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Fundamentals of Welding Tech Day 2
Fundamentals of Welding Tech Day 2
Fundamentals of Welding Tech Day 2
1 1
Manual Metal Arc Welding
1 2
Effect of Amperage too low
Poor penetration or fusion,
unstable arc,
irregular bead shape,
slag inclusion,
porosity,
electrode freezes to the weld,
possible stray arc strikes.
Effect of Amperage too high
Excessive penetration,
burn through,
porosity,
spatter,
deep craters,
undercut,
electrode overheats,
high deposition (positional welding difficult).
1 3
Effect of Voltage too low
Poor penetration,
Electrode freezes to work
Possible stray arcs
Fusion defects
Slag inclusions
Unstable arc
Irregular bead shape.
Effect of Voltage too high
Porosity
Spatter
Irregular bead
Slag inclusion
Very fluid weld pool
positional welding difficult.
1 4
Travel speed too slow
• Excessive deposition
• Cold laps
• Slag inclusions
• Irregular bead shape.
1 5
An electrode connected to the d.c.+ve pole will have two thirds of
the available energy.The remaining one third of the energy in the
parent material
It will result in:
wide and shallow weld pool
Broad HAZ
Slow Rate of Cooling
Hydrogen Intrapment
An electrode connected to the d.c. –ve pole has One third of the
energy develops at the electrode and two thirds of the energy in the
parent material.
This will result in
Weld pool which is narrow, deep and fast freezing
limited h.a.z.
May lead to hydrogen entrapment and a brittle metallurgical structure
1 6
In A.C. The polarity is reversing 100 times per second (50 c.p.s.).
Effect of equalizing the heat distribution
Heat at the electrode and half in the parent material.
1 7
MIG/MAG Welding Process
1 8
MIG/MAG Welding Process
1 9
MIG Welding Process
• When an inert gas is used for shielding the welding, the process
is know as metal inert-gas (MIG) welding
1 10
MAG Welding Process
• CO2 will react with Iron at high temperatures, to produce Iron Oxide
1 12
Metal Transfer Modes in MIG/MAG Welding
1 13
Dip transfer (semi-short circuiting arc)
To achieve this low amperage and low arc volts are required.
This produces relatively cool arc Used on thinner sections for all
positional welding, including Vertical down welding
Globular transfer
This occurs in the intermediate range between Spray and Dip
This has mechanized and automated set up
Pulsed Transfer
Pulses of high powered current are super imposed over a constant
Semi short circuiting background mode
This permits hotter welding with high deposition rates
1 14
For MIG/MAG welding, usually electrode d.c. +ve of a flat
Characteristic is used
Advantages
• Minimal wastage of consumable electrode,
• No frequent changing of consumable electrode,
• Little or no interpass cleaning required (no slag produced)
• Heavier weld beads are produced.
• Faster welding process,
• Low hydrogen process
• Preheat may not be required.
Disadvantages
•Increased risk or porosity – due to displacement of the gas
shield, more maintenance of plant involved
1 15
TIG Welding
1 16
The TIG welding process uses a non-consumable tungsten
electrode to provide an arc.
A shielding gas, e.g. argon, is fed through the welding gun to the
weld area and provides a gas shield to prevent contamination by
the atmospheric gases.
1 17
TIG Welding is used for deposition of high quality root runs
on pipe work.
When high quality root runs are needed, a back purge is used
to prevent oxidizing (coking) of the weld metal.
In most cases electrode d.c. –ve polarity is used
d.c. +ve needs higher voltage and overheat and melt the tip
1 18
The gas shield fulfils two main function
1 19
The inert gas helium is lighter than argon, therefore requires
higher.
1 20
A high o.c.v. of around 90 volts is required for TIG welding to
ensure arc stability at all times.
1 21
Plasma Arc Welding
1 22
The welding torch consists of a non-consumable tungsten electrode
This increases the gas pressure and thus the temperature which
is in the range of 10,000 – 17,000 oC.
1 25
Deep penetration will be achieved because of the high current
used.
Submerged arc welding is widely used in ship building, structural
steel work, general engineering applications, and for the
fabrication of pipes and pipelines.
Carbon steel, alloy steel and stainless steels are the main materials
welded using this process.
Only possible to weld in the flat or horizontal vertical position.
1 26
Fluxes for SAW are divided into two types:
• Fused – granulated.
• Agglomerated – powdered.
Fused fluxes
• The ingredients are mixed and melted at a high temperature
• The mixture is then poured onto large chill blocks or directed into
a stream of water to produce granules which have a hard glassy
appearance.
• The materials is then crushed, sieved for size, and packaged.
1 27
Agglomerated fluxes
• All the flux materials are dry mixed and then bonded with either
potassium or sodium silicate.
• Backed at a temperature below the melting point.
• The powder is sieved for size and packaged
1 28
Electro Slag Welding
1- Plate to be welded
2- Shoes
3- Molten Slag
4- Electrode
5- Molten Metal
6-Finished Weld
7- Pipe for cooling
1 29
Electro Slag Welding
1 30