Welder Training

Welding Process
TECHNICAL TRAINING WORKSHOP
MANSOR BIN IBRAHIM

Welding Processes

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Welding Processes

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Welding
Welding terms Process that produce coalescence of work pieces by using pressure or without under certain temperature. BS 499 prt 1 Welding terms A union between pieces of metal at faces rendered plastic or liquid by heat,pressure or both.

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Welding Processes
SOLID STATE WELDING FUSION WELDING

BRAZING & SOLDERING

ALLIED WELDING PROCESS

RESISTANCE WELDING

OXY FUEL WELDING

LASER WELDING

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Fusion Welding Factors

The four essential factors for fusion welding
1. Fusion is achieved by melting using a high intensity heat source 2. The welding process must be capable of removing any oxide and contamination from the joint 3. Atmosphere contamination must be avoided 4. The welded joint must possess the mechanical properties required by the specification being adapted
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Manual Metal Arc Process (MMA)

SHEILDED METAL ARC WELDING (SMAW)
Electrode covering

Electrode core wire

(Rimming Steel)

Electric Arc

Solidified slag Molten weld pool

Gas shield
(Co2)

Build up of weld metal Penetration

Parent material
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Basic MMA Equipment Diagram

Welding Machine Electrode Holder Work Piece

Power Source
+

Work Cable

Earth

Clamp Return Cable

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Welding Variables

Arc length Angle of electrode Speed of travel

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TYPE OF POLARITY

DIRECT CURRENT
(STRAIGHT POLARITY ve & REVERSE POLARITY +ve)

ALTERNATING CURRENT

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Welding Power Sources Drooping or Constant Current Characteristic

Large arc gap Requires more volts

Small arc gap Requires less volts

As the welder increases the arc gap, more volts are required for the arc to bridge the increased arc gap.

As the welder reduces the arc gap, less volts are required for the arc to bridge the reduced arc gap.

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Welding Power Sources Drooping or Constant Current Characteristic

100 90 80 70

O.C.V. Striking voltage (typical) for arc initiation

Voltage

60 50 40 30 20 10 20 40 60 80 100 120 130 140 160 180

Normal Operating Voltage Range

Large voltage variation, e.g. + 10v (due to changes in arc length) Small amperage change resulting in virtually constant current e.g. + 5A.
200

Amperage
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Manual Metal Arc (MMA)

The three main electrode covering types used in MMA welding

Rutile - general purpose (E6013) Basic - low hydrogen (E7018/7016) Cellulose - deep penetration/fusion (E6010/6011)

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FUNCTION OF FLUX COVERING

ARC STABILIZER Potassium silicate, Titanium and Magnesium Oxide SLAG FORMER Calcium Flouride, Iron Oxide and Titanium Oxide ALLOYING ELEMENT Ferro Manganese and Ferro Silicon ARC IONISER DEOXIDISER Ferro Silicon, Ferro Manganese
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MATERIAL WELDABILITY SIZE : TYPE : 4.78 mm MIN through 25 mm Ferrous Metal and NonFerrous Metal

CONDITION: Moderate Preparations on Welding Area / Joint from Contaminations

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SELECTION OF ELECTRODES TYPE OF MATERIAL 1 . CARBON STEEL 2. STAINLESS STEEL AWS CLASS E7018, E7016, E6010, E6013 E308L, E316L, E347L E1188, E4043,E5356

3. ALUMINIUM

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AWS A5.5 Alloyed Electrodes E 70 1 8 M G

Covered Electrode Tensile Strength (p.s.I) Welding Position Flux Covering Moisture Control Alloy Content
CopyrightTraining Workshop Technical 2003 TWI Ltd
M.S.Rogers MBI

CONSUMABLES SIZE : TYPE : 2.0mm dia through 6.0mm dia Basic, Rutile, Cellulose, Acid

CONDITION: Basic - Bake 350C - Hold 150C - Store / Quiver 75 90C. Rutile Dry Cellulose - Dry
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ADVANTAGES Cheap Equipment Suitable for all weld position Capable of welding thin material. Required moderate welder skill Low in maintenance

DISADVANTAGES Required Proper Inter run cleaning Slow weld process Required proper consumable storage

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TYPICAL DEFECTS
SLAG INCLUSION POROSITY UNDERCUT SPATTERS LACK OF SIDEWALL FUSION LACK OF ROOT FUSION LACK OF ROOT PENETRATION ARC BLOW

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Questions
QU 1. State the main welding parameters of the MMA welding process QU 2. What type of power source characteristic is considered essential for a MMA welding plant? QU 3. Give three advantages of the MMA welding process when compared to the MAG welding process QU 4. State the four criteria that will govern the number of weld passes in a MMA welded joint QU 5. State two types of electrical supply and give the advantages of each
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Tungsten Inert Gas (TIG)

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Tungsten Inert Gas (TIG)

Cap

Switch Filler wire Collet Deposited weld metal

Handle

Switch power cable

Non-consumable electrode Shielding gas Gas inlet & power cable

Molten weld pool

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TIG Torch Assembly

Tungsten housing Fitted ceramic shielding cup On/Off switch Split collet Gas diffuser Spare ceramic shielding cup Torch body Tungsten electrodes Ceramic shield cup Gas lens

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Basic TIG Equipment Diagram

Shielding Gas + Regulator Welding Machine Work Piece

Welding Torch

Earth

Gas Hose

Work Cable Return Cable

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Tungsten Electrodes

Old types
Thoriated: DC -ve electrode - steels and most metals
1% thoriated + tungsten for higher current values 2% thoriated for lower current values

Zirconiated: AC - aluminum alloys and magnesium New types

Cerium: DC -ve elctrode - steels and most metals Lanthanum: AC - Aluminum alloys and magnesium

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Welding Power Sources Drooping or Constant Current Characteristic

100 90 80 70

O.C.V. Striking voltage (typical) for arc initiation

Voltage

60 50 40 30 20 10 20 40 60 80 100 120 130 140 160 180

Normal Operating Voltage Range

Large voltage variation, e.g. + 10v (due to changes in arc length) Small amperage change resulting in virtually constant current e.g. + 5A.
200

Amperage
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Tungsten Inert Gas Welding

1.

2.

3.

4.

5.

1. Pre-flow timer control

Adjusts the time the gas and water valves are open

4. Crater fill control

Current down slope (slope out)

5. Post-flow timer control

Adjusts the time the gas flows after welding

2. Start current control

Current up slope (slope-in)

3. Output control
Welding current control
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Argon (Ar) Inert

Shielding Gases

Suitable for welding carbon steel, stainless

steel, aluminium, reactive material and magnesium

23% heavier than air Forms a tight arc column, high current

density, small arc concentration, lower arc voltage, moderate penetration and moderate thermal conductivity

More suitable for thinner

positional welding

materials and
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Shielding Gases
Helium (He) Inert

Suitable for welding carbon steel, stainless steel,

copper, aluminium and magnesium due to better puddle fluidity and bead wetting

Second lightest gas 1/7 as heavy as air Form a wider arc, lower current density, higher
arc voltage, deeper penetration and high thermal conductivity

Requires higher flow rates

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Shielding Gases
Helium / Helium Argon Mix (He) Inert

Suitable for welding carbon steel,

stainless steel, copper, aluminium and magnesium

High cost, high flow rates More suitable for thicker materials and
materials of high thermal conductivity.

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Shielding Gases
How heat produced from welding gasses

The collisions of electrons with atoms and

molecules produce thermal ionisation of atoms of shielding gas.

The positively charged gaseous atoms are

attracted to the negative electrode , where their kinetic (motion) energy is converted to heat.
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MATERIAL WELDABILITY SIZE : TYPE : 1.0 mm MIN through 6.0 mm Ferrous Metal and NonFerrous Metal

CONDITION: Strictly Clean Preparations on Welding Area / Joint from Contaminations

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CONSUMABLES SIZE : TYPE : 1.0 mm dia through 2.4 mm dia As per parent metal

CONDITION:

Place in the original container & dry

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SELECTION FILLER METAL MATERIAL TYPE 1. CARBON STEEL 2. STAINLESS STEEL AWS CLASS ER70 S-G, ER 308L, ER316L, ER347L ER1188, ER4043, ER5356

3. ALUMINIUM

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HEAT DISTRIBUTION AND CURRENT POLARITY TABLE

DC EP
GRAPH CURRENT FLOW
++ ++

DC EN

AC

- --

- --

+ ++ ++

- + - + -+

PENETRATION

MATERIAL

CARBON STEEL, STAINLESS STEEL, ALUMINIUM, MANGANESE

CARBON STEEL, STAINLESS STEEL, ALUMINIUM, MANGANESE

ALUMINIUM, MAGNESIUM ALLOY

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ADVANTAGES Virtually no spatters produced High quality welds Capable to weld thin material Capable to weld any type of material. Capable to be used in all weld position.

DISADVANTAGES Expensive equipment Required high skill weld technique. Very slow weld process. High in maintenance.

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TYPICAL DEFECTS
TUNGSTEN INCLUSION POROSITY LACK OF SIDEWALL FUSION LACK OF ROOT FUSION LACK OF ROOT PENETRATION

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Questions
QU 1. Give three reasons for the occurrence of tungsten inclusions QU 2. What type of power source characteristic is considered essential for a MMA welding plant? QU 3. Give three advantages of the MMA welding process when compared to the MAG welding process QU 4. State the four criteria that will govern the number of weld passes in a MMA welded joint QU 5. State two types of electrical supply and give the advantages of each
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Metal Active/Inert Gas (MAG/MIG)

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Metal Active/Inert Gas (MAG/MIG)

Wire electrode Current conductor Wire feed rolls

Gas nozzle Gas shield Electric Arc Molten weld pool

Shielding gas in Contact tip and electrode wire guild Build up of weld metal Penetration

Parent material
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Metal Active/Inert Gas (MAG/MIG)

Gas Nozzle Contact Tube/tip

Nozzle to work distance

Filler Extension

Contact Tube to Work Distance

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MAG/MIG Torch Head Assembly

Torch body Torch head assembly (Less nozzle) On/Off switch

Hose port

Nozzles or shrouds Gas diffuser

Spot welding spacer Contact tips

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MAG/MIG Internal Wire Drive

15 Kg Filler Wire Spool Plain top roller

Half grooved bottom roller

Wire guide
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MAG/MIG Wire Spool

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Short Circuit / Dip Transfer:

Metal Transfer Modes for MAG/MIG

Uses small wire diameter, thin (all position) and thick (vertical & o/head) material low deposition rate and filling large gaps.

Voltage ~ < 21 Amperage ~ < 200

Spray Transfer:
Uses larger wire diameter, high deposition rates, t >2.4mm, restricted to flat & horizontal position.

Voltage ~ > 27 Amperage ~ > 250

Globular Transfer: Deposits at high rates & capable producing high

quality welds and for flat & horizontal position.

Between Dip & Spray Transfer Modes.

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Flat or constant voltage characteristic

2 mm

3 mm

4 mm

Arc gap to small, requires the current to be increased to allow the wire to burn back to the correct arc gap

Correct arc gap

Arc gap to large, requires the current to be reduced to slow down the burn off rate to allow the correct arc gap to be maintained MBI

Welding Power Sources Flat or Constant Voltage Characteristic

Flat or Constant Voltage Characteristic SAW < 1000 amps Used With MIG/MAG, ESW &
O.C.V. Arc Voltage Virtually no Change.

33 32 31

Voltage

Small Voltage Change. Large Current Change

100

Amperage

200

300

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Filler Wire Extension

< Filler Extension

> Filler Extension

Shorter filler extension produces burnthrough at welding area

Longer filler extension produces lack of fusion (cold lap), spatter. The wire tends to melt before reaching the weld puddle.

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Shielding Gases
Carbon Dioxide (CO2) Active

Compound of 27% Carbon and 72% oxygen

11/2 times heavier than air At elevated temperature , it will disintegrates to
oxygen and carbon monoxide

Suitable for ferrous metal welding

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Shielding gases Example gases and applications for MIG/MAG welding

Pure argon Argon + 1% to 5% oxygen CO2 Argon + 5% to 25% CO2 Argon + 15% nitrogen 75% helium + 25% argon Aluminium, copper, 9% nickel steel Stainless steel Carbon steel up to 0.4%, low alloy steel Carbon and low alloy steels Copper and its alloys Aluminium and copper

75% helium + 25% argon +Austenitic stainless steel CO2 trace High purity argon Titanium, Zirconium alloys Note: A H2 trace may be added to most gases to increase arc voltage and therefore overall deposition rates.
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Shielding gases

CO2 gas cannot sustain spray transfer, as the

Ionisation Potential of the gas is too high. Affects on welding are : High ionisation potential High thermal conductivity and produces low arc density Very good penetration Unstable arc (at high current value) and lots of spatter. 1.5 (Specific gravity of gas with respect to air)

Helium has a high Ionisation potential and produce

a high arc energy in plasma column. Very high thermal conductivity and produces very low arc density Deep penetration Stable arc 0.14 (Specific gravity of gas with respect to air)

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Shielding gases

Argon has a much lower Ionisation potential and can

sustain spray transfer above 24 welding volts. Argon gives : Very stable arc Little spatter Low thermal conductivity and produces high arc density Lower penetration than CO2. 1.4 (Specific gravity of gas with respect to air) We mix both argon and CO2 gas in mixtures of between 5 20% CO2 in argon to get the benefit of both gases i.e. good penetration with a stable arc and very little spatter (smoother profile). CO2 gas is much cheaper than argon or its mixtures.

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AWS 5.18 Carbon Steel Filler

ER 70 S - 6
Rod Electrode

Alloy Composition Solid Wire Ultimate Tensile Strength

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SELECTION OF FILLER WIRES MATERIAL TYPE 1. CARBON STEEL 2. STAINLESS STEEL AWS CLASS ER70 S-6 ER 308L, ER316L, ER347L ER1188, ER4043, ER5356

3. ALUMINIUM

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Inductance or Choke

Applicable to MIG/MAG process in dip transfer mode. The electrode is fed slowly through the arc until it touches the weld pool, at this point the output from the power supply is short circuited and a very high current flows through the electrode. If this was allowed to continue, the wire would melt and eject excessive amounts of spatter. The inclusion of the choke in the welding circuit controls the rate at which the current rises so that the electrode tip is melted uniformly without excessive spatter
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Flux Cored Arc Welding

Flux core Insulated extension nozzle Current carrying guild tube Flux cored hollow wire Flux powder Wire joint

Flux core wires

Arc shield composed of vaporized and slag forming compounds

Solidified weld metal and slag

Molten weld pool

Metal droplets covered with thin slag coating

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SELECTION OF FILLER WIRES MATERIAL TYPE 1. CARBON STEEL 2. STAINLESS STEEL AWS CLASS E70T-1 E 308LT, E316LT, E 347LT ER1188T, ER4043T, ER5356T

3. ALUMINIUM

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Sub-arc (SAW)

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Sub-arc (SAW)
Filler wire spool Flux hopper

Power supply

Slide rail

Wire electrode

Flux

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Sub-arc (SAW) Fluxes

Fused SAW Fluxes

Agglomerated SAW Fluxes

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APPLICATION S.A.W. IN THE FABRICATION

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Sub-arc Fluxes

Fused Flux

Agglomerated Flux
Granulated appearance High weld quality Addition of alloys Lower consumption Easy slag removal Smooth weld profile
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Flaky appearance Lower weld quality Low moisture intake Low dust tendency Good re-cycling Very smooth weld profile

Questions
QU 1. State the possible problems when using damp and contaminated fluxes when using the sub-arc process QU 2. State the two flux types used in the sub-arc welding process. QU 3. What power source characteristic is required for a 500 amp out-put sub-arc welding plant QU 4. State three main items of sub-arc fluxes, which require inspection QU 5. State the advantages and disadvantages of the sub-arc welding process
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Process Comparisons
Process
MMA TIG MIG/MAG MAG FCAW Sub-arc

Electrical characteristic
Drooping / constant current Drooping / constant current Flat / constant voltage Flat / constant voltage Drooping / constant current > 500amps Flat / constant voltage < 500amps Flat / constant voltage

Electrode current type

DC+ve, DC-ve, DC+ve, DC+ve, DC+ve, DC-ve, DC-ve, AC DC-ve, AC AC

Electro-slag

DC+ve,
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