Arc Welding Processes

Introduction to arc welding
1
Overview of joining methods
 Mechanical methods

Screwed fasteners, bolts, rivets,
 Adhesive bonding
 Brazing and Soldering


Base metal does not fuse.

Molten filler drawn into close-fit joints by capillary
action (surface tension forces).

Brazing filler melts >450 C, solder <450 C
 Welding
2
Weld
 A joint produced by heat or pressure or both so there

is continuity of material.
 Filler (if used) has a melting temperature close to the

base material
3
Introduction to welding
Welding processes
 Fusion welding

Welding in the liquid state with no pressure

Union is by molten metal bridging
 Solid phase welding


Carried out below the melting point without
filler additions

Pressure often used

Union is often by plastic flow
4
Introduction to welding
Basic Requirements of Welding Process
Source of Heat
Chemical Reaction
Electrical - Arc, Resistance, Induction
Mechanical
Protection from Atmosphere

Gas Shielding
Flux
Mechanical Expulsion
Vacuum
5
Fusion welding heat sources
Electric Chemical Electric Power

resistance reaction arc beams
Spot, seam and Oxyfuel MMAW Laser

projection gas GMAW Electron
welding welding GTAW beam
FCAW
Electroslag Thermit SAW
welding PAW
6
• 103 Watts/cm2 melts most metals

6 7
• 10 -10 Watts/cm2 vaporizes most metals
7
• 103 to 106 Watts/cm2 typical for fusion welding
Electric arc
8
The Welding arc  Electric discharge between 2

electrodes through ionised gas

10 to 2000 amps at 10 to 40 V
Peak - Cathode arc voltage
temperatures drop zone
18,000 K  Column of ionised gas at high
temperature
 Forces stiffen the arc column

Transfer of molten metal from
electrode to workpiece
+  Can have a cleaning action,

breaking up oxides on
Anode
workpiece
drop zone
9
Conduction of Current in the Arc
Cathode
Electrons Emitted
Thermal
Ionization Free
Electron
Ion
Plasma
T>10,000K Recombination
Anode Neutral
Gas Atom
Electrons Absorbed
Temperature Distribution in Welding arc
11
Direct Current
Electrode Négative
- DCEN
+ Straight Polarity
+ -
+ -
+ -
+ -
DCEN 12
Direct Current
Electrode Positive
+
DCEP
- Reverse Polarity
+ -
+ -
+ -
+ -
DCEP 13
Heat Distribution in arc
Straight polarity
DCEN Electrode Negative
_
+
1/3
2/3
14
Polarity Influence – cathodic cleaning effect
15
Voltage drop in welding arc
16
Welding Arc – Current Vs Voltage
17
Introduction to Arc Welding
Electrical characteristic of Arc
18
Voltage
Arc voltage
Is directly
In proportion
Current
with
Arc length
19
20
Sudden change in gun position Re-established stable condition
Arc length L’ = 12,7 mm Arc length L = 6,4 mm
Arc voltage = 29V Arc voltage = 24V
Welding current = 220A Welding current = 250A
WFS = 6,4 m/min WFS = 6,4 m/min
Melt off rate = 5,6 Melt off rate = 6,4
m/min m/min
L’ 25 mm 25 mm
L
Voltage (V)
Current (A)
21
22
Lorentz Force
23
Metal Transfer in Arc
24
Arc energy Q = arc energy in kJ/mm
E = current in amps
ExI I = arc voltage
Q= V = travel speed in mm/min
V
Low arc energy High arc energy

• Small weld pool size • Large weld pool size
• Incomplete fusion • Low cooling rate
• High cooling rate • Increased solidification cracking risk
• Unwanted phase • Low ductility and strength
• Precipitation of unwanted phases
transformations (corrosion and ductility)
• Hydrogen cracking 25
Manual Metal Arc Welding
MMAW,
SMAW,
Stick electrode welding
Manual welding
26
Electrical Circuit for SMAW
Electrode Electrode holder

Earth clamp
Electric Arc
Work piece for Welding

welding power source
Welding cable
Earthing
cable
27
10/26/21
Shielded Metal Arc Welding
28
Shielded Metal Arc Welding
29
 Shielded Metal Arc Welding
Heat source - arc between metal and a flux coated

electrode (1.6 - 8 mm diameter)
 Current 30-400A (depends on electrode size)
 AC or DC operation
 Power 1 to 12 kW
30
Process features
 Simple portable equipment
 Widely practiced skills
 Applicable to wide range of materials, joints, positions
 About 1kg of weld per arc-hour deposited
 Portable and versatile
 Properties can be excellent
 Benchmark process
31
Minimum equipment
 Power source (ac or dc, engine driven or mains
transformer)
 Electrode holder and leads


May carry up to 300 amps
 Head shield with lens protects face & eyes
 Chipping hammer to remove slag
 Welding gloves protect hands from arc radiation, hot

material and electric shock
32
Covered electrodes
 Core wire

Solid or tubular

2mm to 6mm diameter,
250 to 350mm long
 Coating

Extruded as paste, dried
to strengthen

Dipped into slurry and
dried (rare)

Wound with paper or
chord (obsolete)
33
Functions of coating
 Slag protects weld pool from oxidation
 Gas shielding also protects weld pool
 Surface tension (fluxing)
 Arc stabilising (ionising)
 Alloying and deoxidation
 Some ingredients aid manufacture (binder and

extrusion aids) 34
Typical coating constituents

 Organic materials (Cellulose)
 Titanium dioxide (rutile)
 Silica, alumino-silicates
 Sodium and potassium silicate binders
 Calcium carbonate and fluoride
 Iron powder, ferro-alloys

35
Applications
 Wide range of welded products:


light structure & Heavy steel structures

Workshop and site

High integrity (nuclear reactors, pressure
equipment)
 Ideal where access is difficult - construction site,

inside vessels, underwater
 Joins a wide range of materials
36
SMAW Advantages
 Most versatile process.

Can be used for all positions and for wide thickness range.
Can be used in Shop and site. Highly portable
 Almost all metals can be welded by this processes.
 External shielding etc is not required. So less number of

equipment and accessories are required.
 The investment for equipment is relatively less,
 Process is simple.
37
Limitations of MMAW
 Low productivity

Low power

Low duty cycle (frequent electrode changes)
 Hydrogen from flux coatings
 Electrode live all the time


Arc strike, stray current and electric shock risks
38
Submerged arc welding

SAW,
Sub-arc
39
Submerged arc welding
40
Equipment
 Power source
 Welding head and

control box
 Welding head travel
 Flux recovery system

(optional)
 Positioners and Fixtures

41
Submerged arc welding - Features
 High productivity

2 to 10 kg/hour

Up to 2 m/min
 Bulky, expensive and
heavy equipment
 Flat and horizontal
positions only
 Thicker sections (3mm
and above)
 Mostly ferrous materials
(also Ni alloys)
42
SAW tandem arc

with two wires
43
Advantages of SAW
• high current density, high deposition rates (up to 10 times those
for MMA), high productivity
• deep penetration allowing the use of small welding grooves
• fast travel speed, less distortion
• De-slagging is easier
• uniform bead appearance & good surface finish give good
fatigue properties
• can be easily performed mechanised, giving a higher duty cycle
and low skill level required
• provide consistent quality when performed automatic or
mechanised
• assured radiographically sound welds
44
• arc is not visible, little smoke/fumes are developed
• limited mainly between flat and horizontal positions

• limited to carbon, low alloy, creep resisting, stainless
steels and nickel alloys
• due to the high heat input, impact strength of weld
metal/HAZ may be low; also high dilution
• slag must be cleared away after welding due to the
danger of slag inclusions
• need flux storage, handling and recirculation control
• difficult to apply on-site due to complicated equipment
• high capital costs
• weld line must be regular (straight or circumferential 45
seams only) with accurate fit-up
Applications of SAW
 Long straight welds in heavier material


Vessel longitudinal and circumferential welds

Flange to web joints of I beams
 Flat or horizontal position


Flux has to be supported
 Access has to be good
46
Consumables for SAW

 Solid or cored wires
 Granular fluxes

Agglomerated, fused or sintered

Alloying activity
• Contribution to weld metal chemistry from flux

Basicity
• Acid fluxes made from manganese oxide, silica, rutile are
easy to use
• Basic fluxes (MgO, CaO, CaF2, Al2O3) provide excellent
toughness welds
47
Process variations
 Surfacing and hardfacing

Wire and strip electrodes
 Semi-automatic
 Multiple electrodes
 2 (and more) electrode wires


From one or more power sources
 Iron powder additions to groove 48

Gas shielded arc process
Gas tungsten arc welding (GTAW)

Tungsten Inert Gas Welding (TIG)
49
Gas Tungsten Arc Welding
50
Gas Tungsten Arc Welding
 Alternative names -
GTAW,TIG (Tungsten Inert
Gas), Argon arc
 Heat source is an electric

arc between a non-
consumable electrode and
the workpiece
 Filler metal is not added or

is added independently
51
Gas Tungsten arc welding
52
 TIG Welding
Heat source - arc between a tungsten tip and the
parent metal
 30 – 400 A, AC or DC
 10 - 20V
 0.3 - 8kW
Inert gas shielding
Consumable filler rod can be used (1 to 4mm

diameter)
53
Process features
 Excellent control

Stable arc at low power (80A at 11V)

Independently added filler

Ideal for intricate welds eg root runs in pipe or thin
sheet

Low productivity 0.5kg/h manual
 High quality

Clean process, no slag

Low oxygen and nitrogen weld metal

Defect free, excellent profile even for single sided
welds 54
Equipment for GTAW
 Welding power source with constant current

characteristic

DC for most metals, AC for Al

Arc starting by high frequency (5000V, 0.05A)

Sequence timers for arc starting, arc finishing &
gas control
 Water- or gas-cooled torch with tungsten electrode


Electrode may contain thoria or zirconia, etc
55
Shielding gases
 Torch is fed with an inert or reducing gas

Pure argon - widespread applications

Argon-helium - Higher arc voltage, inert

Argon-2% hydrogen - Cu alloys & austenitic steel

Torch gas must not contain oxygen or CO2
 Backing (or purge) gas

Used for all single-sided welds except in carbon steel

Argon, nitrogen, formier gas (N2 + H2)
 Supplementary shielding
 Reactive metals: Ti, etc


Gas filled chambers or additional gas supply devices
56
Shielding gas requirements
Shielding gas flow
Pre-flow and Welding current

post-flow
Preflow Postflow
Flow rate Flow rate

too low too high
57
Filler metals
 Autogenous welding (no filler)
 Filler wire or rod of matching composition


C-Mn & low alloy steel

Stainless Steel

Al, Mg, Ti

Cu & Ni
 Consumable inserts - filler preplaced in joint
58
Types of Tungsten Electrodes
Pure
Least expensive, low current capacity
Thoriated
Better arc starting, higher current carrying
capacity, resistant to comtamination
Zirconiated
Has properties of both pure and thoriated
with greater stability for AC welding
Ceriated
Similar properties to thoriated tungsten,
gaining use as a safer alternative
Lanthanated
Similar properties to ceriated tungsten, 59
gaining use as a safer alternative
Penetration
increase
electrode diameter
Increase
2-2,5 times
Vertex
angle
Decrease
Bead width
increase
Electrode tip prepared for Electrode tip prepared for
low current welding high current welding 60
Variations & Effects of Electrode Tip Geometry
15° 60° 120°
Penetration Profiles of GTAW, 150a/dc @ 2s 100% Argon 61

How Current type influence weld
+ - + - + -
+ - + - + -
+ - + - + -
Current type & polarity DCEN AC (balanced) DCEP
Heat balance 70% at work 50% at work 35% at work

30% at electrode 50% at electrode 65% at electrode
Penetration Deep, narrow Medium Shallow, wide
Oxide cleaning action No Yes - every half cycle Yes
Electrode capacity Excellent Good Poor

(e.g. 3,2 mm/400A) (e.g. 3,2 mm/225A) (e.g. 6,4 mm/120A) 62
AC - SQUARE WAVE
 Eliminates rectification
 Insures good cleaning
 Improves arc stability
Reduces Peak
+ Half Cycle Current
63
Reduces Cycle Time
TIG - arc initiation methods
Arc initiation
method
Touch Start HF start
 simple method need a HF generator (spark-
 tungsten electrode is in gap oscillator) that generates
contact with the workpiece!
 high initial arc current due to a high voltage AC output
the short circuit (radio frequency)  costly
 impractical to set arc length reliable method  required on
in advance both DC (for start) and AC (to
 electrode should tap the re-ignite the arc)
workpiece - no scratch!
 ineffective in case of AC can be used remotely
 used when a high quality is HF produce interference
not essential requires superior insulation 64
Pulsed current
 usually peak current is 2-10
Pulse Cycle Peak Background
time time current current times background current
Current (A)
 useful on metals sensitive

to high heat input
 reduced distortions
 in case of dissimilar
thicknesses equal
Average current
penetration can be
Time
achieved
one set of variables can be used in all positions

used for bridging gaps in open root joints
65
require special power source
Tungsten Inert Gas Welding
Advantages Disadvantages
 High quality  High skill factor required
 Good control  Low deposition rate
 All positions  Small consumable range
 Lowest H2 process  High protection required
 Minimal post weld cleaning  Complex equipment
 Autogenous welding  Low productivity
(No filler material)  High ozone levels +HF
 Can be automated
66
GMAW and FCAW
Gas Metal Arc Welding

(MIG, MAG, CO2 Welding)
Flux Cored Arc Welding
67
GMAW and FCAW
68
69
GMAW & FCAW processes
70
GMAW
Developments
71
 MIG Welding
Heat source - arc between parent metal and
consumable electrode wire (0.6 to 1.6mm diameter)
 60 – 500 A, DC only
 16 – 40 V
 1 to 20 kW
72
 A continuous solid wire, small diameter


GMAW uses solid wire, no flux

FCAW uses flux-filled wire
 Fed through the gun to the arc by wire

feeder.
 The weld pool may be protected from

oxidation by shielding gas.
 High productivity 3 kg/arc-hour or more
 Direct current (DCEP mostly) 73

GMAW & FCAW equipment
 Welding power source
 Wire feeder mechanism
 Gun with gas supply & trigger

switch

Manual (semiautomatic) guns

Automatic torches available
Can be fitted to robot etc
74
Gas Metal Arc Welding - GMAW
POWERSOURCE
CONTROL
NEGATIVE
POSITIVE
TERMINAL
TERMINAL
75
Typical air-cooled
MIG/MAG torch
main components
76
MIG/MAG welding
wire-feed unit
77
Types of Metal Transfer
The basic GMAW process includes three distinctive

process techniques:
 Short Circuit (Short Arc)
 Globular Transfer
 Spray Arc Transfer

78
Voltage Burn-back
and unstable arc
Spray
Globular
Short
circuiting No arc (birds-nesting)
Current 79
Electrode diameter = 1,2 mm
Voltage
WFS = 8,3 m/min
Current = 295 A
Voltage = 28V
Globular Spray
transfer transfer
Electrode diameter = 1,2 mm

WFS = 3,2 m/min
Current = 145 A
Dip transfer Voltage = 18-20V
Current
Current/voltage conditions 80
Short Circuiting Transfer
 Operates at low voltages and welding current
 Small fast-freezing weld puddle obtained
 Useful in joining thin materials in any position, as well as

thick materials in vertical and overhead positions
 Metal transfer occurs when an electrical short circuit is

established
81
Globular Transfer
 Welding current and wire speed are increased above
maximum for short arc
 Droplets of metal have a greater diameter than the wire

being used
 Spatter present
 Welding is most effectively done in the flat position when

using globular transfer
82
Spray Transfer
 Occurs when the current and voltage settings are
increased higher than that used for Globular Transfer
 Used on thick sections of base material, best suited

for flat position due to large weld puddle
 Spatter is minimal to none
83
GMAW transfer types
 Spray

Higher current & voltage, argon-rich gas
 Short circuiting (dip)

 Low current and voltage, CO
2
 Globular

Intermediate current
 Pulsed current power sources


Adjustable frequency

One droplet per current pulse. 84
85
Welding
Current •Increasing welding current
•Increase in depth and width
•Increase in deposition rate
Polarity
86
 Arc voltage
•Increasing arc voltage

•Reduced penetration, increased width
•Excessive voltage can cause porosity, spatter
and undercut
 Travel speed
•Increasing travel speed
•Reduced penetration and width, undercut 87
Consumables
 Solid Wires (GMAW)

A wide variety of alloys are available
 Flux cored arc welding (FCAW)


Gas shielded flux cored wires

Self-shielded flux cored wires
• Used outdoors

Metal cored wires
• Light flux cover
88
GMAW Filler Metal Designations
ER - 70S - 6
Composition
Electrode 6 = high silicon
Solid Electrode
Rod (can be used
Minimum ultimate tensile
with GTAW)
strength of the weld metal
89
FCAW Electrode Classification
E70 T - 1
Electrode
Type Gas, Usability
Minimum UTS and Performance
70,000 psi Flux Cored /Tubular
Position Electrode
American Welding Society Specification
AWS A5.20 and AWS A5.29.
90
Torch gas mixtures

 Inert gases (MIG)

Argon or helium or mixtures of these

Active base metals, Al, Mg, Ti
 Active gases (MAG and FCAW)


Carbon dioxide

Argon plus oxygen and/or carbon dioxide

Nitrogen, hydrogen
91
Shielding Gases
 Purpose of shielding gas is the protect the weld area from the
contaminants in the atmosphere
 Gas can be Inert, Reactive, or Mixtures of both
 Gas flow rate is between 25-35 CFH
 Argon, Helium, and Carbon Dioxide are the main three gases used in
GMAW
92
Carbon Dioxide
Advantages
1) Inexpensive
2) Low heat radiation
3) Superior depth to width ratio
4) Lower hydrogen in weld metal
Disadvantages
1) Higher spatter levels
2) Narrow voltage band
3) Does not produce true spray transfer
4) Fully basic wires produce superior physical
characteristics with CO2
93
Shielding Gas Characteristics
Chemically inert, forms no compounds. Used for aluminium and its

Argon alloys in spray transfer and pulse modes. Gives a good, stable arc.
Can promote good penetration; however, weld bead profile tends to
be irregular.
Cheapest welding gas. Used for carbon steels and low alloy steels
Carbon in dip transfer mode. Arc tends to be rather unstable and welding
Dioxide conditions are difficult to optimize. High levels of spatter may be
produced. Penetration is deep and bulbous Will not support spray
transfer conditions.
Gives a good, stable arc. Used for carbon steels and low alloy
Argon 90% steels. Supports all modes of metal transfer. Penetration is
+5%Co2 generally narrow and not as deep as CO2. Weld bead profile fairly
uniform. Less spatter than CO2.
94
Gas Metal Arc Welding-GMAW
Shielding Gas Characteristics
Cheaper than the 95/5 mixture. Gives a stable arc. Widely used
Argon 80% for a broad range of ferrous alloys. Supports all modes of metal
+20%Co2 transfer, but not commonly used for pulse welding Good
penetration, uniform weld bead profile.
Argon 98% For welding stainless steels in the spray and pulsed modes. Gives
a stable arc which is hotter than the above gases. Oxygen reacts
+2%Co2 with weld metal at toes to give smooth, feathered finish .
For aluminium and its alloys. Chemically inert, forms no

Argon/helium compounds. Produces a hotter arc than argon alone, so less
Mixture preheat is required when welding thick sections. Causes more
spatter than pure argon.
95
Gas Metal Arc Welding-GMAW
GMAW Process is
Most suited for
Application
With Robots
96
Plasma Cutting, Welding & Surfacing
97
ANY QUESTIONS
98
99
100
101
Importance of Welding
 Wide use in manufacture
 Occurs late in manufacturing process


Large number of practitioners

Cost is high proportion of manufactured item

Risk and cost of defective welds is high
 Technology is complex

Welding is “Special Process” as per ISO
quality system standards

Process control is key to success
102
Solid phase welding
 Hot processes

Forge welding

Friction welding

Diffusion bonding
 Cold processes

Ultrasonic welding

Explosive welding
103
Allied processes
 Thermal cutting

Oxyfuel gas, plasma, laser cutting
 Gouging

Air-arc, plasma, oxyfuel gas
 Surfacing

Powder and arc spray coating

Clad welding, hardfacing
104
106
Polarity and Current Flow
Welding Electrode or "Electrode"
Anode Cathode
I I
DCEP DCEN
Cathode Anode
Work Electrode or "Work"
Reverse Straight
DCEP DCEN
108
109
Ionization Potential
He 24.6 ev
Ar 15.8
N 15.6
Fe Vapour 7.9
Na Vapour 5.1
K Vapour 4.3
110
111
Polarity Influence – cathodic cleaning effect
112
Constant Voltage Characteristic
OCV Small change in voltage =

large change in
Large arc gap amperage
Small arc gap
The self
Volts adjusting arc.
Amps
113
Flat or Constant Voltage Characteristic
Flat or Constant Voltage Characteristic Used With
MIG/MAG, ESW & SAW < 1000 amps
O.C.V. Arc Voltage
Virtually no Change.
33
32
31
Small Voltage
Change.
Voltage
Large Current Change
100 200 300

Amperage
114
115
Risk of slag
entrapment
Easy slag
removal
116
Submerged arc welding – Tandem arc
117
Tandem arc SAW process - multiple wires

2 to 10 kg/ arc-hour
•only for welding thick

Up to 2m/min welding speed
sections (>30 mm)
•not suitable for use in
 Bulky, expensive and heavy equipment
narrow weld preparations
(root passes)
 Flat and horizontal positions only
•one 4 mm wire at 600 A,
 Thicker sections ( 3 mm and above)
6.8 kg/hr
•tandem two 4 mm wires
 Mostly ferrous materials (also at
Ni 600
alloys)
A, 13.6 kg/hr
118
Submerged arc welding - Features

2 to 10 kg/hour

Up to 2 m/min
 Bulky, expensive and
heavy equipment
 Flat and horizontal
positions only
 Thicker sections (3mm
and above)
 Mostly ferrous materials
(also Ni alloys)
119
Submerged arc welding – Tandem arc
120
High dilution procedures  Square edges
 Low cost of preparation
 Fast travel speeds (acid
fluxes)
Single pass with temporary backing  Maximum thickness

16 mm in one pass, 20 mm
in two
 Location of bead is critical
 High dilution leads to low
toughness
 High cap height, lower
Two pass weld fatigue life
121
Vee butt weld procedures
60
included
One, two or multipass
Vee or U preparations
Lower currents
Unlimited thickness 6mm
Excellent quality
1.5mm max
122
 can be DCEN or DCEP
DC
 DCEN gives deep penetration
AC can be sine or square wave

Type of requires a HF current (continuous
welding or periodical)
current provide cleaning action
 requires special power source

Pulsed  low frequency - up to 20 pulses/sec
current (thermal pulsing)
 better weld pool control
 weld pool partially solidifies
between pulses
123
Arc initiation
method
Lift arc HF start
 simple method need a HF generator (spark-
 tungsten electrode is in contact gap oscillator) that generates a
with the workpiece!
 high initial arc current due to high voltage AC output (radio
the short circuit frequency)  costly
 impractical to set arc length in reliable method  required on
advance both DC (for start) and AC (to
 electrode should tap the re-ignite the arc)
workpiece - no scratch!
 ineffective in case of AC can be used remotely
 used when a high quality is not HF produce interference
essential requires superior insulation
124
 usually peak current is 2-10
Pulse Cycle Peak Background times background current
time time current current
Current (A)
 useful on metals sensitive to

high heat input
 reduced distortions
 in case of dissimilar thicknesses
equal penetration can be
achieved
Average current
Time
one set of variables can be used in all positions

used for bridging gaps in open root joints
require special power source
125
Penetration
increase
electrode diameter
Increase
2-2,5 times
Vertex
angle
Decrease
Bead width
increase
Electrode tip prepared for low Electrode tip prepared for high
current welding current welding 126
Preflow and Shielding gas flow
postflow Welding current
Preflow Postflow
Flow rate Flow rate

too low too high
127
 High quality  High skill factor required
 Good control  Low deposition rate
 All positions  Small consumable range
 Lowest H2 process  High protection required
 Minimal cleaning  Complex equipment
 Autogenous welding  Low productivity
(No filler material)  High ozone levels +HF
 Can be automated
128
Ar Ar-He He CO2
Argon (Ar):
higher density than air; low thermal conductivity  the arc
has a high energy inner cone; good wetting at the toes;
low ionisation potential
Helium (He):
lower density than air; high thermal conductivity 
uniformly distributed arc energy; parabolic profile; high
ionisation potential
Carbon Dioxide (CO2):
cheap; deep penetration profile; cannot support spray
transfer; poor wetting; high spatter
129
130
Automatic orbital GTAW
131
Pulsed Transfer
Transfer-mode advantages
 Good fusion
 Small weld pool allows all-position welding
Transfer-mode disadvantages
 More complex & expensive power source
 Difficult to set parameters - requires power source
manufacturer to provide pulse programmes to suit wire
type, dia. and type of gas
132
Dip Transfer
• Dip transfer occurs when current & voltage settings are low
(typically < ~ 200amps & ~ 22volts)
• There is just enough energy to give an arc and cause fusion at
the tip of the wire
• A droplet grows to a size larger than the wire diameter and
eventually extinguishes the arc - causing a short-circuit
• The short circuit causes the current rises very quickly giving
energy to violently ‘pinch-off’ the droplet
• This is akin to ‘blowing a fuse’ and causes spatter
• When the droplet detaches, the arc is re-established and the
current falls
• This cycle occurs at up to ~ 200 times per second 133
Dip transfer
Transfer occur due to short circuits between
wire and weld pool, high level of spatter,
need inductance control to limit current raise
Can use pure CO2 or Ar- CO2 mixtures as
shielding gas
Metal transfer occur when arc is
extinguished
Requires low welding current/arc voltage, a
low heat input process. Resulting in low
residual stress and distortion
Used for thin materials and all position welds
134
Dip Transfer
• The low energy conditions allow welding in all positions
• It can be used for the root run on single-sided welds
• It can be used for welding thin materials
Transfer-mode disadvantages
• It frequently gives lack of fusion and may not be allowed
in semi-automatic mode for high-integrity applications
• It tends to give spatter
(this can be reduced/controlled by having an 135
‘inductance’ control on the power source)
136
Spray Transfer
When current & voltage are raised together higher energy
is available for fusion (typically > ~ 25 volts & ~ 250 amps)
This causes a fine droplets of weld metal to be ‘sprayed’
from the tip of the wire into the weld pool
• High energy gives good fusion
• High rates of weld metal deposition are given
• These characteristics make it suitable for welding
thicker joints
• Transfer-mode disadvantages
137
• It cannot be used for positional welding
Spray transfer
Transfer occur due to pinch effect
NO contact between wire and weld
pool!
Requires argon-rich shielding gas
Metal transfer occur in small
droplets, a large volume weld pool
Requires high welding current/arc
voltage, a high heat input process.
Resulting in high residual stress
and distortion
Used for thick materials and
flat/horizontal position welds
138
Pulsed transfer
Controlled metal transfer, one droplet per pulse,
No transfer between droplet and weld pool!
Requires special power sources
Metal transfer occur in small droplets (diameter equal
to that of electrode)
Requires moderate welding current/arc voltage, a
reduced heat input . Resulting in smaller residual
stress and distortion compared to spray transfer
Pulse frequency controls the volume of weld pool,
used for root runs and out of position welds
139 of 691
10/26/21
Pulsed transfer
Controlled metal transfer. one droplet

per pulse. NO transfer during
background current!
Requires special power sources
Metal transfer occur in small droplets
(diameter equal to that of electrode)
Requires moderate welding current/arc voltage, reduced
heat input’ smaller residual stress and distortions
compared to spray transfer
Pulse frequency controls the volume of weld pool, used
for root runs and out of position welds
140
MIG/MAG-methods of metal transfer
Globular transfer
Transfer occur due to gravity or
short circuits between drops and
weld pool
Requires CO2 shielding gas
Metal transfer occur in large drops
(diameter larger than that of
electrode) hence severe spatter
Requires high welding current/arc
voltage, a high heat input process.
Resulting in high residual stress
and distortion
Non desired mode of transfer!
141
Current type and polarity
•Usually DCEP, deep
penetration, better
resistance to porosity
•DCEN increase
deposition rate but
reduce penetration
(surfacing)
•AC used to avoid arc

blow; can give unstable
arc
142
Pay off pack drum

And dispenser
143
Gas metal arc welding
144
145
Plasma Cutting, Welding & Surfacing
146
147
148
 can be DCEN or DCEP
DC
 DCEN gives deep penetration
AC can be sine or square wave

Type of requires a HF current (continuos
welding or periodical)
current provide cleaning action
 requires special power source

Pulsed  low frequency - up to 20 pulses/sec
current (thermal pulsing)
 better weld pool control
 weld pool partially solidifies between
pulses
149
Current type influence
+ - + - + -
+ - + - + -
+ - + - + -
Current type & polarity DCEN AC (balanced) DCEP
Heat balance 70% at work 50% at work 35% at work

30% at electrode 50% at electrode 65% at electrode
Penetration Deep, narrow Medium Shallow, wide

Oxide cleaning action No Yes - every half cycle Yes
Excellent Good Poor 150
Electrode capacity
(e.g. 3,2 mm/400A) (e.g. 3,2 mm/225A) (e.g. 6,4 mm/120A)
Stringer Bead Technique Weaving technique
151
 High productivity  Lack of fusion (dip)
 Easily automated  Small range of consumables
 All positional (dip & pulse)  Protection on site
 Material thickness range  Complex equipment
 Continuous electrode  Not so portable
Wide range of application
152
ANY QUESTIONS
153

Arc Welding Processes

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Arc Welding Processes

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Introduction to arc welding

 Brazing and Soldering

 A joint produced by heat or pressure or both so there

 Filler (if used) has a melting temperature close to the

 Solid phase welding

Basic Requirements of Welding Process

Protection from Atmosphere

Fusion welding heat sources

Electric Chemical Electric Power

Spot, seam and Oxyfuel MMAW Laser

• 103 Watts/cm2 melts most metals

The Welding arc  Electric discharge between 2

+  Can have a cleaning action,

Low arc energy High arc energy

Manual Metal Arc Welding

Electrode Electrode holder

Work piece for Welding

 Shielded Metal Arc Welding

Heat source - arc between metal and a flux coated

 Current 30-400A (depends on electrode size)

 Widely practiced skills

 Applicable to wide range of materials, joints, positions

 About 1kg of weld per arc-hour deposited

 Portable and versatile

 Properties can be excellent

 Electrode holder and leads

 Head shield with lens protects face & eyes

 Chipping hammer to remove slag

 Welding gloves protect hands from arc radiation, hot

 Slag protects weld pool from oxidation

 Gas shielding also protects weld pool

 Surface tension (fluxing)

 Arc stabilising (ionising)

 Alloying and deoxidation

 Some ingredients aid manufacture (binder and

Typical coating constituents

 Titanium dioxide (rutile)

 Sodium and potassium silicate binders

 Calcium carbonate and fluoride

 Iron powder, ferro-alloys

 Wide range of welded products:

 Ideal where access is difficult - construction site,

 Joins a wide range of materials

 Most versatile process.

 Almost all metals can be welded by this processes.

 External shielding etc is not required. So less number of

 The investment for equipment is relatively less,

 Hydrogen from flux coatings

 Electrode live all the time

Submerged arc welding

 Welding head and

 Welding head travel

 Flux recovery system

 Positioners and Fixtures

SAW tandem arc

• limited mainly between flat and horizontal positions

 Long straight welds in heavier material

 Flat or horizontal position

 Access has to be good

Consumables for SAW

 2 (and more) electrode wires

 Iron powder additions to groove 48

Gas shielded arc process