Beruflich Dokumente
Kultur Dokumente
To achieve this
• Smooth,flat or matching surfaces
• Surfaces shall be free from contaminants
• Metals shall be free from impurities
• Metals shall have identical crystalline structures
Electric Arc Welding
Electrode
Power
supply
Work piece
Clamp(Earth)
Electric Arc Welding
• Electric discharge produced between cathode and anode by
a potential difference (40 to 60 volts)
• Discharge ionises air and produces -ve electrons and +ve ions
Fillet
Single V
Single Bevel
Corner
Single V
Partial pen.
Double V
Joint Design
Lap Joint
Cruci-form
Edge Weld
Weld Prepareration / Joint Design
BEFORE WELDING C
L
Included angle
60°
Parent metal/
Base metal Angle of bevel
30°
Root Face
2-3mm
Fusion face/ Root Gap
Sidewall or bevel 2-3mm
Single -V Butt
A FINISH WELD
AFTER WELDING
Toes
Fill pass
HAZ Hot Pass Weld Layer
Root run
Penetration
Weld bead Root bead
Root reinforcement
Welding positions - plate
9
Welding positions - pipe
10
Weld joints
Butt Tee
Lap
Corner
Cruciform
MMA
Wire electrode
Shielding gas in
Contact tip and
electrode wire guide
Electric Arc
Gas shield
Molten weld pool Build up of weld metal
Penetration
Parent material
• Shielding gas is based on the base material
• Argon (inert gas) is used for non ferrous metals like
Aluminium,copper
• This is called as MIG Weld
• Welding of ferrous metals, CO2 or mixture of CO2
and argon is used
• Since CO2 is active gas, welding is called as Metal
Active Gas(MAG) weld
• If CO2 alone is used, it is CO2 welding
• Electric arc is between consumable electrode
wire and weld pool.
• Arc and weld pool are protected by externally
supplied shielding gas
• Electrode wire is melted and transferred as
droplets across the arc into the molten weld
pool
CO2 Welding
• At normal temp CO2 is inert
• But at high temp it decomposes to CO and O and
becomes active
• CO2 is also combined with Argon and used as
shielding gas
• Produces a deep penetration. Good finish and less
undercut
• Spatter is high
• Less cost
MIG/MAG/GMAW –DEFECTS
• Lack of penetration
due to narrow joint angle / inadequate
welding current
• Undercut-welding speed high/high current
• Burn through
• Wire sticking
SUBMERGED ARC WELD (SAW)
• Fully automated
• Arc between Consumable electrode , work piece under
granulated welding flux
• Welding flux will not be fully consumed
• Excess can be collected and reused
• Heat loss is low
• No oxidizing effect
• Arc melts the wire , base metal and flux
• Boiler, Pressure vessels and high thickness components
• Welding penetration can be controlled by backing bar
Submerged Arc
Reel feed
Flux
retrieval Consumable
electrode
Flux feed
Slag
Weld metal
Parent metal
Weld defects
• Slag
• Porosity-due to contaminations on the metal
surface or electrode or moisture in flux(damp
flux)
• Due to Gases generated during welding
• crack
FCAW
• Electric arc between Continuously fed flux
filled tubular electrode wire and work piece
• Wire melted by the arc deposits on to the
weld pool
• Shielding given by the core flux by
decomposing into gas
• This type is called as inner shield wire.
Weld defects
• Porosity-due to inadequate shielding/poor gas
quality/contamination on the surface
• Lack of penetration-narrow joint angle/ Less
current
• Slag-improper cleaning
• Undercut-high speed/high current
• Ship building, pipelines , Earth moving
equipment
Weld Discontinuities