carbon/alloy content
of the steel, and the diffusible hydrogen of the weld metal. Preheat is commonly applied
with fuel gas torches or electrical resistance heaters.

The purpose of preheat:

1. Reduce the risk of hydrogen cracking

2. Reduce the hardness of the weld heat affected zone
3. Reduce shrinkage stresses during cooling and improve the distribution of residual
stresses.

If preheat is locally applied it must extend to at least 75mm from the weld location and be
preferably measured on the opposite face to the one being welded.

Heat treatment of welded joints

Heat treatment is an operation that is both time consuming and costly. It can affect the
strength and toughness of a welded joint, its corrosion resistance and the level of residual
 stress but is also a mandatory operation specified in many application codes and standards.
In addition it is an essential variable in welding procedure qualification specifications. Before
discussing the range of heat treatments that a metal may be subjected to, there is a need to
clearly define what is meant by the various terms used to describe the range of heat
treatments that may be applied to a welded joint. Such terms are often used incorrectly,
particularly by non-specialists; for a metallurgist they have very precise meanings.

Annealing This consists of heating a metal to a high temperature, where recrystallisation and/or a
phase transformation take place, and then cooling slowly, often in the heat treatment furnace. This
is often carried out to soften the metal after it has been hardened, for example by cold working; a
full anneal giving the very softest of microstructures. It also results in a reduction in both the yield
and the tensile strength and, in the case of ferritic steels, usually a reduction in toughness.

Normalizing This is a heat treatment that is carried out only on ferritic steels. It comprises heating
the steel to some 30-50°C above the upper transformation temperature (for a 0.20% carbon steel
this would be around 910°C) and cooling in still air. This results in a reduction in grain size and
improvements in both strength and toughness.

Quenching This comprises a rapid cool from a high temperature. A ferritic steel would be heated to
above the upper transformation temperature and quenched in water, oil or air blast to produce a
very high strength, fine grained martensite. Steels are never used in the quenched condition, they
are always tempered following the quenching operation.

Tempering A heat treatment carried out on ferritic steels at a relatively low temperature, below the
lower transformation temperature; in a conventional structural carbon steel this would be in the
region of 600-650°C. It reduces hardness, lowers the tensile strength and improves ductility and
toughness. Most normalised steels are tempered before welding, all quenched steels are used in the
quenched and tempered condition.

Ageing or Precipitation hardening A low temperature heat treatment designed to produce the
correct size and distribution of precipitates, thereby increasing the yield and tensile strength. It is
generally preceded by a solution heat treatment. For steel, the temperature may be somewhere
between 450-740 degree C, an aluminium alloy would be aged at between 100-200°C. Longer times
and/or higher temperatures result in an increase in size of the precipitate and a reduction in both
hardness and strength. Stress relief As the name suggests, this is a heat treatment designed to
reduce the residual stresses produced by weld shrinkage. It relies upon the fact that, as the
temperature of the metal is raised, the yield strength decreases, allowing the residual stresses to be
redistributed by creep of the weld and parent metal. Cooling from the stress relief temperature is
controlled in order that no harmful thermal gradients can occur.

Post heat A low temperature heat treatment carried out immediately on completion of welding by
increasing the preheat by some 100°C and maintaining this temperature for 3 or 4 hours. This assists
the diffusion of any hydrogen in the weld or heat affected zones out of the joint and reduces the risk
of hydrogen induced cold cracking. It is used only on ferritic steels, where hydrogen cold cracking is a
major concern i.e. very crack sensitive steels, very thick joints etc.

Post Weld Heat Treatment (PWHT) So what does the term ‘post weld heat treatment’ mean? To
some engineers it is a rather vague term that is used to describe any heat treatment that is carried
out when welding is complete. To others however, particularly those working in accordance with the
pressure vessel codes such as BS PD 5500, EN 13445 or ASME VIII, it has a very precise meaning.
When an engineer talks of post weld heat treatment, annealing, tempering or stress relief it is
therefore advisable. Heat treatment following welding may be carried out for one or more of three
fundamental reasons:

 to achieve dimensional stability in order to maintain tolerances during machining operations

or during shake-down in service

 to produce specific metallurgical structures in order to achieve the required mechanical

properties

 to reduce the risk of in-service problems such as stress corrosion or brittle fracture by
reducing the residual stress in the welded component

The range of heat treatments to achieve one or more of these three objectives in the range of
ferrous and non-ferrous metals and alloys that may be welded is obviously far too extensive to cover
in great detail within these brief Job Knowledge articles. The emphasis in the following section will
be on the PWHT of carbon and low alloy steels as required by the application standards although
brief mention will be made of other forms of heat treatment that the welding engineer may
encounter in the ferrous alloys. There are two basic mechanisms that are involved, firstly stress relief
and secondly micro-structural modifications or tempering.
Stress Relief Why is it necessary to perform stress relief? It is an expensive operation requiring part
or all of the welded item to be heated to a high temperature and it may cause undesirable
metallurgical changes in some alloys. As mentioned above there may be one or more reasons. The
high residual stresses locked into a welded joint may cause deformation outside acceptable
dimensions to occur when the item is machined or when it enters service. High residual stresses in
carbon and low alloy steels can increase the risk of brittle fracture by providing a driving force for
crack propagation. Residual stresses will cause stress corrosion cracking to occur in the correct
environment eg carbon and low alloy steels in caustic service or stainless steel exposed to chlorides.
What causes these high residual stresses? Welding involves the deposition of molten metal between
two essentially cold parent metal faces.

As the joint cools the weld metal contracts but is restrained by the cold metal on either side; the
residual stress in the joint therefore increases as the temperature falls. When the stress has reached
a sufficiently high value (the yield point or proof strength at that temperature) the metal plastically
deforms by means of a creep mechanism so that the stress in the joint matches the yield strength.
As the temperature continues to fall the yield strength increases, impeding deformation, so that at
ambient temperature the residual stress is often equal to the proof strength (Fig 1). To reduce this
high level of residual stress, the component is reheated to a sufficiently high temperature.

As the temperature is increased the proof strength falls, allowing deformation to occur and residual
stress to decrease until an acceptable level is reached. The component would be held at this
temperature (soaked) for a period of time until a stable condition is reached and then cooled back to
room temperature. The residual stress remaining in the joint is equal to the proof strength at the
soak temperature. Figure 1 shows that residual stress in a carbon manganese steel falls reasonably
steadily from ambient to around 600 degree C but that the high strength creep resistant steels need
to be above 400 degree C before the residual stress begins to fall. Stainless steel is hardly affected
until the temperature exceeds 500 degree C. There is therefore a range of soak temperatures for the
various alloys to achieve an acceptable reduction in residual stress without adversely affecting the
mechanical properties of the joint. In carbon manganese steels this temperature will be between
550-620 degree C, in creep resistant steels somewhere between 650-750 degree C and for stainless
steels between 800-850 degree C.

POST TEST

Multiple Choice

Directions: Read and analyze the statement carefully. Choose the best answer and write the letter
only in your answer sheet.

1.Is a welding process that creates an electric arc between an automatically fed wire
electrode
and the work piece. The arc heat melts the parent metal and filler wire.
a. GMAW b. SMAW c. SAW d. GTAW
2. Is a welding process that creates an electric arc between an automatically fed, hollow wire
filled with flux and the work piece.
a. FCAW b. SAW c. GTAW d. GTAW
3. A supply of flux material is introduced around the arc to contribute to the welding
operation, exclude atmospheric gases from the weld zone and form a slag over the
cooling weld.

a. SAW b. FAW c. GTAW d. SMAW

 4. Is a welding process that creates an electric arc between a non-consumable tungsten
electrode and the work piece.
a. SAW b. FAW c. GTAW d. SMAW
5. Welding process has three type of polarity, the first is Alternating Current (AC), Direct
Current Revers Polarity (DCRP), and Direct Current Straight Polarity (DCSP).
a. SAW b. FAW c. GTAW d. SMAW
6. A work-holding device that holds, supports, and locates the workpiece and guides the one
or more tools to perform a specific operation.
a. Jig b. Fixtures c. Jigs and Fixtures d. Plate Jig
7. The work holding device, which holds, supports and locates the workpiece but not guides
the cutting tool to perform a specific operation.
a. Jig b. Fixtures c. Jigs and Fixtures d. Plate Jig
8. Are used to reduce the nonproductive time of any mass production process.
a. Jig b. Fixtures c. Jigs and Fixtures d. Plate Jig
9. Is commonly applied with fuel gas torches or electrical resistance heaters.
a. Pre heating b. Heat treatment c. Jigs and Fixtures d. Plate Jig
10. Is an operation that is both time consuming and costly.
a. Pre heating b. Heat treatment c. Jigs and Fixtures d. Plate Jig

11. The prefix "E" designates.

a. Electron b. Electrode c. Electrode holder d. Electricity
12. Connects the current from welding machine to electrode which we use to weld the base
metal.
a. Electron b. Electrode cable c. Electrode holder d. Electricity
13. Cable has a function for connecting current from machine to base metal, after that base
metal and electrode touch then will welding process is happening.
a. Massa cable b. Electrode cable c. Electrode holder d. Earth clamp
14. Is a clamping device for holding the electrode securely in any position.
a. Massa cable b. Electrode cable c. Electrode holder d. Earth clamp
15. The symbol E-6013; 60 means
a. Welding position b. Power supply c. Tensile strength d. Flux coating

Reference:

 https://link.springer.com/article/10.1023/A:1008978319436
 https://en.wikipedia.org/wiki/Fixture_(tool)

 https://en.wikipedia.org/wiki/Jig_(tool)