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Lecture 4 p1
Gas Metal Arc Welding (
Process Fundamentals
4 p2
GMAW Process Fundamentals
Electrode
Shielding Gas In
•
Direction
of Travel
/GaSNOZZle
CONSUMABLE
ELECTRODE GAS
_~~~~,~/ SHIELD
BaseMetal~
A~£P~ Metal
Lecture 4 p:
GMAW Metal Transfer Modes (
I
,
p4
GMAW Short Circuiting Transfer
II
(.) ZE~Rn=O==~---~:::=====~------=~-_' - Time
z
o ARCING PERIOD
E
II n
7ize'iiR
~ I
o ---rTTl'-.--.---.-i::=------
Lecture 4 p~
GMAW Globular Transfer Mode (
GAS NOZZLE
p~ELECTRODE
( I r~
I(~L -
I I I I I
'" (AI
R
R-Anode reaction
P-Electromagnetic
"pinch" force
I
{~(~
I I
g I
j
\..
V
IB)
p6
GMAW Spray Transfer
Variation in volume and rate of drop transfer with welding current
300 15.10·'
.
"- ,•• 20
§
0..
I
I 1/16 in. (1.6 mm)
~
~
~
~
E
0 200 DROP I 10 .S E
II:
0 VOLUME I MILD STEEL W 15
W
a! I ELECTRODE. DCRP ::E ::E
...
w 3
~
I ARGON-I% OXYGEN 0
'"z TRANSITIO~
SHIELDING GAS >
~
10
...~0
1/4 in. (6.4 mm)
100 CURRENT I ARC LENGTH 5 a.. ~
0..
0 0
II:
W c 5 ~
i
0 0 0
0 100 200 300 400 600 600
CURRENT, A
Lecture 4 p
GMAW Spray Transfer (
p8
~---~- - - -
GMAW Pulsed Transfer
PULSE PEAK CURRENT SPRAY TRANSFER
«
-,--------
PULSE
TRANSITION
2
3
CURRENT RANGE
- --------
4
GLOBULAR .
5 TRANSFj;R.
1-' CURRENT CURRENT
zUJ RANGE
1
a:
a:
:J 1 2 3 4 5
u
~U~~U
BACKGROUND CURRENT
TIME
Lecture 4 p'
GMAW Welding Procedures (
• Process Variables
- Welding current (electrode melting rate)
- Polarity
- Arc voltage (length)
- Travel speed
- Electrode extension
- Electrode size
- Shielding gas composition
4 p10
GMAW Electrode Melting Rate
-
.-
C 800 20 C
E
c
cLLI
LLI 500
700
600
- E
E
-15 C
-
.-
W
w
a..
en 0-
cLLI 400 10 en
cW
LLI 300
U. W
I&.
LLI 200 5 W
0::
~ 100 -3a:::
0
0 50 100 150 200 250 300 350 400 450
Lecture 4 pl
GMAW Torch Geometry (
Nozzle
p12
GMAW Consumables
• Shielding Gases
- Various shielding gases are used depending on metal
being welded and desired transfer mode
- Principally Ar, C02 and mixtures of Ar-G02, 02 or He
- Several commercial "brand-name" compositions
Lecture 4 pt
GMAW TlPical Welding Procedures (
Carbon Steel
pz ??
R
zzJl/fl ??
zzl T
'Q
~eM+F
~~-
~R
A B C
p14
GMAW Welding Equipment
Welding Gun
Workpiece
(j) WOAK WoO @ CABLEA&SEMIM.Y
(i) WA1eATOQU.I <i> 8HElDING OM FROM cvt.HJER
() WATERFAONQUN ~ WELlllNO OOHTACl'OA CONTflOl
@ GUNSWfTCH CIACUT '" PCMEA CAaE
<!> SHfElDlNG GAS TO GUN ® """"""'H'UTPOWER
Lecture 4 P 1!
GMAW Welding Gun (
WIRE CONOUIT
SHIELDING GAS PATH
ELECTRODE INPUT WATER LINE
Q
o
WATERCHAMBER~~~~'--
CONTACT TIP
CONTROL
GAS NOZZLE POWER BLOCK SWITCH POWER CABlE!
RETURN WATER
4 p16
GMAW Applications
Lecture 4 p17
GMAW Mechanized Application (
Weld preparation
and bead sequence
P 18
. . . .__.. . _--.. .-----.. .
.;.,;,0; Uk ~.U;6lJ
----------""J----------'-~~"'<.c
.1Mf; Ii i!CI : .
after loading
i i '"X:.<'""''''
",52
"'X>
Fuel Bundles '. j-,/, .
,.- '-{".
Lecture 4 p19
(
GMAW: Mechanized applications
Shielded station wall
I
L-----1r----'IC""
I
L------ft----t-"......
l
lop
~
\
1
o Video mon~or
p20
_ _ _ _. . . ._ ......... . . . ._ .......... nl"il"" ~ __ ~ · "
Process Control
Component Status
SEAM
Weld overlap
,
Cycle start
Weld Cycle TIme
,
Cycle end
Tracking
TRACKER
Drive In/Out
Idle
Motion
TURNTABLE
Idle
Welding Current
waDING
EQUIPMENT Shield gas flow
Idle
Lecture 4 P21
GMAW Capabilities & Limitations (
p22
WELDING PROCESSES
Lecture 4 p23
GTAW: Process Fundamentals (
4 p24
GTAW: Process Fundamentals
• DIRECTION OF
WELDING
SHIELDING
GAS IN
I NON-CONSUMABLE
TUNGSTEN ELECTRODE
ARC SOUDIFIED
WELD METAL
Lecture 4 p25,
GTAW: Process Variables (
• Welding current
- DC, pulsed DC, high frequency pulsation, AC, variable
polarity AC -
P 26
GTAW: Current Polarity
Lecture 4
GTAW: Effect of Polarity (
e4 p28
----~-
- .. _ - ._ _- ._ _--_.. _--------- ---------_._-----~
..-,
<{
10
0
0 50 100 150 200 250 300 350 400
ARC CURRENT, A
Lecture 4 P 2~
Pulsed GTAW (PGTAW) (
".I'~
"O.IL
I "'...... Background
- '--- '-- --l::-.......J-+-'>..--L.. current
TIME
Pulsed DC advantages:
,f Greater penetration for given average current
,f Minimizes heat affected zone & distortion
,4 P 30
GTAW: Gas backing
Lecture 4 p3'
GTAW: Pipe internal purge (
,4 P 32
GTAW Equipment Schematic
TORCH ELECTRICAL
CONDUCTOR
POWER
ARC SOURCE
Lecture 4 p3::
GTAWTorch (
/
HANDLE
TUNGSTEN ELECTRODE:- _
4 p34
Mechanized GTAW Applications
• Mechanization of
- weld head travel motions
- wire feed (if required)
- process controls: start/stop sequence, weld current profile,
shielding gas flow, etc
Lecture 4 p35
Hot Wire GTAW (
HEATED
WIRE
4 P 36
GTAW Deposition Rates
20 9
HOT WIRE WITH
'C
.c
18 OSCILLATION~,/ / . 8
:0 16
:::::;.
14
, 7
W
,," 6
~ 12
, ,, 5 ...
,,
Z 10
HOTWlRE
.c
0 8 4~
"
I- COLD WIRE 3
,
-
I
(/) 6
\
I
0 2
a..
--
4
w 1
0 2
0 0
2 4 6 8 10
ARC ENERGY (kW)
Lecture 4 P 37
Narrow-Gap GTAW (
Special Narrow-Gap.
v.::::.-..~Torch
Narrow-Gap Joint
~.Lh4- Preparation
4 p38
GTAW Capabilities & Limitations
+ Superior quality - Low deposition rates
welds free from flux - Higher welder_ skill
residues or spatter required in manual
+ Excellent control of processes
penetration - Gas shielding
+ Applicable to almost sensitive to air
all metals currents
+ Adaptable to manual
or precision
mechanized
applications
Lecture 4 p39