Welding Inspector

MMA Welding Section 10

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MMA - Principle of operation

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MMA welding
Main features:
Shielding provided by decomposition of flux covering Electrode consumable Manual process

Welder controls:
Arc length Angle of electrode Speed of travel Amperage settings
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Manual Metal Arc Basic Equipment

Control panel (amps, volts) Electrode oven

Power source

Holding oven
Inverter power source Electrode holder

Electrodes
Return lead Welding visor filter glass

Power cables

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MMA Welding Plant

Transformer: Changes mains supply voltage to a voltage suitable for welding. Has no moving parts and is often termed static plant. Rectifier: Changes a.c. to d.c., can be mechanically or statically achieved. Generator: Produces welding current. The generator consists of an armature rotating in a magnetic field, the armature must be rotated at a constant speed either by a motor unit or, in the absence of electrical power, by an internal combustion engine. Inverter: An inverter changes d.c. to a.c. at a higher frequency.

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MMA Welding Variables

Voltage The arc voltage in the MMA process is measured as close to the arc as possible. It is variable with a change in arc length O.C.V. The open circuit voltage is the voltage required to initiate, or re-ignite the electrical arc and will change with the type of electrode being used e.g 70-90 volts Current The current used will be determined by the choice of electrode, electrode diameter and material type and thickness. Current has the most effect on penetration. Polarity Polarity is generally determined by operation and electrode type e.g DC +ve, DC ve or AC
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Constant Current Power Source (Drooping Characteristic)

100 90 80 70

O.C.V. Striking voltage (typical) for arc initiation

Voltage

60 50 40 30 20 10 20 40 60 80 100 120 130 140 160 180

Normal Operating Voltage Range

Large voltage variation, e.g. + 10v (due to changes in arc length) Small amperage change resulting in virtually constant current e.g. + 5A.
200

Amperage
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MMA welding parameters

Travel speed
Too low wide weld bead contour Travel speed Too high lack of root fusion incomplete root penetration undercut poor bead profile, difficult slag removal

lack of penetration
burn-through

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MMA welding parameters

Type of current:
voltage drop in welding cables is lower with AC inductive looses can appear with AC if cables are coiled cheaper power source for AC no problems with arc blow with AC DC provides a more stable and easy to strike arc, especially with low current, better positional weld, thin sheet applications welding with a short arc length (low arc voltage) is easier with DC, better mechanical properties DC provides a smoother metal transfer, less spatter

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MMA welding parameters

Welding current
approx. 35 A/mm of diameter
governed by thickness, type of joint and welding

position
Too low poor starting slag inclusions Welding current Too high spatter excess penetration

weld bead contour too high

lack of fusion/penetration
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undercut
burn-through

MMA welding parameters

Arc length = arc voltage
Too low arc can be extinguished stubbing Arc voltage Too high spatter porosity excess penetration undercut burn-through

Polarity: DCEP generally gives deeper penetration

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MMA - Troubleshooting

MMA quality (left to right)

current, arc length and travel speed normal; current too low; current too high; arc length too short; arc length too long; travel speed too slow; travel speed too high

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MMA electrode holder

Collet or twist type

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Tongs type with spring-loaded jaws

MMA Welding Consumables

MMA Covered Electrodes
The three main electrode covering types used in MMA welding

Cellulosic - deep penetration/fusion Rutile - general purpose Basic - low hydrogen

(Covered in more detail in Section 14)

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MMA welding typical defects

Most welding defects in MMA are caused by a lack of welder skill (not an easily controlled process), the incorrect settings of the equipment, or the incorrect use, and treatment of electrodes

Typical Welding Defects:

Slag inclusions Arc strikes

Porosity
Undercut Shape defects (overlap, excessive root penetration, etc.)

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Manual Metal Arc Welding (MMA)

Advantages:
Field or shop use Range of consumables All positions Portable Simple equipment High welder skill required High levels of fume Hydrogen control (flux) Stop/start problems Comparatively uneconomic when compared with some other processes i.e MAG, SAW and FCAW

Disadvantages:

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