4.

5 Semi-automatic and
automatic welding
4.5 Semi-automatic and automatic
welding
4.5.1 Precautions for semi-automatic welding
4.5.2 Precautions for automatic welding
4.5.3 Treatment and maintenance of welding
equipment
4.5 Semi-automatic and automatic welding
4.5.1 Precautions for semi-automatic welding

CO2 gas shielded arc welding and MIG/MAG welding are frequently
used for semi-automatic welding. Precautions to be taken with these
welding processes are as follows;

a. Protection from wind is necessary during welding. Below 1.5-

2m/sec of wind, it is preferable to keep shielding gas atmosphere
at the weld arc over the molten pool. A wind screen or shelter is
usually used in a workshop. An awning or box-shaped frame is
recommended outdoors.

b. The welding groove should be cleaned carefully. Oil, paint, water,

and rust should be removed.
c. Welding conditions should be appropriate. The welding torch
should be operated smoothly and kept at an adequate height
(15-25 mm of wire extension is desirable) and at an adequate
angle to obtain a stable arc, good penetration, and good
appearance of weld bead.

d. Abrupt bending of the conduit cable should be avoided to

maintain a smooth wire feeding. The allowable limit of bending
is approximately 1 turn of 500 mm diameter.

e. A good match between the contact tip's opening and wire

diameter is important for smooth wire feeding and ensuring
good electric contact.

f. Proper training and qualifications (JIS Z 3841) of all welders

involved are necessary.
4.5.2 Precautions for automatic welding
Submerged arc welding has been representative of all automatic welding until
recently, but automatic types of CO2 gas shielded metal arc welding including
MAG/MIG are now also routine. Due to deep penetration, a very accurate weld
groove is required for submerged arc welding. The weld groove should be
cleaned very thoroughly. Oil, water, or rust in or near a weld groove will often
cause blowholes. Precautions for gas shielded metal arc welding are the same as
described in sec. 4.5.1.
Precautions for unmanned automatic welding, such as a robot welding, are as
follows;
a. Accurate parts and accurate assembly works as well as welding groove
accuracy are required.
b. Use of an adequate combination of shielding gas and wire to reduce spatter
is necessary. The choice of welding equipment is also important.
c. A seam tracking device is necessary for welding equipment for large scale
structures.
d. Automatic nozzle cleaners, automatic wire end cutter and automatic tip
changers are desirable.
Narrow gap welding requires an accurate welding
groove.

Accordingly, consideration for the prevention of lack of fusion

and slag removal are required. The required skill of operators
of automatic equipment is not as great as that required for
semi- automatic welding, but substantial training and skill to
operate the equipment, electronic, and mechanical
knowledge, knowledge of materials, welding consumables,
welding conditions, etc. are still required.
4.5.3 Treatment and maintenance of welding
equipment
Automatic and semi-automatic welding equipment should be well
maintained electronically and mechanically. ISO 9000 and ISO
3834 also require periodic maintenance for the equipment and
calibration for the instruments.

Wire feeding devices are the main recipients of daily

maintenance.
4.5.3 Treatment and maintenance of welding
equipment
Other main considerations are listed below;

a. Greasing of wire- feeding gears and bearings.

b. Cleaning and check for wear of wire feeding rollers and pressure
rollers.
c. Cleaning and check for wear of conduit cables and wire passages.
d. Cleaning and periodical checks of contact tips and torch nozzles.
e. Check of shield gas passages and electric cables. As the air cooled
transformer for a DC welding equipment easily deterioration.
Periodical cleaning with an air blower is necessary.