CHAPTER 3

PRINCIPLES OF ARC WELDING

3.0 Introduction
 Arc welding is a family of fusion welding
processes that utilize the heat of an electric
arc for purposes of welding (Fig. 3.1)
 The common arc welding processes
include:
Manual arc welding (MMA)
Submerged arc welding (SA)
Metal inert gas welding (MIG)
Metal active gas welding (MAG)
The Tungsten inert gas welding (TIG)
2
Fig. 3.1: The principle of arc welding
3
Fig. 3.2: Layout of the arc welding process
4
3.1 Electric and welding arc
 Electric arc: Is a flow of electric current
between two electric terminals separated
by a short gap of gas.
 Electrically, this is a flow of electrons from
the negative pole (Cathode) to the positive
pole (Anode) ionizing the gas separating
the two poles and thereby generating heat
and bright light (Fig 3.3). The hot gases
between the poles is called plasma
5
Fig. 3.3: Electric arc and fumes
3.1 Electric and welding arc (Cont..)
 The various processes taking place in plasma
characterize the nature and behaviour of the
electric arc. The various processes taking
place in plasma characterize the nature and
behaviour of the electric arc.
 These are basically excitation, ionization and
a recombination of atoms and molecules
which occur as a result of loss of electric arc
heat. These phenomena centre around the
atom.
7
3.1 Electric and welding arc (Cont..)

 Welding arc: This is electric arc that is

used as a source of heat for arc welding
 The difference between electric arc and a
welding arc lies in the composition of the
plasma of both arcs.
 Electric arc: is made of a plasma consisting
atoms, molecules, ions and electrons from
gases constituting air between the two poles

8
3.1 Electric and welding arc (Cont..)

 Welding arc: the welding arc plasma has

in addition to what is contained in the
electric arc plasma including:
Particles from vapours of elements from w-
piece and electrode materials
Fluxes
Shielding gases
Molten metal droplets on transit to the welding
joint
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3.1 Electric and welding arc (Cont..)

 Thus initiation and stabilization of welding

arc depends on ionization potential of
elements present in the plasma.
 After ignition, the welding arc generates its
own electricity careers (electric charges)
through ionization and dissociation

10
3.2 Structure of the welding arc
 The welding arc has 3 major zones (see Fig. 3.4)
The cathode
The anode
The column
 These are the areas that exercise the greatest
influence on welding arc.
 In actual welding, the anode and cathode zones
are occupied by either the electrode or the
workpiece.
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Fig.3.4: Parts of the welding arc and electric
potential drop
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3.2 Structure of the welding arc (Cont..)

 Cathode zone: This is a small area on the

surface of the cathode that emits electrons.
 It contributes 99% of the current flow in the arc
 It is 10-3 cm high and has the voltage drop of 5 V
to 20V.
 Ions present in the arc are attracted to the
cathode from where they lose their kinetic energy
which is then converted to heat energy which is
responsible for the emission of electrons

13
3.2 Structure of the welding arc (Cont..)
 The electrons from the cathode zone are
attracted to the anode zone through the
arc column
 There are 3 to 4 types of emission in the
cathode zone:
Thermal emission
Field emission
Photo emission
A combination of the above
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3.2 Structure of the welding arc (Cont..

 The Anode Zone:

 This has an average height of 5.x10-3 cm and a
voltage drop of 0 – 30 V and is surrounded by
electrons most which are emitted from the
cathode zone.
 The electrons lose most of their kinetic energy on
reaching the anode zone. The energy is
converted into heat.
 Unlike the cathode zone where 29% is lost
through electrons exit, there is no such loss at the
anode
3.2 Structure of the welding arc (Cont..)

 The no loss of heat at the anode makes

this zone warmer than the cathode and
hence more suitable for welding.

16
Table 3.1:
S/No Cathode Zone Anode Zone
1 Voltage drop: Voltage drop:
5...20V 5...15V
2. Positive Charge Negative charge
3. Height: 10-3 cm Height : 5.10-3cm
4. Field strength: Field strength:
104...106 V/cm 103V/cm
5. Diam: 0.1.....1 mm Diam: 0.1.....1 mm
6. Current: 104..106 Current: 102..104
A/cm2 A/cm2 17
Table3.2: Energy Balance
Cathode Anode Zone
Zone
Impact Energy 85% 81%
Entry Energy - 14%
Arc Radiation 7% 1%
Convection 0 0
Combustion 8% 4%
Total heat energy 71% 100%
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3.2 Structure of the welding arc (Cont..
 The Arc Column: This column is round and has
2 distinct zones
A violet, bright core with the highest
temperature and ionization – called the
plasma – 50000 to 50,0000 K
An outer jacket of the arc column which is
excited but not ionized
 The actual temperature of the arc column
depends on the arc current and the ionization
energy of the plasma gas
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3.3 Metal transfer

 Metal transfer: is the process of

transporting metal in the molten state from
the electrode or filler metal to the weld
pool in arc welding.
 Most of the metal i. e. about 90% is
transferred in the liquid form and about
10% is transferred in vapour form.

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3.3 Metal transfer (Cont..)
 Types of metal transfer
 Short circuit metal transfer: in this type of
metal transfer, molten globule touches the
molten pool before detaching itself from the
electrode causing a short circuit
 The process:
the arc is extinguished on touching
The current density then increases causing
explosive fusion (melting metal bridge) leaving
free space
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3.3 Metal transfer (Cont..)

Arc starts again

 Small current densities ( for uncovered
electrode – less than 50 A/cm2
 Gives scaly reinforced welds
 Good for thin plates – low melting rate

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3.3 Metal transfer (Cont..)

 Globular (Free flight) Metal transfer

Single drop formed at a time. It is
necked off and drops through plasma
(arc column) to the workpiece
Medium current densities (for
uncovered electrodes – 75 A/cm2 ……
150 A/cm2
High melting rates
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Fig. 3.4: Basic features of three modes of
metal transfer 24
1-2 Oct. 2009 ITP Annual Consultative Meeting 25
3.3 Metal transfer (Cont..)

 Spray Metal transfer

Simultaneous transfer of many small droplets
Very high current densities – for uncovered
electrode > 200 A/cm2
 very high melting rates

26
3.3 Metal transfer (Cont..)

 Direct current:
 Is generally preferred in welding because
of its high stability compared to alternating
current
 It remains constant in magnitude and
direction
 The only limiting factor is the cost is higher
than for ac power sources: cost for
generators, rectifiers/inverters etc 27
3.4 Influence of the type of welding
current
 Disadvantages
The blow effects
For multi-arc welding the repulsion and
attraction effects
 In both cases the cause are the magnetic effects
that emerge whenever dc flows in a conductor
 The interaction of between current flow, magnetic
field, magnetic force results in the movement of
the arc away from the intended direction
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3.4 Influence of the type of welding
current
 Arc blow effects can be minimized by:
(a) Change the position of earth wire
(b) Change the position of the w-piece
(c) Wrap the current carrying cable
around the w-piece several times

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3.4 Influence of the type of welding
current
 Alternating current
 The cheapest source of power for normal
welding shops – welding transformer being
the cheapest
 Welding with ac involves electrode and w-
piece alternatingly changing from positive
to negative: the welding arc is
extinguished and re-ignited each time it
goes the zero point
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3.4 Influence of the type of welding
current
 Disadvantage
Instability of the welding process –
electrode/workpiece changing polarity
 This instability is usually minimized by
heavily ionized atmosphere in the arc gap
and the flux covering electrode
 Table 3.4 gives a comparison of the two
types of welding currents

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Table:3.4: Comparison between DC and AC
DC AC
Direct Indirect P
Polarity
Electrode temp Low High medium
Metal transfer Coarse Fine medium

Melting rate High Low medium

(except for (except for
MIG) MIG)
Droplet temp Low High medium
Undercut Small Large medium
Weld surface Coarse Fine medium 32