Basic Welding ESAB

Lesson 2 - Common Electric Arc Welding Processes
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Lesson 1 The Basics of A Welding Lesson 2 Common Electri Arc Welding Processes Lesson 3 Covered Electrodes for Welding Mild Steels
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BASIC WELDING FILLER METAL TECHNOLOGY
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Lesson 4 Covered Electrodes for Welding Low Alloy Steels
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A Correspondence Course
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Lesson 5 Welding Filler Metals for Stainless Steels
Turn Pages Lesson 6 Carbon & Low Alloy Steel Filler Metals GMAW,GTAW,SAW Lesson 7 Flux Cored Arc Electrodes Carbon Low Alloy Steels Lesson 8 Hardsurfacing Electrodes Lesson 9 Estimating & Comparing Weld Metal Costs Lesson 10 Reliability of Welding Filler Metals
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LESSON II COMMON ELECTRIC ARC WELDING PROCESSES

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Lesson 1 The Basics of Arc Welding
Lesson 2 Common Electric Arc Welding Processes
TABLE OF CONTENTS LESSON II COMMON ELECTRIC ARC WELDING PROCESSES

Section Nr. Section Title Page
Go To Test Lesson 3 Covered Electrodes for Welding Mild Steels Print 2.1 2.2 Lesson 4 Covered Electrodes for Welding Low Alloy Steels
2 . 2. 1 2 . 2. 2 2 . 2. 3 2 . 2. 4
I N T R O DU CT I ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 S H IE L DE D ME T AL AR C WE L DIN G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
E q u ip me n t & O p e r a t io n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 We ld ing Po wer So ur ces ....................................................................2 E le c t r o d e Ho ld e r . . . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. .. 4 Gro und Cla mp ...................................................................................4 Weld ing Cables .................................................... .............................4 Co at ed E lect ro d es ............................................................................4
Glossary
2 . 2. 5 2 . 2. 6
2.3 Lesson 6 Carbon & Low Alloy Steel Filler Metals GMAW,GTAW,SAW Lesson 7 Flux Cored Arc Electrodes Carbon Low Alloy Steels
2 . 3. 1 2 . 3. 2 2 . 3. 3 2 . 3. 4 2 . 3. 5 2 . 3. 6
G AS - T U N G S T E N AR C WE L D IN G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
E q u ip me n t & O p e r a t io n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Power Sources ..................................................................................7 Torches........................................................... ...................................10 S h ie ld ing G a se s .... ...... ...... ..... ...... ..... ...... ...... ...... ...... ...... ...... ...... ...... 1 1 E le c t ro d e s ... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .. 1 2 S u mma r y . ...... ...... ...... ..... ...... ...... ..... ...... ...... ...... ...... ...... ...... ...... ...... ..1 3
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2.4
2 . 4. 1 2 . 4. 2
G AS ME T AL AR C WE L D IN G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3
C u r r e nt D e n s it y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 Met al T r ansfer Mo d es ..... ...... ...... ....... ...... ...... ...... ...... ...... ...... ...... ...... 1 5 E q u ip me nt a nd O p e r a t io n . . .. . .. .. . .. .. ... . .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. 17 Power Source....................................................................................18 W ir e Fe e d e r ... ..... ...... ...... ...... ...... ..... ...... ...... ...... ...... ...... ...... ...... ...... . 19 We ld ing G u n.. ...... ..... ...... ...... ...... ...... ... ... ...... ...... ...... ...... ...... ...... ...... . 20 S h ie ld ing G a se s .... ...... ...... ..... ...... ..... ...... ...... ...... ...... ...... ...... ...... ...... 2 1 2 . 4. 7 . 1 2 . 4. 7 . 2 S ho rt C ir c u it ing Tr a nsfe r ...... ...... ....... ...... ...... ...... ...... ...... ... 22 Spra y Arc Transfer ............................................................23
Lesson 8 Hardsurfacing Electrodes
2 . 4. 3 2 . 4. 4 2 . 4. 5
Lesson 9 Estimating & Comparing Weld Metal Costs
2 . 4. 6 2 . 4. 7
Lesson 10 Reliability of Welding Filler Metals

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TABLE OF CONTENTS LESSON II- Con't.
Print
Section Nr.
Section Title
Page Go To Test
Lesson 3 Covered Electrodes for Welding Mild Steels
2.4.8 2.5 2.5.1
2.4.7.3 Pulse Spray Transfer ........................................................ Electrodes ........................................................................................ FLUX CORED ARC WELDING
......................................................
23 23 24 24 25 26 26 26 26 26 27 27 28 28 28 28 29 29 30 30 30 30 31 31 32 Search Glossary
2.5.2 2.5.3 2.5.4 2.5.5 2.5.6 2.5.7 2.5.8 2.6 2.6.1 2.6.2 2.6.3 2.6.4 2.6.5 2.6.6 2.7 2.7.1 2.7.2
Sell-Shielded Process ..... ............ ............ ............ ........... ............ ...... Gas Shielded Process ........... ............ ............ ................. ............ ...... Current Density Equipment ........................................................................................ Power Source . .......... ............ ............ ............ ....... ............ ............ ..... Wire Feeder ..................................................................................... Welding Guns ..... ............ ............ ............ ........... ............ ............ ....... Shielding Gases ............................................................................... SUBMERGED ARC WELDING ...................................................... Submerged Arc Flux . .... ............ ............ ............ ................ ............ .... The Welding Gu n. . ........... ........... ............ ... ......... .......... ............ ........ Power Sources ................................................................................. Equipment ..... ............ ............ ............ ........... ............ ............ ............ Electrodes ..... ............ ............ ............ ........... ............ ............ ............ Summary ..... ............ ............ ............ ........... ............ ............ ............ .. ELECTROSLAG AND ELECTROGAS WELDING ......................... Electroslag Welding.......................................................................... Flux .................................................................................................. Process ..... ............ ............ ............ ........... ............ ............ ............ .... Equipment........................................................................................ Summary ..... ............ ............ ............ ........... ............ ............ ............ .
..... ............ ............ ............ ........... ............ ............ .....
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Lesson 6 Carbon & Low Alloy Steel Filler Metals GMAW,GTAW,SAW
Lesson 7 Flux Cored Arc Electrodes Carbon Low Alloy Steels
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2.7.3 2.7.4 2.7.5
Appendix A- GLOSSARY OF TERMS ................................................................
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LESSON II
COMMON ELECTRIC ARC WELDING PROCESSES

2.1 INTRODUCTION
Go To Test After much ex perimentation by others in the ear(y 1800's, an Eng(ishman named Wi(de obtained the first e(ectric we(ding patent in 1865. He successfu((y joined two sma(( pieces of iron by passing an e(ectric current through both pieces producing a fusion we(d. Approximate(y twenty years (ater, Bernado, a Russian, was granted a patent for an e(ectric arc we(ding Print
process in which he maintained an arc between a carbon e(ectrode and the pieces to be joined, fusing the meta(s together as the arc was manua((y passed o'er the joint to be we(ded. 2.1.0.1 During the 1890's, arc we(ding was accom p(ished with bare meta( e(ectrodes that Glossary
were consumed in the mo(ten pudd(e and became part of the we(d meta(. The we(ds were of poor qua(ity due to the nitrogen and oxygen in the atmosphere forming harmfu( oxides and nitrides in the we(d meta(. Ear(y in the Twentieth Century, the im portance of shie(ding the arc from the atmosphere was rea(ized. Co2ering the e(ectrode with a materia( that decomposed in
Lesson 6 Carbon & Low Alloy Steel Filler Metals GMAW,GTAW,SAW Lesson 7 Flux Cored Arc Electrodes Carbon Low Alloy Steels
the heat of the arc to form a gaseous shie(d appeared to be the best method to accom p(ish this end. As a resu(t, 2arious methods of co2ering e(ectrodes, such as wrapping and dipping, were tried. These efforts cu(minated in the extruded coated e(ectrode in the mid - 1920's, great(y im pro2ing the qua(ity of the we(d meta( and pro2iding what many consider the most significant ad2ance in e(ectric arc we(ding. 2.1.0.2 Since we(ding with coated e(ectrodes is a rather s(ow procedure, more rapid
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we(ding processes were de2e(oped. This (esson wi(( co'er the more common(y used e(ectric arc we(ding processes in use today.
Lesson 8 Hardsurfacin Electrodes
2.2
SHIELDED METAL ARC WELDING
Shielded Metal Arc Welding*, a(so known as manua( meta( arc we(ding, stick we(ding, or e(ectric arc
we(ding, is the most wide(y used of the 2arious arc we(ding processes. We(ding is performed with the heat of an e(ectric arc that is maintained between the end of a coated meta( e(ectrode and the work piece (See Figure 1). The heat produced by the arc me(ts the base meta(, the e(ectrode core rod, and the coating. As the mo(ten meta( drop(ets are transferred across the arc and into
Lesson 10 Reliability of Weldin Filler Metals
the mo(ten we(d pudd(e, they are shie(ded from the atmosphere by the gases produced from the decom position of the f(ux coating. The mo(ten s(ag f(oats to the top of the we(d pudd(e where it protects the we(d meta( from the atmosphere during so(idification.
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Lesson 1 The Basics of Arc Welding Other functions of the coating are to provide arc stabi(ity and contro( bead shape. More Lesson 2 Common Electric Arc Welding Processes information on coating functions wi(( be covered in subsequent (essons.
* Shielded Metal Arc Welding (SMAW) is the terminologyapproved by the American Welding Society. CORE ROD COATING
LESSON II
MOLTEN POOL
SHIELDING GASES SOLIDIFIE D SLAG WELD METAL
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2.2.1
Equipment & Operation - One
WORK PIECE SHIELDED METAL ARC WELDING FIGURE 1
reason for the wide acceptance of the SMAW Lesson 4 Covered Electrodes for Welding Low Alloy Steels process is the simp(icity of the necessary equipment. The equipment consists of the fo((owing items. (See Figure 2) 1. 2. 3. 4. Lesson 6 Carbon & Low Alloy Steel Filler Metals GMAW,GTAW,SAW 5. We(ding power source E(ectrode ho(der Ground c(amp We(ding cab(es and connectors Accessory equipment (chipping hammer, wire brush) 1.
2.2.2
Glossary
AC OR DC POWER SOURCE ELECTRODE CABLE ELECTRODE HOLDER ELECTRODE GROUND WORK CABLE SHIELDED METAL ARC WELDING CIRCUIT
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Protective equipment (he(met, g(oves, etc.)
FIGURE 2
Welding Power Sources - Shie(ded meta( arc we(ding may uti(ize either Search Chapter (Faster Download) Search Document (Slower Download)
a(ternating current (AC) or direct current (DC), but in either case, the power source se(ected must be of the constant current type. This type of power source wi(( de(iver a re(ative(y constant amperage or we(ding current regard(ess of arc (ength variations by the operator (See Lesson I,
Section 1.9). The amperage determines the amount of heat at the arc and since it wi(( remain re(ative(y constant, the we(d beads produced wi(( be uniform in size and shape. 2.2.2.1 Whether to use an AC, DC, or ACIDC power source depends on the type of we(ding
to be done and the e(ectrodes used. The fo((owing factors shou(d be considered: 1. Electrode Selection - Using a DC power source a((ows the use of a greater range of e(ectrode types. Whi(e m ost of the e(ectrodes are designed to be used on AC or DC, some wi(( work proper(y on(y on DC.
2. Metal Thickness - DC power sources may be used for we(ding both heavy sections and (ight gauge work. Sheet meta( is m ore easi(y we(ded with DC because it is easier to strike and maintain the DC arc at (ow currents.
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Lesson 1 The Basics of Arc Welding 3. Distance from Work - If the distance from the work to the power source is great, AC is the best choice since the voltage drop through the cables is lower than with Lesson 2 Common Electric Arc Welding Processes DC. Even though welding cables are m ade of copper or aluminum (both good conductors), the resistance in the ca bles becomes greater as the cable length increases. In other words, a voltage reading taken between the electrode and the work will be somewhat lower than a reading taken at the output terminals of the Lesson 3 Covered Electrodes for Welding Mild Steels power source. This is known as voltage drop.
LESSON II
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4. Welding Position (See Appendix A - Glossary of Terms) - Because DC may be operated at lower welding currents, it is more suitable for overhead and vertical welding than AC. AC can successfully be used for out-of-position work if proper
electrodes are selected. 5. Arc Blow- When welding with DC, m agnetic fields are set up throughout the weldment. In weldments that havevarying thickness and protrusions, this m agnetic field can affect the arc by m aking it stray or fluctuate in direction. This condition is especially troublesome when welding in corners. AC seldom causes this problem Glossa
because of the rapidly reversing m agnetic field produced. 2.2.2.2 Combination power sources that produce both AC and DC are av ailable and provide the versatility necessary to select the proper welding current for the application. Turn Pages
2.2.2.3 When using a DC power source, the question of whether to use electrode negative or positive polarity arises. Some electrodes operate on both DC straight and reverse polarity, and others on DC negative or DC positive polarity only. Direct current flows in one direction in an electrical circuit and the direction of current flow and the composition of the elec trode coating will have a definite effect on the welding arc and weld bead. Figure 3 shows the connections and effects of straight and reverse polarity. 2.2.2.4 Electrode negative (-) produces welds with shallow penetration; however, the electrode melt-off rate is high. The weld bead is rather wide and shallow as shown at 'A' in Search Chapter (Faster Download) Search Document (Slower Download)
Figure 3. Electrode positive (+) produces welds

DC POWER SOURCE A I-IGI-ER BURN-OFF RATE, LESS PENETRATION ELECTRODE B DEEP PENETRATION, LOW BURN-OFF RATE ELECTRODE DC POWER SOURCE
with deep penetration and a narrower weld bead as shown at

'B' in Figure 3.
WORK PIECE
WORK PIECE
STRAIGI-T POLARITY
REVERSE POLARITY
FIGURE 3
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Lesson 1 The Basics of Arc Welding 2.2.2.5 While polarity affects the penetration and burn-off rate, the electrode coating also has a strong influence on arc characteristics. Perform ance of indi.idual electrodes will be Lesson 2 Common Electric Arc Welding Processes discussed in succeeding lessons. 2.2.3 Electrode Holder-The electrode holder connects to the welding cable and con-
LESSON II
ducts the welding current to the electrode. The insulated handle is used to guide the electr ode Lesson 3 Covered Electrode for Welding Mild Steels o'er the weld joint and feed the electrode o'er the weld joint and feed the electrode into the weld puddle as it is consumed. Electrode holders are a. ailable in different sizes and are rated on their current carrying capacity. 2.2.4 Lesson 4 Covered Electrode for Welding Low Alloy Steels Ground Clamp - The ground clamp is used to connect the ground cable to the work Glossary Print Go To Test
piece. It m ay be connected directly to the work or to the table or fixture upon which the work is positioned. Being a part of the welding circuit, the ground clamp must be capable of carrying the welding current without o.erheating due to electrical resistance. 2.2.5 Welding Cables - The electrode cable and the ground cable are important parts of
Lesson 5 Welding Filler Metal for Stainless Steels
the welding circuit. They must be .ery flexible and ha.e a tough heat -resistant insulation. Connections at the electrode holder, the ground clamp, and at the power source lugs must be soldered or well crimped to assure low electrical resistance. The cross -sectional area of the
cable must be sufficient size to carry the welding current with a minimum of oltage drop. Increasing the cable length necessitates increasing the cable diameter to lessen resistance and voltage drop. The table in Figure 4 lists the suggested Mmerican Wire Gauge (MWG) cable size to be used for .arious welding currents and cable lengths.
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Welding Ser.ice Range (Mmperes) 20to 180 30 to 250 60 to 375 80 to 500 100to600
Total Cable Length (Ground Upto50 ft. Upto 100 ft. Cable Voltage Cable Voltage Size Drop Size Drop #3 #2 #0 #00 #00 1.8 1.8 1.7 1.8 2.0 #2 #1 #0 #000 #0000 2.9 2.5 3.0 2.5 2.5
Lead Plus Electrode Lead) Upto250 ft. Upto500 ft. Cable Voltage Cable Voltage Size Drop Size Drop #1 #0 #00 #0000 ... 5.7 5.0 5.9 5.0 ... #0 #0 #000 #0000 ... 9.1 9.9 9.3 9.9
Voltage Drop Figured Mt 180 Mmps 200 Mmps 300 Mmps 400 Mmps 500Mmps
Voltage drops indicated do not include any drop caused by poor connection, electrode holder, or work metal
FIGURE 4
2.2.6 Coated Electrodes - Various types of coated electrodes are used in shielded metal arc welding. Electrodes used for welding mild or carbon steels are quite different than those used for welding the low alloys and stainless steels. Details on the specific types will be covered in subsequent lessons.
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Lesson 1 The Basics of Arc Welding Lesson 2 Common Electric Arc Welding Processes
LESSON II
2.3 GAS TUNGSTEN ARC WELDING

Gas Tungsten Arc Welding* is a welding process performed using the heat of an arc
established between a nonconsumable tungsten electrode and the work piece. See Figure 5. The electrode, the arc, and the area surrounding the molten weld puddle are protected from the atmosphere by an inert gas shield. The electrode is not consumed in the weld puddle as in Go To Test
shielded metal arc welding. If a filler metal is necessary, it is added to the leading the molten puddle as shown in 2.3.0.1 Gas tungsten arc
TRAVEL DIRECTION TORCH
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welding produces exceptionally clean welds no slag is produced, the chance inclusions in the weld metal is
ARC TUNGSTEN ELECTRODE SHIELDING GAS NOZZLE
Glossary
and the finished weld requires virtually no cleaning. Argon and Helium, the primary shielding gases em ployed,
are inert gases. Inert do not chemically combine with other
FILLER @ETAL
gases
WORK PIECE
INERT GAS SHIELD
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GAS TUNGSTEN ARC WELDING
elements and therefore, are used to exclude the reactive gases, such as oxygen and nitrogen, from forming com pounds that could be detrimental to the weld metal.
IGURE 5
2.3.0.2 steel,
Gas tungsten arc welding may be used for welding almost all metals - mild
low alloys, stainless steel, copper and copper alloys, aluminum and aluminum alloys, nickel Lesson 9 Estimating & Comparing Weld Metal Costs and nickel alloys, magnesium and magnesium alloys, titanium, and others. This process is most extensively used for welding aluminum and stainless steel alloys where weld integrity is of the utmost im portance. Another use is for the root pass (initial pass) in pipe welding, which requires a weld of the highest quality. Full penetration without an excessively high inside bead is im portant in the root pass, and due to the ease of current control of this process, it lends itself Lesson 10 Reliability of Welding Filler Metals to control of back-bead size. For high quality welds, it is usually necessary to provide an inert shielding gas inside the pipe to prevent oxidation of the inside weld bead.
* Gas Tungsten Arc Welding (GTAW) is the current terminology approved by the American Welding Society, formerly known as "TIG" (Tungsten Inert Gas) welding.
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Lesson 1 The Basics of Arc Welding 2.3.0.3 Gas tungsten arc welding lends itself to both manual and automatic operation. In manual operation, the welder holds the torch in one hand and directs the arc into the weld joint. Lesson 2 Common Electric Arc Welding Processes The filler metal is fed manually into the leading edge of the puddle. In automatic applications, the torch may be automatically mo' ed o' er a stationary work piece or the torch may be stationary with the work mo' ed or rotated in relation to the torch. Filler metal, if required, is also fed automatically. Lesson 3 Covered Electrodes for Welding Mild Steels
2.3.1 E Q U I P M E N T A N D O P E R A T I O N - Gas tungsten arc welding may be accomplished
LESSON II
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with relati' ely simple equipment, or it may require some highly sophisticated components. Choice of equipment depends upon the type of metal being joined, the position of the weld
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being made, and the quality of the weld metal necessary for the application. The basic equip ment consists of the following: 1. 2. The power source Electrode holder (torch) Shielding gas Tungsten electrode Water supply when necessary Ground cable Turn Pages 7. Protecti'e equipment Glossary
3. 4. 5.
6.
Figure 6 shows a basic gas tungsten arc welding schematic.
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REGULATOR FLOW METER
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GAS HOSE (WATER COOLED ONLY)
( F
TORCH
GAS COOLED ONLY *COMPOSITE CABLE WELDING CABLE WATER COOLER
Search ( S l
WORK

POWER SOURCE WATER FROM TORCH WATER TO TORCH GROUND CABLE SHIELDING GAS SUPPLY GAS TUNGSTEN ARC WELDING CONNECTION SCHEMATIC
* COMPOSITE CABLE
GAS COOLED TORCH. CURRENT IN & GASIN. WATER COOLED TORCH. CURRENT IN & WATER OUT
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FIGURE 6

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2 .3.2 Power Sources
LESSON II
- Both AC and DC power sources are used in gas tungsten arc
we(ding. They are the constant current type with a drooping vo(t-ampere curve. This type of Lesson 2 Common Electric Arc Welding Processes power source produces very s(ight changes in the arc current when the arc (ength (vo(tage) is varied. Refer to Lesson I, Section 1.9. 2.3.2.1 Lesson 3 Covered Electrodes for Welding Mild Steels Lesson 4 Covered Electrodes for Welding Low Alloy Steels The choice between an AC or DC we(der depends on the type and thickness of the Go To Test Print
meta( to be we(ded. Distinct differences exist between AC and DC arc characteristics, and if DC is chosen, the po(arity a(so becomes an important factor. The effects of po(arity in GTAW are direct(y opposite the effects of po(arity in SMAW as described in paragraphs 2.2.2.3 through 2.2.2.5. In SMAW, the distribution of heat between the e(ectrode and work, which determines the penetration and we(d bead width, is contro((ed main(y by the ingredients in the f(ux coating on the e(ectrode. In GTAW where no f(ux coating exists, heat distribution between the e(ectrode and the work is contro((ed so(e(y by the po(arity. The choice of the proper we(ding current wi(( be better understood by ana(yzing each type separate(y. The chart in Figure 7 (ists current recommendations.
Glossary
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WELDING CURRENT Material& Thickness A(uminum Under 1/8 Over1/8' Magnesium Under1/16" Over 1/16 Carbon Stee( Under 1/8 Over1/8' Stain(ess Stee( Under 1/8 Over 1/8' Copper Under 1/8 Over 1/8 Nicke( A((oys Under 1/8 Over 1/8' Titanium Under 1/8 Over 1/8' DCEN 2 2&3 2 DCEP AC High Freq. 1 1 1 1 Argon 1 1 1 1 1 1 1
SHIELDING GAS Helium 2 3 2 Ar/He
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2
1 1 1 1 1 1 1 1 1
3 2 2 1
Se Cha (Fa Dow
1 1 3 2 2 1 2 1
Se Docu (Slo Dow
1 2
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1. Preferred Choice - Manua( We(ding 2. Preferred Choice - Automatic We(ding 3. Second Choice - Automatic We(ding CURRENT/SHIELDING GAS SELECTION, TUNGSTEN GAS ARC WELDING FIGURE 7

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LESSON II 2.3.2.2 Direct current electrode negative (DCEN) is produced when the electrode is connected to the negative terminal of the power source. Since the electrons flow from the
electrode to the plate, appro,imately 70% of the heat of the arc is concentrated at the work, and appro,imately 30% at the electrode end. This allows the use of smaller tungsten elec trodes that produce a relatively narrow concentrated arc. The weld shape has deep penetration and is quite narrow. See Figure 8. Direct current electrode negative is suitable for weld Go To Test Print
ing most metals. Magnesium and aluminum have a refractory o,ide coating on the surface that must be physically removed immediately prior to welding if DCSP is to be used. 2.3.2.3 Direct current electrode positive (DCEP) is produced when the electrode is connected to the positive terminal of the welding power source. In this condition, the electrons
flow from the work to the electrode tip, concentrating appro,imately 70% of the heat of the arc at the electrode and 30% at the work. This higher heat at the electrode necessitates using larger diameter tungsten to prevent it from melting and contaminating the weld metal. Since the electrode diameter is larger and the heat is less concentrated at the work, the resultant weld bead is relatively wide and shallow. See Figure 8.
Glossary
Lesson 5 Welding Filler Metals for Stainless Steels " Lesson 6 Carbon & Low Alloy Steel Filler Metals GMAW,GTAW,SAW !
Electrode Polarity Direct Current

G AS IO NS ELECTRON FLOW
Penetration Deep Penetration Narrow Bead
O, ide Cleaning None
I-eat Concentration
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At Work
Straight Polarity Electrode Negative
Alternating Current
! "
!
Medium Penetration Medium Width Bead Shallow Penetration Wide Bead
Good Cleans O,ide on Each I-alf Ma,imum
Cycle Alternates Between Electrode and Work
Direct Current Reverse Polarity
At Electrode
"
Electrode Positive EFFECTS OF CURRENT TYPE - GAS TUNGSTEN ARC WELDING

FIGURE
2.3.2.4
Aluminum and magnesium are two metals that have a heavy o,ide coating that acts
as an insulator and must be removed before successful welding can take place. Welding with Lesson 9 Estimating & Comparing Weld Metal Costs electrode positive provides a good o,ide cleaning action in the arc. If we were to study the physics of the welding arc, we find that the electric current causes the shielding gas atoms to lose some of their electrons. Since electrons are negatively charged, these gas atoms now are unbalanced and have an e,cessive positive charge. As we learned in Lesson I, unlike Lesson 10 Reliability of Welding Filler Metals charges attract. These positively charged atoms (or positive ions as they are known in
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LESSON II
chemical terminology) are attracted to the negative pole, in this case the work, at high velocity. Upon striking the work surface, they dislodge the oxide coating permitting good electrical
Lesson 2 Common Electric Arc Welding Processes Lesson 3 Cove red Electrodes for Welding Mild Steels Lesson 4 Cove red Electrodes for Welding Low Alloy Steels Lesson 5 Welding Filler Metals for Stainless Steels
conductivity for the maintenance of the arc, and elimi nate the impurities in the weld metal that could be caused by these oxides. 2.3.2.5 Direct current electrode positive is rarely used in gas-tungsten arc welding. Despite the excellent oxide cleaning action, the lower heat input in the weld area makes it a slow process, and in metals having higher thermal conductivity, the heat is rapidly conducted away from the weld zone. When used, DCEP is restricted to welding thin sections (under 118') of magnesium and alumi num. 2.3.2.6 Alternating current is actually a combination of DCEN and DCEP and is widely used for welding alumi num. In a sense, the adva ntages of both DC processes are combined, and the weld bead produced is a compromise of the two. Remember that when welding with 60 Hz current, the electron flow from the electrode tip to the work reverses direction 120 times every second. Thereby, the intense heat alternates from electrode to work piece, allowing the use of an intermediate size electrode. The weld bead is a compromise having medium penetration and bead width. The gas ions blast the oxides from the surface of alumi num and magnesium during the positive half cycle. Figure 8 illustrates the effects of the different types of current used in gas-tungsten arc welding.
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Glossary
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Lesson 6 Carbon & Low Alloy Steel Filler Metals GMAW,GTAW,SAW Lesson 7 Flux Cored Arc Electrodes Carbon Low Alloy Steels Lesson 8 Hardsurfacing Electrodes
2.3.2.7 DC constant current power sources - Constant current power sources, used for shielded metal arc welding, may also be used for gas-tungsten arc welding. In applications where weld integrity is not of utmost importance, these power sources will suffice. With machines of this type, the arc must be initiated by touching the tungsten electrode to the work and quickly withdrawi ng it to maintain the proper arc length. This starting method contami nates the electrode and blunts the point which has been grounded on the electrode end. These conditions can cause weld metal inclusions and poor arc direction. Using a power source designed for gas tungsten arc welding with a high frequency stabilizer will elimi nate this problem. The electrode need not be touched to the work for arc initiation. Instead, the high frequency voltage, at very low current, is superimposed onto the welding current. When the electrode is brought to within approximately 118 inch of the base metal, the high frequency ionizes the gas path, making it conductive and a welding arc i s established.
Lesson 9 Estimating & Comparing Wel Metal Costs Lesson 10 Reliability of Welding Filler Metals
The high frequency is automatically turned off immediately after arc initiation when using direct current. 2.3.2.8
AC Constant Current Power Source - Designed for gas tungsten arc welding,
always incorporates high frequency, and it is turned on throughout the weld cycle to maintain a stable arc. When welding with AC, the current passes through 0 twice in every cycle and the
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Lesson 1 The Basics of Arc Welding arc must be reestablished each time it does so. The oxide coating on metals, such as aluminum and magnesium, can act much like a rectifier as discussed in Lesson I. The positi,e Lesson 2 Common Electric Arc Welding Processes half-cycle will be eliminated if the arc does not reignite, causing an unstable condition. Continuous high frequency maintains an ionized path for the welding arc, and assures arc re-ignition each time the current changes direction. AC is extensi,e ly used for welding aluminum and magnesium. Lesson 3 Covered Electrodes for Welding Mild Steels 2.3.2.9
AC/DC Constant Current Power Sources
LESSON II
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welding, are a,ailable, and can be used for welding practically all metals. The gas tungsten arc welding process is usually chosen because of the high quality welds it can produce. The
metals that are commonly welded th this process, such as stainless steel, aluminum and some of the more exotic metals, cost many times the price of mi ld steel; and therefore, the power sources designed for this process ha,e many desirable features to insure high quality welds. Among these are: Glossary
1.
Remote current control, which allows the operator to control welding amperage ith a hand control on the torch, or a foot control at the welding station.
2. Lesson 6 Carbon & Low Alloy Steel Filler Metals GMAW,GTAW,SAW
Automatic soft-start, which presents a high current surge when the arc is initiated. Turn Pages
Shielding gas and cooling water solenoid valves, which automatically control flow before, during and for an adjustable length of time after the weld is comp leted.
4.
Spot-weld timers, which automatically control all elements during each spot-weld cycle. Search Chapter (Faster Download) Search Document (Slower Download)
Other options and accessories are also a,ailable. Lesson 8 Hardsurfacing Electrodes 2.3.2.10 Power sources for automatic welding with complete programmable output are also
a,ailable. Such units are used extensi,e ly for the automatic welding of pipe in position. The welding current is automatically ,aried as the torch tra,e ls around the pipe. Some units pro,ide a pulsed welding current where the amperage is automatically ,aried between a low
and high se,eral times per second. This produces welds th good penetration a nd impro,ed weld bead shape. - The torch is actually an electrode holder that supplies welding current to
2 .3.3
Torches
the tungsten electrode, and an inert gas shield to the arc zone. The electrode is held in a collet-like clamping de,ice that allows adjustment so that the proper length of electrode pro trudes beyond the shielding gas cup. Manual torches are designed to accept electrodes of 3
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Lesson 1 The Basics of Arc Welding inch or 7 inch lengths. Torches may be either air or water-cooled. The air-cooled types actually are cooled to a degree by the shielding gas that is fed to the torch head through a compos Lesson 2 Common Electric Arc Welding Processes ite cable. The gas actually surrounds the copper welding cable, affording some degree of cooling. Water-cooled torches are usually used for applications where the welding current exceeds 200 amperes. The water inlet hose is connected to the torch head. Circulat ing around the torch head, the water leaves the torch via the current -in hose and cable assembly. Lesson 3 Covered Electrodes for Welding Mild Steels Cooling the welding cable in this manner allows the use of a smaller diameter cable that is more flexible and lighter in weight. 2.3.3.1 Lesson 4 Covered Electrodes for Welding Low Alloy Steels The gas nozzles are made of ceramic materials and are available in various sizes
LESSON II
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and shapes. In some heavy duty, high current applications, metal water -cooled nozzles are used. 2.3.3.2 A switch on the torch is used to energize the electrode with welding current and start Glossary
the shielding gas flow. High frequency current and water flow are also initiated by this switch if Lesson 5 Welding Filler Metals for Stainless Steels the power source is so equipped. In many installations, these functions are initiated by a foot control that also is capable of controlling the welding current. This method gives the operator full control of the arc. The usual welding method is to start the arc at a low current, gradually increase the current until a molten pool is achieved, and welding begins. At the end of the Lesson 6 Carbon & Low Alloy Steel Filler Metals GMAW,GTAW,SAW weld, current is slowly decreases and the arc extinguished, preventing the crater that forms at the end of the weld when the arc is broken abruptly.
2.3.4 Shielding Gases - Argon and helium are the major shielding gases used in gas
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tungsten arc welding. In some applications, mixtures of the two gases prove advantageous. To a lesser extent, hydrogen is mixed with argon or helium for special applications. 2.3.4.1 Argon and helium are colorless, odorless, tasteless and nontoxic gases. Both are Search Chapter (Faster Download) Search Document (Slower Download)
inert gases, which means that they do not readily combine with other elements. They will not Lesson 8 Hardsurfacing Electrodes burn nor support combustion. Commercial grades used for welding are 99.99% pure. Argon is .38% heavier than air and about 10 times heavier than helium. Both gases ionize when present in an electric arc. This means that the gas atoms lose some of their electrons that have a negative charge. These unbalanced gas atoms, properly called positive ions, now Lesson 9 Estimating & Comparing Weld Metal Costs have a positive charge and are attracted to the negative pole in the arc. Whe n the arc is positive and the work is negative, these positive ions impinge upon the work and remove surface oxides or scale in the weld area. 2.3.4.2 Lesson 10 Reliability of Welding Filler Metals Argon is most commonly used of the shielding gases. Excellent arc starting and
ease of use make it most desirable for manual welding. Argon produces a better cleaning action when welding aluminum and magnesium with alternating current. The arc produced is
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Lesson 1 The Basics of Arc Welding relatively narrow. Argon is m ore suitable for welding thinner material. At equal amperage, helium produces a higher arc voltage than argon. Since welding heat is the product of volts Lesson 2 Common Electric Arc Welding Processes times amperes, helium produces m ore available heat at the arc. This makes it m ore suitable for welding heavy sections of metal that have high heat conductivity, or for automatic welding operations where higher welding speeds are required. 2.3.4.3 Argon-helium gas mixtures are used in applications where higher heat input and the
LESSON II
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desirable characteristics of argon are required. Argon, being a relatively heavy gas, blankets the weld area at lower flow rates. Argon is preferred for many applications because it costs less than helium. Print
2.3.4.4
Helium, being approximately 10 times lighter than argon, requires flow rates of 2
3 times that of argon to satisfactorily shield the arc. 2.3.5 Electrodes - Electrodes for gas tungsten arc welding are available in diameters
Glossary
from .010' to 114' in diameter and standard lengths range from 3' to 24'. The m ost comm only used sizes, however, are the .040', 1116', 3132', and 118' diameters. 2.3.5.1 The shape of the tip of the electrode is an imp ortant factor in gas tungsten arc Turn Pages
welding. When welding with DCEN, the tip must be ground to a point. The included angle at which the tip is ground varies with the application, the electrode diameter, and the welding current. Narrowjoints require a relatively small included angle. When weldi ng very thin material at low currents, a needlelike point ground onto the smallest available electrode may
be necessary to stabilize the arc. Properly ground electrodes will assure easy arc starting, good arc stability, and proper bead width. 2.3.5.2 When welding with AC, grinding the electrode tip is not necessary. When proper Search Chapter (Faster Download) Search Document (Slower Download)
welding current is used, the electrode will form a hemispherical end. If the proper welding Lesson 8 Hardsurfacing Electrodes current is exceeded, the end will become bulbous in shape and possibly melt off to contaminate the weld metal. 2.3.5.3 The American Welding Society has published Specification AWS A5.12 -80 for Lesson 9 Estimating & Comparing Weld Metal Costs tungsten arc welding electrodes that classifies the electrodes on the basis of their chemical comp osition, size and finish. Briefly, the types specified are listed below< 1) Pure Tungsten (AWS EWP) Color Code: Green Used for less critical applications. The cost is low and they give good results at Lesson 10 Reliability of Welding Filler Metals relatively low currents on a variety of metals. Most stable arc when used on AC, either balanced waveor continuous high frequency.
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LESSON II Lesson 1 The Basics of Arc Welding
2) 1% Thoriated Tungsten (AWS EWTh-1) Color Code: Yellow Good current carrying capacity, easy arc starting and pro ide a stable arc. Less susceptible to contamination. Designed for DC applications of nonferrous materials.
3) 2% Thoriated Tungsten (AWS EWTh-2) Color Code: Red

Longer life than 1% Thoriated electrodes. Maintain the pointed end longer, used for Go To Test
light gauge critical welds in aircraft work. Like 1%, designed for DC applications for nonferrous materials.
4) .5% Thoriated Tungsten (AWS EWTh-3) Color Code: Blue

Sometimes called "striped" electrode because it has 1.0-2.0% Thoria inserted in a
Print
wedge-shaped groo e throughout its length. Combines the good properties of pure and thoriated electrodes. Can be used on either AC or DC applications. 5) Zirconia Tungsten (AWS EWZr) Color Code: Brown
Glossary
Longer life than pure tungsten. Better performance when welding with AC. Melts more easily than thoriam-tungsten when forming rounded or tapered tungsten end. Ideal for applications where tungsten contamination must be minimized.
2.3.6
Summary - Gas Tungsten Arc Welding is one of the major welding processes
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today. The quality of the welds produced and the ability to weld ery thin metals are the major features. The weld metal quality is high since no flux is used, eliminating the problem of slag inclusions in the weld metal. It is used extensi ely in the aircraft and aerospace industry, where high quality welds are necessary and also for welding the more expensi e metals where the weld defects become ery costly. Metals as thin as .005" can be welded due to th e ease of controlling the current. 2.3.6.1 The major disad antages of the process are that it is slower than welding with Search Chapter (Faster Download) Search Document (Slower Download)
consumable electrodes and is little used on thicknesses o er 114"for this reason. Shielding gas and tungsten electrode costs make the process relati ely expensi e.
2.4
GAS METAL ARC WELDING
Gas Metal Arc Welding* is an arc welding process that uses the heat of an electric arc established between a consumable metal electrode and the work to be welded. The electrode is a bare metal wire that is transferred across the arc and into the molten weld puddle. The
* Gas Metal Arc Welding (GMAW) is the current technology approved by the American Welding Society. Formerly known as "M IG"
(Metal Inert Gas) Welding.
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Lesson 1 The Basics of Arc Welding wire, the weld puddle, and the area in the arc zone are protected from the atmosphere by a gaseous shield. Inert gases, reacti,e gases, and gas mixtures are used for shielding. The Lesson 2 Common Electric Arc Welding Processes metal transfer mode is dependent on shielding gas choice and welding current le,el. Figure 9 is a sketch of the process showing the basic features.
LESSON II
TRAVEL DIRECTION
WELDING WIRE WELDING CABLE SHIELDING GAS GAS NOZZLE
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SOLID WIRE ELECTRODE
GAS SHIELD ARC WELD METAL
CONTACT TIP
Glossary
WORK PIECE
MOLTEN POOL GAS METAL ARC WELDING

FIGURE 9
2.4.0.1
Gas metal arc welding is a ,ersatile process that may be used to weld a wide
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,ariety of metals including carbon steels, low alloy steels, stainless steels, aluminum alloys, magnesium, copper and copper alloys, and nickel alloys. It can be used to weld sheet metal or
relati,ely hea,y sections. Welds may be made in all positions, and the process may be used for semiautomatic welding or automatic welding. In semiautomatic welding, the wire feed speed, ,oltage, amperage, and gas flow are all preset on the control equipment. The operator needs merely to guide the welding gun along the joint at a uniform speed and hold a relati,ely constant arc length. In automatic welding, the gun is mo unted on a tra,el carriage that mo,es Search Chapter (Faster Download) Search Document (Slower Download)
along the joint, or the gun may be stationary with the work mo,ing or re,ol,ing beneath it. 2.4.0.2 Practically all GMAW is done using DCEP (Electrode positi,e). This polarity
pro,ides deep penetration, a stable arc and low spatter le,els. A small amo unt of GMAW Lesson 9 Estimating & Comparing Weld Metal Costs welding is done with DCEN and although the melting rate of the electrode is high, the arc is erratic. Alternating current is not used for gas metal arc welding.
2.4.1 Current Density- To understand why gas metal arc welding can deposit weld
metal at a rapid rate, it is necessary that the term ' current density' be understood. Figure 10 Lesson 10 Reliability of Welding Filler Metals shows a 114' coated electrode and a 1116' solid wire drawn to scale. Both are capable of carrying 400 amperes. Notice that the area of the 1116' wire is only 1116 that of the core wire of the coated electrode. We can say that the current density of the 111 6' wire is 16 times
COPYRIGHT 1998 THE ESAB GRO~P, INC.
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Lesson I The Basics of Arc Welding greater than the current density of the 114' wire at equal welding Lesson 2 Common Electric Arc Welding Processes currents. The resultant melt-off rate of the solid wire is very high. If we were to increase the current t h r o u g h t h e Lesson 3 Covered Electrodes for Welding Mild Steels 1 1 4 ' c o a t e d electrode to increase the current density, the resistance heating through the 14'electrode length would be excessive, and the rod would Lesson 4 Covered Electrodes for Welding Low Alloy Steels
FLU( COATING CORE WIRE AREA .049 SQ. IN.
x
Current
LESSON II
Chapter Table of Contents
AREA x .0031 SQ. IN. COATED ELECTRODE Ax 16 A
1/16' RELATIVE SIZE OF ELECTRODES FOR WELDING AT 400 AMPS SOLID WIRE
F~GJRE10
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1/4'
.049* .0031 x 16
become so hot that the coating would crack, rendering it useless. The 1116'wire carries the high current a distance of less than 314', the appro0imate distance from the end of the contact tip to the arc.
2 .4.2 Metal Transfer Modes
Glossary
2.4.2.1
Spray transfer
is a high current density process that rapidly deposits weld metal in
droplets smaller than the electrode diameter. They are propelled in a straight line from the center of the electrode. A shielding gas mixture of Argon with 1% to 2% O0ygen is used for Lesson 6 Carbon & Low Alloy Steel Filler Metals GMAW,GTAW,SAW Lesson 9 Lesson 7 Flux Cored Arc Electrodes Carbon Low Alloy Steels welding mild and low alloy steel, and pure Argon or Argon-Helium mixtures are used for welding aluminum, magnesium, copper, and nickel alloys. Welding current at which spray transfer Turn Pages
F~GJRE ii

SPRAY TRANSFER GLOBULAR TRANSFER PULSE TRANSFER 1 2 3 SHORT CIRCUITING ARC METAL TRANSFER
Lesson 8 Hardsurfacing Electrodes Estimating & Comparing Weld Metal Costs
MODES OF METAL TRANSFER
takes place is relatively high and will vary with the metal being welded, electrode diameter, an d the shielding gas being used. Deposition rates are high and welding is usually limited to the
flat or horizontal fillet position. See Figure 11.
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LESSON II
2.4.2.2
Globular transfer takes place at lower welding currents than spray transfer. There
is a transition current where the transfer changes to globular e'en when shielding gases using
Lesson 2 Common Electric Arc Welding Processes Lesson 3 Covered Electrodes for Welding Mild Steels Lesson 4 Covered Electrodes for Welding Low Alloy Steels Lesson 5 Welding Filler Metals for Stainless Steels
a high percentage of argon are used. When carbon dioxide (CO2) is used as a shielding gas, the transfer is always globular. In globular transfer, a molten drop larger than the electrode diameter forms on the end of the electrode, mo'es to the outer edge of the electrode and falls into the molten puddle. Occasionally, a large drop will 'short circuit' across the arc, causing the arc to extinguish momentarily, and then instantaneously reignite. As a result, the arc is somewhat erratic, spatter le'el is high, and penetration shallow. Globular transfer is not suitable for out-of-position welding. See Figure 11. 2.4.2.3 Short circuiting transfer is a much used method in gas metal arc welding. It is
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produced by using the lowest current-'oltage settings and the smaller wires, usually .030', .035', and .045' diameters. The low heat input makes this process ideal for sheet metal, out of-position work, and poor fit-up applications. Often called 'short arc welding'because metal transfer is achie'ed each time the wire actually short circuits (makes contact) with the weld puddle. This happens 'ery rapidly. It is feasible for the short circuit frequency to be 20-200 times a second, but in practice, it occurs from 90-100 times a second. Each time the electrode touches the puddle, the arc is extinguished. It happens so rapidly that it is 'isible only on high speed films.
Glossary
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2.4.2.4
Pulse transfer is a mode of metal transfer somewhat between spray and short
circuiting. The specific power source has built into it two output le'els: a steady background le'el, and a high output (peak) le'el. The later permits the transfer of metal across the arc. This peak output is controllable between high and low 'alues up to se'eral hundred cycles per second. The result of such a peak output produces a spray arc below the typical transition current. 2.4.2.4.1 Figure 11 shows the transfer method. The arc is initiated by touching the wire to the
work. 1pon initial contact, a bit of the wire melts off to form a molten puddle. The wire feeds forward until it actually contacts the work again, as at 1 in Figure 11, and the arc is extinguished. The short circuiting current causes the wire to neck down, as shown in 1, until it melts off, as shown at 2. As soon as the wire is free of the puddle, the arc is reignited and a molten ball forms at the end of the electrode, as at 3. The wir e continues to mo'e forward until
Lesson 9 Estimating & Comparing Weld Metal Costs Lesson 10 Reliability of Welding Filler Metals
it makes contact with the puddle, and the cycle is repeated. 2.4.2.5 Gas metal arc spot welding is a 'ariation of the process that allows spot welding
of thinner gauge metals, or of a thin gauge metal to a hea'ier section. The gun is placed directly against the work and is equipped with a special nozzle to allow escape of the shielding gas. When the trigger switch is actuated, the following sequence takes place. The shielding
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Lesson 1 The Basics of Arc Welding gas flows for a short inter$al before wire feeding starts; wire feeding starts; the arc is initiated and continues for a preset time (usually a few seconds). The welding current and wire feeding Lesson 2 Common Electric Arc Welding Processes stops, and the shielding gas flows for a short inter$al before it automatically stops. The process is also useful for tacking welding pieces in position prior to running the final weld bead.
2.4.3 EQUIPMENT AND OPERATION - The equipment used for gas metal arc welding
LESSON II
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is more complicated than that required for shielded metal arc welding. Initial cost is relati$ely high, but the cost is rapidly amorti2ed due to the sa$ings in labor and o$erhead achie$ed by the rapid weld metal deposition. Print
2.4.3.1 1) 2)
The equipment necessary for gas metal arc welding is listed below6 Glossary Power source Wire feeder Welding gun Shielding gas supply Solid electrode wire Protecti$e equipment Turn Pages
3) 4) 5)
6) 2.4.3.2 in Figure 12.
The basic equipment necessary for semiautoma tic gas metal arc welding is shown
GAS HOSE FLOWMETER REGULATOR TRIGGER CONTROL LEAD FEED ROLLS WIRE SPOOL WIRE FEEDER VALVE
MAGNETIC WELD CABLE 115V CONTACTOR

~
SHIELDING GAS
~
POWER SOURCE
WELDING GUN
GROUND CABLE WORK SCHEMATIC DIAGRAM SEMI-AUTOMATIC GMAW EQUIPMENT

FIGURE 12
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2.4.4 Power Source - A direct current, constant voltage power source is recommended
LESSON II
for gas metal arc welding. It may be a transformer-rectifier or a rotary type unit. The lower Lesson 2 Common Electric Arc Welding Processes open circuit voltage and self-correcting arc length feature, as described in Lesson I, makes it m ost suitable. Constant voltage power sources used for spray transfer welding and for flux cored electrode welding (to be covered later) are the same. However, if the unit is to be used for short-circuiting arc Lesson 3 Covered Electrodes for Welding Mild Steels welding, it must have 'slope' or slope control.
25 Slope control is a
OPERATING POINT V O CONSTANT VOLTAGE VIA CURVE
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Print
means of limiting the20 Lesson 4 Covered Electrodes for Welding Low Alloy Steels
15
Glossary
high short-circuit current

T
that is characteristic of
S
this type welder. Figure

SHORT CIRCUITING CURRENT WITH SLOPE
SHORT CIRCUITING CURRENT NO SLOPE
10
13 shows the effect of Lesson 6 Carbon & Low Alloy Steel Filler Metals GMAW,GTAW,SAW Lesson 7 Flux Cored Arc Electrodes Carbon Low Alloy Steels slope on the short5
200
400
e00
800
1000
1200
1400
EFFECT OF SLOPE ON SHORT CIRCUITING CURRENT FIGURE 13
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circuiting current. 2.4.4.1 I f w e w e r e s h o r t - a r c w e l d i n g a t approximately 150 amperes and 18 v olts, as shown in Figure 13, and had no slope comp onents in the power source, the current at short-circuit or when the wire touches the work, would be over 1400 amperes. At this high current, a good length of the wire w ould literally explode off the end, cause much spatter, and the arc would be erratic. With the slope comp onents in the circuit, the short-circuiting current is in the neighborhood of 400 amperes, and the m olten ball is sort of pinched off the end of the wire m ore gently. For those with an electrical background, it might be added that in some machines, slope is achieved by adding a reactor in the AC secondary of the power source. In others, a slope resistor is added in the DC output portion of the circuit. Slope may be adjustable for varying wire diameter s or it may be fixed, giving a good average value for .035' and .045' diameter wires, the two most popular sizes.
2.4.4.2
Another factor influencing the arc in short-circuiting welding is the rate that the
amperage reaches the short-circuiting current level. Using the example in Figure 13, we know that the current goes from 150 amperes to 400 amperes during each shorting period. If we were to plot the current rise on a graph, as in Figure 14, we would see that the current rise if very rapid, as shown by the broken line.
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LESSON II
This rapid current rise can be by using a device called an

WITHOUT IND~CTANCE
(sometimes called a stabilizer) output circuit of the welder. An

400 AIVPS
merely an iron core wound turns of heavy wire. It does c urre nt flow, but Go To Test Print
Lesson 3 Cove red Electrodes for Welding Mild Steels
WITH INDIJCTANCE
i t a c t s somewhat like a fly wheel or
Lesson 4 Cove red Electrodes for Welding Low Alloy Steels
damp er by retarding the rate

150 AMPS TIIvE - MILLISECONDS EFFECT OF IND~CTANCE ON CLRRENT RISE
FIGURE 14
of rise as shown by the solid line. By prev enting the rapid current rise, the arc becomes smoother, spatter is reduced, and bead shape and
Glossary
Lesson 5 Welding Filler Metals for Stainless Steels appearance are Lesson 6 Carbon & Low Alloy Steel Filler Metals GMAW,GTAW,SAW
improv ed. Because the inductor influences the time function, its design determines arc on-off time, and short-circuit frequency. Some power sources have a selector that can switch in sev eral different inductance values to finely tune the arc.
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2.4.4.4
Welding power sources designed for gas metal arc welding have a 115 volt outlet to Search Chapter (Faster Download) Search Document (Slower Download)
provide power to operate the wire feeder. They also have a receptacle to receive the electrical power required to close the main contactor in the power source, which turns on the welding power to the welding gun when the gun trigger is actuated.
2.4.4.5
Additional advancements in equipment technology have introduced many new
models. Inv erters, as well as microprocessor controls, have created the greatest attention. In addition, multipurpose machines have provided the user with greater fle6ibility with a variety of Lesson 9 Estimating & Comparing Weld Metal Costs capabilities. 2.4.4.6 Global competition will continue to have a profound influence on future
advancements in arc welding equipment. As energy prices rise, greater demands for mor e efficient equipment will follow.
2.4.5
Wire Feeder - When welding with a constant voltage power source, as is the case
in most gas metal arc welding applications, the prime function of the wire feeder is to deliv er the welding wire to the arc at a very constant speed. Since the wire feed speed determines the amperage, and the amperage deter mines the amount of heat at the arc, inconsistent wire feed speed will produce welds of varying penetration and bead width. Advanced electronics
COPYRIGHT 1998 THE ESAB GRO~P, INC.
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Lesson 1 The Basics of Arc Welding technology makes it possible to design motor speed controls that will produce the same speed, e'en though the load on the motor 'aries or the input 'oltage to the motor may fluctuate. Lesson 2 Common Electric Arc Welding Processes 2.4.5.1 A li mited amount of gas metal arc welding is performed with con stant current type power sources. In this case, the motor speed automatically 'aries to increase or decrease the wire feed speed as the arc length 'aries to maintain a constant 'oltage. Lesson 3 Covered Electrodes for Welding Mild Steels 2.4.5.2 The wire feeder also controls the main contactor in the power source for safety
LESSON II
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reasons. This assures that the welding wire will only be energized when the switch on the welding gun is depressed. 2.4.5.3 The flow of shielding gas is controlled by a solenoid 'al'e (magnetic 'al'e) in the
wire feeder to turn the shielding gas on and off when the gun switch is actuated. Most feeders utilize a dynamic breaking circuit to quickly stop the motor at the end of a weld to pre'ent a long length of wire protruding from the gun when the weld is terminated. Most feeders ha'e a
Glossary
burn-back circuit that allows the welding current to stay on for a short period of time after wire feeding has stopped, to allow the wire to burn back exactly the right amount for the next arc initiation. 2.4.5.4 The feed rolls, sometimes called dri'e rolls, pull the wire off the spool or reel, and Turn Pages
push it through a feed cable or conduit to the welding gun. These rolls must usually be changed to accommodate each different wire diameter, although some rolls are designed to feed a combination of sizes.
2.4.6 Welding Gun - The function of the welding gun, sometimes referred to as a torch, is
to deli'er the welding wire, welding current, and shielding gas to the welding arc. Guns are a'ailable for semi-automatic operation and for automatic operation, where they are fixed in the automatic welding head.
2.4.6.1
Guns for GMAW ha'e se'eral characteristics in common. All ha'e a copper alloy
shielding gas nozzle, that deli'ers the gas to the arc area in a nonturbulent, angular pattern to pre'ent aspiration of air. The nozzle may be water cooled for semiautomatic welding at high amperage and for automatic welding where the arc time is of long duration. Welding current is
transferred to the weldingwire as the wire tra'els through the contact tip or contact tube located inside the gas nozzle (Refer to Figure 9). The hole in the contact tip through which the wire passes is only a few thousandths of an inch larger than the wire diameter. A worn contact tip will result in an erratic arc due to poor current transfer. Figure 15 shows a few different semiautomatic gun configurations that are commonly used for GMAW.

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LESSON II
Current Chapter Table Contents
of
CURVED NECK
PISTOL TYPE
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SELF CONTAINED PU:i TYPE
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SEMI-AUTOMATIC GMAW GUN TYPES
FIGURE 15
Glossary
2.4.6.2 The cur~e d neck or 'goose neck'type is probably the most commonly used. It allows the best access to a ~ariety of weld joints. The wire is pushed to this type of gun by the
feed rolls in the wire feeder through a feed cable or conduit that usually is 10 or 12 feet in length. The shielding gas hose, welding current cable, and trigger switch leads are supplied with the welding gun.
2.4.6.3 The pistol type gun is similar to the cur~e d neck type, but is less adaptable for difficult to reach joints. The pistol type is also a 'push' type gun and is more suitable for gas metal arc spot welding applications. 2.4.6.4 The self contained type has an electric motor in the handle and feed rolls that pull the wire from a 1 or 2 pound spool mounted on the gun. The need for a long wire feed cable is eliminated, and wire feed speed may be controlled by the gun. Guns of this type are often used for aluminum wire up to .045'diameter, although they may also be used for feeding steel or other hard wires.
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2.4.6.5 The pull type gun has either an electric motor or an air motor mounted in the handle that is coupled to a feeding mechanism in the gun. The spool of wire is located in the control cabinet that may be located as far as fifty feet from the gun. When feeding such long
distances, a set of 'push' rolls located in the control cabinet assist in feeding the wire. This then becomes known as a push-pull feed system and is especially useful in feeding the softer wires such as aluminum.
SHIELDING GASES - In gas metal arc welding, there are a ~ariety of shielding gases that can be used, either alone or in combinations of ~arying degrees. The choice is dependent on the type of metal transfer employed, the type and thickness of metal, the bead 2.4.7
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Lesson 1 The Basics of A Welding
LESSON II profile (See Figure 16), penetration, and speed of welding. In our discussion, we will deal with the more common choices used for the various transfer processes.
Lesson 2 Common Electri Arc Welding Processes Lesson 3 Covered Electrodes for Welding Mild Steels Lesson 4 Covered Electrodes for Welding Low Alloy Steels Lesson 5 Welding Filler Metals for Stainless Steels
FERROUS METALS
NON-FERROUS METALS
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CO2 ARGON + CO2 ARGON + O2 BEAD PROFILE
FIGURE 16
ARGON
HELIUvI
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2.4.7.1 Short Circuiting Transfer - Straight carbon dioxide (CO2) is often used for short circuiting arc welding because of its low cost. The deep penetration usually associated with CO 2 is minimized because of the low amperage and voltage settings used with this process. Compared to other gas mixes, CO 2 will produce a harsher arc and therefore, greater spatter levels. Usually, this is minimized by maintaining a short arc length and by careful adjustment of the power supply inductance. The temperatures reached in welding will cause carbon dioxide to decompose into carbon monoxide and oxygen. To reduce the possibility of porosity caused by entrapped oxygen in the weld metal, it is wise to use electrodes that contain deoxidizing
Glossary
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elements, such as silicon and manganese. If the current is increased above the short circuiting range, the use of carbon dioxide tends to produce a globular transfer. 2.4.7.1.1 smoother arc and reduce spatter levels. It will also widen the bead profile, reduce penetration, and encourage 'wetting'. Wetting, i.e., a uniform fusion, along with joining edges of the base metal and the weld metal, minimizes the weld imperfection known as undercutting (See Figure 17). Mixing argon in proportions of 50-75% with carbon dioxide will produce a
UNDERCUT
FIGURE 17
WETTING
2.4.7.1.2 The 75% ArgonI25 CO 2 mixture is often chosen for short circuit welding of thin sections, whereas the 50-50 combination works well on thicker sections. 2.4.7.1.3 It should be noted that shielding gases can affect the metallurgy of the weld metal. As an example, a combination of argon and carbon dioxide may be used for welding stainless steel, but as the carbon dioxide breaks down, excessive carbon may be transferred into the
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Lesson 1 The Basics of Arc Welding weld metal. Corrosion resistance in stainless steel is reduced as the carbon content increases. To counteract this possibility, a less reactive mixture of 90% helium - 7-112% argon Lesson 2 Common Electric Arc Welding Processes 2-112% CO 2 is sometimes chosen. This combination, known as a trimi provides good arc stability and wetting. 2.4.7.2 Lesson 3 Covered Electrodes for Welding Mild Steels Spray Arc Transfer - Pure argon produces a deep constricted penetration at the
LESSON II
center of the bead with much shallower penetration at the edges (Figure 16). Argon performs well on nonferrous metals, but when used on ferrous metals, the transfer is somewhat erratic with the tendency for the weld metal to moveaway from the center line. To make argon suit able for spray transfer on ferrous metals, small additions of 1 to 5% oxygen have proven to
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provide remarkable improvements. The arc stabilizes, becomes less spattery, and the weld metal wets out nicely. If the percentage of argon falls below 80%, it is impossible to achieve true spray transfer. 2.4.7.2.1 Pure helium or combinations of helium and argon are used for welding nonferrou Glossary
metals. The bead profile will broaden as the concentration of helium increases. 2.4.7.3 Pulse Spray Transfer - The selection of shielding gas must be adequate enough to support a spray transfer. Material type, thickness, and welding position are essential variables
in selecting a particular shielding gas. The following is a list of recommended gases: Carbon Steel Alloy Steel ArgonICO20O20He (He less than 50%) ArgonICO20O20He (He less than 50%) ArgonilO20CO2 (CO2max. 2%) ArgonlHelium ArgonlHelium
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Stainless Copper, Nickel, & Cu-Ni Alloys Aluminum
2.4 .8
Electrodes - The solid electrodes used in GMAW are of high purity when they come
from the mill. Their chemistry must be closely controlled and some types purposely contain high levels of deoxidizers for usewith CO 2 shielding.
2.4.8.1
The electrode manufacturer draws down the electrode to a finished diameter that,
with GMAW, is usually quite small. Diameters from .030' thru 1116' are common. 2.4.8.2 Most steel GMAW electrodes are copper plated as a means of protecting the
surface. The copper inhibits rusting, provides smooth feeding, and helps electrical conductivity. 2.4.8.3 Information on types and classifications will be covered in a future lesson.
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LESSON II
2.5 FLUX CORED ARC WELDING

Flux CoredArc Weld~ng (FCAW) is quite similar to GMAW as far as operation and
equipment are concerned. The major difference is that FCAW utilizes an electrode that is -e ry different from the solid electrode used in GMAW. The flux cored electrode is a fabricated electrode and as the name implies, flux material is deposited into its core. The flux cored Go To Test
electrode begins as a flat metal strip that is formed first into a 'U shap e. Flux and alloying elements are deposited into the 'U' and then the shape is closed into a tubular configuration by a series of forming rolls. 2.5.0.1 The flux cored electrode is a continuous electrode that is fed into the arc where it is
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melted and transferred into the molten puddle. As in GMAW, the flux cored process depends on a gas shield to protect the weld zone from detrimental atmospheric contamination. With FCAW, there are two prima ry ways this is accomplished (See Figure 18). The gas is either a pplied externally, in which case the electrode is referred to as a gas shielded flux cored electrode, or it Glossary
is generated from the decomposition of gas forming ingredients contained in the electrode's core. In this instance, the electrode is known as a self-shielding flux cored electrode. In addition to the gas shield, the flux co red electrode produces a slag co-e ring for Turn Pages
CONTACT TIP GAS CUP GAS SHIELD
CONTACT TIP INSULATED GUIDE TUBE
FLUX CORE
FLUX CORE
GAS SHIELDED FLUX-CORED ARC WELDING
SELF SHIELDED
FIGURE 1
further protection of the weld metal as it cools. The slag is manually remo-ed with a wire brush or chipping hammer.
2.5.1 S e l f S h ie l de d P r o ce s s - The ma in ad -a n ta ge o f t he se l f s hie ld i ng me t ho d is t hat
its operation is somewhat simplified because of the absence of external shielding equipment.
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COPYRIGHT 1998 THE ESAB GROUP, IN
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Lesson 1 The Basics of Arc Welding Although self shielding electrodes have been developed for welding low alloy and stainless steels, they are most widely used on m ild steels. The self shielding method generally uses Lesson 2 Common Electric Arc Welding Processes a long electrical stick-out (distance between the contact tube and the end of the unmelted electrode) commonly from one to four inches. Electrical resistance is increased with the long extension, preheating the electrode before it is fed into the arc. This enables the electrode to burn off at a faster rate and increases deposition. The preheating also decreases the Lesson 3 Covered Electrodes for Welding Mild Steels heat ava ilable for melting the base metal, resulting in a more shallow penetration than the gas shielded process. 2.5.1.1 Lesson 4 Covered Electrodes for Welding Low Alloy Steels A major drawback of the self shielded process is the metallurgical quality of the
LESSON II
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deposited weld metal. In addition to gaining its shielding ability from gas forming ingredients in the core, the self shielded electrode contains a h igh level of deoxidizing and denitrifying alloys, primarily aluminum, in its core. Although the alum inum performs well in neutralizing the affects of oxygen and nitrogen in the arc zone, its presence in the weld metal will reduce Glossary
ductility and impact strength at low temperatures. For this reason, the self shielding method is usually restricted to less critical applications. 2.5.1.2 The self shielding electrodes are more suitable for welding in drafty locations than Turn Pages
the gas shielded types. Since the molten filler metal is on the outside of the flux, the gases formed by the decomposing flux are not totally relied upon to shield the arc from the atmosphere. The deoxidizing and denitrifying elements in the flux further help to neutralize the affects of nitrogen and oxygen present in the weld zone.
2.5.2 The Gas Shielded Process - A major advantage with the shielded flux cored
electrode is the protective envelope formed by the auxiliary gas shield around the molten puddle. This envelope effectively excludes the natural gases in the atmosphere without the need for core ingredients such as aluminum. Because of this more thorough shielding, the
weld metallurgy is cleaner which makes this process suitable for welding not only m ild steels, but also low alloy steels in a wide range of strength and impact levels. 2.5.2.1 The gas shielded method uses a shorter electrical stickout than the self shielded
process. Extensions from 112' to 314' are common on all diameters, and 314' to 1 -112' on Lesson 9 Estimating & Comparing Weld Metal Costs larger diameters. Higher welding currents are also used with this process, enabling high deposition rates to be reached. The auxiliary shielding helps to reduce the arc energy into a columnar pattern. The combination of high currents and the action of the shielding gas contributes to the deep penetration inherent with this process. Both spray and globular transfer are utilized with the gas shielded process.

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2.5.3
Current Density
LESSON II
- Flux cored arc welding utilizes the same principles of current
density, as explained in section 2.4.1, but there is one significant difference between the flux cored electrode a nd the solid elect rode. Wit h t he flux co red elect rode, the gra nular core ingred ie nts are poor electrica l co nd ucto rs and t he re fo re, the c urre nt is carried pri marily through the outer metal sheathing. When an equal diameter cross section of the two are compared (See Figure 19), it is seen that the
CURRENT PATH
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flux cored electrode has a smaller current carrying area than the soli electrode. This greater concentration of current in a smaller area increases the burnoff rate. Glossary 2.5.3.1 equal, When all other factors are
1/16 FLU?-CORED ELECTRODE
FIGURE 19
the deposition rate of the flux cored electrode is so mewhat higher than the solid electrode.
2.5.4 EQUIPMENT - The equipment used for flux cored arc welding is the same as
1/16 SOLID ELECTRODE
shown previously in Section 2.3.2.2, Figure 12, with the exception that the self shielded method does not need the external gas apparatus. 2.5.4.1 Flux cored arc welding is done with direct current. All of the gas shielded electrodes
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are designed for DCEP operation. The self shielded electrodes are either designed specifically for DCEN or DCEP.
2.5.5
Power Source
- The recommended power source is the direct current constant
voltage type. The constant current type can be used but with less satisfactory results. Lesson 8 Hardsurfacing Electrodes
2.5.6
Wire Feeder
- The function of the wire feeder in FCAW is the same as discussed in
the section on GMAW. Since the flux cored electrode is tubular in construction, precautions must be taken not to flatten the electrode. To facilitate feeding by means other than pressure
alone, specially designed feed rolls with knurled or groove d surfaces are used. Some feeders use four feed rolls rather than two to minimize unit pressure on the electrode.
2.5.7 The Welding Gun
- As compared to GMAW, the main difference in FCAW welding guns
is in those used with the self shielding process. The gun is somewhat more compact due to the Lesson 10 Reliability of Welding Filler Metals absence of an external gas shielding nozzle. Since the self shielding process normally requires a longer electrode extension, the self shielding gun may have an insulated guide tube (Refer back to Figure 18) to give stability to the electrode. Water cooled guns are available for high duty semi-automatic welding and for automatic welding.
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Lesson 1 The Basics of Arc Welding 2.5.7.1 Lesson 2 Common Electric Arc Welding Processes Flux cored welding generates fumes, that for environmental reasons, must be removed from the welding area. This is usually done with an external exhaust system, but welding guns with internal fume extractors have been developed. They are heavier than the regular gun and must be properly maintained so that the extracting mechanism does not disturb the shielding gas.
2.5.8 SHIELDING GASES - Carbon dioxide is the most widely used gas for auxiliary
LESSON II
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shielding of the flux cored electrode. The other commonly used gas is a mixture of 75% Argon and 25% CO2. 2.5.8.1 A ca rbon dioxide shield produces deep penetration and the transfer is globular. As Glossary
previously discussed, CO 2 will dissociate in the heat of the arc. To counteract this characteristic, deoxidizing elements are added to the core ingredients of the electrode. The deoxidizers react to form solid oxide compounds that float to the surface as part of the slag covering.
2.5.8.2 The addition of Argon to CO 2 will increase the wetting action, produce a smooth arc arc, and reduce spatter. The transfer is spray-like, and the penetration is somewhat less than with the straight carbon dioxide.
2.5.8.3
While some flux cored electrodes are designed to operate well on both the 100%
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CO2 or the 75125 mixture, others are formulated specifically for the CO 2 shield or the Argonl CO 2 mixture. If the recommended gas is not used with these electrodes, the weld chemistry
may be affected. The reason for this is that inert gas, such as Argon, does not react with the other elements; therefore, allowing them to be transferred across the arc into the weld metal. An electrode designed for CO 2 shielding contains deoxidizing elements, such as silicon and manganese. If a high percentage of Argon is used in the shielding medium, a large portion of these elements may pass into the weld metal causing the weld metallurgy to be less ductile Search Chapter (Faster Download) Search Document (Slower Download)
than intended. 2.5.8.3 The opposite happens with electrodes formulated for a 75125 mixture. These
electrodes are usually designed for high yield and tensile strength. If a high percentage of CO 2 Lesson 9 Estimating & Comparing Weld Metal Costs is used with them, the CO 2 may react with the elements needed to attain these strength levels, thereby preventing them from passing into the weld metal.
2.6
SUBMERGED ARC WELDING
Submerged Arc Welding (SAW) is different from the previously explained arc welding processes in
that the arc is not visible. The arc is submerged beneath loose granular flux. A continuous electrode is fed by automatic drive rolls through an electrode holder where current
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Lesson 1 The Basics of Arc Welding is picked up at the contact tube. The electrode mo'es into the loose flux and the arc is initiated. The flux is deposited from a separate container that mo'es at the same pace as the Lesson 2 Common Electric Arc Welding Processes electrode assuring complete co'erage (See Figure 20). 2.6.1 Submerged Arc Flux - The flux helps form the molten puddle, slows the cooling
LESSON II
rate, and acts as a protecti'e shield. The flu which is in close contact wi th the arc, is fused into a slag co'er and that which is not fused is collected for reuse. The flux can contain alloying Go To Test Print
elements that, when molten, will pass into the weld metal affecting the metallurgy. Some fluxes are specifically prepared for their alloy altering capabilities while others, known as neutral fluxes, are chosen when a minimal alloy change is desired. Although these latter fluxes are called 'neutral', they still ha'e the ability to slightly alter the weld chemistry.
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Gloss
FLUX HOPPER
ELECTRODE
LOOSE GRANULAR FLUX
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BASE METAL MOLTEN PUDDLE
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Lesson 7 Flux Cored Arc Electrodes Carbon Low Alloy Steels 2.6.2 Lesson 8 Hardsurfacing Electrodes
SUBMERGED ARC WELDING

FIGURE 20
The Welding Gun - Although there are hand-held welding guns for the submerged
arc process, the majority of SAW is done with fully automa tic equipment. The basic compo nents include a wire feeder, a power source, a flux deli'ery system, and in some instances, an automa tic flux reco'ery system. 2.6.3 Lesson 9 Estimating & Comparing Weld Metal Costs Power Sources - The power source can be a constant current AC transformer, or i
may be a DC rectifier or generator of either the constant current or constant 'oltage 'ariety. The power source must be rated for high current output. When current requirements exceed the 'alue of a single machine, two or more of the same type may be connected in parallel. 2.6.4 Equipment - Most submerged arc welding is done wi th DCEP because it pro'ides
easy arc starting, deep penetration and excellent bead shape. DCEN pro'ides the highest
COPYRIGHT 1998 THE ESAB GROUP, IN
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Lesson 1 The Basics of Arc Welding deposition rates but minimum penetration. Alternating current is often used as a trailing arc in tandem arc applications. In this type of application, the leading DCEP arc provides deep Lesson 2 Common Electric Arc Welding Processes penetration, and the closely trailing AC arc provides high deposition with a minimum of arc blow.
2.6.5 Electrodes - A variety of ferrous and nonferrous electrodes are used in submerged
LESSON II
arc welding. They are usually solid electrodes refined with the a ppropriate alloys at the steel mill, and then shipped to electrode manufacturers where they are drawn down to a specific diameter and packaged. There is another type of sub arc electrode known as a composite electrode, that is fabricated in the same manner as a flux cored electrode. A chief adv antage
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of this type is that the alloying elements can be added to the core of the electrode more cheaply than a steel mill can produce those same alloys in a solid form. The electrodes for SAW vary in diameter from 1116 inch to 114 inch with the larger diameters being the most widely used. Glossary
2.6.6
Summary - Submerged arc welding has some advantages over other welding
processes. Since the radiance of the arc is blanketed by the loose flux, there is no need for a protective welding hood (although safety glasses are recommended), there is no spatter and only a very minim al amount of fumes escape from under the blanket. High welding currents,
quite commonly in the 300 to 1600 ampere range, are used. These high currents, combined with fast travel speeds, m ake SAW a high deposition process that is especially suitable for applications that require a series of repetitious welds. Some setups allow two or more elec trodes to be fed simultaneously into the joint, further increasing the deposition rate and speed.
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2.6.6.1
Although SAW has these advantages, it does have some limitations. The flux must
be deposited and collected for every welding pass. This requires additional equipment and handling. Also because of the loose flu the process is limited to the flat and horizontal positions. The equipment for SAW is commonly quite bulky which limits its mobility, and
although the process works well on thick m aterials, it usually is not satisfactory for thin gauge m aterial. The process requires care in the operation. The amperages commonly used m ay cause excessive heat buildup in the base metal, that m ay result in distortion or brittleness.

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LESSON II
2 . 7 E L E C T R O S L A G A N D E L E C T R OG A S W E L D I N G
Electroslag Welding (ESW) and Electrogas Welding (EGW) comprise only a minor portion of all welding done in the country, but they are uniquely adapted to certain applications, primarily the joining of -ery thick materials. The joining of a 12 inch material along a 40 foot line is not an uncommon application for the Electroslag process.
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Electroslag Welding (See Figure 21) is technically not an arc welding process,
although it utilizes a current carrying consumable electrode. The only time there is an arc between the electrode and the work piece is when current is initially charged through the electrode. This initial charge heats a layer of loose flux that becomes molten and extinguishes
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the arc. Glossary

WATER INLET/OUTLET ELECTRODE
COPPER SHOE GUIDE TUBE (CONSUVIABLE GUIDE IvETHOD) BASE IVETAL
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MOLTEN FLUX
WELD POOL ELECTROSLAG WELDING

FIGURE 2
SOLIDIFIED METAL
2.7.2 Flux - The flux used in ESW is high in electrical resistance. As current is applied, enough heat is generated from this resistance to keep the flu base metal, and electrode in a molten state. This axis of the weld joint is on a -ertical plane. The two pieces of metal, usually of the same thickness, are positioned so that there is an opening between them. One or more electrodes
are fed into the opening through a welding bead that tra-els -ertically as the joint is filled. To contain the molten puddle, water cooled copper shoes or dam s are placed on the sides of the -ertical ca-ity. As the weld joint solidifies, the dam s mo-e-ertically so as to always remain in contact with the molten puddle.
2.7.3
Process - A -ariation of ESW is the consumable guide method. The process is the
same with this method except that the guide tube that feeds the electrode to the molten pool is
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LESSON II
also consumed. The chief ad antage with this method is the elimination of the electrode holder which must mo e ertically with the weld pool. Also since the guide tube is consumed, the deposition
rate is slightly increased with this method.
2.7.4
Equipment - T h e equipment used in E S W is all automatic and of special design.
The power source may use either AC or DC current. The electrode may be either solid or flux cored, although if the flux cored is used, it must be specially formulated so as not to contain its normal
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amount of slag forming ingredients.
2.7.5
Summary - Electrogas Welding is similar to E S W as far as the mechanical as-
pects are concerned. The equipment is automatic, the welding head tra els ertically, and the molten puddle is retained by shoes on the sides of the joint. The difference is that Electrogas Welding
Glossary
utili2es an arc and it is externally gas shielded. The power source is also limited to DC operation. The electrodes used in EGW can be either solid or flux cored.
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Lesson 1 The Basics of Arc Welding Lesson 2 Common Electric Arc Welding Processes Lesson 3 Cove red Electrodes for Welding Mild Steels Lesson 4 Cove red Electrodes for Welding Low Alloy Steels Lesson 5 Welding Filler Metals for Stainless Steels
LESSON II
APPENDIX A
LESSON II- GLOSSARY OF TERMS
Arc Blow
- Deviation of the direction of the welding arc caused by magnetic fields in the work piece when welding with direct current.
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Straight Polarity Reverse Polarity
- Welding condition when the electrode is connected to the negative terminal and the work is connected to the positive terminal of the welding power source.
Glossary
- Welding condition when the electrode is connected to the positive terminal and the work is connected to the negative terminal of the welding power source. Slag - The brittle mass that forms over the weld bead on welds made with coated e le c t ro des , flu x c o re d e le ct r o des, s ub me r ge d a rc w e ld ing a nd other slag p ro d u c in g w e ld in g p r o c e s s e s . W e ld s ma d e w it h
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t h e g a s m e t a l a r c a n d t h e gas tungsten arc welding processes are slag free.
Lesson 8 Hardsurfacing Electrodes Lesson 9 Estimating & Comparing Weld Metal Costs
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Manual Arc Welding
- Welding with a coated electrode where the operator 1s hand controls travel speed and the rate the electrode is fed into the arc.
Semi-Automatic Welding - Welding with a continuous solid wire or flux cored electrode where the wire feed speed, shielding gas flow rate, and voltage are preset on the equipment, and the operator guides the hand held welding gun along the joint to be welded. Slag Inclusion - A weld defect where slag is entrapped in the weld metal before it can float to the surface. Root Pass - The initial pass in a multi-pass weld, usually requiring 100% penetration.
Sea Cha (Fa Dow
Sea Docu (Slow Down
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LESSON II Gas Ions - Shielding gas atoms that, in the presence of an electrical current, lose one or more electrons and therefore, carry a positi'e electrical charge. The pro'ide a
Lesson 2 Common Electric Arc Welding Processes Lesson 3 Covered Electrodes for Welding Mild Steels Lesson 4 Covered Electrodes for Welding Low Alloy Steels Lesson 5 Welding Filler Metals for Stainless Steels
more electrically conducti'e path for the arc between the electrode and the work piece. High Frequency - (as applied to gas-tungsten arc welding) An alternating current consisting of o'er 50,000 cycles per second at high 'oltage, low amperage that is superimposed on the welding circuit in GTAW power sources. It ionizes a path for non-touch arc starting and stabilizes the arc when welding with alternating current. Inert Gases - Gases that are chemically inacti'e. They do not readily combine with other elements. Flux - In arc welding, fluxes are formulations that, when subjected to the arc, act as a cleaning agent by dissol'ing oxides, releasing trapped gases and slag and generally cleaning the weld metal by floating the impurities to the surface where they solidify in the slag co'ering. The flux also ser'e s to reduce spatter and contributes to weld bead shape. The flux may be the coating on the
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Glossary
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Lesson 6 Carbon & Low Alloy Steel Filler Metals GMAW,GTAW,SAW Lesson 7 Flux Cored Arc Electrodes Carbon Low Alloy Steels Lesson 8 Hardsurfacing Electrodes Lesson 9 Estimating & Comparing Weld Metal Costs Lesson 10 Reliability of Welding Filler Metals
electrode, inside the electrode as in flux cored types, or in a granular form as used in submerged arc welding. Current Density - The amperes per square inch of cross-sectional area of an electrode. High current density results in high electrode melt-off rate and a concentrated, deep penetrating arc. Slope or Slope Control - A necessary feature in welding power sources used forshort circuiting arc welding. Slope Control reduces the short circuiting current each time the electrode touches the weld puddle (See Section 2.5.3). Inductance - (as applies to short circuiting arc welding) A feature in welding power sources designed for short circuiting arc welding to retard the rate of current rise each time the electrode touches the weld puddle.
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Contact Tip
LESSON II
- That part of a gas metal arc welding gun or flux cored arc welding
Lesson 2 Common Electric Arc Welding Processes Lesson 3 Covered Electrodes for Welding Mild Steels
gun that t r a n s fe r s t h e w e ld in g c u r r e n t t o t h e w e l d i n g w i r e i m m e d i a t e l y b e fo r e t h e w i r e enters the arc.
Spray Transfer
- Mode of metal transfer across the arc where the molten metal droplets are smaller than the electrode diameter and are axially directed to the
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weld puddle. Requires high volta ge a nd a mp era ge set tings a nd a s hie lding gas of at leas t 80% argon.
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Lesson 4 Covered Electrodes for Welding Low Alloy Steels Lesson 5 Welding Filler Metals for Stainless Steels
Globular Transfer
- Mode of metal transfer across the arc where a molten ball larger than the electrode diameter forms at the tip of the electrode. On detachment, it takes on an irregular shape and tumbles towards the weld puddle sometimes shorting between the electrode and work at irregular intervals. Occurs when using shielding gases other than those consisting of at least 80% argon and at medium current settings.
Pulse
- Mode of metal transfer somewhat between spray and short circuiting. The specific power source has built into it two output levels: a steady background level, and a high output (peak) level. The later permits the transfer of metal across the arc. This peak output is controllable between high and low values up to several hundred cycles per second. The result of such a peak output
Transfer
Glossary
produces a spray arc below the typical transition current.
Short-circ uiting Transfer
- Mode of metal transfer in gas metal arc welding at low voltage and amperage. Transfer takes place each time the electrode touches or short-circuits to the

Trimixor
weld puddle, extinguishing the arc. The short-circuiting current causes the electrode to neck down, melt off, and then repeats the cycle.
Turn Pages
- A shielding gas consisting of approximately 90% helium, 7 -112% argon, and 2-112% carbon dioxide used primarily for short-circuiting arc welding of stainless steels. Maintains corrosion resistance of the stainless steel and produces good wetting and excellent weld bead shape.
Triple Mix

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Electrical
LESSON II
- In any welding process using a solid or flux cored wire, the electrical stick -out is the distance from the contact tip to the unmelted electrode end. Sometimes called the 'amount of wire in resistance'. This distance influ ences melt-off rate, penetration, and weld bead shape.
Stick-Out
Go To Test
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Lesson 3 Covered Electrodes for Welding Mild Steels Lesson 4 Covered Electrodes for Welding Low Alloy Steels Lesson 5 Welding Filler Metals for Stainless Steels
Out-of-Position Welds Weld Positions
- Welds made in positions other than flat or horizontal fillets.
Prin
-
Glos
FLAT HORIZONTAL FILLET
Turn Lesson 6 Carbon & Low Alloy Steel Filler Metals GMAW,GTAW,SAW Lesson 7 Flux Cored Arc Electrodes Carbon Low Alloy Steels
HORIZONTAL BUTT POSITIONED FILLET (FLAT) VERTICAL OVERHEAD
Se D
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Basic Welding ESAB

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Lesson 2 - Common Electric Arc Welding Processes

Current Chapter Table of Contents

BASIC WELDING FILLER METAL TECHNOLOGY

Lesson 2 - Common Electric Arc Welding Processes

Lesson 2 - Common Electric Arc Welding Processes

LESSON II COMMON ELECTRIC ARC WELDING PROCESSES

ES ABWel di ng& Cutting Products

Lesson 2 - Common Electric Arc Welding Processes

Lesson 1 The Basics of Arc Welding

Lesson 2 Common Electric Arc Welding Processes

TABLE OF CONTENTS LESSON II COMMON ELECTRIC ARC WELDING PROCESSES

Current Chapter Table of Contents

Lesson 5 Welding Filler Metals for Stainless Steels

Search Chapter (Faster Download) Search Document (Slower Download)

Lesson 8 Hardsurfacing Electrodes

Lesson 9 Estimating & Comparing Weld Metal Costs

Lesson 10 Reliability of Welding Filler Metals

Lesson 2 - Common Electric Arc Welding Processes

Lesson 1 The Basics of Arc Welding

Current Chapter Table of Contents

TABLE OF CONTENTS LESSON II- Con't.

Lesson 2 Common Electric Arc Welding Processes

Lesson 3 Covered Electrodes for Welding Mild Steels

2.4.8 2.5 2.5.1

Lesson 4 Covered Electrodes for Welding Low Alloy Steels

Lesson 5 Welding Filler Metals for Stainless Steels

Lesson 6 Carbon & Low Alloy Steel Filler Metals GMAW,GTAW,SAW

Lesson 7 Flux Cored Arc Electrodes Carbon Low Alloy Steels

Lesson 8 Hardsurfacing Electrodes

2.7.3 2.7.4 2.7.5

Lesson 9 Estimating & Comparing Weld Metal Costs

Appendix A- GLOSSARY OF TERMS ................................................................

Lesson 10 Reliability of Welding Filler Metals

COPYRIGHT 2000 THE ESOS GROUP, INC

Lesson 2 - Common Electric Arc Welding Processes

Lesson 1 The Basics of Arc Welding

Current Chapter Table of Contents

COMMON ELECTRIC ARC WELDING PROCESSES

Lesson 3 Covered Electrodes for Welding Mild Steels

Lesson 4 Covered Electrodes for Welding Low Alloy Steels

Lesson 5 Welding Filler Metals for Stainless Steels

Search Chapter (Faster Download) Search Document (Slower Download)

Lesson 8 Hardsurfacin Electrodes

SHIELDED METAL ARC WELDING

Lesson 9 Estimating & Comparing Weld Metal Costs

Lesson 10 Reliability of Weldin Filler Metals

COPYRIGHT 19 98 THE ESAB GROUP, INC

Lesson 2 - Common Electric Arc Welding Processes

Current Chapter Table of Contents

Lesson 3 Covered Electrodes for Welding Mild Steels

SHIELDING GASES SOLIDIFIE D SLAG WELD METAL

Equipment & Operation - One

WORK PIECE SHIELDED METAL ARC WELDING FIGURE 1

Lesson 5 Welding Filler Metals for Stainless Steels

Protective equipment (he(met, g(oves, etc.)

Lesson 7 Flux Cored Arc Electrodes Carbon Low Alloy Steels

Lesson 8 Hardsurfacing Electrodes

Lesson 9 Estimating & Comparing Weld Metal Costs

Lesson 10 Reliability of Welding Filler Metals