Gas Tungsten Arc Welding

By L D Poyyara
GTAW
Fusion Welding Process
Arc Between Non-Consumable Tungsten
Rod And Work
Arc & Weld Pool Shielded By Argon
Filler Wire Separately Added To Weld Pool
Welding Torch & Tungsten Rod Cooled by
Flow OF Argon / Cooling Water
Shielding Gas
Inert Gas - Argon , Helium
Common Shielding Gas Argon
When Helium Is Used Called Heli Arc Welding
When Argon Is Used Called Argon Arc Welding
Inert Gas Prevents Contamination Of Molten Metal
It Prevents Oxidation Of Tungsten Rod
It Ionizes Air Gap and Stabilizes Arc
It Cools Welding Torch & Tungsten Rod

Equipment & Accessories
+
Argon Gas In
Flow Meter
Welding Cable & Cooling
Water In Tube
HF Unit &
Water Cooling
System
Argon Cylinder
Pressure Regulator
Cooling Water In
Cooling Water Out
Argon Shielding
Tungsten Rod
Power Source
Work
Arc
+
High Frequency
Connection
Solenoid
Valve
Ceramic Cup
Pedal Switch
Gas Lens
GTAW Equipment &
Accessories
Power Source Inverter, Thyrester,Rectifier,
Generator
High Frequency Unit
Water Cooling System
Welding Torch- (Ceramic Cup, Tungsten Rod,
Collet, Gas-lens)
Pedal Switch
Argon Gas Cylinder
Pressure Gauge, Regulator, Flow Meter
Earthing Cable With Clamp

Types Of GTAW Power Source
Inverter- DC

Thyrester DC

Motor Generator DC

Rectifier DC

Transformer AC (For Aluminium Welding Only)

Power Source
Provides Electric Energy Arc Heat

Drooping Characteristic

OCV Appx. 90V,

Current Range 40 A to 300 A ( Capacity Of M/s)

Arc Voltage 18V to 26V
Characteristic Of GTAW
Power Source

A
Vertical
Curve
V1
V2
A1 A2
Drooping Constant Current
V
High Frequency Unit
Provides High Voltage Electric Energy With
Very high Frequency 10000 Cycles / Sec.

Initiates low energy Arc / Spark & Ionize Air
Gap.

Electrically charges Air Gap For welding
Current to Jump Across the Tungsten Tip &
BM to Form An Arc.

HF Gets Cut Off, Once Welding Arc Struck.
Water Cooling System

Provides Cooling Water To Welding Torch.

Cools Tungsten Rod, Torch handle & Welding
Cable.

Cooling Water Returns through Flexible Tube
Which Carries welding cable within.
GTAW TORCH
Tungsten Rod
Ceramic Cup
Arc
Argon Gas Inlet
Cooling Water Outlet
Cooling Water Inlet Tube with cable
Base Metal
Torch Handle
Cap with collet For
Holding Tungsten
Argon Shielding Gas
Earthing Cable
Pedal Switch
Switches system
on And off in
sequence
When Pedal Pressed
Solenoid valve opens, Argon gas
flows
High Frequency current jumps from
tungsten rod generating sparks
Welding current flows generating an
arc across tungsten rod and work.
High frequency gets cut off from the
system & welding continues.
When Pedal Released
1 Current gets cut off, Arc extinguishes
2 Gas flow remains for few more
seconds before it stops.
Argon Gas Cylinder- Pressure
Regulator + Flow Meter
Cylinder Stores Argon
At High Pressure

Regulator Regulates
Cylinder Pressure to
Working Pressure

Flow Meter Controls
Flow Rate
Argon Cylinder
Flow Meter
Pressure Regulator
Flow Regulator
Pressure gauges
Cylinder Valve
Connection To Torch
Shielding Gas
Argon - Purity 99.95%

Impure Argon Results In Porosities

Purity Verified by Fusing BQ CS plate

Leakage of Argon in Torch Results in
Porosity.

Check Leakage by Closing the Ceramic
Cup With Thump

Argon Gas Cylinder
Light Blue In Colour

Full Cylinder Pressure: 1800 psi ( 130 Kgs / Cm
2
)

Volume Of Argon In Full Cylinder: 7.3 M
3


Commercial Argon (99.99%) Cost: Rs 70/- Per M
3

High Purity Argon (99.999) Cost: Rs 87/- Per M
3

Back Purging
Purging Gas Commercial
Argon or Nitrogen
Applicable to Single
Sided full penetration
Prevents oxidation of
root pass from opposite
side of weld
Essential for high alloy
steels, nonferrous
metals and alloys
Desirable For All
Material
Welding Torch
Root Pass
Purging Gas In
Purging
Gas Out
Purging
chamber
Filler Wire
Tools For GTAW

Head Screen

Hand gloves

Chipping Hammer

Wire Brush

Spanner Set
Tungsten Rod

Non Consumable Electrode.

Maintains Stable Arc

Tip to be Ground to a cone Shape of 60
to 30 angle

Thoriated Tungsten for General
Application, Zerconiated Tungsten for
Aluminium Welding

Sizes :- 2, 2.4 & 3 mm
Tungsten Rod
Ground to
50 ankle
Filler Wire

Added Separately to the weld pool.

Compatible to base metal

Used in cut length for manual welding.

Used from layer wound spool for
automatic welding.

Sizes :- 0.8, 1, 1.2, 1.6, 2, 2.4 & 3 mm
ASME Classification Of Filler Wire
SS Filler Wire:
SFA-5.9, ER 308, 308L, 316, 316L, 347, 309
LAS Filler Wire:
SFA 5.28, ER 70S A1, ER 80S B2, ER90S D2,
ER 80S Ni2
CS Filler Wire:
SFA- 5.18 , ER 70S2
C = 0.07%, Mn = 0.9% 1.4%, Si = 0.4 0.7%, P = 0.025%, S = 0.035%


Dos & Don'ts In GTAW
Always Connect
Electrode Ve
Keep Always Flow
Meter Vertical
Check & Confirm
Argon Purity
Clean Groove & Filler
wire With Acetone
Grind Tungsten Tip to
Point
Dont Strike Arc With
Electrode + Ve
Dont strike Arc Without
Argon Flow
Dont Strike Arc By
touching Tungsten Rod
Dont Touch Weld Pool
With Tungsten Rod
Dont Lift and break Arc

Dos Donts
Dos & Don'ts In GTAW
Break The Arc Only By
Pedal Switch
Lift The Torch only After
5 Sec Of Arc Break.
Ensure Pre Purging &
Post Purging of 5Sec
Ensure Argon Flow &
Water Circulation To
Torch
When Arc is Stopped
Dont Lift Torch
immediately.
Dont Weld With Blend
Tungsten Rod
Dont Weld With Argon
Leaking Torch
Dont Weld Without
Water Circulation
Dos Donts
Dos & Don'ts In GTAW
Provide Back Purging
For Single Sided Full
Penetration Welds
Use N
2
or Argon as
Back Purging Gas For
CS & LAS
Use Argon As Back
Purging Gas For SS &
Non Ferrous Alloys
Dont Weld Single Sided
Full Penetration Welds
Without Back Purging
Dont Use N
2
As Back
Purging Gas For Non
Ferrous Alloys
Dont Empty Ag
Cylinders Fully.


Dos Donts
Defects In GTAW
1. Cracks 2. Lack Of Fusion
3. Porosity 4. Undercut
5.Lack Of Penetration 6. Excess Penetration
7.Overlap 8. Suck Back
9. Under Flush 10. Burn Through
11. Tungsten Inclusion 11.Stray Arcing

Crack
Cause Remedy
1) Wrong Consumable
2) Wrong Procedure
3) Improper Preheat
4) Inadequate Thickness
In Root Pass
1) Use Right Filler Wire
2) Qualify Procedure
3) Preheat Uniformly
4) Add More Filler Wire
in root Pass
crack
Lack Of Fusion
Cause Remedy
1) Inadequate Current
2) Wrong Torch angle
3) Improper bead placement
1) Use Right Current
2) Train /Qualify welder
3) Train/Qualify Welder

Lack Of Fusion
Porosity
Cause Remedy
1) Impure Argon Gas
2) Argon Leak Within Torch
3) Defective Filler Wire
4) Wet surface of BM
5) Rusted / Pitted Filler wire
6) Improper Flow Of Argon
1) Replace Argon Cylinder
2) Replace Leaking Torch
3) Replace Filler Wire
4) Clean & Warm BM
5) Clean Filler Wire
6) Provide Gas lens

Porosity
. .
Undercut
Cause Remedy
1) Excess Current
2) Excess Voltage
3) Improper Torch angle
1) Reduce the Current
2) Reduce Arc length
3) Train & Qualify the Welder
Under cut
Lack Of Penetration*
Cause Remedy
1) Excess Root Face
2) Inadequate Root opening
3) Over size Filler Wire
4) Wrong Direction of Arc
5) Improper bead placement
6) Improper weaving technique
1) Reduce Root Face
2) Increase Root Opening
3) Reduce Filler Wire size
4) Train / Qualify Welder
5) Train / Qualify Welder
6) Train & Qualify Welder
LOP
* Applicable to SSFPW
Excess Penetration*
Cause Remedy
1)Excess root opening
2) Excess Current
3) Inadequate root face
4) Excess Weaving
5) Wrong Direction Of Arc
1) Reduce root gap
2) Reduce Current
3) Increase Root face
4) Train Welder
5) Train Welder
Excess Penetration
* Applicable to SSFPW
Overlap
Cause Remedy
1) Wrong Direction Of Arc
2) Inadequate Current
3) Excess Filler Wire
1) Train & Qualify Welder
2) Increase Current
3) Reduce Filler Metal

Overlap
Suck Back*
Cause Remedy

1) Excess weaving in root
2) Excess Current
3) Inadequate root face
4) Wrong Electrode angle

1) Reduce weaving
2) Reduce Current
3) Increase root face
4) Train / Qualify Welder
Suck Back
* Applicable to SSFPW in 4G, 3G & 2G
Under flush
Cause Remedy
1) Inadequate weld beads in
final layer
2) Inadequate understanding on
weld reinforcement
3) Wrong selection of filler wire
size

1) Weld some more beads
in final layer
2) Train / Qualify welder

3) Train / Qualify Welder

Under flush
Burn through*
Cause Remedy
1) Excess Current
2) Excess Root opening
3) Inadequate Root face
4) Improper weaving
1) Reduce the Current
2) Reduce root opening
3) Increase root face
4) Train / Qualify Welder

Burn trough
*Applicable to root pass
Tungsten Inclusion
Cause Remedy
1) Ineffective HF
2) Improper Starting of Arc

3) Tungsten Tip Comes in
Contact With Weld
1) Rectify HF Unit
2) Never Touch Weld
With Tungsten Rod
3) Train / Qualify welder

Tungsten Inclusion
Stray Arcing
Cause Remedy
1) HF Not In Operation
2) Inadequate Skill of Welder
1) Rectify HF Unit
2) Train the Welder
Arc Strikes

Thanks
Gas Metal Arc Welding
By L D Poyyara
What Is GMAW ?
A Fusion Welding Process Semi Automatic
Arc Between Consumable Electrode &Work
Arc Generated by Electric Energy From a Rectifier
/ Thyrester / Inverter
Filler Metal As Electrode Continuously fed From
Layer Wound Spool.
Filler Wire Driven to Arc By Wire Feeder through
Welding Torch
Arc & Molten Pool Shielded by Inert Gas through
Torch / Nozzle
Gas Metal Arc Welding
MIG Shielding Gas Ar / Ar + O2 / Ar + Co2

MAG Shielding Gas Co2

FCAW Shielding Gas Co2 With Flux cored
Wire
Note:- Addition of 1 5% of O2 or 5 10% of Co2 in Ar.
increases wetting action of molten metal
Power Source For MIG / MAG
Inverter- DC
Thyrester DC
Motor Generator DC
Rectifier DC

Characteristic Of GMAW Power
Source
Constant V / Linier Characteristic
Appx. Horizontal
Curve
V1
V2
A1 A2
A
V
Current & Polarity
DC- Electrode +Ve
Stable Arc
Smooth Metal Transfer
Relatively Low Spatter
Good Weld Bead Characteristics
DC- Electrode Ve, Seldom Used
AC- Commercially Not In use
Accessories Of GMAW
Power Source
Wire Feed Unit
Shielding Gas Cylinder, Pressure gauges/
Regulator, Flow meter ( Heater For Co2 )
Welding Torch
Water Cooling System (For Water cooled Torch)
Earthing Cable With Clam
Tools For GMAW
Head Screen With DIN 13 / 14 Dark Glass
Hand Wire Brush / Grinder With Wire Wheel
Cutting Pliers
Hand Gloves
Chipping Hammer / Chisel & hammer
Spanner Set
Cylinder Key
Anti-spatter Spray
Earthing Cable With Clamp
GMAW Torch
Torch Handle
Spring Conduit
Job
Arc
Gas Cup
Shielding Gas
Filler Wire - Electrode
Nozzle Tip
On / Off Switch
Equipment & Accessories
+
Wire Inside Spring Lining
Flow Meter
Welding Torch Wire Feeder
Shielding Gas
Cylinder
Pressure Regulator
Argon / Co2
Shielding
Power Source
With Inductance
Work
Arc

Solenoid
Valve
Copper Cup
Wire
Spool
Electrode /
Wire
Shielding Gas
Heater
(Only For
Co2)
Contact Tip
Switch
Torch With Cable Max. 3Mtr
Types Of Wire Feeding In
GMAW
Push Type
Wire fed in to The torch by Pushing through Flexible
Conduit From A Remote Spool
Pull Type
Feed Rollers Mounted on The Torch Handle Pulls the
Wire From A Remote spool
Self Contained
Wire Feeder & The Spool On the Torch


Function Of Shielding Gas In
GMAW
Prevents Air contamination of weld Pool
Prevents Contamination During Metal
Transfer
Increases fluidity of molten metal
Minimizes the spatter generation
Helps in even & uniform bead finish


Shielding Gases For GMAW
MIG: Argon Or Helium
For SS, CS, LAS & Non-ferrous Mt & Al
MIG: Ar + 1 to 2 % O2, Wire With Add. Mn & Si
For SS, CS, LAS & Non-ferrous Mt & Al
MIG: Ar + 5 to 20 % Co2 Wire With Add. Mn & Si
For SS, CS, LAS & Non-ferrous Mt & Al
MAG: Co2 With Solid Wire
For CS & LAS
FCAW: Co2 With Flux Cored Wire
For CS, LAS & SS Overlay

ASME Classification For CS
GMAW Wire
SFA 5.18 : - CS Solid Wire
ER 70 S 2, ER 70 S 3
ER 70 S 6, ER 70 S 7

SFA 5.20 :- CS Flux Cored Wire
E 71 T-1, E 71 T-2 ( Co2 Gas )
E 71 T-1M, E 71 T-2M ( Ar + Co2 Mix)


GMAW CS Wire
Generally Copper Coated
Prevents Oxidation / rusting in Storage
Promotes Electric Conductivity in Arcing
Available In Solid & Flux Cored
Size in mm 0.8, 1, 1.2, 1.6, 2, 2.4, 3
Manganese & Silicon ( Mn 1 2 %, Si Max 1%)
Act As Deoxidizing Agents
Eliminate Porosity
Increase Wetting Of Molten Pool

Metal Transfer In MIG
Short-Circuiting / Dip Transfer

Globular Transfer

Spray Transfer

Metal Transfer In MIG
Dip/Short Circuiting Globular
Spray
CS Solid Wire 1.2 mm
Above230A
24 35 V
120 to 250A
16 24 V
Up to 120A
14 22V
Co2 or Ar Co2 or Ar Only Ar / Ar+O2
Short-Circuiting / Dip Transfer
Wire In Contact With Molten Pool 20 to 200 times
per Second
Operates in Low Amps & Volts Less Deposition
Best Suitable for Out of Position Welding
Suitable for Welding Thin Sheets
Relatively Large opening of Root Can be Welded
Less Distortion
Best Suitable for Tacking in Set up
Prone to Get Lack of Fusion in Between Beads



Globular Transfer
Metal transferred in droplets of Size grater
than wire diameter
Operates in Moderate Amps & Volts
Better Deposition
Common in Co2 Flux Cored and Solid Wire
Suitable for General purpose Welding


Spray Transfer
Metal transferred in multiples of small droplets
100 to 1000 Droplets per Second
Metal Spray Axially Directed
Electrode Tip Remains pointed
Applicable Only With Inert Gas Shielding
Not With Co2
Operates in Higher Amps & Volts Higher
Deposition Rate
Not Suitable for Welding in Out of Position.
Suitable for Welding Deep Grooves


Pulsed Spray Welding
Power Source Provides Two different
Current LevelsBackground and Peakat
regular interval
Background & Peak are above and
below the Average Current
Best Suitable for Full Penetration Open
Root Pass Welding
Good Control on Bead Shape and Finish
Synergic Pulse GMAW
Parameters of Pulsed Current (Frequency,
Amplitude, Duration, Background Current)
Related to Wire feed Rate
One Droplet detaches with each pulse
An Electronic Control unit synchronizes wire feed
Rate with Pulse Parameters
Best Suitable for Most Critical Full Penetration
Open Root Pass Welding
Good Control on Open Root penetration, Bead
Shape and Finish
GMAW Process Variables
Current
Voltage
Travel Speed
Stick Out / Electrode Extension
Electrode Inclination
Electrode Size
Shielding Gas & Flow Rate
Welding Position
Parameter For 1.2 FC Wire
Current 200 to 240 A
Voltage 22-24
Travel Speed 150 to 250 mm / min
Stick Out / Electrode Extension 15 to 20 mm
Electrode Inclination Back Hand Technique
Shielding Gas Co2, 12 L/Hr

Parameter For 1.2 Solid Wire
Current 180 to 220 A
Voltage 20-22
Travel Speed 150 to 200 mm / min
Stick Out / Electrode Extension 10 to 20 mm
Electrode Inclination Back Hand Technique
Shielding Gas Co2 12 L/Hr

Results In Change Of Parameters
Increase In Current
More deposition, More Penetration, More BM Fusion
Increase In Voltage
More Weld Bead Width, Less Penetration, Less
Reinforcement, Excess Spatter
Increase In Travel Speed
Decrease in Penetration, Decrease in Bead Width,
Decrease In Gas Flow rate
Results In porosity
Long Stick Out / Electrode Extension
Excess Weld Deposit With Less Arc intensity, Poor Bead
Finish, Shallow Penetration


Common Defects In GMAW
1. Porosity 2. Spatters
3. Lack Of Fusion 4. Under Cut
5. Over Lap 6. Slag
7. Crack 8. Lack Of Penetration
9. Burn Through 10. Convex Bead
11. Unstable Arc 12. Wire Stubbing

Porosity
Cause Remedy
1) Less Mn & Si In Wire
2) Rusted / Unclean BM / Groove
3) Rusted wire
4) Inadequate Shielding Gas

1) Use High Mn & Si Wire
2) Clean & warm the BM
3) Replace the Wire
4) Check & Correct Flow Rate

Porosity
. .
Spatters
Cause Remedy
1) Low Voltage
2) Inadequate Inductance
3) Rusted BM surface
4) Rusted Core wire
5) Quality Of Gas
1) Increase Voltage
2) Increase Inductance
3) Clean BM surface
4) Replace By Rust Free wire
5) Change Over To Ar + Co2

Spatters

Lack Of Fusion
Cause Remedy
1) Inadequate Current
2) Inadequate Voltage
3) Wrong Polarity
4) Slow Travel Speed
5) Excessive Oxide On Joint
1) Use Right Current
2) Use Right Voltage
3) Connect Ele. + Ve
4) Increase Travel speed
5) Clean Weld Joint
Lack Of Fusion
Undercut
Cause Remedy
1) Excess Voltage
2) Excess Current
3) Improper Torch angle
4) Excess Travel Speed
1) Reduce Voltage
2) Reduce Current
3) Train & Qualify the Welder
4) Reduce Travel Speed
Under cut
Overlap
Cause Remedy
1) Too Long Stick Out

2) Inadequate Voltage
1) Reduce Stick Out

2) Increase the Voltage

Overlap
Slag
Cause Remedy
1) Inadequate Cleaning
2) Inadequate Current
3) Wrong Torch angle
4) Improper bead placement
1) Clean each bead
2) Use Right Current
3) Train / Qualify welder
4) Train / Qualify Welder

Slag
Crack
Cause Remedy
1) Incorrect Wire Chemistry
2) Too Small Weld Bead
3) Improper Preheat
4) Excessive Restrain
1) Use Right Wire
2) Increase wire Feed
3) Preheat Uniformly
4) Post heating or ISR
crack
Lack Of Penetration*
Cause Remedy
1) Too Narrow Groove Angle
2) Inadequate Root opening
3) Too Low Welding current
4) Wrong Torch angle
5) Puddle Roll In Front Of Arc
6) Long Stick Out
1) Widen The Groove
2) Increase Root Opening
3) Increase Current
4) Train / Qualify Welder
5) Correct Torch Angle
6) Reduce Stick Out
LOP
* Applicable to SSFPW
Burn through*
Cause Remedy
1) Excess Current
2) Excess Root opening
3) Inadequate Root face
4) Too Low Travel Speed
5) Quality Of Gas
1) Reduce the Current
2) Reduce root opening
3) Increase root face
4) Increase Speed
5) Use Ar + Co2

Burn trough
*Applicable to root pass
Convex Bead Finish
Cause Remedy
1) Low Current
2) Low Voltage
3) Low Travel Speed
4) Low Inductance
5) Too Narrow Groove

1) Increase Current
2) Increase Voltage
3) Increase Travel Speed
4) Increase Inductance
5) Increase Groove Width

Uneven bead finish
Unstable arc
Cause Remedy
1) Improper Wire Feed
2) Improper Gas Flow
3) Twisted Torch Conduit
1) Check Wire Feeder
2) Check Flow Meter
3) Straighten Torch Cab
Wire Stubbing
Cause Remedy
1) Too Low Voltage
2) Too High Inductance
3) Excess Slope
4) Too Long Stick Out
1) Increase Voltage
2) Reduce Inductance
3) Adjust Slope
4) Reduce Stick Out
Important Terminology used in
Critical Welding
Preheating
Post Heating or Dehydrogenation
Intermediate Stress leaving
Inter pass Temperature
Post Weld Heat Treatment

What Is Preheating?
Heating the base metal along the weld joint to a
predetermined minimum temperature immediately before
starting the weld.
Heating by Oxy fuel flame or electric resistant coil
Heating from opposite side of welding wherever possible
Temperature to be verified by thermo chalks prior to
starting the weld


Why Preheating?
Preheating eliminates possible cracking of weld and HAZ
Applicable to
Hardenable low alloy steels of all thickness
Carbon steels of thickness above 25 mm.
Restrained welds of all thickness

Preheating temperature vary from 75C to 200C
depending on hardenability of material, thickness & joint
restrain
How does Preheating Eliminate Crack?
Preheating promotes slow cooling of weld and
HAZ
Slow cooling softens or prevents hardening of
weld and HAZ
Soft material not prone to crack even in
restrained condition
What Is Post Heating?
Raising the pre heating temperature of the weld joint to a
predetermined temperature range (250 C to 350 C) for
a minimum period of time (3 Hrs) before the weld cools
down to room temperature.
Post heating performed when welding is completed or
terminated any time in between.
Heating by Oxy fuel flame or electric resistant coil
Heating from opposite side of welding wherever possible
Temperature verified by thermo chalks during the period

Why Post Heating?
Post heating eliminates possible delayed cracking
of weld and HAZ
Applicable to
Thicker hardenable low alloy steels
Restrained hardenable welds of all thickness
Post heating temperature and duration depends on
hardenability of material, thickness & joint
restrain
How does Post Heating Eliminate
Crack?
SMAW introduces hydrogen in weld metal
Entrapped hydrogen in weld metal induces
delayed cracks unless removed before cooling to
room temperature
Retaining the weld at a higher temperature for a
longer duration allows the hydrogen to come out
of weld
What Is Intermediate Stress Relieving?
Heat treating a subassembly in a furnace to a
predetermined cycle immediately on completion of
critical restrained weld joint / joints without
allowing the welds to go down the pre heat
temperature. Rate of heating, Soaking temperature,
Soaking time and rate of cooling depends on
material quality and thickness
Applicable to
Highly restrained air hardenable material

Why Intermediate Stress Relieving?
Restrained welds in air hardenable steel highly
prone to crack on cooling to room temperature.

Cracks due to entrapped hydrogen and built in stress

Intermediate stress relieving relieves built in stresses
and entrapped hydrogen making the joint free from
crack prone
What Is Inter- Pass Temperature?
The temperature of a previously layed weld bead
immediately before depositing the next bead over
it
Temperature to be verified by thermo chalk prior
to starting next bead
Applicable to
Stainless Steel
Carbon Steel & LAS with minimum impact



Why Inter Pass Temperature?
Control on inter pass temperature avoids over
heating, there by
Refines the weld metal with fine grains
Improves the notch toughness properties
Minimize the loss of alloying elements in
welds
Reduces the distortion
What Is Post Weld Heat Treatment?
Heat treating an assembly on completion of all
applicable welding, in an enclosed furnace with
controlled heating/cooling rate and soaking at a
specific temperature for a specific time.
Rate of heating, Soaking temperature, Soaking time
and rate of cooling depends on material quality and
thickness
Applicable to
All type of CS & LAS
Why Post Weld Heat Treatment?
Welded joints retain internal stresses within the
structure
HAZ of welds remains invariably hardened
Post Weld Heat Treatment relieves internal stresses
and softens HAZ. This reduces the cracking
tendency of the equipment in service
Thanks
Submerged Arc Welding
By L D Poyyara
Poyyara Consultants
SAW
Fusion Welding Process
Automatic / Semi Automatic
Arc Between Consumable Electrode And Work
Arc Covered Under granular Flux
Wire / Electrode Continuously Fed To Weld Pool
Wire / Arc Under Flux Moves Along The Groove
Wire, BM & Flux Close to Arc Melt Under Flux
On Cooling Weld Metal Solidifies
Molten Flux Forms Thick Slag Coating On Weld

Poyyara Consultants
SAW
Poyyara Consultants


+

Wire
Flux
Slag
Weld
Base Metal
Hopper
Power Source
Flux
+
Arc
Flux For SAW
Sodium Chloride
Potassium Chloride
Titanium Dioxide
Sodium Silicate
Deoxidizing Agents
Poyyara Consultants
Types Of Flux
Fused Flux

Agglomerated Flux
Neutral Flux
Active Flux
Poyyara Consultants
Types Of Flux
Neutral Flux
-Wire compatible to base metal
- Single flux suitable for several material
Active Flux
- Single flux suitable for specific application
- Wire may be different from base metal
- To be welded within the recommended parameters

Poyyara Consultants
Function Of Flux In SAW
Stabilizes Arc
Prevents contamination of weld metal
Cleans the weld from unwanted impurities
Increases Fluidity of molten metal
Generates inert gas shielding while metal transfers
Forms slag after melting & covers weld
Allows deposited metal to cool slowly
Compensates alloying elements Within the weld
Eliminates spatter generation
Helps in even & uniform bead finish

Poyyara Consultants
Baking Requirements For Flux
Spread the loose Flux in a Tray Of baking Oven
Identify The Tray With The Quality/Grade Of Flux
Bake Tray in an Oven Between 300 C to 350 C
Baking Time 2Hrs to 3 Hrs
Reduce the temperature to 100 C to 150 C
Hold the Flux at this temperature till use
Poyyara Consultants
Why Baking Flux?
To remove the moisture (H2O)

To avoid possible cracking of weld due
to H2

Poyyara Consultants
How Does Moist Flux Generate
Crack Within Weld?
Moist Flux introduce atomic hydrogen at high
temperature in weld
On cooling, atomic hydrogen try to form
molecules
The reaction results in stresses and fine cracks
Cracks occur within hardened metal - HAZ
Known as Hydrogen Embitterment or Under
Bead Crack or Delayed Crack

Poyyara Consultants
Reuse Of Flux
Flux May Be Reused Provided
- Weld Not Highly Critical In Impact / Chemistry
- Reuse Limited To Maximum Twice
- All Slag Particles Are sieved & Removed
- Rebaked If not Remained In Hot
- Minimum 50% Fresh Flux Well Mixed
- Customer Spec. Doesn't Prohibit The Same
Poyyara Consultants
Types Of Power Source

Thyrester DC

Rectifier DC

Motor Generator DC

Transformer - AC

Poyyara Consultants
Characteristic Of Power Source
Poyyara Consultants
Machine welding
Drooping Cons. A Linear Cons. V
V V
A
A
V1
V2
V2
V1
A2 A1
A2
A1
SAW Wire - Electrode
Consumable Electrode / Wire
Layer Wound On Spool / Coil
CS & LAS Wires Coated with Cu
Conducts Current and generates Arc
Chemistry Compatible To Base Metal
Grade Of Flux Can Be Same For CS & LAS
Wire melts & deposited as filler in joint
Poyyara Consultants
Typical Welding Parameter
Poyyara Consultants
Sr.
no
Wire
mm
Current A
Voltage
V
Speed
mm/min
Dep. Rate
Per Arc Hr
Wire & Flux
1 1.6 200-300 22-26 750-1500 3 4 kgs.
CS wire
+
Neutral
Flux
2 2 250-350 24-26 750-1250 3- 4.5 kgs.
4 2.5 300-350 25-27 750-1250 4 4.5 kgs.
5 3 400-500 28-30 500-100 5 5.5 kgs.
6 4 550-650 30-32 400-750 5.5 - 7 kgs.
7 5 600-800 30-34 350-700 6 - 8 kgs.
Important Terminology used in
Critical SAW
Preheating
Post Heating or Dehydrogenation
Intermediate Stress leaving
Inter pass Temperature
Post Weld Heat Treatment

Poyyara Consultants
What Is Preheating?
Heating the base metal along the weld joint
to a predetermined minimum temperature
immediately before starting the weld.
Heating by Oxy fuel flame or electric
resistant coil
Heating from opposite side of welding
wherever possible
Temperature to be verified by thermo chalks
prior to starting the weld
Poyyara Consultants
Why Preheating?
Preheating eliminates possible cracking of weld
and HAZ
Applicable to
-Hardenable low alloy steels of all thickness
-Carbon steels of thickness above 25 mm.
-Restrained welds of all thickness
Preheating temperature vary from 75C to 200C
depending on hardenability of material, thickness
& joint restrain
Poyyara Consultants
How does Preheating Eliminate
Crack?
Preheating promotes slow cooling of weld
and HAZ
Slow cooling softens or prevents hardening
of weld and HAZ
Soft material not prone to crack even in
restrained condition
Poyyara Consultants
What Is Post Heating?
Raising the pre heating temperature of the weld
joint to a predetermined temperature range (250
C to 350 C) for a minimum period of time (3 Hrs)
before the weld cools down to room temperature.
Post heating performed when welding is completed
or terminated any time in between.
Heating by Oxy fuel flame or electric resistant coil
Heating from opposite side of welding wherever
possible
Temperature verified by thermo chalks during the
period
Poyyara Consultants
Why Post Heating?
Post heating eliminates possible delayed
cracking of weld and HAZ
Applicable to
-Thicker hardenable low alloy steels
-Restrained hardenable welds of all
thickness
Post heating temperature and duration
depends on hardenability of material,
thickness & joint restrain
Poyyara Consultants
How does Post Heating Eliminate
Crack?
SAW introduces hydrogen in weld metal
Entrapped hydrogen in weld metal induces
delayed cracks unless removed before
cooling to room temperature
Retaining the weld at a higher temperature
for a longer duration allows the hydrogen to
come out of weld
Poyyara Consultants
What Is Intermediate Stress
Relieving?
Heat treating a subassembly in a furnace to
a predetermined cycle immediately on
completion of critical restrained weld joint /
joints without allowing the welds to go down
the pre heat temperature. Rate of heating,
Soaking temperature, Soaking time and rate
of cooling depends on material quality and
thickness
Applicable to
Highly restrained air hardenable material
Poyyara Consultants
Why Intermediate Stress
Relieving?
Restrained welds in air hardenable steel
highly prone to crack on cooling to room
temperature.

Cracks due to entrapped hydrogen and built
in stress

Intermediate stress relieving relieves built in
stresses and entrapped hydrogen making
the joint free from crack prone
Poyyara Consultants
What Is Inter- Pass Temperature?
The temperature of a previously layed weld
bead immediately before depositing the next
bead over it
Temperature to be verified by thermo chalk
prior to starting next bead
Applicable to
Stainless Steel
Carbon Steel & LAS with minimum
impact

Poyyara Consultants
Why Inter Pass Temperature?
Control on inter pass temperature avoids
over heating, there by
-Refines the weld metal with fine grains
-Improves the notch toughness properties
-Minimize the loss of alloying elements in
welds
-Reduces the distortion

Poyyara Consultants
What Is Post Weld Heat
Treatment?
Heat treating an assembly on completion of
all applicable welding, in an enclosed
furnace with controlled heating/cooling rate
and soaking at a specific temperature for a
specific time.
Rate of heating, Soaking temperature,
Soaking time and rate of cooling depends on
material quality and thickness
Applicable to
-All type of CS & LAS
Poyyara Consultants
Why Post Weld Heat Treatment?
Welded joints retain internal stresses within
the structure

HAZ of welds remains invariably hardened

Post Weld Heat Treatment relieves internal
stresses and softens HAZ. This reduces the
cracking tendency of the equipment in
service
Poyyara Consultants
Thanks
Shielded Metal Arc Welding
By L D Poyyara
What Is Welding ?
Process of joining metals / alloys

The process performed by Heat with or without
Pressure

Filler metal may or may not be used

The joint will be homogeneous
Classification Of Welding
1 Pressure Welding With Heat &
Pressure


2 Fusion Welding With Heat & mostly
with Filler

Pressure Welding Process
Metal parts heated to forging temperature
Heating by Oven, Oxy fuel flame or Electric
Resistance
Pressure applied on heated parts by
Hammer, Hydraulic Press or Mechanical
lever
The Parts remain permanent homogeneous
joint
Types Of Pressure Welding

Forge Welding
Resistance Butt / Flash Butt / Stud Welding
Resistance Spot Welding
Resistance Seam welding
Fusion Welding Process
Metal parts locally heated to melt along the joint.

Heating by oxy fuel flame or electric Arc.

Invariably filler metal added to molten pool.

On cooling, molten puddle solidifies to permanent
homogeneous joint.
Types Of Fusion Welding
Shielded Metal Arc Welding- SMAW
Gas Tungsten Arc Welding - GTAW
Gas Metal Arc Welding - MIG / MAG
Submerged Arc Welding SAW
Gas welding Oxy Fuel Gas
Electron Beam Welding - EBW
Thermit Welding
An electric Arc struck between
electrode and base metal joint
Base metal melts under arc
Electrode tip melts in drops and
transfers to molten pool of BM
Electrode with Arc moves along
the joint keeping constant arc
length
On cooling pool solidifies
Arc
Base Metal
Flux Coating
Core Wire
Pool
SMAW Process
Equipment, Accessories & tools
Power Source

Welding Cables, Holder & Earthing Clamp

Head Screen, Hand gloves, Chipping
Hammer & Wire Brush
Types Of Power Source
Inverter- DC

Thyrester DC

Motor Generator / Diesel Generator Set -DC

Rectifier DC

Transformer - AC

Characteristic Of Power Source
Manual welding Machine welding
Drooping Cons. A Linear Cons. V
V V
A
A
Vertical
Curve
Horizontal
Curve
V1
V2
A1 A2
V1
V2
A1 A2
Electrode
Consumable

Metallic Wire Coated with Flux

Conducts Current and generates Arc

Wire melts & deposited as filler in joint
Flux Coating On Electrode
Sodium Chloride
Potassium Chloride
Titanium Dioxide
Sodium Silicate
Ferrosilicon
Iron Powder
Alloying Elements
Binding Material
Function Of Flux In welding
Stabilizes Arc
Prevents contamination of weld metal
Cleans the weld from unwanted impurities
Increases fluidity of molten metal
Generates inert gas shielding while metal
transfers
Function Of Flux In welding
Forms slag after melting & covers weld
Allows deposited metal to cool slowly
Introduces alloying elements in the weld
Increases deposition efficiency
Minimizes the spatter generation
Helps in even & uniform bead finish
CS & LAS Electrode Sizes &
Recommended Currents
No
Core Wire in mm
Gage Current
Time required
for burning in
seconds
Average
electrodes
consumed in 8
Hrs shift
Dia Length
1 2 300 14 40 60 A 50-55 ---
2 2.5 350 12 60 85 A 60-65 ---
3 3.15 450 10 100 130 A 80 -85 120 - 140
4 4 450 8 130 180 A 85-90 110 - 120
5 5 450 6 150 210 A 90-95 80 - 90
6 6.3 450 4 240 250 A 95-100 60 -70
ASME Classification Of Electrodes
SFA 5.1
E 7018
E = Electrode
70 = UTS in 1000 psi ( 60/70/80/90/100/ 110)
1 = Position (1= all, 2= 1G, 1F & 2F, 3= 1G &
1F)
8 = Type of coating (0,1,2,3,5,6,8)
Baking Of Basic Coated Electrodes
Bake the loose electrodes in a baking Oven
Baking Temperature 250

C to 300

C
Baking Time 2Hrs to 3 Hrs
Reduce the temperature to 100

C to 150

C
Hold the electrodes at this temperature till use
Unused / left over electrodes to be re-baked
Why Baking?
To remove the moisture (H
2
O) from coating to
avoid possible cracking of weld
How Does Moist Electrode Generate
Crack Within Weld?
Moist electrodes introduce atomic hydrogen at high
temperature in weld
On cooling, atomic hydrogen try to form molecules
The reaction results in stresses and fine cracks
Cracks occur within hardened metal - HAZ
Known as Hydrogen Embrittlement , Under Bead
Crack, HIC, Delayed Crack
Important Terminologies used in Critical
Welding Operation
Preheating
Post Heating or Dehydrogenation
Intermediate Stress leaving
Inter pass Temperature
Post Weld Heat Treatment
What Is Preheating?
Heating the base metal along the weld joint to a
predetermined minimum temperature immediately
before starting the weld.
Heating by Oxy fuel flame or electric resistant coil
Heating from opposite side of welding wherever
possible
Temperature to be verified by thermo chalks prior to
starting the weld


Why Preheating?
Preheating eliminates possible cracking of weld and
HAZ

Applicable to
Hardenable low alloy steels of all thickness
Carbon steels of thickness above 25 mm.
Restrained welds of all thickness

Preheating temperature vary from 75

C to 200

C
depending on hardenability of material, thickness &
joint restraint
How does Preheating Eliminate Crack?
Preheating promotes slow cooling of weld and
HAZ
Slow cooling softens or prevents hardening of
weld and HAZ
Soft material not prone to crack even in
restrained condition
What Is Post Heating?
Raising the pre heating temperature of the weld joint to
a predetermined temperature range (250 C to 350 C)
for a minimum period of time (3 Hrs) before the weld
cools down to room temperature.
Post heating performed when welding is completed or
terminated any time in between.
Heating by Oxy fuel flame or electric resistant coil
Heating from opposite side of welding wherever
possible
Temperature verified by thermo chalks during the
period

Why Post Heating?
Post heating eliminates possible delayed cracking
of weld and HAZ
Applicable to
Thicker hardenable low alloy steels
Restrained hardenable welds of all
thickness
Post heating temperature and duration depends on
hardenability of material, thickness & joint
restrain
How does Post Heating Eliminate
Crack?
SMAW introduces hydrogen in weld metal

Entrapped hydrogen in weld metal induces
delayed cracks unless removed before cooling to
room temperature

Retaining the weld at a higher temperature for a
longer duration allows the hydrogen to come out
of weld
What Is Intermediate Stress Relieving?
Heat treating a subassembly in a furnace to a
predetermined cycle immediately on completion
of critical restrained weld joint / joints without
allowing the welds to go down the pre heat
temperature. Rate of heating, Soaking temperature,
Soaking time and rate of cooling depends on
material quality and thickness
Applicable to
Highly restrained air hardenable material

Why Intermediate Stress Relieving?
Restrained welds in air hardenable steel highly
prone to crack on cooling to room temperature.

Cracks due to entrapped hydrogen and built in stress

Intermediate stress relieving relieves built in
stresses and entrapped hydrogen making the joint
free from crack prone
What Is Inter- Pass Temperature?
The temperature of a previously layed weld bead
immediately before depositing the next bead over
it
Temperature to be verified by thermo chalk prior
to starting next bead
Applicable to
Stainless Steel
Carbon Steel & LAS with minimum impact

Why Inter Pass Temperature?
Control on inter pass temperature avoids over
heating, there by
Refines the weld metal with fine grains
Improves the notch toughness properties
Minimize the loss of alloying elements in welds
Reduces the distortion
What Is Post Weld Heat Treatment?
Heat treating an assembly on completion of all
applicable welding, in an enclosed furnace with
controlled heating/cooling rate and soaking at a
specific temperature for a specific time.
Rate of heating, Soaking temperature, Soaking
time and rate of cooling depends on material
quality and thickness
Applicable to
All type of CS & LAS
Why Post Weld Heat Treatment?
Welded joints retain internal stresses within the
structure
HAZ of welds remains invariably hardened
Post Weld Heat Treatment relieves internal
stresses and softens HAZ. This reduces the cracking
tendency of the equipment in service
Welding Terminologies used in
Qualifications
Heat In Put
Heat Effected Zone HAZ
Dilution
Overlap In Weld Overlay
Tempering Bead
What Is Heat In Put In Welding?
The extent of heat energy generated in Joules per
unit length while making each weld bead.
Heat In Put is the Function of Welding
Current, Arc Voltage, And the Welding Speed
It is measured in Joules -
Heat In Put In Joules / mm
= (A x V x 60) Travel Speed in mm / min
Why Control On Heat in Put?
Heat In put controls the grain size of weld
metal.
Lower the Heat in put finer the grain size.
Finer the Grain size Better the impact properties
Heat In Put Also controls Dilution, HAZ &
Geometry of Bead size
What Is Heat Affected Zone (HAZ)









A small volume of BM adjacent to weld fusion
line, which is totally changed in its structure due
to intense heat of each weld bead is known HAZ
Weld Zone
HAZ
Diluted BM
Diluted BM
Weld Zone
Fusion Line
What Is Significant Of HAZ









It is a part and parcel of weld joint
It is inevitable
It has properties different from BM & Weld
Metal
Weld Zone
HAZ
Diluted BM
Diluted BM
Weld Zone
Fusion Line
What Is Dilution In Weld









In all Fusion welding, a small portion of BM
very close to the welding heat gets melted and
added to weld zone / fusion zone. Dilution is
the ratio of molten base metal volume (Area)
to the volume ( Area) of total fusion zone
HAZ
Diluted BM
Weld / Fusion Zone
Fusion Line
% Dilution = (Area of Diluted BM Total Fused Area) 100
What Is Significant Of Dilution









Weld metal chemistry changes depending on
the extent of dilution
Chemical elements influence Physical properties
of the joint.
Weld chemistry influences corrosion resistance
of weld overlays
Weld Zone
HAZ
Diluted BM
Diluted BM
Weld Zone
Fusion Line
What Is Overlap In Weld Overlay?
The extent of covering or over lapping of
previous weld bead by the adjacent bead.

40 to 50 % Over Lap
Less Dilution More Dilution
10 to 15 % Over Lap
More Thickness
Less Thickness
What Is Significant Of Overlap In
Weld Overlay?
Overlap of 40 to 50% results in Less Dilution & more weld
overlay Thickness per layer
Less dilution results weld metal chemistry more towards filler
metal chemistry
40 to 50 % Over Lap 10 to 15 % Over Lap
Less Dilution More Dilution
More Thickness
Less Thickness
What Is Temper Bead Technique?
In a multi pass groove & Fillet Welds, each bead & its
HAZ are getting tempered (heat treated) by the welding
heat of the next bead.
Thus all beads & their HAZ, except those in last layer,
are tempered.
Temper beads are the specially & carefully welded
temporary beads on the top of final weld reinforcement
with out allowing to generate any HAZ within the BM.
Temper beads are to be ground flush with the required
reinforcement.
Temper Bead
Temper Bead T1 & T2 Not To Generate HAZ
In BM
Temper Beads To Be Ground Flush
T2 T1
2
1
3
3
4
4
5
5
T1 & T2 To be ground Flush
HAZ
Rqd. Reinforcement
Common Defects In SMAW
1. Cracks 2. Lack Of Fusion
3. Slag 4. Porosity
5. Pinhole 6. Piping
7. Undercut 8. Overlap
9. Lack Of Penetration 10. Excess Penetration
11. Spatters 12. Suck Back
13. Under Flush 14. Burn Through
15. Uneven Bead 16.Stray Arcing
Crack
Cause Remedy
1) Wrong Consumable
2) Wrong Procedure
3) Improper Preheat
4) Excessive Restrain
1) Use Right Electrode
2) Qualify Procedure
3) Preheat Uniformly
4) Post heating or ISR
crack
Lack Of Fusion
Cause Remedy
1) Inadequate Current
2) Wrong Electrode angle
3) Improper bead placement
1) Use Right Current
2) Train /Qualify welder
3) Train/Qualify Welder
Lack Of Fusion
Slag
Cause Remedy
1) Inadequate Cleaning
2) Inadequate Current
3) Wrong Electrode angle
4) Improper bead placement
1) Clean each bead
2) Use Right Current
3) Train / Qualify welder
4) Train / Qualify Welder
Slag
Porosity
Cause Remedy
1) Damp Electrode
2) Damaged coating
3) Wet surface of BM
4) Rusted core wire
1) Bake the electrodes
2) Replace the electrodes
3) Clean & warm the BM
4) Replace the electrodes
Porosity
. .
Pinhole
Cause Remedy
1) Damp Electrode
2) Damaged coating
3) Wet surface of BM/WM
4) Rusted core wire
1) Bake the electrodes
2) Replace the electrodes
3) Clean & warm the BM
4) Replace the electrodes
Pinhole


Piping
Cause Remedy
1) Damp Electrode
2) Damaged coating
3) Previous beads wet
4) Rusted core wire
1) Bake the electrodes
2) Replace the electrodes
3) Clean & warm the weld
4) Replace the electrodes

Piping

Undercut
Cause Remedy
1) Excess Current
2) Excess Voltage
3) Improper Electrode angle
4) Eccentric Coating
1) Reduce the Current
2) Reduce Arc length
3) Train & Qualify the Welder
4) Replace the electrode
Under cut
Overlap
Cause Remedy
1) Wrong Electrode Angle

2) Inadequate current
1) Train & Qualify welder

2) Increase the current

Overlap
Lack Of Penetration*
Cause Remedy
1) Excess Root Face
2) Inadequate Root opening
3) Over size electrode
4) Wrong Electrode angle
5) Improper bead placement
6) Improper weaving technique
1) Reduce Root Face
2) Increase Root Opening
3) Reduce electrode size
4) Train / Qualify Welder
5) Train / Qualify Welder
6) Train & Qualify Welder
LOP
* Applicable to SSFPW
Excess Penetration*
Cause Remedy

1) Excess root opening
2) Excess Current
3) Inadequate root face
4) Wrong Electrode angle

1) Reduce root gap
2) Reduce Current
3) Increase Root face
4) Train / Qualify Welder
Excess Penetration
* Applicable to SSFPW
Spatters
Cause Remedy
1) Excess Current
2) Excess Voltage
3) Wrong Polarity
4) Wet Electrodes
5) Rusted BM surface
6) Rusted Core wire
7) Eccentrics coating
1) Reduce to Right Current
2) Reduce Arc length
3) Correct the polarity
4) Use Baked electrodes
5) Clean BM surface
6) Replace the electrodes
7) Replace the electrodes
Spatters

Suck Back*
Cause Remedy
1) Excess weaving in root
2) Excess Current
3) Inadequate root face
4) Wrong Electrode angle
1)Reduce weaving
2) Reduce Current
3) Increase Root face
4) Train / Qualify Welder
Suck Back
* Applicable to SSFPW in 4G, 3G & 2G
Under Flush
Cause Remedy
1) Inadequate weld beads in
final layer
2) Inadequate understanding on
weld reinforcement requirement
3) Wrong selection of Electrode
size for final layer
1) Weld some more beads
in final layer
2) Train / Qualify welder

3) Train / Qualify Welder
Under flush
Burn through*
Cause Remedy
1) Excess Current
2) Excess Root opening
3) Inadequate Root face
4) Improper weaving
1) Reduce the Current
2) Reduce root opening
3) Increase root face
4) Train / Qualify Welder
Burn trough
*Applicable to root pass
Uneven Bead Finish
Cause Remedy
1) Improper bead
placement
2) Excess Voltage
3) Excess / inadequate
current
1) Train & Qualify the Welder
2) Reduce Arc length
3) Train & Qualify the Welder
Uneven bead finish
Stray Arcing
Cause Remedy
1) Wrong Arc Striking Practice
2) Inadequate Skill of Welder
1) Train the Welder
2) Train the Welder
Arc Strikes

Good Engineering Practices in
Shielded Metal Arc Welding
Good Engineering Practices In
SMAW
Do Welding with properly baked electrodes
Basic coated CS electrodes to be baked to
250

C to 300

C for two hours

Baked electrodes to be directly used on job or
to be retained in a hold over oven at 100

C to
150

C until use
Unused balance electrodes shall be returned to
baking oven
Do not weld with damp Electrodes
Do not try to heat electrodes by touching the
job (Short circuiting)
Do not use electrodes with damaged coating
Do not use electrodes with cracked coating
Do not bend the electrodes after holding it in
the holder

Good Engineering Practices In
SMAW
Do not weld on groove / surface with mill
scale or rusting
Prior to welding, clean the weld groove with
power wire wheel
Do not weld with unidentified electrodes
Do not leave balance electrodes unattended
on shop
Good Engineering Practices In
SMAW
All connections with earthing and welding
cables shall be tight fitted
Earthing clamp shall always be tightly
connected to the job
Burn the full length of electrode till 37 mm
stub length
Good Engineering Practices In
SMAW
Earthing cable shall directly connect to the
job with an earthing clamp.
Tacks for set up shall be minimum 5 times the
electrode diameter
Weaving shall be limited to three times the
electrode diameter.
Only trained & qualified welders shall be
employed for welding
Good Engineering Practices In
SMAW
Do not direct fan or blower to welding arc
Remove paint if any from the area near
welding
While welding in open, area shall be covered
to protect from rain water & breeze
Weld edge preparation shall be free from
serrations
Good Engineering Practices In
SMAW
Use poison plates between the job material &
structural supports.
Do not damage parent metal while removing
temporary supports.
Locations where from temporary supports are
removed shall be touched up by welding /
grinding and PT checked.
Good Engineering Practices In
SMAW
Remove visible defects from welds before
placing the subsequent beads
Do not weld over a visible crack
Electrodes kept out side more than 2 Hrs shall
be returned to baking oven
Maximum 15 electrodes at a time shall be
taken from oven for welding
Good Engineering Practices In
SMAW
When preheat is required, heat from opposite
side of welding.
Use temperature indicating crayons for
checking temperature
Do not Weld more than specified weld size-
Fillet / Reinforcement.
Good Engineering Practices In
SMAW
Safety Precautions in
Shielded Metal Arc Welding
Safety Precautions In SMAW
Welders shall use safety devises Hand
gloves, Head screen with right glass & Safety
shoes
Welders shall use full sleeve boiler suit
Use welding glass-DIN 11/12 up to 250
Amps and 13 above 250 Amps
Do not look at the arc with naked eyes


Do not throw Stubs on ground. They shall be
placed in stub collector.
Do not keep electrode in the holder when
work is not in progress
Do not touch the electrode held on holder and
the the job when the power source is on
Keep welding cables duly wound near power
source when no welding is done
Safety Precautions In SMAW
Do not breath welding fumes
When working in confined area, ensure
adequate ventilation / exhaust
Gas cutting torch / preheating burner shall not
be taken inside confined area unless the flame
is lit
When not in use, switch off the the power
source from electric supply
Safety Precautions In SMAW
Acetone / inflammable liquids (Chemical for
dye penetrant test) shall not be brought near
welding
Gas cutting unit / fuel gas cylinders shall be
away from welding area
Wet safety Shoes or wet hand gloves shall not
be worn while welding
Safety Precautions In SMAW