Pengelasan Fusi

(Fusion Welding)
Welding)
Ir. Tri Prakosa, M. Eng.

Proses Manufaktur II,

Februari 2011

Fusion Welding
1. Oxyfuel Gas Welding
2. Arc-Welding Processes: Consumable
Electrode
3. Arc-Welding Processes: Nonconsumable
Electrode

Thermit Welding
Electrom Beam Welding
Laser Beam Welding

OXYFUEL GAS WELDING

Oxyfuel gas welding /OFW

Developed in the early 1900s, this process
utilizes the heat generated by the combustion of
acetylene gas (C2H2) in a mixture with oxygen.

The heat is generated in accordance with the
following chemical reactions. The primary
combustion process, which occurs in the inner
core of the flame, is
C2H2 + O2
2CO + H2 + Heat

Oxyfuel gas welding /OFW

This reaction dissociates the acetylene into
carbon monoxide and hydrogen and produces
about 1/3 of the total heat generated in the flame.
The second reaction is:
2CO + H2 + 1.502
2C02 + H2O + heat

which results in burning of the hydrogen and

combustion of the carbon monoxide, producing
about 2/3 of the total heat.
5

Types of flames

The proportions of acetylene and oxygen in the
gas mixture are an important factor in oxyfuel gas
welding.

At a ratio of 1 : 1, that is, when there is no excess
oxygen, it is considered to be a neutral flame.

a) Neutral Flame
6

Types of flames

With a greater oxygen supply, it becomes an
oxidizing flame. This flame is harmful, especially
for steels, because it oxidizes the steel. Only in
copper and copper-base alloys is an oxidizing
flame desirable because a thin protective layer of
slag forms over the molten metal.

b) Oxidizing Flame
7

Types of flames

If the supply of oxygen is lowered, it becomes a
reducing or carburizing flame. The temperature of a
reducing, or excess-acetylene, flame is lower.

Hence it is suitable for applications requiring low
heat, such as brazing, soldering, and flame
hardening.

c) Carburizing Flame
8

Filler metals

Filler metals are used to supply additional material
to the weld zone during welding.

They are available as rods or wire, and are made of
metals compatible with those to be welded.

These consumable filler rods may be bare, or they
may be coated with flux.

The purpose of the flux is to retard oxidation of the
surfaces of the parts being welded, by generating a
gaseous shield around the weld zone.
9

Filler metals

The flux also helps dissolve and remove oxides and
other substances from the workpiece, resulting in a
stronger joint.

The slag developed protects the molten puddle of
metal against oxidation as it cools.

10

Welding Torch yang digunakan pada

Pengelasan Oxyacetylene
(a) Gambar umum dan
(b) Penampang torch yang
digunakan pada
pengelasan oxyacetylene.

Pertama kali katup acetylene dibuka; gas

dinyalakan dengan korek api atau penyala;
kemudian katup oksigen dibuka dan nyala diatur.

11

High Pressure Gas Cylinders yang

Digunakan pada Pengelasan Oxyacetylene
(c) Peralatan dasar yang
digunakan pada oxyfuelgas welding.

Untuk memastikan
hubungan adalah benar,
semua ulir pada
sambungan acetylene
adalah ulir kiri,

Tabung oksigen
sedangkan pada oksigen
biasanya dicat merah,
adalah ulir kanan.
sedangkan tabung
acetylene dicat hijau.
12

ARC-WELDING PROCESSES:
ARCCONSUMABLE ELECTRODE
13

Shielded metalmetal-arc welding (SMAW)

(Las Busur Listrik
Listrik))

Shielded metal-arc welding (SMAW) is one of the
oldest, simplest, and most versatile joining
processes.

Currently, about 50% of all industrial and
maintenance welding is performed by this process.

The electric arc is generated by touching the tip of a
coated electrode against the workpiece and then
withdrawing it quickly to a distance sufficient to
maintain the arc.

14

Las Busur Listrik (Shielded

Metal-- Arc Welding/SMAW)
Metal
Ilustrasi skematik proses
pengelasan dengan elektroda
terselubung (shielded metalarc welding). Sekitar 50%
operasi di industri ukuran
besar menggunaan proses ini.
Ilustrasi skematik operasi
shielded metal-arc welding
(dikenal juga sebagai stick
welding, karena bentuk
elektroda berupa batang).
15

Las Busur Rendam

Submerged arc welding/SAW)

In submerged arc welding (SAW), the weld arc is
shielded by granular flux, consisting of lime, silica,
manganese oxide, calcium fluoride, and other
elements.

The flux is fed into the weld zone by gravity flow
through a nozzle. See the following figure.

16

Las Busur Rendam (Submerged

Submerged-Arc Welding/SAW)

Ilustrasi Skematik Las Busur Rendam (submerged-arc welding)

dan peralatannya. Flux yang tidak terproses, akan digunakan
kembali. Sumber: American Welding Society.
17

Gas metalmetal-arc welding /GMAW

In gas metal-arc
welding (GMAW),
the weld area is
shielded by an
external source,
such as argon,
helium, carbon
dioxide, or various
other gas mixtures
Ilustrasi Skematik proses pengelasan busur
logam-gas (gas metal-arc welding), dahulu
sering disebut dengan pengelasan MIG (metal
inert gas).
18

Gas metalmetal-arc welding /GMAW

Peralatan dasar
yang digunakan
pada operasi
gas metal- arc
welding.
Sumber:
American
Welding Society.

The consumable bare wire is fed automatically

through a nozzle into the weld arc.
19

Gas metalmetal-arc welding /GMAW

In spray transfer, small droplets of molten metal
from the electrode are transferred to the weld area
at rates of several hundred droplets per second.

The transfer is spatter-free and very stable.

High dc current and voltages and large diameter
electrodes are used, with argon or argon-rich gas
mixtures used as the shielding gas.

20

Gas metalmetal-arc welding /GMAW

The average current required in this process can be
reduced by pulsed arcs, which are high-amplitude
pulses superimposed over a low, steady current,
and the process can be used in all welding
positions.

In globular transfer, CO2 rich gases are utilized, and
globules propelled by the forces of the electric arc
transfer the metal, resulting in considerable spatter.

21

Gas metalmetal-arc welding /GMAW

High welding currents are used, with greater weld
penetration and welding speed than in spray
transfer.

Heavier sections are commonly joined by this
method.

In short circuiting, the metal is transferred in
individual droplets, at rates of more than 50 per
second, as the electrode tip touches the molten
weld metal and short circuits.

22

Flux--cored arc welding /FCAW

Flux

The flux-cored arc welding (FCAW) process is similar to
gas metal-arc welding, with the exception that the
electrode is tubular in shape and is filled with flux (hence
the term flux cored).
Iustrasi skematik
proses pengelasan
busur - dengan inti
flux (flux-cored arcwelding). Operasi
ini mirip dengan gas
metal-arc welding.

23

Flux--cored arc welding /FCAW

Flux

Cored electrodes produce a more stable arc,
improve weld contour, and improve the mechanical
properties of the weld metal.

The flux in these electrodes is much more flexible
than the brittle coating used on SMAW electrodes.

Thus the tubular electrode can be provided in long
coiled lengths.

The electrodes are usually 0.5-4 mm (0.020-0.15
in.) in diameter.
24

Flux--cored arc welding /FCAW

Flux

The power required is about 20 kW.

Self-shielded cored electrodes are also available.

These electrodes do not require external gas
shielding because they contain emissive fluxes that
shield the weld area against the surrounding
atmosphere.

25

Flux--cored arc welding /FCAW

Flux

Small-diameter electrodes have made welding of
thinner materials not only possible but often
desirable.

Also, small-diameter electrodes make it relatively
easy to weld parts out of position, and the flux
chemistry enables welding of many base metals.

26

Electrogas welding /EGW

Electrogas welding
(EGW) is used primarily
for welding the edges of
sections vertically in
one pass with the
pieces placed edge to
edge (butt).

It is classified as a
machine welding
process because it
requires special
equipment
27

Ilustrasi skematik proses pengelasan electrogas.

Sumber:American Welding Society.

Electrogas welding /EGW

The weld metal is deposited into a weld cavity
between the two pieces to be joined.

The space is enclosed by two water-cooled copper
dams (shoes) to prevent the molten slag from
running off.

Mechanical drives move the shoes upward.

Circumferential welds such as on pipes are also
possible, with the workpiece rotating.

28

Electrogas welding /EGW

Single or multiple electrodes are fed through a
conduit and a continuous arc is maintained, using
flux-cored electrodes at up to 750 A, or solid
electrodes at 400 A.

Power requirements are about 20 kW.

Shielding is by inert gas, such as CO2, Ar, or He,
depending on the type of material being welded.

The gas may be provided from an external source,
or it may be produced from a flux-cored electrode,
or both.
29

Electroslag welding /ESW

Developed in the
1950s,
electroslag
welding (ESW)
and its
applications are
similar to
electrogas
welding.
Peralatan yang digunakan untuk operasi pengelasan
electroslag. Sumber: American Welding Society.

30

Electroslag welding /ESW

The main difference is that the arc is started
between the electrode tip and the bottom of the
part to be welded.

Flux is added and melted by the heat of the arc.

After the molten slag reaches the tip of the
electrode, the arc is extinguished.

Energy is supplied continuously through the
electrical resistance of the molten slag.

31

Electroslag welding /ESW

Thus because the arc is extinguished, ESW is not
strictly an arc welding process.

Single or multiple solid as well as flux-cored
electrodes may be used.

The guide may be non-consumable (conventional
method) or consumable.

32

ARC-WELDING PROCESSES:
ARCNONCONSUMABLE ELECTRODE
33

Gas tungstentungsten-arc welding /GTAW

In gas tungsten-arc
welding (GTAW),
the filler metal is
supplied from a
filler wire.

Proses pengelasan busur - gas tungsten, dahulu dikenal

sebagai pengelasan TIG (tungsten inert gas).

34

Gas tungstentungsten-arc welding /GTAW

Because the tungsten electrode is not consumed in
this operation, a constant and stable arc gap is
maintained at a constant current level.

The filler metals are similar to the metals to be
welded, and flux is not used.

The shielding gas is usually Ar or He, or a mixture of
the two.

Welding with GTAW may be done without filler
metals, as in welding close-fit joints.
35

Gas tungstentungsten-arc welding /GTAW

The power supply is either dc at 200 A, or ac at
500 A, depending on the metals to be welded.

Perlengkapan untuk operasi pengelasan busur - gas tungsten. Sumber: American Welding
Society.
36

Gas tungstentungsten-arc welding /GTAW

In general, ac is preferred for aluminum and
magnesium because the cleaning action of ac
removes oxides and improves weld quality.

Thorium or zirconium may be used in the tungsten
electrodes to improve their electron emission
characteristics.

Power requirements range from 8 kW to 20 kW.

Contamination of the tungsten electrode by the
molten metal can be a significant problem,
particularly in critical applications, as it can cause
discontinuities in the weld.
37

Gas tungstentungsten-arc welding /GTAW

Thus contact of the electrode with the molten metal
pool should be avoided.

38

Atomic hydrogen welding /AHW

Atomic hydrogen welding (AHW) uses an arc in a
shielding atmosphere of hydrogen.

The arc is between two tungsten or carbon
electrodes.

Thus the workpiece is not part of the electrical
circuit, as it is in GTAW.

The hydrogen gas also cools the electrodes.

39

Atomic Hydrogen Welding Torch

Sumber: http://www.gbwelding.com/data/welding_processes/ahw.htm

40

Atomic hydrogen welding

Sumber: http://www.gbwelding.com/data/welding_processes/ahw.htm

41

Plasma--arc welding /PAW

Plasma

In plasma-arc welding (PAW), developed in the
1960s, a concentrated plasma arc is produced and
aimed at the weld area.

The arc is stable and reaches temperatures as high
as 33,000 C (60,000 F).

A plasma is ionized hot gas, composed of nearly
equal numbers of electrons and ions.

The plasma is initiated between the tungsten
electrode and the orifice, using a low-current pilot
arc.
42

Plasma--arc welding /PAW

Plasma

Unlike other processes, the plasma arc is
concentrated because it is forced through a
relatively small orifice.

Operating currents are usually below 100 A, but
they can be higher for special applications.

When a filler metal is used, it is fed into the arc, as
in GTAW.

Arc and weld-zone shielding is supplied through an
outer shielding ring by gases such as Ar, He, or
mixtures.
43

Plasma--arc welding /PAW

Plasma

There are two methods of plasma-arc welding.
{ Transferred-arc method
{ Nontransferred method

In the transferred-arc method (Figure a), the

workpiece being welded is part of the electrical
circuit.

The arc thus transfers from the electrode to the
workpiece-hence the term transferred.

44

Plasma--Arc Welding /PAW

Plasma

Dua jenis proses pengelasan busur plasma: (a) transferred,

(b) nontransferred. Lasan yang dalam dan sempit dapat
dilakukan dengan proses ini, dengan kecepatan pengelasan
yang tinggi.
45

Plasma--arc welding /PAW

Plasma

In the nontransferred method (Figure b), the arc is
between the electrode and the nozzle, and the heat
is carried to the workpiece by the plasma gas.

The thermal transfer mechanism is similar to that for
oxyfuel flame.

46

THERMIT WELDING

47

Thermit welding

Thermit welding (TW) gets its name from thermite,
which is based on the word therm meaning heat; the
word Thermit is a registered trademark.

The process involves exothermic (heat producing)
reactions between metal oxides and metallic
reducing agents.

The heat of the reaction is then utilized in welding.

This process dates back to the early 1900s.

48

Thermit welding

The most common mixture of materials used in
welding steel and cast iron is finely divided
particles of iron oxide (Fe3O4), aluminum oxide
(Al203), iron, and aluminum.

The basic reactions are:
Fe 3O4 + 2Al  94Fe + Al2O3 + heat
3 FeO + 2Al  3 Fe + Al2O3 + heat
Fe3O4 + 2Al  2 Fe + Al2O3 + heat

49

Thermit welding

This nonexplosive mixture produces a maximum
theoretical temperature of 3200 C (5800 F) within
less than a minute.

In practice, however, this temperature is only about
2200-2400 C (4000-4350 F).

The mixture may also contain other materials to
impart special properties to the weld.

50

Thermit welding

The reaction is started by applying a magnesium
fuse to special compounds of peroxides,
chlorates, or chromates, known as oxidizing
agents, with an ignition temperature of about
1200 C (2200 F).

Welding copper, brasses, and bronzes, and
copper alloys to steels, involves the following
reactions:
3CuO + 2Al  3Cu + Al2O3 + heat
3Cu2O + 2Al  6Cu + Al2O3 + heat
51

Thermit welding

Oxides of copper, nickel, chromium, and
manganese are also used in Thermit welding,
resulting in temperatures ranging up to 5000 C
(9000 F).

52

ELECTRON--BEAM WELDING
ELECTRON

53

Electron--Beam Welding /EBW

Electron

In electron-beam welding (EBW), heat is generated
by high-velocity narrow-beam electrons.

The kinetic energy of the electrons is converted into
heat as they strike the workpiece.

This process requires special equipment to focus
the beam on the workpiece in a vacuum.

The higher the vacuum, the more the beam
penetrates and the greater the depth-to-width ratio
is.
54

Electron--Beam Welding /EBW

Electron

Almost any metal can be welded by EBW, with
workpiece thicknesses ranging from foil to plate.

The intense energy is also capable of producing
holes in the workpiece.

Generally, no shielding gas, flux, or filler metal is
required. Capacities of electron beam guns range to
100 kW.

Developed in the 1960s, EBW has the capability to
make high-quality welds that are almost parallel
sided, are deep and narrow, and have small HAZ
(heat-affected zones).
55

LASER--BEAM WELDING
LASER

56

Laser--Beam Welding /LBW

Laser

Laser-beam welding (LBW) utilizes a high-power
laser beam as the source of heat to produce a
fusion weld.

Because the beam can be focused to a very small
area, it has high-energy density and, therefore, has
deep penetrating capability.

The beam can be directed, shaped, and focused
precisely on the workpiece.

57

Laser--Beam Welding /LBW

Laser

Consequently, this process is particularly suitable
for welding deep and narrow joints, with depth-towidth ratios typically ranging from 4 to 10.

The laser beam may be pulsed (milliseconds) for
applications such as spot welding of thin materials,
with power levels up to 100 kW.

Continuous multi-kW laser systems are used for
deep welds on thick sections.

58

Contoh Pengelasan dengan Laser

Pengelasan Laser
pada pisau cukur.
59

TERIMA KASIH