Professional Documents
Culture Documents
Introduction To Material Joining
Introduction To Material Joining
Keywords Welding Flux, Inert Shielding Gas, Shielded Metal Arc Welding (SMAW), Gas Metal Arc Welding (GMAW), Metal Transfer Mode, Flux Cored Arc Welding FCAW), Submerged Arc Welding (SAW),
Electric Arc
All arc welding processes employ some means of shielding the molten weld pool from the air
Welding Flux
Three forms
Granular Electrode wire coating Electrode core
Fluxes melt to form a protective slag over the weld pool Other purposes
Contain scavenger elements to purify weld metal Contain metal powder added to increase deposition rate Add alloy elements to weld metal Decompose to form a shielding gas
Shielding Gas
Shielding gas forms a protective atmosphere over the molten weld pool to prevent contamination Inert shielding gases, argon or helium, keep out oxygen, nitrogen, and other gases Active gases, such as oxygen and carbon dioxide, are sometimes added to improve variables such as arc stability and spatter reduction
Argon
Helium
Oxygen
Carbon Dioxide
Turn to the person sitting next to you and discuss (1 min.): What would happen if there was no flux on the wire to decompose into gas or no inert shielding gas was provided? What would the weld metal look like?
E7018
E indicates electrode 70 indicates 70,000 psi tensile strength 1 indicates use for welding in all positions 8 indicates low hydrogen
E7018-A1-H8R
ANSI/AWS - 5.1 : Specification for Covered Carbon Steel ANSI/AWS - 5.5 : Specification for Low Alloy Steel ANSI/AWS - 5.4 : Specification for Corrosion Resistant Steel
SMAW Advantages
Easily implemented Inexpensive Flexible Not as sensitive to part fit-up variances
Advantages
Equipment relatively easy to use, inexpensive, portable Filler metal and means for protecting the weld puddle are provided by the covered electrode Less sensitive to drafts, dirty parts, poor fit-up Can be used on carbon steels, low alloy steels, stainless steels, cast irons, copper, nickel, aluminum
Quality Issues
Discontinuities associated with manual welding process that utilize flux for pool shielding
Slag inclusions Lack of fusion
Limitations
Low Deposition Rates Low Productivity Operator Dependent
Other Limitations
Heat of welding too high for lead, tin, zinc, and their alloys Inadequate weld pool shielding for reactive metals such as titanium, zirconium, tantalum, columbium
Turn to the person sitting next to you and discuss (1 min.): Wood (cellulose) and limestone are added to the coating on SMAW Electrodes for gas shielding. What gases might be formed? How do these gases shield?
Short Circuiting
Pulsed Spray
ER - 70S - 6
Electrode Rod (can be used with GMAW) Composition 6 = high silicon Solid Electrode Minimum ultimate tensile strength of the weld metal
AWS Specifications for GMAW Wire AWS A5.18 - Carbon Steel Electrodes AWS A5.28 - Low Alloy Steel Electrodes
Shielding Gas
Shielding gas can affect
Weld bead shape Arc heat, stability, and starting Surface tension Drop size Puddle flow Spatter
Ar
Ar-He
He
CO2
GMAW Advantages
Deposition rates higher than SMAW Productivity higher than SMAW with no slag removal and continuous welding Easily automated
Quality
Spatter
Droplets of electrode material that land outside the weld fusion area and may or may not fuse to the base material
Porosity
Small volumes of entrapped gas in solidifying weld metal
Limitations
Equipment is more expensive and complex than SMAW Process variants/metal transfer mechanisms make the process more complex and the process window more difficult to control Restricted access
GMAW gun is larger than SMAW holder
Turn to the person sitting next to you and discuss (1 min.): When comparing processes that have spray and globular metal transfer, which type of transfer mode do you thnk results in more spatter? Why?
E70 T - 1
Electrode Minimum UTS 70,000 psi Position Type Gas, Usability and Performance Flux Cored /Tubular Electrode
Advantages
High deposition rates Deeper penetration than SMAW High-quality Less pre-cleaning than GMAW Slag covering helps with larger out-of-position welds Self-shielded FCAW is draft tolerant.
Limitations
Slag must be removed More smoke and fumes than GMAW and SAW Spatter FCAW wire is more expensive Equipment is more expensive and complex than for SMAW
Turn to the person sitting next to you and discuss (1 min.): What do you suppose would happen if the powder inside the core did not get compacted good?
F7A2-EM12K
F indicates flux
70-95 ksi UTS, 58 ksi minimum yield strength, 22% elongation A - as welded; P - postweld heat treated 2 - minimum impact properties of 20 ft-lbs @ 20F
Advantages
High deposition rates No arc flash or glare Minimal smoke and fumes Flux and wire added separately - extra dimension of control Easily automated Joints can be prepared with narrow grooves Can be used to weld carbon steels, low alloy steels, stainless steels, chromiummolybdenum steels, nickel base alloys
Limitations
Flux obstructs view of joint during welding Flux is subject to contamination porosity Normally not suitable for thin material Restricted to the flat position for grooves - flat and horizontal for fillets Slag removal required Flux handling equipment
Do Homework Assignment 2, Arc Welding Processes from the Assignment Page of the WE300 Website. Turn in next Class Period.