Beruflich Dokumente
Kultur Dokumente
Handbook
For Gas Shielded Arc Welding, Oxy Fuel Cutting & Plasma Cutting
Published by:
Air Products PLC
Copyright:
Air Products PLC 1999 3rd Edition
CONTENTS
Introduction
Fusion welding
Welding terms
MIG/MAG welding
TIG welding
10
Plasma welding
17
Welding sheet
18
Welding plate
20
Welding pipes
22
Defects in welds
24
26
TIG welding
29
Welding data:
MIG/MAG welding
30
33
TIG welding
34
37
Plasma cutting
44
Safety always
46
Conversion data
Fusion welding
'T' joint
The most widely used welding processes rely on fusion of the components
at the joint line.
fillet
weld
arc
high current
low voltage
supply
Butt joint
Electric arc
blowpipe
Gas flame
The molten metal must be protected
from the atmosphere - absorption of
oxygen and nitrogen leads to a poor
quality weld.
Air in the weld area can be replaced by
a gas which does not contaminate the
metal, or the weld can be covered with
a flux.
butt
weld
INTRODUCTION
Which process?
Factors in choosing
welding process:
type of metal
leak tight,
type of joint
reproducible,
production constraints
equipment availability
labour availability
health, safety and the
environment
costs of consumables
on site
labour costs
for
material thickness
sheet
plate
pipe
sections
ARC WELDING
WELDING TERMS
pure argon
nozzle to plate
distance-kept at
about 19-25mm
arc length
spool of wire
work
power
supply unit
keeps arc
length
constant
gas nozzle
shielding gas
MIG/MAG WELDING
Operation
overhead
vertical
voltage
high
correct
low
Current controls:
-8
75
0
heat input
size of weld
depth of penetration
Wire diameter depends on the current
required. The table gives a guide to
the selection of wire diameter but the
exact relationship depends on the
material and the shielding gas.
450 - 550
Diameter
(mm)
Current
range
(A)
Wire feed
speed
(m/min)
0.6
40100
25
0.8
40150
36
1.0
100280
312
1.2
120350
418
MIG/MAG WELDING
joint
tungsten
electrode
weld pool
10
TIG WELDING
Operation
TIG welding is suitable for both manual
and mechanised welding.
In manual welding, the operator points
the electrode in the direction of
welding and uses the arc to melt the
metal at the joint.
If filler metal is required, for example
when making a fillet weld, it is added
to the leading edge of the weld pool.
Filler is supplied as cut lengths of wire
- usually 1 metre long.
Choice of current
25mm
11
Crater filling
Automatic gradual reduction of the
current at the end of a weld run avoids
the formation of a crater.
welding current
arc extinguished
time
crater
crater or
ofhole
holeatat
end
end of
of weld
weld
welding current
current
reduced in
steps
weld surface
smooth at end of
weld run
12
TIG WELDING
Electrode
diameter
mm
Alternating
Current (ac)
1.6
60150
60125
2.4
170250
120210
3.2
225330
150250
4.0
350480
240350
4.8
500675
330460
13
torch body
ceramic
nozzle
gas
gas
gas lens
tungsten
electrode
uniform laminar gas flow
penciltorch
torch
pencil
swivel
swivelhead
headtorch
torch
14
TIG WELDING
Pulsed TIG
At low currents, a TIG arc becomes
difficult to control. Pulsing the current
gives stable operation at low heat
input levels.
weld
consists
of overlapping
circular weld pools
direction of
welding
high level
pulse
mean
pulse
low level
time pulse
pulse height
current amps
pulse duration
15
Gas backing
clamp
joint
line
clamp
work
piece
nozzle placed
in contact sheet
to give correct
arc length
copper backing
bar with holes at
5mm intervals
16
TIG WELDING
tungsten
electrode
shielding
gas
work piece
keyhole
direction of weld
17
'T' joint
Corner joint
no gap
gap not
greater than half sheet thickness
18
75
0
-8
copper
backing bar
450 - 550
mm
10
mm
50
75
19
_ 80
Double 'V'
Type
Thickness
Aluminium
Up to 6mm
g = 1/2t
g = 1/2t
6mm
to
18mm
A = 60
Rf = 1.5mm max
g = 1mm max
A = 65-70
Rf = 1.5mm max
g = 1.5mm max
Above
18mm
A = 50
Rf = 1 to 2mm
g = nil
A = 80-90
Rf = 1.5mm max
g = 1.0mm max
Square edge
t
g
Single V
A
Rf
Double V
Rf
20
WELDING PLATES
filling passes
capping pass
root run
root-run
root
run
fixed
into
fixed into
backing
strip
backing strip
copper
backing bar
21
roller manipulator
flat
butt
vertical
overhead
branch
tack weld
22
WELDING PIPES
fillet
butt
backing strip
flange rotated
23
Lack of fusion
Defects in welds
Porosity
blocked nozzle
draughty conditions
A
A
B
B
A-lack of inter-run fusion
B-lack of side fusion
Lack of penetration
Undercut
poor technique
poor technique
misaligned joint
24
WELDING DEFECTS
Tungsten inclusions
Spatter
insufficient inductance (MAG)
TIG welding
rusty plate
25
General guidelines:
Penetration increases with the
addition of helium. Penetration
also increases with higher
carbon dioxide contents.
Choose Ferromaxx 7 if work
is wholly thin material. Ferromaxx 15 gives better results
on a wider range of material
thicknesses with the benefit of
reduced ozone emissions. It
can be used successfully on
thin materials but penetration in
butt joints may be more difficult
to control.
Ferromaxx Plus
CO2
26
Ferromaxx
7
Ferromaxx
15
Ferromaxx
Plus
Carbon
dioxide
Carbon,
Carbon-manganese
Structural
Carbon-molybdenum
1.5%Cr 0.5%Mo
2.5%Cr 1%Mo
See Note
See Note
5%Cr 1%Mo
Notes: In many applications Argon-2% oxygen is preferred for the welding of steels containing 5% Cr.
Always seek technical advice before recommending a gas for these steels.
Benefits of Ferromaxx
less spatter
smooth surface
stable arc gives
uniform width
better profile
27
Stainless steel
Inomaxx Plus
Inomaxx 2
argon + 1% to 3%
oxygen
argon
argon + 15% to
25% nitrogen
argon
argon
28
Metal
Pure argon
Alumaxx Plus
Helium 75%
argon 25%
Inomaxx TIG
argon + 1% to 3%
hydrogen
argon + 5%
hydrogen
improved penetration
less surface oxidation
deeper penetration
29
0.6
40100
0.8
40150
1.0
100280
1.2
120350
1.6
150450
Electrode
diam mm
0.8
125
122
364
1.0
95
93
276
1.2
55
54
160
1.6
30
29
87
m/min
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
700
m
m
500
400
0.
8
600
1.0
m
m
mm
1.2
300
m
1.6 m
200
100
50
100
150
200
250
Welding current A
30
300
350
400
450
WELDING DATA
Joint Electrode
gap mm dia mm
Current
A
Voltage
V
Gas (1)
Carbon steel
0.9
20
/32
0.8
0.8
55 - 65
16 - 17
Ferromaxx Plus
1.2
18
/64
0.8
0.8
80 - 100
17 - 19
Ferromaxx Plus
1.6
16
/16
0.8
0.8
90 - 110
17 - 19
Ferromaxx Plus
2.0
14
/64
0.8
0.8
110 - 130
18 - 20
Ferromaxx Plus
3.2
10
/8
0.8
1.0
180 - 200
20 - 23
Ferromaxx Plus
4.0
/32
1.2
1.0
180 - 200
20 - 23
Ferromaxx Plus
6.0(2)
/4
1.6
1.0
180 - 200
20 - 23
Ferromaxx Plus
Stainless steel
1.6
16
/16
1.0
0.8
70 - 90
19 - 20
Inomaxx Plus
2.0
14
/64
1.0
1.0
75 - 95
19 - 20
Inomaxx Plus
3.2
10
/8
1.0
1.0
90 - 130
18 - 21
Inomaxx Plus
6.0(2)
/4
1.6
1.2
180 - 240
22 - 26
Inomaxx Plus
16
/18
1.0
1.0
70 - 100
17 - 18
Alumaxx Plus
2.0(3)
14
/64
1.0
1.0
70 - 100
17 - 18
Alumaxx Plus
3.2
10
/8
1.0
1.2
100 - 130
19 - 20
Alumaxx Plus
6.0(2)
/4
1.6
1.2
150 - 200
26 - 29
Alumaxx Plus
Notes: (1) Gas flow rate: 14 to 16l/min (higher flow rates may be required with gases containing helium)
(2) Welded from both sides
(3) Pulsed transfer
31
Wire
dia mm
Current
A
1.0
90100
1719
Second
1.2
260270
2931
Filling
1.2
280300
3133
Leg
length
mm
Wire
dia mm
1.2
300320 3133
10
1.2
290310 3032
12
1.2
290310 3032
Current
A
Voltage
V
Number
of
runs
0.8
8085
1921
Second
1.6
220230
2224
Filling
1.6
265275
2527
4
1.0
8595
2022
Second
1.6
210220
2426
Filing
1.6
230240
2426
use a
triangular
weave
ensure
fusion
in the
root
mm
mm
1.0
8095
1718
10
1.0
70180
1920
12 (1)
1.0
8095
1718
12 (2)
1.0
70180
1920
(1) Root run deposited vertical-down (2) Filling run deposited with weave moving up the joint.
32
Current
range A
Wire
dia mm
Current
range A
1.2
100 - 280
2.4
300 - 525
1.6
140 - 350
3.2
400 - 650
2.0
200 - 425
Wire
dia mm
Current
A
Voltage
V
Root
1.2
140 - 180
18
Second
2.4
350 - 430
25
Filling
2.4
350 - 430
25
Wire
dia mm
Current
A
Voltage
V
Root
1.2
130 - 165
18
Second
1.2
150 - 170
18
Filling (weaved)
1.2
170 - 200
20
Wire
dia mm
Current
A
Voltage
V
4.5
2.0
325 - 375
25
6.0
2.4
400 - 450
30
10.0
2.4
450 - 525
32
33
o
65 - 75 o
removable backing
no sheet
root gap
gap=half
thickness
1mm
up to 3.2mm
up to 3.2mm
Metal
thickness
mm
Electrode
diameter
mm
Filler rod
diameter
mm
Welding
current
A
1.6mm
Shielding
gas flow
l/min
1.6
60 80
3.2
3.2
2.4
125 145
4.8
4.0
3.2
180 220
10
6.0
4.8
4.8
235 275
12
1.6
1.6
60 70
3.2
2.4
2.4
70 95
4.8
2.4
3.2
100 120
6.0
3.2
4.0
135 160
1.6
1.6
60 70
3.2
1.6 or 2.4
2.4
75 95
4.8
2.4
3.2
110 130
6.0
3.2
4.8
155 175
34
Metal
thickness
mm
Electrode
diameter
mm
up to
to 3.2
3.2mm
- no gap
up
mm - no gap
4.8mm
- 0.8mm
over 4.8
m - 0.8
mm gap gap
Filler rod
diameter
mm
Welding
current
A
Shielding
gas flow
l/min
2.4
1.6
60 80
3.2
3.2
2.4
130 160
4.8
3.2 or 4.0
3.2
195 230
6.0
4.0 or 4.8
4.8
260 295
10
1.6
1.6
50 70
3.2
2.4
2.4
85 105
4.8
2.4
3.2
120 145
6.0
3.2
4.0
165 180
1.6
1.6
50 70
3.2
1.6 or 2.4
2.4
90 120
4.8
2.4
3.2
135 175
6.0
3.2
4.8
170 200
35
no gap
1mm gap
up to 3.2mm thickness
Metal
thickness
mm
Electrode
diameter
mm
Filler rod
diameter
mm
Welding
current
A
Shielding
gas flow
l/min
2.4
1.6
50 70
3.2
2.4 or 3.2
2.4
100 120
4.8
3.2 or 4.0
3.2
175 210
10
6.0
4.0 or 4.8
4.8
220 260
12
1.6
1.6
40 55
3.2
2.4
2.4
50 75
4.8
2.4
3.2
90 110
6.0
3.2
4.0
125 150
10
1.6
1.6
40 60
3.2
1.6 or 2.4
2.4
70 90
4.8
2.4
3.2
110 130
6.0
3.2
4.8
155 175
10
36
OXYGEN CUTTING
preheat
flame
cut face
Metal
Cutting response
Very good
Stainless steel
Aluminium,
copper etc
Unsuitable
37
Equipment
The essential equipment for cutting
comprises:
flow
cutting oxygen
pre-heat oxygen
pre-heat fuel
seatings
nut
nozzle
38
OXYGEN CUTTING
Preheat flame
The preheat flame:
Apachi+
Acetylene
Propane
Cutting speed
Ease of handling
= best choice
= worst choice
39
kerf width
Quality of cut
sharp edge
no slag bridge
Condition
Effect
Nozzle-to-plate
distance
too low
too high
undercutting
Cutting oxygen
pressure
too low
cutting stops
too high
too low
too high
too small
cutting stops
Cutting speed
Preheat flame
too big
edge rounded
undercut
40
OXYGEN CUTTING
Operating techniques
Manual cutting is used for short cuts
and the removal of defective parts.
It is difficult to achieve a uniform cut
with manual techniques. Variations in
travel speed and nozzle-to-plate
distance give irregular cut faces.
41
Operating techniques
Mechanised cutting produces a
superior finish to manual operation.
A variety of mechanised traversing
systems are available or the torch
can be moved along a straight line or
by hand to produce a complex shape.
leading trailing
nozzle nozzle
42
OXYGEN CUTTING
12
18
25
35
50
Nozzle size - in
1/32
1/32
3/64
3/64
1/16
1/16
1/16
Cutting speed
in/min
mm/sec
24
10.2
22
9.3
21
8.9
15
6.3
13
5.5
12
5.1
11.5
4.9
pressure bar
pressure psi
1.8
25
1.8
25
2.1
30
2.1
30
2.8
40
3.2
45
3.2
45
650
950
1150
1600
2000
2500
3300
pressure bar
pressure psi
.14
2
.21
3
.21
3
.21
3
.30
4
.30
4
.30
4
250
900
260
950
295
1025
295
1025
340
1150
400
1350
400
1350
Acetylene
oxygen
310
340
320
355
340
375
340
375
400
440
430
475
430
475
Propane
oxygen
255
1080
265
1125
300
1275
300
1275
350
1475
400
1720
400
1720
Cutting oxygen
Preheat gas
Note: These conditions provide a starting point. Precise settings depend on the type of nozzle,
nozzle-to-plate distance and the condition of the plate surface.
43
ceramic shroud
tungsten electrode
plasma gas
shielding gas
plasma (arc) stream
44
Hytec 35
Benefits of Hytec 35
Aluminium
Stainless
Steel
Orifice size
mm
Power
kW
Flow rate
l/min
7607
60
82.6
12
2536
70
82.6
25
1268
80
94.4
50
507
80
94.4
75
380
90
94.4
100
304
90
94.4
12
2536
60
70.8
25
1268
80
80.2
50
507
100
94.4
75
406
100
94.4
100
203
100
94.4
For specific parameters and gas flow rates consult your equipment manual.
45
46
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DIRECT
0800 389 02 02
www.airproducts.com/maxx