WELDING PROCESSES

Resumes Last Week:

WELDING PROCESSES

Arc welding (las busur listrik):

 Shielded metal arc welding (SMAW), which often
called stick welding / Manual Metal Arc Welding
 Gas tungsten arc welding (GTAW)/ TIG Welding
 Gas metal arc welding (GMAW)/ MIG/MAG Welding
SHIELDED METAL ARC WELDING
1. Stop kontak 2. Mesin Las
3. Kabel 4. Kabel
5. Electrode Holder
6. Electrode
7. Ground Klemp
8. Base Metal
9. Arc
10. Inti Kawat las
11. Flux
12. Tetesan Kawat
13. Gas Pelindung
14. Slag Cair
15. Slag beku
16. Weld Metal Cair
17. Weld Metal Beku
PROCESS
ADVANTAGES:
1. Low initial investment cost
2. Simple and operationally reliable
3. Low cost filler materials
4. Wide range of filler materials
5. Same equipment for all materials
6. Spans a large thickness range
7. All welding positions
DISADVANTAGES:

1. Slow (changing electrodes)

2. A layer of solidified slag must be removed
3. Low-hydrogen electrodes require special
storage
4. Low deposition efficiency
 Gas Tungsten Arc Welding
1. Stop kontak
2. Mesin Las
3. Kabel
4. Kabel
5. Ground klemp
6. Tabung gas argon
7. Selang gas argon
8. TIG Torch
9. Filler Metal
10. Base Metal
11. Tungsten
12. Penjepit Tungsten
13. Arc
14. Weld Metal Cair
15. Weld Metal Beku
16. Gas Pelindung
Gas Tungsten Arc Welding

GTAW / TIG SMAW / MMA

 Gas Tungsten Arc Welding

GAS PELINDUNG
Gas Tungsten Arc Welding (TIG):
Argon
Helium
Mix. Argon & Helium

Tungsten Electrode :
* Ceriated – Oksida Cerium (Ce2O3)
•Thoriated - Oksida Thorium 1 ~ 2% ( ThO2)
• Lanthatiated –Oksida Latnanum (La2O3)
•JIS Z3233 (Ref. !)
GTAW TORCH COOLING SYSTEM
GTAW TORCH COOLING SYSTEM
ELECTRODE TIP SHAPE
TYPES OF WELDING CURRENTS
 GAS TUNGSTEN ARC WELDING (GTAW)
• Elektroda Tungsten tidak melebur, dan leburan logam cair
berasal dari filler material yang disebut welding rod
• Menggunakan arus AC, dan DC (DCEP dan DCEN)
AC --- Aluminum, DCEN ---- Al tebal, DCEP --- Mg
• Gas pelindung Argon, Helium atau campurannya
DCEN ---- Helium
AC ---- Argon
ADVANTAGES

• The GTAW process is capable of welding virtually all metals, even

extremely thin materials.

• The principal advantage of GTAW is that high-quality welds with

excellent visual appearance can be produced.

• Because no flux is used, the process is quite clean and there is no

slag to remove after welding.

• Little/no spatter.

• Arc and weld pool are clearly visible to the welder.

• All positions.

• Cleaning action with DCEP and AC.

DISADVANTAGES

• The skill level necessary to produce high-quality welds is acquired only

after much experience in manipulating the electrode and feeding the filler
wire.

• Because the process has a low tolerance for contamination, the base and
filler metals must be extremely clean prior to welding.

• GTAW is among the slowest of the available welding processes.

• Low productivity.

• Higher initial cost.

GAS METAL ARC WELDING

5. Gas Bottle
1. Stop contact 6. Ampere cabel 10. Workpiece Connection
2. Power Source 7. Consumable electrode 11. Work Piece
3. Roll Filler metal 8. Gas tube 12. Workpiece lead
4. Wire feeder 9. Mig Gun 15. Arc
 GAS METAL ARC WELDING
7. Filler Metal
11. Benda Kerja
13. Contactube
14. Nozzle
15. Arc
16. Tetesan Filler
17. Cairan Filler
18. Weld metal
19. Gas pelindung
GAS METAL ARC WELDING

GAS PELINDUNG

* Metal Inert Gas (MIG):

Argon, Helium, Mix. Argon & Helium

* Metal Active Gas (MAG):

CO2, Mix. Argon / Helium & CO2

 GAS METAL ARC WELDING (GMAW)

• Arus yang dipakai DCEP

• Menggunakan filler metal yang diumpankan semi otomatis
• Memakai gas CO2, He, atau Argon sebagai gas pelindung
• Jenis transfer logam cair : Spray Transfer, Globular Transfer
dan Short Circuiting
• Pengelasan paduan Ni, Cu, Al, gas bersifat inert sehingga
disebut MIG (Metal Inert Gas)
• Pengelasan Stainless, gas yang dipakai CO2, sehingga disebut
MAG
Advantages

• Can be effectively used to join or overlay many types of ferrous and

nonferrous metals.
• Gas shielding can reduce the possibility of hydrogen being introduced into the
weld zone.
• High deposition rate compared to SMAW.
• High efficiency and utilization of filler material because the continuous spool
of wire does not require changing as often as the individual electrodes used in
SMAW.
• Due to the lack of a slag coating that must be removed after welding, GMAW
is well suited for automatic and robotic welding or high production.
• GMAW is a clean process, because there is no flux present. When no slag is
present, the welder can more easily observe the action of the arc and the
weld puddle to improve control.
• Extremely versatile, wide and broad application ability.
Disadvantages

• Since GMAW uses shielding gas alone to protect the puddle from the
atmosphere excessive contamination of the base metal may cause porosity.
• Drafts or wind may disperse shielding gases, which makes GMAW
unsuitable for field welding.
• The equipment used is more complex than that used for SMAW, increasing
the possibility of mechanical problems that can lead to quality problems.
• Higher-price equipment.
• The use of short-circuiting transfer can lead to lack of fusion discontinuities.
• Inability to reach inaccessible welding areas.
• Limited distance.
• Inability to push small diameter, soft electrode through long cable.
Keuntungan proses GMAW
• Pengelasan kontinu (tanpa henti)
• Posisi las bervariasi
• Pengamatan visual dari busur dan kampuh lasan lebih mudah
• Cocok digunakan untuk lasan secara otomatis atau robotik, &
• Peralatan menjadi sederhana untuk las yang semi otomatis

Keterbatasan adalah kebutuhan perlindungan dari angin saat

mengelas di lapangan (field), dan sensitif terhadap masalah
Arc Blow
FLUX-CORED ARC WELDING
Flux cored arc welding (FCAW) uses the same
type of equipment that is used for the gas metal arc
welding process. A major advantage of this process
is that with the addition of flux to the center of the
filler wire the weld's properties can be changed.
Although welds must be cleaned after completion,
the improved quality, flexibility, and welding speed
offset this requirement.
FLUX CORED ARC WELDING

Flux Cored Arc Welding (FCAW) hampir sama dengan proses

GMAW, mesin las maupun cara pengelasannya, hanya wire rod
yang berbeda.
GMAW -- PEJAL / Solid
FCAW -- Wire dengan Flux (Flux cored Wire)

PENTING
FCAW - Single Shieding (Flux)
FCAW - Double Shielding Flux dan CO2)
FLUX CORED ARC WELDING

Tanpa Gas Pelindung

PRINCIPLES OF OPERATION

FCAW uses the heat of an arc between a continuous filler metal electrode
and the work, which is similar to GMAW, except that in FCAW the
electrode is tubular and contains a granular flux instead of the solid wire
used in GMAW.

Shielding is obtained, in whole or in part, from a flux contained within the

tubular electrode.

The flux inside the electrode provides the molten weld pool with protection
from the atmosphere, improves strengths through chemical reactions and
alloys, and improves the weld shape.

Self-shielded electrodes require no external gas protection, while other

flux cored electrodes use additional external gas shielding supplied through
the welding gun.
PRINCIPLES OF OPERATION

If external shielding is provided, the choice of shielding gas is usually

carbon dioxide, argon, or a mix of carbon dioxide and argon.
Thus, 75% argon - 25% carbon dioxide can be used to improve the
operating characteristics of the arc and provide excellent mechanical
properties of the finished weld.
PRINCIPLES OF OPERATION

Strength and other physical or corrosive properties of the finished weld are
improved by the flux.
Small additions of alloying elements, deoxidizers, and slag agents all can
improve the desired weld properties.
Carbon, chromium, and vanadium can be added to improve hardness,
strength, creep resistance, and corrosion resistance.
Aluminum, silicon, and titanium all help remove oxidizes and/or nitrides in
the weld.
Potassium, sodium, and zirconium are added to form slag.
PRINCIPLES OF OPERATION
PRINCIPLES OF OPERATION

A slag covering of the weld is useful for several reasons.

Slag helps the weld by protecting the hot metal from the effects of the
atmosphere, controlling the bead shape by serving as a dam or mold, and
serving as a blanket to slow the weld's cooling rate, which improves its
physical properties.
PRINCIPLES OF OPERATION

Similar to GMAW, FCAW uses constant voltage (CV) type power supply.

CV power supplies provide a controlled voltage (potential) to the welding

electrode. The amperage (current) varies with the speed that the electrode
is being fed into the molten weld pool.

Just like GMA welding, higher electrode feed speeds produce higher
currents and slower feed speeds result in lower currents, assuming all other
conditions remain constant.

The effects on the weld of electrode extension, gun angle, welding

direction, travel speed, and other welder manipulations are similar to those
experienced in GMA welding.
PRINCIPLES OF OPERATION
PRINCIPLES OF OPERATION
ELECTRODES
FLUX CORED ARC WELDING
SUBMERGED ARC WELDING
SUBMERGED ARC WELDING

LAS BUSUR RENDAM

Adalah merupakan salah satu dari jenis arc

welding, dimana busur listrik yang terjadi
karena hubungan pendek antara filler metal
yang mendapat aliran listrik dari contact tube
dengan base metal.
Sebagai pelindung arc adalah FLUX
DESCRIPTION OF THE PROCESS
DESCRIPTION OF THE PROCESS
DESCRIPTION OF THE PROCESS
DESCRIPTION OF THE PROCESS

In submerged arc welding, the arc is covered by a flux.

This flux plays a main role in that:

(1) the stability of the arc is dependent on the flux,
(2) mechanical and chemical properties of the final weld deposit
can be controlled by flux, and
(3) the quality of the weld may be affected by the care and handling of
the flux.
 SUBMERGED ARC WELDING
1. Stop Kontak
2. Mesin Las
3. Kabel
4. Kabel
5. Wire Rot Roll
6. Wire Feeder
7. Contactube
8. Ground Klemp
9. Base Metal
10. Flux
11. Flux Cair
12. Slag Beku
13. Penghisap Flux
14. Wire Rot
15. Weld Metal Cair
16. Weld Metal Beku
SUBMERGED ARC WELDING
SUBMERGED ARC WELDING
SUBMERGED ARC WELDING
SUBMERGED ARC WELDING

Penetrasi proses ini sangat baik

SUBMERGED ARC WELDING

HANYA UNTUK POSISI

FLAT (1G, 1F) DAN 2F,
HORIZONTAL
SUBMERGED ARC WELDING

SAW - Narrow Gap Welding

 SUBMERGED ARC WELDING

Contoh Penetrasi arus listrik AC dan DC

 SUBMERGED ARC WELDING

•Arus yang dipakai DCEP

•Fluks diumpankan didepan elektroda
•Arc dan logam cair dilindungi fluks cair
•Digunakan untuk pengelasan pelat atau pipa (shop)
•Dapat dipakai mengelas baja karbon, baja paduan rendah, baja
stailess, baja paduan Nikel
•Keuntungan : a. Kualitas logam seragam
b. Tingkat ketelitian tinggi
c. Tidak perlu melihat welding area
d. Mengelas material tebal (penetrasi dalam)
•Kerugian : Biaya peralatan tinggi
ADVANTAGES

• Highest deposition rate & speed

Using large-diameter wires, more than 18 kg/hr can be deposited. This rate
is nearly two times the rate of FCAW and four times that of SMAW.
• High utilization of electrode wire
With SAW, there is no spatter to waste metal and cause cleanup problems.
All of the electrode is transferred and becomes weld deposit. Only the melted
flux needed for the weld is lost. Unfused granular flux can be retrieved and
reused. The amount of flux consumed can be controlled by varying the arc
length, which is done by changing the arc voltage.
• Weld size
Flat groove or fillet welds as thick as 25 mm can be made in one pass using
a single electrode. Larger sizes are possible with multiple electrodes. SAW has
very deep penetrating capabilities.
• High-quality welds, smooth, uniform finished weld
Many codes permit SAW to be used on structural iron, pressure vessels,
cryogenic cylinders, and in many other critical applications.
ADVANTAGES

• Easily adapted
With this process, the flux and wire are purchased separately. The flux can be
used to change the alloys in the weld metal deposited from the electrode. By
changing the flux, the properties of the weld are altered. The composition of
the flux is easily changed to meet specific metallurgical properties. Two or
more fluxes can be mixed, or granulated metal can be added to a flux or
mixture to meet individual needs.
• SAW can be performed on numerous metals.
• Minimum operator protection required
Because of the lack of an arc, the operator has no need for a filter lens and
other heavy protective clothing. Another benefit is that there is less smoke
generated than with the other processes.
• Submerged arc welding is a versatile production welding process
capable of making welds with currents up to 2000 amperes, AC or DC,
using single or multiple wires or strips of filler metal. Both AC and DC
power sources may be used on the same weld at the same time.
DISADVANTAGES

• Restricted to flat position and horizontal fillets.

• Welding parameters need careful control
Because the arc flux hides the weld pool, welding conditions must be preset
on the basis of experiments or with proven tabular information, including the
contact tip-to-work distance, the current, the travel speed, and the voltage.
Arc voltage must be carefully controlled to ensure the proper weld profile.
Equally important, deviations in arc voltage can cause significant changes in
the weld composition when using the fluxes as the source of alloys.
• Cleaning the work surfaces and aligning the machine travel with the
joint are particularly important. Improper alignment will result in offset
beads with incomplete joint penetration. In a highly restrained joint, joint
misalignment may also cause cracks.
• The flux is of a low-hydrogen type that may require storage in
heated ovens.
• Because of its deep penetrating arc it may have an extreme width to depth
ratio, that can lead to centerline cracking.
Oxyacetylene is one part of the larger group of processes known as
oxyfuel gas (OF). This group of processes can be used for welding
(OFW), cutting (OFC), and brazing (TB). This group is one of the most
versatile of the welding processes. The equipment required is
comparatively inexpensive, and the cost of operation is low, Figure 1-7.
 Oxy Acetylene Welding (OAW)

Adalah proses pengelasan dimana

panas didapat dari campuran gas
Oxygen dan Acetylene
Pengelasan ini sering disebut Las
Autogen atau yang lebih populer di
Indonesia disebut Las Karbit
Oxy Acetylene Welding ( OAW )
Oxygen
Las Gas

Gas Pembakar Acetylene C2H2

Penamaan pengelasan gas Propan C3H8

tergantung dari gas pembakar
yang digunakan Other Gas
Oxy-Acetylene
Oxy-Hydrogen
Oxy-Fuel
Dan lain lain
Oxy Acetylene Welding ( OAW )

Cara Untuk Mendapatkan Oxygen

Oxy Acetylene Welding ( OAW )

Cara Untuk Mendapatkan Acetylene

Oxy Acetylene Welding ( OAW )
Panas yang dihasilkan mencapai
2600OF ~ 10000OF Diatas titik lebur
baja.
Sehingga dengan mudah baja dapat
mencair
Oxy Acetylene Welding ( OAW )

Tekanan Kerja Gas (pada Regulator)

Pengelasan
O2 = 2 ~ 3 Bar
C2H2 = 0.5 Bar

Pemotongan
O2 = 5.0 Bar
C2H2 = 0.5 Bar
Oxy Acetylene Welding ( OAW )

Penyalaan

1. Buka katub O2 pada Brander Las

2. Buka Katub C2H2 pada Brander Las
3. Biarkan < 5 detik beri percikan api
4. Atur Nyala Api Las
Oxy Acetylene Welding ( OAW )

Pematian
1. Tutup katub C2H2 pada Brander Las
2. Tutup katub O2 pada Brander Las
3. Tutup katub O2 dan C2H2 pada Regulator
4. Buang gas yang tersisa pada selang dengan
membuka katub pada brander Las kemudian
tutup kembali
Oxy Acetylene Welding ( OAW )

API BALIK
LAKUKAN LANGKAH
PEMATIAN DAN APABILA
BRANDER LAS PANAS BISA
DIDINGINKAN DENGAN AIR
Oxy Acetylene Welding ( OAW )
Macam nyala api las
Oxy Acetylene Welding ( OAW )

1. Tabung Gas O2 6. Brander Las

2. Tabung Gas C2H2 7. Filler Metal
3. Katub pukul balik 8. Nozzle Las
4. Selang O2 9. Benda kerja
5. Selang C2H2 10. Api Las
Oxy Acetylene Welding ( OAW )

Arah maju / ke kiri

Untuk pengelasan pelat
tipis

Arah mundur / ke kanan

Untuk pengelasan pelat
tebal
Oxy Acetylene Welding ( OAW )

BRAZING

Api yang digunakan

adalah Carborizing /
kelebihan C2H2
Proses Potong (Cutting)
 Proses Potong (Cutting)

Pemotongan Nyala Api – Flame Cutting

Oxy Acetylene Cutting
 Oxy Acetylene Cutting

Ring Block Schlitz Tangga

Type Brander Oxy Acetylene Cutting

 Proses Potong (Cutting)
Pemotongan dengan busur Plasma – Plasma Arc Cutting
 Proses Potong (Cutting)
Water Jet Cutting
Posisi elektroda
Bead (kampuh) yang baik
tergantung pada:

• Elektroda
• Arus
• Polaritas
• Panjang busur
• Travel speed/kecepatan
• Feeding
• Gerakan yang tidak perlu
Bentuk – bentuk las
Bagian – bagian dari las
Daerah pada pengelasan
Penggantian elektroda

Kapan sebaiknya elektroda diganti?

Elektroda diganti jika panjangnya tinggal 1,5 in (38 mm)

Ayunan elektroda