Electric Arc Welding

Electricity is passed through an

electrode which jumps between the
electrode and the work piece. This
causes an arc which produces great
heat melting the electrode and the
work piece causing the edges to fuse
together. (consumable electrode.)
Manual Metal Arc Welding.
 Operation of the electrode
• The weld pool is protected from oxidation
by the gasses produced by melting the
chemicals on the electrode coating.
• This wire electrode also acts as a filler
material to fill the gap between the two
parts being joined.
• Its third function is to form a slag which
protects the weld area form cracking as it
allows the joint cool slowly and protect it
from oxidation.
 Uses

This has many operational uses such

as repair work to constructional steel.
It is ideal for outdoor uses as the
gasses needed to form the shield are
not blown away.
The Transformer.
• This is a device used to change the
voltage of A.C. current. It can either
step up (increase) or step down
(decrease) the voltage. It is necessary
to change the voltage when welding
thicker or different types of steel.
Transformer-rectifier circuit
Transformer-rectifier circuit - A.C. to D.C.
• The transformer circuit element of the circuit
take AC current and pass it through a step down
transformer reducing the voltage, the current is
increased.
• The low voltage AC is then passed through a
series of diodes which only allow current flow in
one direction causing it to be changed into Direct
Current, this is called a bridge rectifier.
• Finally the DC current is passed through a
‘smoothing’ capacitor which causes the current
flow more evenly.
 Electric Arc Welding Safety
• Pg 370
Metal Arc Gas Shielded Welding.
(MAGS/MIG)
 MIG (Metal Inert Gas) welding
• Also called MAGS (Metal Arc Gas Shielded)
welding
• It uses an inert gas such as Argon or CO2 to
shield the weld
• The bare wire electrode is fed continuously to
the weld - semi-automatic process
• Can be used on light and heavy plate.
• Does not produce a slag and can be used for
multi run welds and by robots.
Metal Arc Gas Shielded Welding.
(MAGS/MIG)
Electricity is passed through an electrode
which jumps between the electrode and the
work piece. The electrode is touched briefly
against the work, this causes an arc which
produces great heat melting the electrode and
the work piece causing the edges to fuse
together.
Metal Arc Gas Shielded Welding.
(MAGS/MIG)
Uses.

• This is one of the most common

ways of welding. It can be used to
weld sheet metal as well as heavy
plates. As the electrode is fed
automatically and no slag is formed it
is ideal for robotic welding for
example car production.
Tungsten Arc Gas Shielded Welding.
(TAGS/TIG)
Tungsten Arc Gas Shielded Welding.
(TAGS/TIG)
Principle.
• Two separate current flow in the circuit in this welding
process. One is for the arc and is similar to MAGS, the other is
a high frequency current used to start the arc. This means an
arc is not stuck by touching the work piece as before.
Operation.
1. The arc melts the two edges to be joined as well as the filler
rod forming the weld pool.
2. Gas is pumped through the nozzle protecting the weld pool
from oxidation.
3. The electrode is only to maintain the arc supplying the heat. A
consumable filler rod fed by the operator gives the extra metal
necessary for the weld pool.
Tungsten Arc Gas Shielded Welding.
(TAGS/TIG)
Uses.
• This is suitable for welding most metals and generally uses
DC current for the power source. However when welding
aluminium AC is used. This is necessary to breakdown the
oxide layer on the outside of the aluminium which has a high
melting point. It is also suitable for stainless steel.
 Fluxes
• Active fluxes – these fluxes are able to dissolve oxide
films and will prevent oxides reforming. Zinc chloride is an
active flux. Active fluxes are corrosive. Active fluxes remaining
on the surface of the steel will corrode the surface in a very
short time.

• Passive fluxes – all the joint surfaces must be thoroughly

cleaned before using a passive flux. It does not have the ability
to remove oxides from the surface.
Submerged Arc Welding (SAW)
 Submerged Arc Welding (SAW)
Principle.
• Electricity is passed through an electrode which jumps
between the electrode and the work piece. The arc produces
great heat melting the electrode and the work piece causing the
edges to fuse together. The electrode is a wire fed consumable.
Operation.
1. The arc melts the two edges to be joined as well as the
electrode forming the weld pool.
2. The arc is submerged by a granulated flux released from a
hopper ahead of it. This flux melts with the heat of the arc
protecting the weld pool and forming a slag that controls
cooling.
Uses.
• This is an ideal automated welding process. It is ideal for long
runs. It is used for producing steel girders or beams used in
Electro-Slag Welding.
 Electro-Slag Welding.
Principle.
• Electricity is passed between two couples on either side of the
plates. This causes the materials in the gap to melt as well as
the edges of the plates. This form the weld pool.
Operation.
1. Two pieces of metal are placed between the electrodes.
2. The electrodes are then closed on the piece causing the circuit
to complete.
3. The resistance in the metal between the electrodes causing
them to melt and fuse together.
Uses.
• This is generally used to join very thick plates together giving
a series of overlapping welds until the two plates are fully
joined. It is suitable for automatic welding as it is used on
large plates usually.
Resistance Welding. (Spot
Welding)
 Resistance Welding. (Spot
Welding)
Principle.
• Electricity is passed between two electrodes with the pieces
to be joined in between. As the electricity passes through the
material the resistance of the metals cause the metals to melt
fusing them together.
Operation.
1. Two pieces of metal are placed between the electrodes.
2. The electrodes are then closed on the piece causing the
circuit to complete.
3. The resistance in the metal between the electrodes causing
them to melt and fuse together.
Uses.
• This is generally used to join light gauge steel sheet metal.
Sheets that are too thick will prevent the current from
flowing and will not work
 Resistance Seam Welding.
Principle
• This is exactly the same as spot welding except that a
continuous is produced.
Operation.
1. The first method is similar to spot welding. Here however the
spots are overlapped to form a continuous seam. This is called
Stitch welding.
2. The second method is to replace the electrodes with rollers
that cause a continuous seam to be produces.
Uses.
• This is also used to weld sheet metal except that a continuous
seam is required perhaps the production of a water proof tank.
 Welding Terms
Multi-runs.
• This is a method of welding two pieces of thick
metal together. A number of welding runs are
necessary to build up the gap between the two
pieces.
Flash back arrestor.
• This is a safety device used in gas welding. It
prevents the flame from the burning gas traveling
through the hose and into the tanks.
Dissolved acetylene.
• This is the form that acetylene is stored in the
tank. The tank is similar to a sponge which
absorbs the acetylene. Liquid acetylene would
explode in the tank.
Shielded arc.
• This is the protection of the weld pool by an inert
gas preventing oxidation of the weld.
Edge preparation.
• This is the preparation of the edges to be welded.
They should be free of rust and oil to allow for a
quality weld and should be tapered slightly to
allow for a good joint.
Slag inclusion.
• This is a fault where the slag drops into the weld
pool and becomes part of it weakening the weld.
This is caused by moving the welding apparatus
to slowly. Welding at the correct pace will
prevent this.
Porosity.
• Porosity is the presence of air bubbles in the
weld. This is caused by moving the welding
apparatus to quickly not giving the weld pool a
chance to form properly. This is controlled by
welding at the correct pace.
Lack of penetration.
• This is again a problem with the weld pool.
Due to a lack of temperature the edges to be
joined do not melt to form the weld pool and
fuse together. This can be prevented by setting
the welder to the correct power setting.
 Gas welding
• Metals are fused together and the gap is filled
with a filler rod
• Oxygen and acetylene are mixed together to
generate a flame to melt the weld joint.
• Oxygen is pressurised into the cylinder.
• Acetylene is dissolved in a porous material
called acetone, which will absorb 25 times it’s
own volume of Acetylene. Acetylene would
explode if it were stored under pressure.
Gas Welding
Oxy-acetylene flames