Beruflich Dokumente
Kultur Dokumente
WORKSHOP TECHNOLOGY 2
JJ204
GROUP MEMBERS
KATHIRAVAN S/O PARAMASIWAN
NAAVINDRA PRASAD S/O GANESAN
SIM KAH TIANG
INTRODUCTION
GAS SHIELDED ARC WELDING
The primary goal of any welding operation is to make a weld that
has the same properties as the base metal.
The only way to produce such-a weld is to protect the molten puddle
from the atmosphere
The two general types of gas shielded-arc welding processes are
gas tungsten-arc welding (GTA) and gas metal-arc welding (GMA).
GTA is often tilled TIG (tungsten inert gas) and GMA is referred to as
MIG(metal inert gas).
The term inert refers to a gas that will not combine chemically with
other elements
DIFFERENCE BETWEEN
GAS SHIELDED ARC WELDING
AND
NORMAL ARC WELDING
ARC WELDING
Arc welding is a type of welding that uses
a welding power supply to create an
electric arc between an electrode and the
base material to melt the metals at the
welding point
They can use either direct (DC) or
alternating (AC) current,
Inert gases:helium,argon
Semi-inert:oxygen,carbon dioxide,hydrogen,nitrogen
Their purpose is to protect the weld area from oxygen, and water
vapour.
METHOD OF WELDING
FOR
TIG WELDING
1.
Put on safety
gear
3.
Plug your foot
pedal into
the machine
2.
Connect the TIG
torch
4.
Select the polarity.
5.
Grind the
tungsten
7.
Set the amperage
6.
Set up the gas flow.
8.
Clean your
welding material
9.
Insert the
tungsten
electrode into its
collet
11.
Tack weld
the parts
together
10.
Clamp the
parts together
12.
Hold the TIG
torch in your
hand
13.
Practice using the foot
pedals to control the
heat
14.
Pick up the
filler rod in
your other
hand
15.
Use your torch to heat up the
base metal
METHOD OF WELDING
FOR
MIG WELDING
1.
Assemble
your safety
gear
3.
Prepare the
area to be
welded in
2.
Select a
comfortable MIG
gun
4.
Obtain the
proper wire
5.
Prepare
the reel
7.
Adjust the
tension
6.
Feed the wire
to the torch
8.
Set the welding
machine
polarity to
DCEP.
9.
Keep a
consistent
electrode
length
10.
Use the
proper
shielding
gas
11.
Weld a joint using a drag or push
welding technique.
EXAMPLE
OF
TIG WELDING
MACHINE
EXAMPLE
OF
MIG WELDING
MACHINE
TYPES OF CURRENT
Both direct current (DC) and alternating
current (AC) are used for welding.
The form of the weld pool and of the weld
seam can be influenced by current type
and electrode polarity.
EFFECTS OF POLARIITY
Direct current, straight polarity (electrode
negative, DC-EN) deep penetration
Direct current, reverse polarity (electrode
positive, DC-EP) low penetration
Alternating current (AC) medium
penetration
ADVANTAGES
OF
TUNGSTEN INERT GAS
WELDING
DISADVANTAGES
OF
TUNGSTEN INERT GAS
WELDING
ADVANTAGES
OF
METAL INERT GAS
WELDING
Simple to use
MIG welding is a simple process. In just a few hours,
welders will be able to learn how to MIG weld. As a
matter of fact, the basic MIG welding training can only
last for 20 minutes.
Increases productivity
A lot of welders have improved productivity with the
use of MIG welding. They dont need to regularly
change rods or even repeatedly brush the weld. As a
result, they will able to work faster and in a cleaner
way.
Great and Simple Welds
MIG welding offers better weld pool visibility. The
welding process is very simple and gives you better
control. As a result, you will be able to produce a great
looking weld.
Versatile
MIG welding has the ability to weld various types of
alloys and metals. You can operate it in a fully
automatic or semi automatic way. As a matter of fact, a
lot of industries are benefitting a lot from the use of MIG
welding. It is used for various metals like copper, mild
steel, aluminum, nickel, magnesium, mild steel, and
many more.
Efficient welding
MIG welding does not only improve the welding speed,
but it as well improves the quality and overall weld
control.
Cleanliness and efficiency
With the use of MIG welding, the loss of alloying
elements will be reduced and minor weld spatter is
produced.
DISADVANTAGES
OF
METAL INERT GAS
WELDING
Expensive
MIG welding is actually more expensive primarily
because of the complexity of usage. The frequent
replacement of nozzles can actually add up to the total
cost.
Not recommended for outdoor welding
MIG welders are highly discouraged to work outside
because MIG welding uses shielding gas and welding
outside can actually affect the purity of the weld. The
wind outside can compromise the quality of the weld.
Fast Cooling Rates
MIG welding is not covered with slag and so you can
expect that the welded metal will cool at higher rates
DEFECTS
OF
TUNGSTEN INERT GAS
WELDING
AND
METHOD TO
PREVENT IT
Check the gas cylinder label to make sure youre using the right
type of gas for TIG welding (generally 100 percent argon, or an
argon/helium mix for aluminum)
Check all fittings and hoses for leaks. Use a gas leak detection
fluid, available at most welding suppliers, over the hose and all
fittings. If bubbles form, you have a leak and need to replace
defective components.
SUGARING ON STAINLESS
Sugaring (oxidation) occurs around the weld
when it is exposed to oxygen in the air. The
best way to prevent sugaring is to ensure you
have adequate gas coverage on the front and
back of the weld and to be sure that you do not
overheat the weld.
CRATERS
Craters occur at the end of the weld and lead to
cracking. Causes include instantly dropping the weld
power and removing the filler rod too quickly. Adjust
your technique and continue to feed the filler rod while
slowly reducing current at the end to fill in the crater.
Using a TIG welder with a crater control function may
also help.
DIRTY BASE AND/OR FILLER METAL
All base and filler metals need to be cleaned, whether
its mill scale, oxide on aluminum, or dirt and grease.
Grind, brush and wipe away all potential contaminants.
For cleaning aluminum, dedicate a stainless steel brush
to the task to prevent contamination from other metals.
Never use brake cleaner!
DEFECTS
OF
METAL INERT GAS
WELDING
AND
METHODS TO
PREVENT IT
Porosity
Gas flow too low or too high
Blocked nozzle
Leaking gas lines
Draughty conditions
Nozzles distance from work is too great
Painted, wet or oily plate
Wet or rusty electrode/wire
Lack of penetration -Current too low
Preparation too narrow
Root face too large
Root gap too small
Worn contact tip causing irregular arc
Incorrect alignment of plates
THANK YOU