Welds
• An ideal weld must give a strong bond between
materials with the interfaces disappearing
• Order and direction in which joints , welds are
made is called weld sequence
To achieve this
• Smooth,flat or matching surfaces
• Surfaces shall be free from contaminants
• Metals shall be free from impurities
• Metals shall have identical crystalline structures
Electric Arc Welding
Electrode
Power
supply
Work piece
Clamp(Earth)
Electric Arc Welding
• Electric discharge produced between cathode and anode by
a potential difference (40 to 60 volts)
• Discharge ionises air and produces -ve electrons and +ve ions
• Electrons impact upon anode, ions upon cathode
• Impact of particles converts kinetic energy to heat (7000o C)
and light
• Amperage controls number of ions and electrons, Voltage
controls their velocity
Electric Arc Welding
Arc Welding Processes
• Manual metal arc (MMA) / Shielded Metal Arc Welding
(SMAW) / Stick
• Tungsten Inert Gas (TIG)/ Gas Tungsten Arc Welding(GTAW)
/TAG)
• Metal Inert Gas (MIG) / Metal Active Gas (MAG) / Gas Metal
Arc Weld(GMAW)
• Flux cored arc welding (FCAW)
• Submerged Arc (SAW)
Differences between them
Methods of shielding the arc
Consumable or Non-consumable electrode
Degree of automation
Joint Design
Fillet
Single V
Single Bevel
Corner
Single V
Partial pen.
Double V
Joint Design
Lap Joint
Corner fillet weld
Cruci-form
Edge Weld
Weld Prepareration / Joint Design
BEFORE WELDING C
L
Included angle
60°
Parent metal/
Base metal Angle of bevel
30°
Root Face
2-3mm
Fusion face/ Root Gap
Sidewall or bevel 2-3mm
Single -V Butt
A FINISH WELD
AFTER WELDING
Weld width Weld reinforcement
Weld cap
Capping
Crown Surface
Toes
Fill pass
HAZ Hot Pass Weld Layer
Root run
Penetration
Weld bead Root bead
Root reinforcement
Welding positions - plate
Flat 1G Horizontal Vertical Overhead
2G 3G 4G
Up or Down
9
Welding positions - pipe
Axis vertical Axis horizontal Axis inclined 45°
2G 5G 6G
10
Weld joints
Butt Tee
Lap
Corner
Cruciform
MMA
Manual Metal Arc Process (MMA)
(USA: SMAW)
Definition
Electrode Uses an arc to produce weld metal in
core wire between a consumable electrode and
parent metal
Electrode
covering Type of process
Manual
Electric Arc
Gas shield Solidified slag
Molten weld pool Build up of weld metal
Penetration
Parent material
Manual Metal Arc Welding
• Shielding provided by Welder controls
decomposition of flux • Arc length
covering • Angle of electrode
• Electrode consumable • Speed of travel
• Manual process • Amperage settings
Defects in MMA Welding
• Crack
• LF
• ICP
• PORES / GH(Start-stop porosity)
• SWLF
• SLAG
• Delayed hydrogen crack
TIG WELDING
• Arc is formed between a tungsten electrode
and the work piece in an inert atmosphere of
Argon or Helium
• Electrode is not consumed
TIG
Tungsten Inert Gas (TIG)
Definition
Uses an arc to produce weld metal in (USA: GTAW)
between a non consumable electrode and
parent metal Cap Switch
power
Type of process cable
Switch
Manual / fully auto Handle
Filler wire Tungsten
Shielding gas
Deposited Gas
weld metal inlet
TIG WELD-Defects
• Tungsten inclusion
Due to contact of electrode/filler wire
Contaminations of electrode tip by spatter
Excess current
inadequate shielding of gas
Inclusions
Cracking in the electrode
• ICP
GMAW /MIG/MAG/FCAW
• The gas metal-arc welding process (GMAW), often called
Metal Inert Gas (MIG) , has revolutionized arc welding. In
this process:-
• A consumable electrode (in the form of wire) fed from a
spool through the torch (welding gun) at a preset controlled
speed.
• As the wire passes through the contact tube of the gun, it
picks up the welding current.
• Semi Auto / fully auto
• Low Hydrogen weld process
Metal Active Gas / Metal Inert Gas (MAG / MIG) - USA: GMAW
Wire electrode
Shielding gas in
Contact tip and
electrode wire guide
Electric Arc
Gas shield
Molten weld pool Build up of weld metal
Penetration
Parent material
• Shielding gas is based on the base material
• Argon (inert gas) is used for non ferrous metals like
Aluminium,copper
• This is called as MIG Weld
• Welding of ferrous metals, CO2 or mixture of CO2
and argon is used
• Since CO2 is active gas, welding is called as Metal
Active Gas(MAG) weld
• If CO2 alone is used, it is CO2 welding
• Electric arc is between consumable electrode
wire and weld pool.
• Arc and weld pool are protected by externally
supplied shielding gas
• Electrode wire is melted and transferred as
droplets across the arc into the molten weld
pool
CO2 Welding
• At normal temp CO2 is inert
• But at high temp it decomposes to CO and O and
becomes active
• CO2 is also combined with Argon and used as
shielding gas
• Produces a deep penetration. Good finish and less
undercut
• Spatter is high
• Less cost
MIG/MAG/GMAW –DEFECTS
• Lack of penetration
due to narrow joint angle / inadequate
welding current
• Undercut-welding speed high/high current
• Burn through
• Wire sticking
SUBMERGED ARC WELD (SAW)
• Fully automated
• Arc between Consumable electrode , work piece under
granulated welding flux
• Welding flux will not be fully consumed
• Excess can be collected and reused
• Heat loss is low
• No oxidizing effect
• Arc melts the wire , base metal and flux
• Boiler, Pressure vessels and high thickness components
• Welding penetration can be controlled by backing bar
Submerged Arc
Reel feed
Flux
retrieval Consumable
electrode
Flux feed
Slag
Weld metal
Parent metal
Weld defects
• Slag
• Porosity-due to contaminations on the metal
surface or electrode or moisture in flux(damp
flux)
• Due to Gases generated during welding
• crack
FCAW
• Electric arc between Continuously fed flux
filled tubular electrode wire and work piece
• Wire melted by the arc deposits on to the
weld pool
• Shielding given by the core flux by
decomposing into gas
• This type is called as inner shield wire.
Weld defects
• Porosity-due to inadequate shielding/poor gas
quality/contamination on the surface
• Lack of penetration-narrow joint angle/ Less
current
• Slag-improper cleaning
• Undercut-high speed/high current
• Ship building, pipelines , Earth moving
equipment
Weld Discontinuities
Weld process Discontinuity type
Crack ICP LF Pores Slag Tn Inclusion
SMAW X X X X X ****
SAW X X X X X ****
GTAW X X X X **** X
GMAW X X X X **** ****
FCAW X X X X X ****
