WELDING PROCESSES

GENERAL

WHAT IS WELDING PROCESSES

Welding is the process of joining two or more piece of material together by bringing
the atom of each piece into such close contact that an atomic bond takes place the
separate piece fuse together to form one.

Fusion welding is the alternative process to welding with process.

Welding with pressure is to obtain a welded joint between two materials without
Melting them .

Fusion welding processes require a local application of heat in order to bring the
Material to a temperature at which it will fuse, for steels is approximately 1400 C
to 1500 C. The temperature in the molten weld pool may be in the 2500 C to 3000 C
range . The average temperature in the are is 6000 C .

TYPE OF WELDING

1) OXY – GAS WELDING

2) MANUAL METAL ARC WELDING ( M.M.A / SMAW )

3) METAL INERT GAS & METAL ACTIVE – GAS

WELDING

4) TUNGSTEN INERT GAS ( T.I.G ) WELDING

5) SUBMERGED ARC WELDING ( S.A.W )

6) ELECTROSLAG WELDING ( E.S.W )

7) PLASMA ARC WELDING ( P.A.W )

 WELDING PROCESSES

(1) OXY – GAS WELDING

The them oxy- gas welding is a genetic term for a fusion welding process which uses a
fuel and oxygen to provide a flame hot enough to weld the material to be joined.
Oxy – acetylene welding is suitable for the welding of most metals including
Carbon steels , stainless , cast iron , bronze , copper , aluminums .
The main area of application for Oxy – gas welding is on metals than less 5mm
thickness , although , thicker section may be welded. The main disadvantage for this
welding is slow speed travel and the therefore heat input

Process technique

Two main welding techniques are used for Oxy – gas welding

1) Forehand technique

The filler wire precedes the blowpipe along the seam to be welded. This technique is
for general purpose work.

2) Backhand technique

The backhand technique is vice versa to forehand example blowpipe precedes the
filler wire along the welded joint. It can be use on thicker and with modifications on
positional work

The Oxy – acetylene flame

The are three main distinct flame type can be set with oxy – acetylene

1) OXIDIZING = Sharp inner cone, deeper color in center

2) NEUTRAL = Fully luminous inner cone

3) CARBURIZING = Feather of excess acetylene around inner cone

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WELDING PROCESSES

(2) MANUAL METAL – ARC WELDING ( MMA / SMAW )

Manual metal arc welding is the most versatile of the welding processes, suitable for
almost all thickness and type of ferrous and most non – ferrous metal. Welding can
carry out in all positions relatively, economic with reasonable ease of use.
Manual metal arc welding used an electric arc between a flux covered metal electrode
and the metal being welding welded (base metal).Heat from the electric are melts both
the end of the electrode and the base metal to be joined. The is temperature 6000
C.

POWER REQUIREMENT

M.M.A welding is carried out using either AC or DC current. Power for M.M.A can
be obtained from either transformers, transformers –rectifiers, generator or
inverters.

CURRENT (AMPERAGE)

Welding current measure in amperes, to control electrode burn off rate and depth
of penetration. The possible effects of having an incorrect amperage when
using the MMA welding is

Amperage too low: Poor penetration or fusion, unstable arc, irregular bead shape,
Slag inclusion, porosity, electrode freezes to the weld and
Arc strikes.

Amperage too high: Excessive penetration, burn throughs, porosity, spatter,

Deep crater, under cut, electrode overheats and
High deposition.

VOLTAGE

The welding potential (voltage) to control the weld pool fluidity. The possible effects
Of having incorrect voltage when using MMA welding is

Voltage too low: Poor penetration, electrode freezes to work, arc strikes, fusion,
Slag inclusion, unstable arc and irregular bead sharpe.

Voltage too high: Porosity, spatter, arc wander, irregular bead slag inclusion,
Positional welding difficult.
SPEED OF TRAVEL

The speed of travel effects heat input and therefore also affects metallurgical and
mechanical condition. The possible effects of having an incorrect welding speed is

Travel speed to fast: Narrow thin bead, slag inclusion, fast cooling, undercut,
Poor fusion/penetration and metallurgical effects.

Travel speed to slow: Excessive deposition, cold laps, slag inclusion and
Irregular bead shape.

CONSUMABLE ELECTRODE

1) RUTILE : E6013, E7016, E7018 (Low Hydrogen) - structure use

2) CELLULOSE : E6010 - pipeline use

3) BASIC : E6018

Important item for MMA welding

1) DCRP - direct current reverse polarity

2) DCSP – direct current straight polarity
3) POWER SOURCE-AC/DC
4) EARTH
5) PARENT METAL
6) ELECTRODE CORE WIRE
7) ELECTRIC ARC
8) ELECTRODE COATING
9) GAS SHIELDED
10) SLAG LAYER
11) WELD DEPOSIT
12) HOLLER WELD POOL

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WELDING PROCESSES

(3) METAL INERT GAS & METAL ACTIVE – GAS

WELDING

MIG and MAG welding may be considered together because welding equipment
including power source is essentially the same.(shielding gas and filler wire)
The MIG/MAG welding process uses a bare wire consumable electrode to provide
the arc and weld metal. The wire typically 0.8-1.6 mm diameter, is continuously fed
from a coil through a specially designed welding gun.

SHIELDING GASES

The gas shield fulfils two main functions

1) It provides a suitable ionizable atmosphere for the electric arc.

2) It protects the weld pool from atmosphere contamination.

EXAMPLE GASES APPLICATION FOR MIG/MAG WELDING

1) PURE ARGON = ALUMINIUM, COPPER, 9% NICKLE STEEL

2) ARGON + 1% TO 5% OXYGEN = STAINLESS STEEL
3) CO2 (carbon dioxide) = C STEEL UP TO 0.4% C, LOW ALLOY STEEL
4) ARGON + 5% TO 25% CO2 = CARBON STEEL AND LOW ALLOW STEELS
5) ARGON + 5% HYDROGEN = NICKLE AND ITS ALLOYS
6) ARGON + 15% NITROGEN = COPPER AND ITS ALLOYS
7) 75% HELIUM + 25% ARGON = ALUMINIUM AND COPPER
8) 75% HELIUM + 25% ARGON + CO2 TRACE = AUSTENITIC S/STEEL

METAL TRANSFER MODES

1) Spray or free flight transfer

2) Dip transfer (semi – short circuiting arc)
3) Globular transfer
4) Pulsed transfer