Process Stability Evaluation of Basic Coated Manual Metal Arc Welding Electrodes

B C Sharma, Non-member
Experimental investigations have been carried out to study the behaviour of basic type coated electrodes (IS: E614514 HJ, AWS: E7018, DIN: E5144B 1026) of different sizes produced by different manufacturers for evaluation of process stability. Time analysis, voltage analysis and current analysis have been carried out using an Analyser Hannover. This is a digital measuring and analyzing system. It classifies electronically pulse width in steps of 0.1 x n ms in 256 classes and stores the frequencies in the memory. The data are transferred to the computer for storage on the disc for further analysis. The time analysis does not indicate any definite trend so results have been interpreted on the basis of voltage and current analysis. The experimental results reveal that the arc stability has no definite trend for the electrodes produced by a particular manufacturer. However, relatively better arc stability is associated with the electrodes of a particular manufacturer depending upon the size of electrode.
Keywords : Stability evaluation; Welding electrode; Coated metal

INTRODUCTION Manual metal arc welding (MMAW) was the first welding process after which other welding processes were developed. In spite of the development of various sophisticated welding processes, the MMAW has its own identity in the welding industry. The MMAW is the most widely used welding process for joining the metal parts, mainly, because of its versatility. A stable welding operation should have the following features smooth burning arc with small change in arc length uniform metal transfer low spatter loss rapid re-ignition after every shortest and zero current points in AC welding Statistical methods have been developed for evaluating the welding process stability and the microprocessor controlled measuring system is very helpful in analyzing the welding voltage and current waveform, metal transfer behaviour and thus determine the welding process stability. This waveform gives reproducible information and criteria about metal transfer behaviour of different covered electrodes. The obtained criteria can be used for monitoring the quality of the electrode during production and for further developing special characteristics of the metal transfer behaviour. Suban and Tuak1 described several methods used for arc stability in MIG / MAG welding. The experimental investigations have been carried out to evaluate the arc stability for some basic type of electrodes of various sizes produced by different manufacturers. The comparison of data obtained from different types of electrodes by different manufacturers will help in selection of electrodes as well as the improvement in the composition of the coating of electrodes.
B C Sharma is with G B Pant Engineering College, Pauri (Garhwal), Uttaranchal-246001. This paper was received on September 10, 2004. Written discussion on the paper will be received until May 31, 2006.

MANUAL METAL ARC WELDING (MMAW) Manual metal arc welding is an arc welding process in which the heat for welding is generated by an arc established between a flux covered consumable electrode and the surface of work. It is the most widely used welding process for joining metal parts, mainly because of its versatility2. The core of the flux covered electrode consists of either a solid metal rod of drawn or cast material, fabricated by enhancing metal powders in a metallic shealth. In MMAW, an arc is struck by touching the work-piece and the tip of the electrode. Sufficient electric current is required to melt the tip of the electrode and surface of the work beneath the arc. The typical current range used for MMAW is between 50 A and 500 A. In this manner the filler material is deposited as the electrode is progressively consumed3. The tip of the electrode must be close enough to the work to ensure that molten metal from electrode will be transferred directly into the weld pool. Many types and sizes of power sources are used for MMAW. The current may be either alternating or direct, dependind on the type of covering and type of electrode used. Constant current or dropping type of power source is preferred because it produces a small change in amperage with considerable change in arc length. The steeper the slope of volt-ampere curve within the welding range, the smaller the current change for a given change in arc voltage4,5. The open circuit voltage (OCV) of the power source must be high enough to enable the arc to be started. In shielded metal arc welding combustion and decomposition of the electrode covering generates the gaseous shield around the arc that excludes the atmosphere from the weld area. Most electrode coverings contain deoxidizers, arc stabilizers, binder, slag former, etc. Electrode covering may also be used to introduce alloying additions into the weld2,6. Composition of the electrode covering determines the performance of an electrode and the soundness of the weld. Covering of the electrode performs one or more of the following functions3. Provide a gas to shield the arc and prevent atmospheric contamination of the molten filler metal IE(I) JournalPR

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Provide a slag blanket to protect the hot weld metal pool from the air and enhance the mechanical properties of the weld metal Provide means of adding alloying elements to change the mechanical properties of the weld metal Provide scavengers, deoxidizers and fluxing agents Establishes the electrical characteristics of the electrode Some typical composition of basic and rutile type of electrodes and primary and secondary functions of constituents of the covering are listed below2,7. Constituents of Covering

classification and analysis of the arc welding process. The statistical analysis of voltage and current signals can be used for the investigations into the stability of the welding process, evaluation of power sources, survey and control during the welding and judging the skill of the welding10,12. The information about the stability of the process is readily obtained from the amplitude density distribution through measurement and can be utilized in controlling the welding processes13. The application of the microcomputer can provide a quick qualitative assessment of the welding arc stability. The voltage setting which produces greatest regularity in short circuiting event in dip mode of Electrode Class with / Composition Range, % E6013 (Rutile) 2-12 0-5 30-55 0-20 0-15 0-10 5-10 5-15 E7018 (Basic) 15-30 15-30 0-5 0-5 25-40 0-5 5-10

Function of Constituent Primary Secondary Fluxing agent Fluxing agent Arc stablizer Stablizer Stablizer Slag former Contact welding Fluxing agent Binder

Cellulose Calcium carbonate Fluosphar (CaF2) Titanium dioxide (Rutile) Feldspar (Silicate of aluminium with potassium) Mica Clay Iron powder Sodium silicate Potassium silicate STATISTICAL ANALYSIS

Shielding gas Shielding gas Slag former Slag former Slag former Extrusion Extrusion Deposition rate Binder Arc stablizer

Since the studies carried out regarding metal transfer and arc stability using short circuit counter by McMaster, et al 8, lot of further development have taken place toward studying the stability of the welding processes using the method of statistical analysis of the voltage and current waveforms during welding. Such studies are based on the fact that variations occur in one or more welding parameters because of different factors such as fluctuations in the line voltage, characteristic of the process, that is, variation in the arc length and heat input to the work piece, etc. These shall lead to the changed welding condition and thus the fluctuations in the welding parameters like the arc voltage and welding current are generated. Such variations can be used to analyze the welding process. As the voltage time fluctuation of an arc welding process is not deterministic, but a stochastic signal so the statistical theory has to be applied to describe and characterize such function. Sunnen9 studied also the stability of the welding process by counting the number of arc voltage peaks after reignition of the arc. Voltage cumulative graphs are also obtained using the technique of microphotometry to determine the stability of the process. It has been reported that the electrical signals can be used for the Vol 86 , March 2006

metal transfer, also produces satisfactory weld bead profiles14,15. However, it has been found in addition to welding voltage, current and short circuiting frequency analysis, the arc burning time distribution analysis is also necessary to determine the stability of the process. The analysis based on only short circuiting frequency distribution is insufficient to define the stability of welding process16. It has been reported that the coefficient of variation for the short circuit mean time eventually arc burning mean time could represent a suitable criteria for the stability of welding process17. For shielded metal arc welding electrode, it has been reported that the standard deviation of the welding voltage values can be used as a criteria for the evaluation of the stability of the welding process15,18,19. EXPERIMENTAL SET-UP The block diagram of the experimental set-up is shown in Figure 1. The electronically controlled electrode feeder unit has been used for feeding the electrode at constant arc length. Mild steel plates of sizes 2000 mm x 40 mm x 10 mm have been used for depositing the weld beads. The welding has been done for about 60s. Welding time and electrode length before and after the welding have been recorded for determining the welding rate. Welding speed of 22 cm/min has been 77

Electrode Feed Unit Electrode Feed Control Unit Electrode Holder Welding Power Source V Shunt Electrode

Amplifier mV

Welding Table

Light Beam Recorder

Low Pass Filter

Analyser Hannover V

Plotter

Computer Basis 10 B

Printer Figure 1 Block diagram of the experimental set-up

selected for depositing the weld. Welding current and voltage for each electrode have been recorded separately. The welding voltage has been measured between the electrode holder and the work piece with the help of digital voltmetre. A voltage signal proportional to the welding current has been obtained from a high frequency shunt for the measurement of the welding current. A Thyristorised welding power source (Thyroarc 402) has been used as the welding power source. An electronic control panel is used to adjust the arc length for obtaining the best possible bead. Similar type of electrode manufactured by various manufacturers have also been used in this study. The specifications of the electrode used for the above investigations are given below. Type Code : : BASIC AWS E7018 IS: E614514 HJ DIN: E5144B 1026 Length, mm Dia, mm 78 : : 450 3.15, 4 and 5

Sampling and Data Recording The Analyser Hannover has been used for statistical analysis of voltage and current waveforms during welding. Figure 2 shows the controlling, monitoring and analyzing system used. The other equipments used for the experimental investigations and analysis are given in Table 1 with specific purpose. Annalyser Hannover which is a digital measuring and analyzing system is able to classify electronically pulse width in steps of 0.1 x n ms in

Figure 2 Picture showing analyser hannover, computer (Basic 108) and printer

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Table 1 Equipment used for experimental investigation with purpose Equipment Basis 108 128KB computer Annalyser Hannover uP-Ah-V Digital measuring and analysing system Siemen Oscillofil C1400 Light beam recorder Paper speed, 25-100 mm/s. KEITHTHLEY MODEL 177 MICROVOLT DMM, digital voltmeter, dc voltage range, 2mV-1200V Electrode feeding set-up Input supply 220 V, 50Hz Thyristorised welding rectifier Make: Advani Oerlikon Model: Thyroarc 402 Range : 10 A 400 A Input Supply : 415 V, 35 Amp. OCV : 80V Weight: 290 kg. DC Generator Make : Kjelberg Type: KW 510 VC 01, 35 Current Range : 80 A -500 A Voltage range: 180 A -40 V Purpose Data collection control and analysis Recording of instantaneous values of arc voltage and welding current Recording current and voltage oscillograms For recording welding voltage and current values To feed MMAW electrode for constant arc length Welding power source

Table 2 Selected welding variables for arc welding and time analysis Type of Analysis Arc Voltage Analysis Number of samples Class width, v Duration of measurement, s Welding Current Analysis Number of samples Class width, v Duration of measurement, s Time Analysis Class width for T1 (Short Circuit time) Class width for T2 (Arc Burning time) Threshold voltage, v Duration of measurement, s Specification 10 00 000 0.50 11.75 10 00 000 4 and 8 11.75 0.50 1.10 10 10

For 4-mm electrode the lowest standard deviations for the voltage and current analysis correspond to the electrode produced by manufacturer M1 where the coefficients of variations are also lower as compared to the other manufacturers. For 5-mm electrode the standard deviations and coefficient of variations are also lower for the same electrode.

Welding power source

256 classes and stores the frequencies in the memory. The value of n is an integer, 1 or more. The classifications can be done for both the short circuiting time (T1) and arc burning time (T2). Frequency of sampling is about 85 kHz and data of three or more trials, each with one million samples, have been overlapped in each case. The sampling of data has been done when the welding process stabilized, that is, normally 10s after the start of the welding. After completion of the data sampling these data have been transferred to computer for storage on the disc for further analysis. Table 2 gives the sampling variables which have been selected for the statistical analysis of arc voltage, welding current, short circuiting and arc burning durations. RESULTS AND DISCUSSION Figure 3 and Figure 4 show the representative probability density distribution function of the instantaneous values of welding voltage and current. Figure 5 and Figure 6 show the representative frequency distribution of the short circuiting and arc burning time, respectively. Figure 7 and Figure 8 show the voltage and current oscillograms for typical welding conditions for different electrodes. Table 3 gives the various statistical parameters of the statistical analysis of the probability density distribution function for voltage and current analysis, respectively. Table 3 provides various values of statistical parameters for time analysis for different sizes of electrodes produced by numerous manufacturers. From Table 3 and Table 4, it is observed that the values of standard deviation for voltage and current analysis are lowest for 3.15 mm electrode produced by manufacturer M3. Further, the coefficients of variations are also lowest in the case of the same manufacturer. Vol 86 , March 2006

From Table 5, the relative short circuit time and the arc burning time are practically same for all sizes of electrode produced by different manufacturers. However, short circuiting frequency reduces with the increase in the size of the electrode. Relative arc burning time is of the order of around 96% so it seems that almost all cases the metal transfer, explosive transfer and very little by dip, that is, short circuit mode of metal transfer. In almost all cases, it has been observed that very large number of short circuits have less than 1ms short circuit time. This indicates that during the large number of short circuits no metal transfers but these occur only due to movement of molten weld pool and the droplet at the electrode tip making and breaking the contact as the number of short circuits are very low as the mean short circuit times are also very low in comparison to mean arc burning time. So it is very difficult to draw any inference from time analysis for different sizes of electrodes produced by diverse manufacturers. Therefore, within the range of investigation it can be inferred that the arc stability for E7018 (IS: E614514 HJ) basic coated electrodes, can be evaluated on the basis of statistical analysis of the welding voltage and current waveforms during welding. Further no definite trend has been observed with respect to a particular manufacturer for all sizes of the electrodes. Relatively better arc stability has been achieved for a particular electrode produced by a particular manufacturer depending upon the size of the electrode. CONCLUSION On the basis of experimental investigations, the following inferences can be drawn. No definite trend exists with respect to arc stability with the basic electrodes (IS: E614514 HJ, AWS: E7018) produced by various manufacturers. However, better arc stability has been observed for electrodes produced by manufacturers M3, M1, and M2 for the electrode sizes of 3.15 mm, 4 mm and 5 mm, respectively. 79

Table 3 Voltage analysis for different sizes of electrodes Electrode Size Manufacturer Mean voltage, V Standard deviation, V Cofficient of variation, % M1 21.05 4.72 22.40 3.15 mm M2 21.89 4.94 22.60 M3 21.93 4.65 21.20 M1 21.08 4.67 22.20 4 mm M2 21.51 5.06 23.52 M3 20.65 4.84 23.40 M1 5 mm M2 22.00 4.79 21.80 M3 20.49 5.07 24.70

Table 4 Current analysis for different sizes of electrodes Electrode Size Manufacturer Mean current, A Standard deviation, A Cofficient of variation, % M1 120.81 28.30 23.40 3.15 mm M2 120.45 28.53 23.70 M3 119.20 27.94 23.40 M1 161.49 27.51 17.00 4 mm M2 162.28 28.31 17.40 M3 162.29 27.53 17.00 M1 5 mm M2 202.99 26.90 13.30 M3 204.83 27.94 13.60

Table 5 Time analysis for different sizes of electrodes Electrode Size Manufacturer Short Circuit Time Distribution Short circuit frequency (sec-1) Mean short circuit time, ms Standard deviation, ms Relative short circuit time, % Arc Burning Time Distribution Mean arc burning time, ms Standard deviation, ms Relative arc burning time, % 70.02 67.1 96 75.20 67.97 95 97.73 82.59 96 97.92 95.59 96 98.91 85.97 95 107.40 109.59 96 161.47 157.54 97 132.28 125.24 98 13.60 3.18 3.60 4 12.70 3.62 3.84 5 9.80 4.32 4.22 4 9.80 3.78 5.07 4 9.60 5.06 5.87 5 8.80 4.30 5.79 4 5.90 5.29 7.85 3 6.60 6.23 8.19 4 M1 3.15 mm M2 M3 M1 4 mm M2 M3 M1 5 mm M2 M3

100

100

10

10

N, %

N, %

0.1

0.1

0.01

0.01 -32 -16 0 16 32 48 Volt > -384 <PDDF> -256 -128 0 128 256 384 Ampere >

-48 <PDDF>

Figure 3 Probability density distribution of welding ARC voltage values for M1 (21 V, 157 A, = 4 mm)

Figure 4 Probability density distribution of welding current values for M1 (22 V, 160 A, = 4 mm)

The arc stability has been evaluated on the basis of current and voltage analysis for the above-mentioned electrodes because of the fact that time analysis does not indicate any 80

definite trend. Time analysis is also not suitable for these electrodes because relative arc burning time is practically 96 % in all cases. IE(I) JournalPR

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10
T1, 1/s

1 .1

4 8 12 Classwidth T1 : 0.5 ms

.01

16

20

24

28

32

36 Class

Figure 5 Frequency distribution of short circuiting time for M1 (22 V, 160 A, = 4 mm) 100

Figure 7 Voltage and current oscillogram for M1 (21 V, 157 A, = 4 mm) (paper speed = 100 mm, s)

10
T2, 1/s

.1

.01

7 14 21 Classwidth T2 : 8 ms

28

35

42

49

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63 Class Figure 8 Voltage and current oscillogram for M2 (22 V, 160 A, = 4 mm) (paper speed = 100 mm, s) 12. D Rehfeldt, J Seyferth and P W Uhlig. Statistical Analysis of AC-Welding with Coated Electrodes by Means of a New Microprocessor Controlled System. Proceedings of Welding Conference, IIW Trichy Branch, 1981, p J1. 13. H E Weinschenk and N Schellhase. Statistical Analysis of Arcing Voltage in the CO2 Shielded Welding Process. Conference on Arc Physics and Weld Pool Behaviour, London, 1979, Paper 14. 14. W Lucas, Naseer Ahmed and G A Hutt. Process Stability in MIG Welding. The Welding Institute Research Bulletin (U K), October 1983, p 329. 15. D Rehfeldt, A Bollman and P C Gupta. Methods and Computerized Equipment for Analyzing and Monitoring Arc Welding Processes. Proceedings of the International Conference on Joining of Metals, Helsingor, Denmark, December 1986, p 1. 16. S R Gupta, D Rehfeldt and J Seyferth. Computerized Evaluation of Process Stability for Gas Metal Arc Welding. IIW Document, 212-611-85. 17. K Alexander. Device for Evaluation of Welding Properties in Arc Welding A Technical Report. Welding Research Institute, Brotislava, Chechoslovakia, p 43. 18. D Rehfeldt and A Bollman. Comparing Investigations of Covered Electrodes of Different Fabrications by Statistical Process Analysis. IIW Documebt, 212-677-87. 19. D Rehfeldt and A Bollman. Statistical Investigations of the Welding Behavoiur and Metal Transfer Characteristics of Filler Materials. Proceedings of International Conference on Equipment and Power Sources for Welding and Allied Processes, Ohrid, May 1988.

Figure 6 Frequency distribution of ARC burning time for M1 (22 V, 160 A, = 4 mm)

REFERENCES
1. M Suban and J Tusak. Methods for the Determination of Arc Stability. Journal of Materials Processing Technology, 2003. 2. 3. Metals Handbook. American Society of Metals, vol 6. Welding Handbook. American Welding Society, vol 2.

4. Welding Technology Data (sheet 18). Welding and Metal Fabrication, February 1971, p 60. 5. A F Manz. Advances in Power Supplies for Industries. Welding Journal, September 1963, p 719. 6. M P Tyagi, S R Gupta and P C Gupta. Influence of Electrode Coating and Polarity on Melting Rate in Manual Metal Arc Welding. Proceedings of Fourth ISME Conference, October 1981, p 239. 7. S S Richard. Function Properties and Coding of Welding Electrode Coverings. Plant Engineering, September 15, 1977, p 201. 8. R C McMAster, D C Martin and A Leatherman. Analysing Metal Transfer in Arc Welding. The Welding Journal, Research Supplement, December 1979, p 575. 9. J F Sunnen. Electrical Parameters During Metal Transfer. Proceedings of the Conference on Physics of the Welding Arc, 1966, p 67. 10. D Rehfeldt, J Seyferth and P W Uhlig. Statistical Analysis of Arc Welding Process. IIW Document, 212-511-81. 11. D Rehfeldt. Monitoring and Analyzing Systems for the Arc Welding Processes. Proceedings of the International Conference on Joining of Metals, Helsingor, Denmark, 1981, p 331.

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