Project Report (Arc Weldinng)

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ABSTRACT
Arc-welding is the most commonly and widely used welding technique for variety of purposes.
Welded joint may not be very reliable unless the weld is of reasonably good quality. Improving
the weld quality is of prime concern. This project work is intended to investigate the effect of
magnetic field on the structure and properties of weld in shielded metal arc welding. The
objective is to study the effect of welding parameters and to use magnetic field advantageously to
improve the weld qualities and properties (such as strength and hardness). However there is lack
of information for optimum parameters, very little work has been reported in this direction. A
magnetic field externally applied to the welding arc, deflects the arc by electromagnetic force in
the plane normal to the field lines. The magnetic field exerts force on the electrons and ions
within the arc, which causes the arc to be deflected away from the normal arc path. The welding
arc can be deflected forward, backward, or sideways with respect to electrode and welding
direction depending upon the direction of an external magnetic field
In this project work various mechanical properties tests as tensile strength, harness, toughness
etc. are conducted to see the effect of external magnetic field on it. A set of weld-pieces( with
magnetic field and without magnetic field) are tested for various mechanical properties and
comparable study is done to know the change in these properties.
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TABLE OF CONTENTS
page
CERTIFICATE .ii
DECLERATION . ..iii
ACKNOWLEDGEMENT iv
ABSTRACT ..v
Chapter 1: Introduction
1.1 General .1
1.2 Shielded metal arc welding (SMAW)...2
1.3 Gas Tungsten Arc Welding (GTAW)...3
1.4 Gas Metal Arc Welding (GMAW)....4
1.5 Gas Welding..5
Chapter 2: Review of Literature
2.1 Summary of shielded metal arc welding ...6

2.2 AC/DC Power Sources..7
2.3 Electrode used in SMAW...9
2.4 Welding process...10
2.5 Influence of magnetic field...11
2.6 Objective ..13
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Chapter 3: application of magnetic field
3.1 Longitudinal magnetic field.14

3.2 Transverse magnetic field15
Chapter 4: Weld quality and weld geometry
4.1 Defects in weld-pieces.16

4.2 Geometry of weld-pieces.19
Chapter 5: Welding set-up on lathe
5.1 Automation to welding process...20

5.2 Arrangement for magnetic field...21
5.3 Equipments and instruments used...................21
5.4 Line diagram of set-up.23
Chapter 6: Welding with the set-up
6.1 Preparation of specimens...24

6.2 Welding with magnetic field(M)24
6.3 Welding without magnetic field(WM)...25
6.4 Grouping and cutting of weld-pieces 26
Chapter 7: Weld tests
7.1 Hardness test.. .29

7.2 Tensile strength test.. ..31
7.3 Impact test36
Chapter 8: Effect of magnetic field
8.1 Visual effects. .38

8.2 Effect on weld properties.40
8.3 Effect on weld geometry..43
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Chapter 9: conclusion and suggestions for further work
9.1 Conclusions45
9.2 Suggestions for further work..46
References..47
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INTRODUCTION
1.1 General
Welding is a process in which materials of the same fundamental type or class are brought
together and caused to join (and become one) through the formation of primary chemical
bonds under the combined action of heat and pressure . The definition found in IS0 standard
is Welding is an operation in which continuity is obtained between parts for assembly, by
various means. Hence, the welding is the fusion of two or more pieces of metal together by
using the heat produced from an electric arc welding machine. Arc welding dates back to the
late 1800s, when a man was welding with a bare metal rod on iron, the sparks from the
welding caught a stack of newspapers on fire near him and while welding, he noticed that his
welds started looking a lot better. The reason for this was the smoke took the oxygen out of
its welding environment and decreased porosity. The arc is struck between the electrode and
the metal. It then heats the metal to a melting point. The electrode is then removed, breaking
the arc between the electrode and the metal. This allows the molten metal to freeze or
solidify. The arc is like a flame of intense heat that is generated as the electrical current
passes through a highly resistant air gap.
Types of arc Welding processes: -
SMAW (Shielded Metal Arc Welding)
GMAW (Gas Metal Arc Welding)
GTAW (Gas Tungsten Arc Welding)
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1.2 SMAW (Shielded metal arc welding):
SMAW is the most common form of welding. An arc welding machine supplies electric
current to an electrode wire. The electric current travels through the air gap between the end
of the electrode wire and the base metal. As the electric current flows through this air gap, an
electric arc is formed. The electric arc produces heat that heats the base metal to its melting
temperature. The heat from the base metal produces a shielding gas that protects the base
metal, arc, electrode, and weld from the atmosphere during the welding process. As the flux
covering on the electrode wire melts, a shielding gas is created. When the flux cools, it
solidifies and forms a protective slag over the weld bead. As the electrode wire melts, it
becomes the filler metal to the weld.
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Fig -1.1 Shielded metal arc

GTAW (Gas Tungsten Arc Welding):
Gas Tungsten Arc Welding (GTAW), also known as tungsten inert gas (TIG) welding is a
process that produces an electric arc maintained between a non consumable tungsten
electrode and the part to be welded. The heat-affected zone, the molten metal and the
tungsten electrode are all shielded from atmospheric contamination by a blanket of inert gas
fed through the GTAW torch. Inert gas (usually Argon) is inactive or deficient in active
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chemicalproperties.
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Fig 1.2 -Gas Tungsten Arc Welding
The shielding gas serves to blanket the weld and exclude the active properties in the
surrounding air. Inert gases such as Argon and Helium do not chemically react or combine
with other gases. They pose no odor and are transparent,
Permitting the welder maximum visibility of the arc. In some instances Hydrogen gas may
be added to enhance travel speeds. The GTAW process can produce temperatures of up to
35,000 F (19,426 C). The torch contributes heat only to the work-piece. If filler metal is
required to make the weld, it may be added manually in the same manner as it is added in the
oxyacetylene welding process. GTAW is used to weld stainless steel, nickel alloys such as
Monel and in conel, titanium, aluminum, magnesium, copper, brass, bronze and gold. GTAW
can also weld dissimilar metals to one another such as copper to brass and stainless to mild
steel.
1.2 GMAW (Gas Metal Arc Welding):

Gas Metal Arc Welding (GMAW) is a welding process which joins metals by heating the
metals to their melting point with an electric arc. The arc is between a continuous,
consumable electrode wire and the metal being welded. The arc is shielded from
contaminants in the atmosphere by a shielding gas.
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Fig.1.3- Gas Metal Arc Welding

CHAPTER 2
REVIEW OF LITERATURE
2.1 Summary of Shielded Metal Arc Welding:
The process produces a protective slag that will need to be removed for cleanliness and to
prevent slag inclusions in multiple pass welds. The process also produces spatter, which is a
visual defect. However, the spatter can be easily removed with a grinder.
There are several advantages to SMAW.
Low Start Up Costs - SMAW welding machines are relativity inexpensive
Portability - SMAW is a very portable process because it does not require any external
shielding gas and equipment due to the ability of the electrode to produce its own shielding
gases.
Outdoor Weld ability - SMAW welding can be done outdoors. The shielding of the weld
puddle from the coating of the electrode is not susceptible to winds and draft, and therefore,
is an excellent choice for outdoor welding.
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All Position Welding - SMAW can be done in all welding positions, which eliminates the
need for expensive fixture or manipulation of the part being welded.
Variety of Materials - Many base materials and alloys can be welded with the SMAW
process.
There are certain disadvantages of SMAW:
Low Efficiency - The efficiency of a SMAW electrode can be defined as the percentage of
the electrode that is consumed and becomes part of the weld. SMAW electrodes are 60%-
65% efficient. The primary reason for this low efficiency is stub loss, or the portion of the
electrode that is unused and discarded. .
Operating Factor - Operating factor can be defined as the amount of arc on time in a shift of
work, labeled as a percentage. SMAW welding has an operating factor of approximately
25% - 30%--workday is spent arc welding.
Restarts - SMAW electrodes are only 9-18 in length. When the electrode is consumed in
the arc, it needs to be replaced with a new one. This means that welding stops, and time is
taken to replace each electrode.
Operator Skill - SMAW welding requires a high level of operator skill. This process is one
of the hardest arc welding processes to learn.
Slag & Spatter.
2.2 AC/DC power sources:

AC (Alternating Current)-- Current direction alternates, between positive & negative.
DC (Direct Current) -- Current flows in one direction
a. DC Positive (STRAIGHT)
Electrode negative, work positive
b. DC Negative (REVERSE)
Electrode positive, work negative
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AC/DC Rectifiers
Fig.2.1- AC Power source
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Fig.2.2 - DC Power source
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2.3 Electrode used in SMAW:
The American Welding Society or AWS sets guidelines for SMAW electrodes with which
manufacturers have to comply. These guidelines include chemistry and mechanical
properties, and usability tests. Each letter and digit stands for something very specific. The E
stands for electrode. AWS defines an electrode as the current carrying device, not
necessarily the consumable that becomes the weld-ment. In the case of SMAW, the electrode
core is consumed as well as any metallic elements in the coating to become the weld deposit.
70 stand for minimum tensile strength in 10,000 psi. The weld deposit made by this SMAW
electrode must consistently meet a minimum tensile strength requirement of 70,000 pounds
per square inch (psi). The next digit is either a 1 or a 2 and indicates welding position. A 1
indicates that the electrode is an all position electrode-- (flat, horizontal, vertical up, vertical
down, and overhead). While the 2 stands for welds that can only be made in the
flat/horizontal position. The 3rd and 4th digit combined indicates the type of current the
electrode operates on and the type of coating.
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Fig.2.3- Designation of welding electrode
2.4 Welding process of SMAW :
Shielded metal arc welding (SMAW), also known as manual metal arc (MMA) welding, flux
shielded arc welding or informally as stick welding, is a manual arc welding process that
uses a consumable electrode coated with flux to lay the weld. An electric current, in the form
of either alternating current or direct current from a welding power supply, is used to form an
electric arc between the electrode and the metals to be joined. As the weld is laid, the flux
coating of the electrode disintegrates, giving off vapors that serve as a shielding gas and
providing a layer of slag, both of which protect the weld area from atmospheric
contamination.
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Fig.2.4- Welding process with end view
2.5 Influence of Magnetic Field:
Application of external magnetic field has been reported in the literature to affect the
characteristics of the welding arc and the weld properties. Magnetic field can be applied to
the welding arc in three different modes. If magnetic field is in the direction of electrode
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travel, it is considered to be a longitudinal magnetic field. if the field is perpendicular to the

direction of electrode travel and electrode axis, it is referred to as a transverse field.
Factors which affect the arc behavior during the application of a magnetic field are as
follows:
1. Distance between the electrodes
2. Magnetic field intensity
3. Arc current
4. Weld material
Fig.2.5- Without magnetic field
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Fig. 2.6- Arc deflection in magnetic field
Fig.2.7-
Flemings Left Hand Rule
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2.6 Objective: -
The objective of this project work is to study effect of magnetic field on the weld quality and
geometry when the field is applied longitudinal to the electrode travel i.e. the field lines are
perpendicular to the electrode travel. The material of the weld-piece taken is mild steel and
the welding process is shielded metal arc welding. The weld quality of the pieces will be
checked by conducting different weld test as hardness, tensile strength and impact test. The
tensile test will be conducted on the UTM and hardness test is on hardness tester with steel
ball penetrator. The impact test will be conducted on the impact testing machine. Charpy test
will be conducted to check the toughness of the weld-piece. The weld geometries will be
checked through the visual inspection and penetration depth, reinforcement height and weld
bead width will be considered.
Objective of the project work at a glance :-
To study the effect of magnetic-field on weld-quality and weld geometry when the field
is applied-longitudinal to electrode.
To compare the process of arc-welding with magnetic-field and without magnetic-field.
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CHAPTER 3
APPLICATION OF MAGNETIC FIELD
3.1 Longitudinal magnetic field:

A magnetic force acts on the arc, in this system when the angle between the direction of the
electron stream and magnetic lines of force are not zero. As the arc has a conical shape and
the current carrying electrons also moves along the surface of the arc, their motions can be
resolved in two components, one along the axis of the arc and other perpendicular to it. The
component along the arc does not contribute to the magnetic movement. The component
perpendicular to arc exerts a force on the arc causing the arc to rotate clockwise or
anticlockwise depending upon the direction of the magnetic field and polarity used.
Fig.3.1- Longitudinal magnetic field
3.2 Transverse magnetic field:-
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According to the Flemings left hand rule the arc in the influence of transverse magnetic
field will be deflected forward or backward depending upon the direction of magnetic field
lines force and the polarity of welding system. Work of earlier investigation can be analyzed
keeping this in mind.
Kovalev showed that the transverse magnetic field can be used as automatically regulating
the depth of penetration. Hicken and Jackson found beneficial effects of constant transverse
magnetic field when the arc was deflected forward with respect to the electrode travel speed.
It was possible to increase the welding speed four times and steel obtains the welds free from
undercuts. Weld width was found to reduce with increase in magnetic field. Sheinkin found
the application of transverse magnetic field to increase the productivity of the submerged arc
welding process used for making butt joints between prepared edges.
Fig.3.2 Transverse magnetic field
CHAPTER- 4
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WELD QUALITY AND WELD GEOMETRY
4.1 Weld quality: -
To ensure the satisfactory performance of a welded structure, the quality of the welds must
be as per acceptance standards. The quality of the welds must be determined by adequate
testing procedures. These tests includes measure of various defects occur in a weld. The
acceptance standards are the minimum weld quality which must be achieve for satisfactory
performance of welds.
Defects in weld-pieces-
The defects which occur in the weld-pieces due to the imperfect welding conditions and their
causes are as follows:
1. Undercutting:-
Undercutting is the burning away of the base metal at the toe of the weld.
Causes:
Current adjustment that is too high.
Arc gap that is too long.
Failure to fill up the crater completely with weld metal.
2. Incomplete penetration:- This term is used to describe the failure of the filler and base
metal to fuse together at the root of the joint.
Causes:
The rate of travel is too high.
The welding current is too low
3. Lack of fusion:-
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Lack of fusion is the failure of a welding process to fuse together layers of weld metal or
weld metal and base metal.
Causes:
Failure to raise to the melting point the temperature of the base metal or the previously
deposited weld metal.
Dirty plate surfaces.
Improper electrode size or type.
Wrong current adjustment.
4. Slag inclusion:-
Slag inclusions are elongated or globular pockets of metallic oxides and other solid
compounds. They produce porosity in the weld metal.
Causes: Failure to remove the slag between the layers causes slag inclusions
5. Porosity:
Porosity is the presence of pockets which do not contain any solid material. They differ from
slag inclusions in that the pockets contain gas rather than a solid.
Gases are derived from:

Gas released by cooling weld
Gases formed by the chemical reactions in the weld.
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Fig.4.1- Welding defects
4.2 Geometry of weld-pieces:-
Weld Bead Geometry

The mechanical properties of the welded joints greatly depend on weld bead geometry,
which in turn, is influenced by welding parameters like arc current arc voltage, and arc travel
speed. The bead geometry is specified by weld bead width, reinforcement height,
reinforcement area, penetration height, penetration area and the contact angle of weld bead.
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Other factors like nugget area, percent dilution, pool shape factor, bead shape factor and
ripple shape factor may also be included in the bead geometry. Fig shows some aspects of
weld bead geometry. The Weld Bead Width is the maximum width of the weld metal
deposited. It increases with arc current, arc voltage, electrode weaving and decreases as arc
travel speed increases.
Penetration:
Depth of penetration or simply penetration is the distance from base plate top surface to the
maximum extent of the weld nugget. Penetration determines the load carrying capacity of a
welded structure. Penetration area is that covered by the fusion line below the base metal
level. Penetration area affects the weld strength.
Reinforcement Height:
Reinforcement height is the maximum distance between the base metal level and the top
point of the deposited metal and Reinforcement Area is one included between the contour
line of the deposited metal above the base metal level.
CHAPTER 5
WELDING SET-UP ON LATHE
5.1 Automation to welding process:
A lathe machine is used to provide the semi-automation to the welding process. A wooden
block covered by a metallic sheet is fixed on the carriage and the means of magnetic field is
attached with the tailstock. The arrangement is shown in fig.
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Fig.5.1- Welding set-up on lathe
The welding electrode with holder is to be operated manually while the weld-piece is moved
through the lead screw of lathe automatically with a fixed speed. A metallic rod is also used
to provide the electric connection within the work-piece. This rod is so connected that there
will be no any gap produce which can fluctuate the electric supply. There is a proper gap
maintained within the magnet and work-piece throughout the welding process.
5.2 Arrangement for magnetic field :
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A bar magnet is used for the production of magnetic field. In the first arrangement we used a
solenoid but a problem occurred with current carrying capacity and the strength of produced
magnetic field. A Gauss-meter is used for measuring the magnetic field.
Fig.5.2- Magnetic field measurement by Gauss-meter
5.3 Current and Voltage measurement:
Current and voltage measuring devices used are clamp-meter and multi-meter respectively.
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Fig.5.3- Clamp-meter & Multi-met
5.4 Line diagram of set up:
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Fig.5.4- Set-up on lathe in Magnetic field

1. Multi-meter, 2. Battery Eliminator, 3. Electric Board, 4. Gauss-Meter,
5. Table, 6. Measuring-Probe, 7. Transformer Welding-Set, 8. Clamp-meter
9. Tail-Stock, 10. Sleeve, 11. Link (Wood), 12. Solenoid, 13. Tool post,
14. Iron sheet, 15. Work-piece, 16. Electrode, 17. Electrode Holder, 18. Metal-Strip
Connected with head stock, 19. Head stock, 20. Connection Wires.
CHAPTER 6
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WELDING WITH THE SET-UP
6.1 Preparation of Specimens:
The mild steel pieces of the dimension 150 mm X 50 mm X 6 mm are used as a work-piece
for the welding. Each metal piece first cleaned for dust and rust. Before the actual welding
process the space between the specimens is fixed with a support. The space between the
specimens for the butt welding is depends upon the thickness of the work-piece. For a 6 mm
thickness there is no requirement of making groove, so a 3 mm gap is maintained during the
whole process of welding. The quality and geometry of weld is much depends on correct and
same gap throughout length of the specimen.
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6.2 Welding In Magnetic Field(M):
The magnetic field is applied as per the set-up and then the arc welding machine and
electrodes are fixed at their respective places. Multi-meter, clamp-meter and gauss-meter are
placed and connected to take the readings. As per the semi-automation to the process feed
rod is connected with the work-piece motion. The weld-pieces obtained after the process is
shown in fig. different readings obtained with the process are tabulated and it is shown in the
table no. 6.1.
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WORK- CURRENT VOLTAG

PIECE NO. (A) E (V)
M1, M2, 110 - 120 23-26

M3
M4, M5, 125-135 18-22

M6
M7, M8, 90-100 27-30

Welding M9 Without Magnetic
Field (WM):
The similar setting as with magnetic welding is used in without magnetic field process of
welding. Only change is that the magnetic field arrangement is removed. The range of
current and voltage are remained similar to the magnetic field welding. The weld-pieces
obtained in this process are shown below and the readings are tabulated.
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TABLE NO. 6.2
WORKPIECE CURRENT(A) VOLTAGE

NO. (V)
WM1, WM2, 110 - 120 23-26
WM3
WM4, WM5, 125-135 18-22
WM6
WM7, WM8, 90-100 27-30
WM9
6.3 Grouping and cutting of weld-pieces:
Each weld-piece (with and without magnetic field) cut into three pieces and grouped
according to the range of current and voltage and provided a specific code. Now, the total no.
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of weld-pieces is 9 and their corresponding parametric readings are tabulated as below. Each
weld specimen has a code which shows its specifications. The letter shows the weld-piece is
from the category of magnetic field or without magnetic field. The letter M shows magnetic
field and WM shows without magnetic field. The number provided to the code shows its
range of current and voltage. The number 1, 2, 3 shows the range of current 110-120 Ampere
and voltage 23-26 volts.
Weld-pieces with magnetic field:-
Table No. 6.3
WORK-PIECE CURRENT(A) VOLTAGE (V) MAGNETIC-FIELD WELDING SPEED

NO. INTENSITY (GAUSS) (mm/min )
M1. 120 24.5 70 60
M2. 110 23.7 70 60
M3. 115 23 70 60
M4. 135 18.5 70 60
M5. 125 21.5 70 60
M6. 130 19 70 60
M7. 90 27.5 70 60
M8. 95 27.7 70 60
M9. 100 28.5 70 60
Weld-pieces without magnetic field:-
Table No. 6.4
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WORK-PIECE CURRENT(A) VOLTAGE (V) WELDING SPEED

NO.
(mm/min)
WM1. 115 23 60
WM2. 120 24.7 60
WM3. 110 23 60
WM4. 135 18.6 60
WM5. 125 21.3 60
WM6. 130 23 60
WM7. 95 28.7 60
WM8. 100 31 60
WM9. 90 31.5 60
CHAPTER 7
WELD TESTS
7.1 Hardness test:
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Hardness may be defined as the ability of a substance to resist indentation of localized

displacement. A hardness test is used to determine the hardness of weld metal. In the
Rockwell hardness test, the specimen is mounted on the anvil of the machine and a load is
applied against a hardened steel ball which is in contact with the surface of the specimen
being tested.
The load is allowed to remain 1/2 minute and is then released, and the depth of the
depression made by the ball on the specimen is measured. The resultant Rockwell hardness
number is obtained from the dial.
Rockwell hardness tester:
The principle of the Rockwell tester is essentially the same as the Brinell tester. It differs
from the Brinell tester in that a lesser load is impressed on a smaller ball or cone shaped
diamond. The depth of the indentation is measured and indicated on a dial attached to the
machine. The hardness is expressed in arbitrary figures called "Rockwell numbers." These
are prefixed with a letter notation such as "B" or "C" to indicate the size of the ball used the
impressed load, and the scale used in the test.
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Fig.7.1- Rockwell Hardness Tester
The test result of the hardness test was conducted on both type of weld-pieces (with
magnetic field and without magnetic field) are shown in the table below.
Table No.7.1
WORK-PIECE NO. PARENT METALWELDMETAL (RHN)

(RHN)
M2. 90 83
M5. 92 80
M8. 89 84
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Table No.7.2
WORK-PIECE NO. PARENT METAL WELD METAL

(RHN)
-
(RHN)
WM2. 93 85
WM5. 95 86
7.2 Tens WM8. 92 88 ile
strength test:
This test is used to measure the tensile strength of a welded joint. The tensile strength, which
is defined as stress in kgf per square meter. It is calculated by dividing the breaking load of
the test piece by the original cross section area of the specimen. The test result which is
conducted on universal testing machine ( UTM) is given in the table. The gripping and
rupture points located in the figures. This test is used to measure the strength of a welded
joint. A portion of the welded plate is locate the weld midway between the jaws of the testing
machine. The width thickness of the test specimen are measured before testing, and the area
in square inches is calculated by multiplying these before testing , and the area in square
inches is calculated by multiplying these two figures.
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Fig.7.2- Tensile Testing Process

The tensile test specimen is then mounted in a machine that will exert enough pull on the
piece to break the specimen. The testing machining may be either a stationary or a portable
type. A machine of the portable type, operating on the hydraulic principle and capable of
pulling as well as bending test specimens.
The specimen is ruptured under tensile load, and the maximum load in pounds is determined.
The shearing strength of the weld in pounds per linear inch is determined by dividing the
maximum load by the length of fillet weld that ruptured. The shearing strength in pounds per
square inch is obtained by dividing the shearing strength in pounds per linear inch by the
average throat dimension of the weld in inches. The test specimens are made wider than
required and machined down to size.
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Fig.7.3-UTM Used for tensile test
Fig. 7.4 specimen for tensile test
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Fig.7.5- Gripping of work-piece
Fig 7.6 :FRACTURE OF TEST PIECE
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Table for the tensile test of the weld-pieces with magnetic field-
Table No.7.3
WORK-PIECE TENSILE LOAD CROSS-SECTIONAL TENSILE

(IN Kgf) AREA (mmXmm)
NO. STRENGTH
(Mpa)
M1. 10480 290 354.51
M4. 10320 287 352.75
M6. 10560 292 354.77
Table for tensile test without magnetic field specimens-

Table No.7.4
WORK-PIECE TENSILE LOAD CROSS-SECTIONAL TENSILE

(IN Kgf) AREA (mmXmm)
NO. STRENGTH
(MPa)
WM1. 10160 300 332.23
WM4. 10240 294 333.67
WM6. 10000 304 330.44
7.3 Impact Test:
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The two kinds of specimens used for impact testing are known as Charpy and Izod. Both test
pieces are broken in an impact testing machine. The only difference is in the manner that
they are anchored. The Charpy piece is supported horizontally between two anvils and the
pendulum strikes opposite the notch. The Izod piece is supported as a vertical cantilever
beam and is struck on the free end projecting over the holding vise
A Charpy test measures the welds ability to withstand an Impact force. Low Charpy test
readings indicate brittle weld metal Higher Charpy readings indicate the samples toughness.
Fig.7.7- Weld-pieces for Charpy test
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Table No.7.5 Table No.7.6
WORKPIECE NO. TOUGHNESS
(J)
WM3. 59
WM6. 64
WM9. 62
The toughness values of the weld-pieces are tabulated above. Weld-pieces are placed at the
impact testing machine as simply supported. The hammer of the heavy weight is then
released and corresponding values of weight provides the toughness values for weld-pieces.
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CHAPTER 8
EFFECT OF MAGNETIC FIELD
8.1 Visual effects:
The welding process is semi-automated and this result there is a little improvement in weld
quality. Welding speed is also increasing as the weld width is shaped by itself. The effect of
magnetic field is to deflect the arc as perpendicular to the weld bead. This implies to increase
in weld speed. Some weld defects are also reduced as weld spattering and incomplete
penetration. Complete penetration occurs due to attraction of molten material. Welding
process which is applied here is providing the ease to welder and improves the weld quality.
Some of visual effects are as follows:
Welding speed:
Welding speed is the linear rate at which an arc is moved along the weld joint. With any
combination of welding voltage and welding current, the effect of changing the welding
speed confirms to a general pattern. If the welding speed is increased, power or heat input
per unit length of weld is decreased and less filler metal is applied per unit length of the
weld, resulting in less weld reinforcement. Thus, the weld bead becomes smaller. Weld
penetration is affected more by welding speed than any variable other than current. This is
true except for excessively slow speeds when the molten weld pool is beneath the welding
electrode. Then the penetrating force of the arc is cushioned by the molten pool. Excessive
speed any cause undercutting, porosity, arc blow, uneven bead shape, cracking and higher
slag inclusion in the weld metal.
Higher welding speed results in less heat affected zone and finer grains. Within limits,
welding speed can be adjusted to control weld size and penetration. Relatively slow welding
speed provides time for gases to escape from the molten metal, thus reducing porosity. An
excessive slow speed produces a convex bead shape which is subject to cracking and
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excessive arc exposure which is uncomfortable for the operator. Too low welding speed may
also result in a large molten pool that flows around the arc, resulting in rough bead, slag
inclusions and burn through of the weld plate. Here the application of magnetic field is
significantly increases the welding seed. The semi-automation provided to the welding
process is also helping to increase the welding speed.
Fig.8.1-Speed vs. Depth of Penetration
Spatter on weld metal:
It has appeared that the welding with magnetic field has less spattering action on the weld
metal than the without magnetic field. fig shows it below.
xlvi
Fig .8.2
8.2 Effect on weld properties:
The effect of magnetic field on the weld quality is checked through the various tests for
mechanical properties. The weld properties which we have considered here are hardness,
tensile strength and toughness. The specimens for each welding test are prepared and the
tests are conducted on them. Test results for various mechanical properties are tabulated
above.
Tensile test:
The effect of magnetic field on the tensile strength is to increase it. The weld test conducted
on the pieces shows the increase of tensile strength. The change in the properties is
calculated in terms of percentage and there is an increase of 6.6% on an average. This shows
xlvii
that a magnetic field applied longitudinal to weld bead, deflected the arc such that the tensile
properties of the weld-pieces increases.
Table No.8.1
PROPERTIES WITHOUT MAGNETIC CHANGE

MAGNETIC FIELD
FIELD
TENSILE 332.11 354.01 6.6%

STRENGTH INCREASE
HARDNESS 86.33 82.33 INCREASE
TOUGHNESS 61.66 73.66 16.2%

INCREASE
Hardness test:
The hardness of the material and weld section both are checked and result is found which shows
the decrease in the hardness of weld metal. When we are comparing the weld-pieces which are
welded without magnetic field the hardness is decreases. The hardness value of the materials are
taken in terms of RHN ( Rockwell hardness number ). When the RHN increases it shows the
increase in hardness of the material. All the hardness reading in our work is taken at the B scale
of the Rockwell hardness tester.
Toughness:
Toughness test is used to check the ability of a weld to absorb energy under impact without
fracturing. This is a dynamic test in which a test specimen is broken by a single blow, and the
xlviii
energy used in breaking the piece is measured in foot-pounds. This test compares the toughness
of the weld metal with the base metal. It is useful in finding if any of the mechanical properties of
the base metal were destroyed by the welding process.
The two kinds of specimens used for impact testing are known as Charpy and Izod. Both test
pieces are broken in an impact testing machine. The only difference is in the manner that they are
anchored. The Charpy test piece is supported horizontally between two anvils and the pendulum
strikes opposite to the notch. The Izod piece is supported as a vertical cantilever beam and is
struck on the free end projecting over the holding vice .the magnetic field applied longitudinal to
work-piece increases the toughness of the material. This effect is obtained as per the impact test
which is conducted on the specimens of Charpy test. Result shows the change in the value of
impact load sustained by both type of specimens.
8.3 Effect on weld geometry:
Bead width-
The effect of longitudinal magnetic field is to deflect the arc perpendicular to welding
direction. As alternating current changing its direction, direction of electrons changes and
this changes the direction of force on them. Hence arc is deflecting right and left to the line
of weld. This movement increases the bead width. The weld bead width is the maximum
width of the weld metal deposited. It influences the flux consumption rate and chemistry of
the weld metal. Weld bead width is directly proportional to arc current, welding voltage and
xlix
electrode diameter and indirectly proportional to the welding speed. The bead width
increases with an increase in electrode diameter. It observed that bead width increased with
an increase in current until it reaches a critical value and then it decreases with an increase in
welding current. The bead width was not affected significantly by the types of power source
(constant voltage or constant current) when an acidic fused flux was used. However, using a
basic fused flux with constant current operation showed somewhat larger bead width than
with welds laid using acidic fused flux.
Penetration:
The penetration depth is increased when magnetic field applied. Weld bead penetration is the
maximum distance between the base plate top surface and depth to which the fusion has
taken place. The more the penetration, the less is the number of welding passes required to
fill the weld joint which consequently results in higher production rate. It is observed that the
penetration is influenced by welding current, polarity, arc travel speed and physical
properties of the flux. It was observed that penetration was directly proportional to welding
current. It was further investigated that the penetration was indirectly proportional to welding
speed and electrode diameter. Penetration decreases with the increase in welding speed
because the time during which the arc force is allowed to penetrate into the material. The
penetration decreases with the increase in electrode diameter due to decrease in current
density reported that the penetration decreased with the decrease in electrode extension and
included angle of the joint. The effect of magnetic field when applied longitudinally shows
that the depth of penetration is decreases. This is the most significant effect which is found
during the visual inspection. Although the value of this change, not measured in this project
work.
Reinforcement Height-
Reinforcement is decreases as the bead width of the weld increasesReinforcement is the

maximum distance between the base metal level and the top point of the deposited metal.
Reinforcement is the crown height of the weld bead from the base plate. It affects the strength of
the weld joint and welding wire consumption rate. It increases with the increase in welding wire
feed rate irrespective of the welding current and the type of polarity employed .It is indirectly
l
proportional to welding voltage, welding speed and electrode diameter. Increase of reinforcement
with an increase of welding filler wire feed rate is mainly due to the larger amount of metal
deposited per unit length. The decrease of reinforcement with the increase in voltage is due to
increase in weld bead width. The magnetic field increases the bead width and this leads to the
decreases in the reinforcement height.
CHAPTER 9
CONCLUSIONS AND SUGGESTIONS
9.1 Conclusions :
On the basis of different experiments, automation of welding process and effect of magnetic
field the following conclusions are derived:
li
1. The welding set-up on lathe provides automatic motion to the work-piece and welder has
to provide only the feed to electrode. This provides the smoothness in welding process.
2. Effect of magnetic field applied transverse to welding direction affects the bead width of
joint and increases it.
3. Undercuts, spatter etc. welding defects are reduced.
4. The tensile strength of the weld joint is on improvement side due the refinement of grains.
5. Hardness of the weld decreases as compared with the weld-pieces which are welded
without magnetic field.
6. Reinforcement height of weld reduces as the weld bead width is increasing.
7. Toughness of the weld metal increases.
Hence, we can say that the use of external magnetic field transverse to the welding direction
is helping in improvement of weld quality and weld geometry. Here we can say that the
transverse magnetic field can also affect the weld quality .
9.2 Suggestions For Further Work:
In this project we have constrained our work by testing the effect of magnetic field in
longitudinal direction only. Further this can be study for
Magnetic field in transverse direction of weld bead
Magnetic field applied axial to the electrode
Further the study can be extended by conducting the following mechanical properties test
Bend test
Non destructive tests
In this project work the weld geometry tests are not conducted only the visual inspection is
done and the results based on that are considered. Further the study can be extended by
performing the macro structure study of the weld metal. This can be done on polishing and
lii
grinding machines. This could be result in perfect testing of weld bead width and penetration
depth.
REFERENCES
1. Serdyuk, d. b., and Kornienko, a. n.1963. The welding arc in an alternating

transverse magnetic field. Automatic welding (10):713.
2. A study on the modeling of magnetic arc deflection and dynamic analysis of arc
sensor by Y. H. Kang and s. j. na. Welding journal 13-s.
3. Mallya, U. D., and Srinivas, h. s. 1993. Magnetic steering of arc and bead
characteristics in submerged arc strip cladding. welding journal 72 (11): 517-s to
522s
4. Engineering Principles of Welding- processes, physics, chemistry and metallurgy by
Robert, Wissler 2004, and welding journal.
5. Dennary F., (1966), Electric field distribution in welding arc, physics of welding arc,
sym.IW, Cam UK.
6. Amstead, B.H., P.F. Ostwald, and M.L.begman (1979), manufacturing processes,
john wiley, N. Y.
7. Serdjuk, G.B.,(1966), magnetic forces in arc welding metal transfer, physics of
welding arc, SYM. IW, Cambridge, London.
8. Khan M.I. (1979), a study of Hardfacing under magnetic field, proc. ISME conf.
New Delhi, paper E.P. 4.1 Dec., PP.174.-176.
9. Khan M.I., (1992), study of effect of superimposition of longitudinal magnetic field
onarc characteristics, bead geometry, microstructure and mechanical properties.
Conf. on prod. Engg. Design and control, university of Alexandria, Egypt, dec. 1992.
liii
10. Mandal, N. R. (2004), Welding and Distortion Control, Narosa.

11. Needham, J.C., (1978), (Tech. Dir) Advances in welding process, 4 th Int. Conf.
Herrogate, IW Cambridge, London.
12. Nikolaev, G., and N. Olshansky, (1977), advanced welding processes, mir pub.,
Moscow.
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Chapter 2: Review of Literature

2.1 Summary of shielded metal arc welding ...6

Chapter 3: application of magnetic field

3.1 Longitudinal magnetic field.14

Chapter 4: Weld quality and weld geometry

4.1 Defects in weld-pieces.16

Chapter 5: Welding set-up on lathe

5.1 Automation to welding process...20

Chapter 6: Welding with the set-up

6.1 Preparation of specimens...24

Chapter 7: Weld tests

7.1 Hardness test.. .29

Chapter 8: Effect of magnetic field

8.1 Visual effects. .38

Chapter 9: conclusion and suggestions for further work

Types of arc Welding processes: -

SMAW (Shielded Metal Arc Welding)

GMAW (Gas Metal Arc Welding)

GTAW (Gas Tungsten Arc Welding)

1.2 SMAW (Shielded metal arc welding):

Fig -1.1 Shielded metal arc

Fig 1.2 -Gas Tungsten Arc Welding

1.2 GMAW (Gas Metal Arc Welding):

Fig.1.3- Gas Metal Arc Welding

2.1 Summary of Shielded Metal Arc Welding:

There are certain disadvantages of SMAW:

2.2 AC/DC power sources:

Fig.2.1- AC Power source

Fig.2.2 - DC Power source

2.3 Electrode used in SMAW:

Fig.2.3- Designation of welding electrode

2.4 Welding process of SMAW :

Fig.2.4- Welding process with end view

2.5 Influence of Magnetic Field:

travel, it is considered to be a longitudinal magnetic field. if the field is perpendicular to the

Fig.2.5- Without magnetic field

Fig. 2.6- Arc deflection in magnetic field

Objective of the project work at a glance :-

To compare the process of arc-welding with magnetic-field and without magnetic-field.

APPLICATION OF MAGNETIC FIELD

3.1 Longitudinal magnetic field:

Fig.3.1- Longitudinal magnetic field

3.2 Transverse magnetic field:-

Fig.3.2 Transverse magnetic field

WELD QUALITY AND WELD GEOMETRY

4.1 Weld quality: -

Gases are derived from:

Fig.4.1- Welding defects

4.2 Geometry of weld-pieces:-

Weld Bead Geometry

WELDING SET-UP ON LATHE

5.1 Automation to welding process:

Fig.5.1- Welding set-up on lathe

5.2 Arrangement for magnetic field :

Fig.5.2- Magnetic field measurement by Gauss-meter

5.3 Current and Voltage measurement:

Fig.5.3- Clamp-meter & Multi-met

5.4 Line diagram of set up:

Fig.5.4- Set-up on lathe in Magnetic field

WELDING WITH THE SET-UP

6.1 Preparation of Specimens:

6.2 Welding In Magnetic Field(M):

WORK- CURRENT VOLTAG