Beruflich Dokumente
Kultur Dokumente
Welding
Duration : 1 Hr
© SSIPL 2009
Theory + Practical
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Safety First!
Wear Face Shield Before Welding
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Safety First!
Wear Nose Mask Before Welding
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Safety First!
ELECTRIC SHOCK can kill
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Safety First!
Wear Gloves Before Starting Work
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Safety First!
Wear Grinding glasses
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SYNOPSIS:
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Process Schematic diagram :
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Schematic diagram of Torch:
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Primary Gases for Fabrication :
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Cylinder pressure Gauge Kit :
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Welding Coils :
The predominantly used welding coil for welding MS material is ER 70 S 6
E R 70 S 6
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Preliminary Welding Symbols :
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Preliminary Welding Symbols :
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WELDING POSITIONS:
PA Flat position
PC Horizontal position
PF Vertical up Position
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Types of Joints:
The predominant joints used in most of the welding
processes are
• Butt Joint
• Fillet Joint
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DETAILED VIEW OF BUTT & FILLET:
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FILLET WELD : Symbol
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Arc Length Parameters :
The electrical stick-out is the distance between the end of the contact tip and the end
of the wire. It is either called STICK OUT or ARC LENGTH
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Concave Fillet Weld :
A fillet weld in which the contour of the weld metal lies outside a
straight line joining the toes of the weld.
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Torch angle for Fillet Weld :
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BUTT WELD:
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When welding butt welds, the torch should be
positioned within the
centre of the groove and positioned at an angle
of 90⁰
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The travel speed will influence the weld bead profile and the reinforcement
height.
If the travel speed is too slow, a wide weld bead with excessive
rollover will result.
Conversely, if the travel speed is too high, a narrow weld bead with
excessive Reinforcement will result.
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WELD DEFECTS :
1) Porosity
2) Weld cracks
3) Lack of penetration
4) Excess penetration
5) Undercut
6) Under fill
7) Excess concavity
8) Excess Convexity
9) Burn through
10) Lack of fusion
11) Excess weld reinforcement
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OVERVIEW OF WELDING DEFECTS:
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OVERVIEW OF WELDING DEFECTS:
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POROSITY
Porosity − small cavities or holes resulting from gas pockets in weld metal.
Welding over slag from covered electrode Store the Electrodes properly
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WELD CRACK
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LACK OF PENETRATION:
shallow fusion between weld metal and base metal.
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EXCESS PENETRATION
Excessive Penetration − weld metal melting through base metal and hanging underneath
weld.
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UNDERCUT
Incorrect current and voltage . Use the correct welding current and voltage
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UNDER FILL
Improper Welding voltage & current parameters Set proper Current and voltage parameters
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EXCESS CONCAVITY
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EXCESS CONVEXITY
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BURN THROUGH
Burn-Through − weld metal melting completely through base metal resulting in holes
where no metal remains.
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LACK OF FUSION
Failure of weld metal to fuse completely with base metal or a preceding weld bead.
Improper angle & position of torch Plan the welding passes for proper fusion
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EXCESS WELD REINFORCEMENT
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SPATTERS
Scattering of molten metal particles that cool to solid form near weld bead.
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Thank you….
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