Introduction to Welding Processes Welding

Consumables
Welding Stages:
1-Solid State Friction Welding Plasticity
2-Solidering Liquid Filler Material Liquid Soldering > 450°C
Base Metal Not Melted Brazing upto 450°C Furnace
3- Liquid State Heat Source
i) Chemical (Oxy Fuel Welding / Cutting)
ii) Electrical (Arc & Resistance)
ARC Resistance
Consumable / Non-Consumable Spot & Seam Welding
SMAW GTAW
GMAW SAW

FOR: SMAW, GMAW, SAW

SMAW DC+ AC DC- High
Deposition
GMAW
SAW
LOF Spatter
LOP Undercut Deep Penetration /
Poor Toe Ampere Low to High  Ex Penetraion Contour Bead
Slag BT
Amp

Spatter on Bead
If Amp Low:
Poor starting, Slag inclusions, Weld bead contour too high, Lack of fusion/penetration
If Amp High:
Spatter, Excess penetration, Undercut, Burn-through
Arc Volt / Length Low to High 

Wider Bead
Arc
Voltage
Arc
Length

Arc length = arc voltage Spatter on Sides of Bead

If Arc Length Low:

Arc can be extinguished, “stubbing” Ex Penetration,
BT If Arc Length High:
 Spatter, Porosity, Excess penetration, Undercut, LOP, LOF Travel Speed Slow to High Thin Bead
Travel Speed

If Travel Speed is Low: Slow Speed =

Wide weld bead contour, Excess penetration, Burn-through Deep Penetration
If Travel Speed is Too High:
Lack of root fusion, incomplete root penetration, undercut, Poor bead profile, difficult slag removal

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