Welding machine
Power for arc welding-AC or DC???
• When using AC power source, the +ve and –ve parts will get changed periodically.
• Which means cathode and anode changes continuously which is not preferable.
• Hence DC power source is always preferred for arc welding.
• If incoming power supply is AC, the welding machine will convert it to DC using a rectifier which is in built in
the welding machine. Also it will contain a step down transformer for reducing voltage.
• Switching to AC can help to fix arc blow problems, which means that the arc starts wandering or blows out of
the joint. The cause of arc blow can be magnetism of the metal you’re welding or the arc’s current. The
alternating current between positive and negative polarity enables a steadier arc when welding magnetic
parts.
RAVI VISHWAKARMA 1
Electrodes for arc welding
NON CONSUMABLE
ELECTRODES ARE
DIVIDED IN TO TWO
CATEGORIES CONSUMABLE
• In case of consumable electrode, the function of electrode is
A. to act as anode/cathode and produce the arc
B. also the electrode melts itself and get transferred in to the weld pool in the form
of molten metal and forms the bond on solidification. i.e. Electrode acts as the
filler.
• In case of non consumable electrode, the function of electrode is
A. to act as anode/cathode and just to produce the arc. It doesn't gets melted.
Filler metal has to be introduced separately
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Electrodes for arc welding
NON CONSUMABLE CONSUMABLE ELECTRODE
ELECTRODE
• Non consumable electrode,
A. High melting point so that electrode doesn’t get melted
B. Normally used electrodes are carbon(called carbon arc welding),tungsten(called
tungsten inert gas arc welding or TIG welding)
• In case of consumable electrode,
A. Melting point of electrode will be same as that of work piece.
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B. Normally used electrodes are MS, SS, cast iron etc. Welding process
3
normally
referred as metal arc welding.
Electrodes for arc welding
Consumable electrode are again classified in to 2 i.e bare electrode and coated
electrode
NON CONSUMABLE
ELECTRODES BARE ELECRODE
CONSUMABLE
COATED ELECRODE
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Electrodes for arc welding
NON CONSUMABLE
ELECTRODES BARE ELECRODE
CONSUMABLE
COATED ELECRODE
Coated electrode Bare electrode
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Electrodes for arc welding-
Function of coating
• Functions of coatings are,
A. Generates inter gases like CO2 which will shield the weld metal pool and prevents
the molten metal from reacting with atmospheric oxygen, hydrogen, nitrogen etc.
Hence weld will be strong.
B. Contains flux which will react with atmospheric oxygen and form slag which will
be less denser than molten metal and hence will settle at top of molten metal.
This slag will protect the molten metal from atmospheric oxygen, hydrogen,
nitrogen etc. The slag is later removed by chipping.
C. The metal pool is covered by slag. Helps in gradual cooling of metal as metal is
not in direct contact with air.
D. Coatings are a means to introduce alloying elements to make the weld strong.
E. Helps to stabilize the arc.
The weld pool is thus shielded by shielding gas from the generated from the coating
during welding and also by the formation of slag. Thus this welding process is
popularly known as shielded metal arc welding or SMAW.
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RAVI VISHWAKARMA
Electrodes for arc welding-
Disadvantages of coating
Coating will absorb moisture. At welding temperatures, H2O will split in to H2 and O2
This O2 will go in to the weld pool. Hence oxidation of weld joint will take place leading to
less strength.
Preventive measure : Preheating of electrode in oven to remove moisture from coatings
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Ovens for heating
RAVI VISHWAKARMA 7
RAVI VISHWAKARMA
Bare electrodes for
arc welding
NON CONSUMABLE
ELECTRODES BARE ELECRODE
CONSUMABLE
COATED ELECRODE
• When coated electrodes are used, the coating will form slag and protect the weld pool
from getting contaminated….
• What protect the weld pool when bare electrodes are used????
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When bare electrodes are
used for arc welding
• When coated electrodes are used, a shielding gas, usually an inert gas like argon is
supplied which will protect the weld pool.
• Eg : MIG welding
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When non consumable electrodes are used for
arc welding
NON CONSUMABLE
ELECTRODES BARE ELECRODE
CONSUMABLE
COATED ELECRODE
• Non consumable electrode,
A. Electrode doesn’t get melted. It only forms the arc.
B. Electrodes will have high melting point.E.g,tungsten(when tungsten is used as
non consumable electrode, welding is called tungsten inert gas arc welding or
TIG welding)
• When coated electrodes are used, the coating will form slag and protect the weld
pool from getting contaminated….
• What protect the weld pool when non consumable electrodes are used????
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When non consumable electrodes are used for
arc welding
NON CONSUMABLE
ELECTRODE
• When non consumable electrodes
are used, a shielding gas, usually
an inert gas like argon is supplied
which will protect the weld pool.
• Eg : TIG welding
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Classification of arc welding based on electrode used
Metal arc welding
Shielded metal arc welding(SMAW)
Electro slag welding
CONSUMABLE
ELECTRODE Metal inert gas welding(MIG/GMAW-gas
metal arc weldig)
ARC WELDING
CLASSIFICATIN BASED Submerged arc welding
ON ELECTRODE USED
Tungsten inert gas welding(TIG/GTAW)
Carbon arc welding
NON CONSUMABLE Atomic hydrogen welding
ELECTRODE
Plasma arc welding
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Effect of Shielding Gas in Welding
• The primary purpose of shielding gas is to prevent exposure of the molten weld pool to oxygen,
nitrogen and hydrogen contained in the air atmosphere. The reaction of these elements with the
weld pool can create a variety of problems, including porosity (holes within the weld bead) and
excessive spatter.
• The typical welding gases are: Carbon Dioxide, Argon and Argon blends (with Carbon Dioxide,
Helium, Nitrogen, Hydrogen and Oxygen).
• Gases can be separated into two categories: Inert and Reactive.
Inert Gases
• Argon and Helium are inert gases. This means that neither gas will chemically react with the
molten weld pool. Argon is the most widely use inert gas since it is readily available and
inexpensive compared to helium. It produces a finger-like penetration profile (see images below).
Helium has a very high thermal conductivity compared to Argon and it is used for a hotter
arc. Helium provides a broad but shallow penetration.
Reactive Gases
• Carbon Dioxide, Oxygen, Nitrogen and Hydrogen are reactive shielding gases. These gases
combine chemically with the weld pool affecting mechanical and chemical properties of the weld
metal. Carbon Dioxide is the only one that can be used alone. All can be combined with Argon to
get binary shielding gas blends.
