Electric Arc Welding

Definition

Electric arc welding: A group of fusion welding processes that use an

electric arc to produce the heat required for melting
the metal and filler material.

Advantages of electric arc compared to gas welding?

Advantages

Inexpensive power source

Relatively inexpensive equipment
Welders use standard domestic current.
Portable equipment is available
Process is fast and reliable
Short learning curve
Equipment can be used for multiple functions
No gas cylinders

Electric arc is about 9,000 oF

Common Electric Arc Welding Processes

1. SMAW

Shielded Metal Arc Welding

2. GMAW

Gas metal arc welding

3. FCAW

Flux core arc welding

4. GTAW

Gas tungsten arc welding

Additional Arc Welding Processes

1. SAW

Submerged Arc Welding

2. ESW

Electroslag Welding

3. EGW

Electrogas Welding

4. PAW

Plasma Arc Welding

5. ASW

Arc Stud Welding

Arc welding equipment

Arc Welding Equipment

Both direct current (DC) and alternating current (AC) are used in arc welding.
AC machines are less expensive to purchase and operate, but are generally
restricted to welding of ferrous metals.
DC equipment can be used on all metals with good results and is generally
noted for better arc control.

Arc Length
For good welds, a short arc length is necessary, because:
1. Heat is concentrated.
2. More stable
3. More protective atmosphere.
A long arc results in
Large heat loss into atmosphere.
Unstable arc.
Weld pool is not protected.
Weld has low strength, less ductility, poor fusion and excessive spatter.

Arc Welding Electrical Terms

To understand how an electric arc welder produces the correct heat
for arc welding, you must understand the following fourteen (14)
electrical terms.
1. Electrical Circuit

8.

Constant potential

2. Direct current (DC)

9.

Constant current

3. Alternating current (AC)

10.

Voltage drop

11.

Open circuit voltage

12.

Arc voltage

13.

Polarity

14.

Watt

4. Ampere
5. Volt
6. Resistance

7. Ohms Law

Terms
1 - Electrical Circuit

An electrical circuit is a complete path for

electricity.
Establishing an arc completes an electric
circuit .

Why is this important for

arc welding?

Current will not flow through an open circuit.

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Terms
2 - Direct Current
Direct current: A type of
current where the flow of
electrons is in one
direction.
In arc welding the direction
of flow is called the polarity.

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Terms
3 - Alternating Current

Alternating current: The type

of current where the flow of

electrons reverses direction
at regular intervals.

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Terms
4 - Ampere

Amperes: the unit of measure for current flow.

One ampere is equal to 6.241509481018 electrons
passing by a point per second.
Electricity passing through a resistance causes heat.
An air gap is a high resistance

Arc welding requires large electrical currents 100-1000A.

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Terms
5 - Voltage

Voltage is the measure of electromotive

force (Emf).

Emf is measured in units of volts

Voltage is between 20-50 V

The voltage at the electrode for SMAW

determines the ease of starting and the
harshness of the arc.

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Terms
6 - Resistance

Resistance is the characteristic of a material that impedes the flow of

an electrical current.

Measured in units of Ohms ( )

When an electrical current passes through a resistance heat is

produced.

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Terms
7 - Ohms Law

E = IR

Commonly expressed as:

Voltage is equal to amps x resistance

For arc welding rearranged as:

Amperage is the voltage divided by
the resistance.

E
I=
R

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Terms
8 - Constant Potential
A constant potential power supply is designed to produce a relatively
constant voltage over a range of amperage changes.
Primarily used for
GMAW
FCAW

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Terms
8 - Constant Potentialcont.
80
70
60

Volts

50
40
30
20
10
0
0

50

100

150

200

250

A nperes

The voltage has only a small change for a large change in amperage.

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Terms
9 - Constant Current
In a constant current power supply, the current (amperage)
stays relatively constant over a narrow range of voltages.

Primarily used for:

SMAW
TIG

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Terms
9 - Constant Current-cont.
Increasing the voltage from 20 to 25
volts (25 %) causes the amperage to
change from 123 to 132 Amp (4.8%).
The voltage is not adjustable for most
constant current power supplies.

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Terms
10 - Voltage Drop

Voltage drop is the reduction in voltage in an electrical circuit between

the source and the load.

Primary cause is resistance.

Excessive voltage drop reduces the heat of the arc.

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Terms
11 - Open Circuit Voltage

Open circuit voltage is the potential voltage between the electrode and
the work when the arc is not present.

The higher the OCV the easier the arc is to start.

The higher the OCV the steeper the volt amp curve.

Is the OCV on a welding power supply adjustable?

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Terms
12 - Arc Voltage
Arc voltage is the electrical potential between the electrode and the metal
after the arc has started.
The arc voltage depends only upon the arc length
V = k1 + k2l Volts
Where l is the arc length in mm and k1 and k2 are constants,
k1 = 10 to 12; and k2 = 2 to 3
The minimum Arc voltage is given by
Vmin = (20 + 0.04 l) Volt

Which will have the higher value, OCV or arc voltage?

Is the arc voltage constant once the arc has started?

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Terms
13 - Polarity
Polarity (positive & negative) is present in all electrical circuits.
Electricity flows from negative to positive
Controlling the polarity allows the welder to influence the location of the
heat.
When the electrode is positive (+) it will be slightly hotter than the base
metal.

When the base metal is positive (+) the base metal will be slightly hotter
than the electrode.

What abbreviations are used to indicate the polarity of the electrode?

DCEN or DCSP [direct current electrode negative or direct current straight
polarity]
DCEP or DCRP [direct current electrode positive or direct current reverse
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polarity]

Terms
13 - Polarity
65%to 75%heat is generated at the anode.
If DC is used and the work is positive (the anode of the circuit), the
condition is known as straight polarity (SPDC).
Work is negative and electrode is positive is reverse polarity (RPDC).
SPDC conditions are preferred.
DC arc welding maintain a stable arc and preferred for difficult tasks such
as overhead welding.
For a stable arc, the gap should be maintained.

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Terms
13 - Polarity
Arc welding equipments
1. Droopers: Constant current welding machines
Good for manual welding
2. Constant voltage machines
Good for automatic welding

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Terms
14 - Watt

Watts are a measure of the amount of electrical energy being consumed.

Watts = Volts x Amps
The greater the Watts of energy flowing across an air gap the greater the
heat produced.
Power to drive the operation is the product of the current I passing through
the arc and the voltage E across it.
This power is converted into heat, but not all of the heat is transferred to the
surface of the work.
Convection, conduction, radiation, and spatter account for losses that
reduce the amount of usable heat

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Arc Welding Power Supplies--cont.

The type of current and the polarity of the welding current are one of the
differences between arc welding processes.
SMAW

Constant current (CC), AC, DC+ or DC-

GMAW

Constant voltage (CV) DC+

FCAW

Constant voltage (CV) DC-

GTAW

Constant Current (CC) ), AC, DC+ or DC-

What should be changed when switch a MIG welder between the GMAW
and the FCAW process?

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Twelve (12) Considerations When Selecting

An Arc Welding Power Supply

1. Maximum Amperage
2. Duty cycle
3. Amperage range
4. Amperage adjustment
mechanism
5. Input power requirements
6. Initial cost and operating cost

8. Future needs for a power

supply
9. Available skills
10. Safety
11. Manufacturer's support
12. Open circuit voltage

7. Size and portability

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1: Amperage Output

The maximum output of the power supply

determines the thickness of metal that can be
welded before joint beveling is required.
185 to 225 amps is a common size.
Welding current depends upon: the thickness
of the welded metal, type of joint, welding
speed, position of the weld, the thickness and
type of the coating on the electrode and its
working length.
Welding current, I = k. d, amperes; d is dia.
(mm)

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2: Duty cycle

The amount of continuous welding time a

power supply can be used is determined by
the duty cycle of the power supply.
Duty cycle is based on a 10 minute interval.
Many power supplies have a sloping duty
cycle.
Note in the picture there is a circle around
the 75 amp setting. Why is it there?

What is the guaranteed outcome of exceeding

a power supply duty cycle?

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2: Duty cycle
The percentage of time in a 5 min period that a welding machine can be used
at its rated output without overloading.
Time is spent in setting up, metal chipping, Cleaning and inspection.
For manual welding a 60% duty cycle is suggested and for automatic welding
100% duty cycle.

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Atomic hydrogen welding

An a.c. arc is formed between two tungsten electrodes along which streams
of hydrogen are fed to the welding zone.
The molecules of hydrogen are dissociated by the high heat of the arc in
the gap between the electrodes.
The formation of atomic hydrogen proceeds with the absorption of heat:

This atomic hydrogen recombines to form molecular hydrogen outside the

arc, particularly on the relatively cold surface of the work being welded,
releasing the heat gained previously:

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Atomic hydrogen welding

Temperature of about 3700oC.

Hydrogen acts as shielding also.
Used for very thin sheets or small diameter wires.
Lower thermal efficiency than Arc welding.
Ceramics may be arc welded.
AC used.

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