Materials Joining

Homework

1. Advantages : - Can be applied in various applications

- Low cost
- Portable
Disadvantages : -Inefficient when changing electrode
- Not as good as continuous wire processes
- High metal wastage
2. Advantage of TIG :
Weld more metals and alloys than any other process
Create high quality, clean welds
Use one shielding gas (Argon) for all applications
Disadvantage of TIG :
Complexity the TIG welding process is more complex and therefore more
difficult to become proficient at than other processes.
Speed because of its complexity TIG welding is also slower than other
processes.
Expensive
3. Advantage of SAW :
Molten flux provides very suitable conditions for high current to flow.
Great intensities of heat can be generated and kept concentrated to
weld thicker sections with deep penetrations.
Because of high heat concentration, considerably higher welding speeds
can
be caused.
Because of high heat concentration and high welding speeds weld
distortion
is much less.
High metal deposition rates can be achieved. Single pass welds can be
made
in thick plates with normal equipment.
Disadvantage of SAW :
Since the operator cannot see the welding being carried out, he cannot
judge
the progress of welding accurately. Therefore accessories like jigs and
fixtures, pointers, light beam focusing devices or roller guides may be
used for proper welding at the joint.
The flux needs replacing of the same on the joint which is not always
possible.
The progress is limited to welding in flat position and on the metal more
than 4.8 mm thick. In small thicknesses burn through is likely to occur.

 The process requires edge preparation and accurate fit up on the joint.
Otherwise the flux may spill through the gap and arc may burn the
workpiece edges.
4. Advantages of SMAW
Adaptable to remote locations
Suitable out of position
Low cost
Simplicity
Disadvantages of SMAW
Current limits lower
Costly to given quantity
Not productive enough
Relatively high wastage
Advantages SAW

Minimum weld fume

Suited welding thickness
Suitable welding carbon
High metal deposition

Disadvantages SAW

Flat/horizon position only

Need to pay attention on alignment
Tip and weld pool underneath solid flux
Position correct electrode

5. a. In the case of shielding gas containing argon mixed with 20% of CO2 gas, the
metal transfer mode become spray transfer when the welding speed is lower than
certain critical value.
b. Comparing with 100% CO2 gas shielded arc welding under the same welding
parameters, MAG welding with using mixed gas of 80% argon and 20% of CO2
has wider bead, but easily gets more spatter.
6. TIG Welding vs SMAW Welding
TIG has no flux (welding started)
TIG is faster than SMAW
TIG could weld many kind of metals compared to SMAW
7. Advantages of MAG compared to SAW :
1. Required less post-weld cleaning
2. Could be used for all positive welding solution
3. More suitable for constructional welding because it uses MIG (metal inert
gas) weld.
Disadvantages of MAG compared to SAW :
1. Initial setup is more complicated than SAW.

2. Because it uses inert gas, the welding could not be commenced in an open
air situation .
3. Defect could easily occur due to the use of bad shielding gas.
8. Advantages of FCAW compared to MAG :
1. More Efficient
2. Uses less electrode
3. High deposition process rate
4. Could be done automatically and semi-automatically
Disadvantages of FCAW compared to MAG :
1. The process produces lots of pollution smoke
2. The process produces lots of UV radiation
3. Slag must be cleaned immediately.